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NORDSON CORPORATION � Duluth, Georgiawww.nordson.com

TM4 Adhesive Applicators

Customer Product ManualPart 237 500E

237 500EIssued 9/05

� 2005 Nordson CorporationAll rights reservedManual 41-TM4-MA-01

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. No part of this document may be photocopied, reproduced, or translated to another language without the prior written

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

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax,Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry,Econo-Coat, e.dot, EFD, ETI, e.Stylized, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix,

Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, Little Squirt, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium,Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus,

Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback,Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, Trends, Tribomatic, Ultrasaver, UpTime, Veritec,

VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AquaCure, ATS, Auto-Flo, AutoScan, Blue Series, Check Mate, Classicblue, Controlled Fiberization,Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, Easy Clean, EasyOn, Eclipse, E-Nordson, Equi=Bead, ESP, Fill Sentry,G−Net, G−Site, HDLV, iON, Iso-Flex, iTrend, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, Minimeter, Multifil, Myritex,

OptiStroke, PatternPro, PCI, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic,Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave,

Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation.

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

Parker Lubricant is a registered trademark of Parker Seal.

Never Seez is a registered trademark of Bostik Corporation.

Viton is a registered trademark of DuPont Dow Elastomers.

Table of Contents i

� 2005 Nordson CorporationAll rights reserved

237 500EIssued 9/05

Manual 41-TM4-MA-01

Table of Contents

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

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

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

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

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

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

Less-obvious Dangers 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

2. Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Functional Description 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequential Startup 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Operations 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Major Components 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Filter 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-pressure Regulator and Gauge With Air Filter 2-7. . . . . . . . . . .

Section 1Safety

Section 2Description

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5. Control System 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features of the Operator Panel 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

System Status Area 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT Light 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READY Light 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displays Area 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selector Display and Up Key 2-10. . . . . . . . . . . . . . . . . . . . . . . . . .

Multipurpose Display and Keys 2-11. . . . . . . . . . . . . . . . . . . . . . . .

Actual Temperature Display 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Key 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Setup Area 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up and Down Keys 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Key 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEMPERATURE Area 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM SETTINGS Area 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOCK Area 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PATTERN CONTROL Area 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . .

System Controls Area 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MONITOR/SCAN Key and Light 2-17. . . . . . . . . . . . . . . . . . . . . . .

STANDBY Key and Light 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATERS Key and Light 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOCK Key and Light 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP Key and Light 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAR FAULTS Key 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PATTERN CONTROL Keys and Lights 2-19. . . . . . . . . . . . . . . . .

POWER Switch 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Specifications 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2Description (contd.)

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

2. Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Equipment Location 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Maximum System Power Consumption 3-4. . . . . . . . . . . . . . . . . . . . . .

Step 1 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Mechanical Installation 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Air Supply 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Automatic Guns 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Hoses 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Circuit Board Protection 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventing Electrostatic Discharge 3-13. . . . . . . . . . . . . . . . . . . . . . .

Ensuring a Proper Ground 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using an Electrostatic Discharge Wrist Strap 3-14. . . . . . . . . . . . . .

8. Electrical Installation 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Hose and Gun Cordsets 3-15. . . . . . . . . . . . . . . . . . . . .

Opening the Electrical Enclosure 3-16. . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Output Contacts 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Electrical Service 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing the Electrical Enclosure 3-30. . . . . . . . . . . . . . . . . . . . . . . .

Systems Settings 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3Installation

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

2. System Programming Procedures 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Keeping a Record of System Settings 4-3. . . . . . . . . . . . . . . . . . . . .

Programming System Controls 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Optional Features 4-6. . . . . . . . . . . . . . . . . . . . . . . . . .

Programming SYSTEM SETTINGS Controls 4-6. . . . . . . . . . . . . . .

Programming TEMPERATURE Controls 4-8. . . . . . . . . . . . . . . . . . .

Temperature Setting Guidelines 4-9. . . . . . . . . . . . . . . . . . . . . . . .

Program All Zones to the Same Temperature 4-10. . . . . . . . . . .

Program Setpoint and Standby Temperatures Individually 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming CLOCK Controls 4-13. . . . . . . . . . . . . . . . . . . . . . . . . .

Set the Clock 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating the Seven-day Clock 4-15. . . . . . . . . . . . . . . . . . . . . . . .

Set Standby and Heater Times 4-16. . . . . . . . . . . . . . . . . . . . . . . .

Change a Standby or Heater Set Time 4-18. . . . . . . . . . . . . . . . .

Delete a Standby or Heater Set Time 4-18. . . . . . . . . . . . . . . . . .

Delete Times for an Entire Day 4-19. . . . . . . . . . . . . . . . . . . . . . . .

An Example of How to Use the Seven-day Clock Feature 4-19.

3. System Preparation 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Operation 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank With Adhesvie 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the System 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operating Procedures 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Adhesive Level 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manually Starting Up the Applicator 4-25. . . . . . . . . . . . . . . . . . . . . .

Automatically Starting Up the Applicator 4-25. . . . . . . . . . . . . . . . . .

Manually Shutting Down the Applicator 4-26. . . . . . . . . . . . . . . . . . .

Automatically Shutting Down the Applicator 4-26. . . . . . . . . . . . . . .

Section 4Operation

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Checking Temperatures 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing the System in Standby 4-27. . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the System from Standby 4-27. . . . . . . . . . . . . . . . . . . . . .

Checking Programmed SYSTEM SETTINGS 4-27. . . . . . . . . . . . . .

Running a System Test 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Total Hours Heaters Have Been Running 4-28. . . . . . . . .

Changing Adhesives 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Optional Features 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Records of System Settings 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Records of Operating Temperature Setpoints 4-31. . . . . . . . . . . . . .

Records of Standby Temperature Setpoints 4-32. . . . . . . . . . . . . . .

Record of Set Times for Heaters On and Heaters Off 4-33. . . . . . .

Record of Set Times for Entering and Exiting Standby 4-34. . . . . .

Record of Customized System Settings Features 4-35. . . . . . . . . .

Record of System Faults 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Overview of the Hydraulic System 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Troubleshooting Tables 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive Application Defective 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Not Working 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Troubleshooting Test Procedures 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 5-9. . . . . . . . . . . . . . . . . . . . . .

Manifold Blockage Check 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Siphon Ball and Seat Check 5-10. . . . . . . . . . . . . . . . . . . . . . .

Actuator Check 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Solenoid Valve Check 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Solenoid Voltage 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Air Section Check 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5Hydraulics

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4. Pump Repair Procedures 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Pump 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for Pump Removal 5-16. . . . . . . . . . . . . . . . . . . . . . . .

Pump Removal 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Air Valve 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuator and Air Cylinder Assembly Removal 5-18. . . . . . . . . . .

Magnet Assembly Removal 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Spool and Sleeve Removal 5-20. . . . . . . . . . . . . . . . . . . . . .

Valve Spool and Sleeve Installation 5-22. . . . . . . . . . . . . . . . . . . .

Actuator and Air Cylinder Assembly Installation 5-23. . . . . . . . . .

Replacing the Piston Cups 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Shifter Fork 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Replacing the Pump Body 5-26. . . . . . . . . . . . . . . . . .

Pump Components Removal 5-27. . . . . . . . . . . . . . . . . . . . . . . . . .

Siphon Ball and Pressure Ball Components Removal 5-28. . . .

Cleaning Pump Components 5-29. . . . . . . . . . . . . . . . . . . . . . . . . .

Siphon Ball and Pressure Ball Components Installation 5-30. . .

Pump Components Installation 5-30. . . . . . . . . . . . . . . . . . . . . . . .

Pump Installation 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Restoration 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Illustrated Parts List 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . .

14:1 Piston Pump Uptime Pack 5-34. . . . . . . . . . . . . . . . . . . . . . . . . .

14:1 Piston Pump Parts List 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Pressure Regulator Parts List 5-38. . . . . . . . . . . . . . . . . . . . . . . .

Section 5Hydraulics (contd.)

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1. Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Overview of the Control System 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicator Not Powering On 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control System Indicating a Warning or Fault 6-5. . . . . . . . . . . . . . .

3. Troubleshooting Procedures 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Under-Temperature Conditions 6-8. . . . . . . . . . . .

Troubleshooting Over-Temperature Conditions 6-10. . . . . . . . . . . . .

Troubleshooting an RTD or RTD Circuit 6-11. . . . . . . . . . . . . . . . . . .

Troubleshooting Control Board Faults 6-15. . . . . . . . . . . . . . . . . . . .

Enabling the Display Heater Proportioning Feature 6-15. . . . . .

Solving Zone Faults 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Fault or Warning Log 6-18. . . . . . . . . . . . . . . . . . . . . . .

3. Repair Procedures 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safely Accessing Electrical Components 6-20. . . . . . . . . . . . . . . . . .

Replacing a Board Fuse 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Power Board 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Power Board 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Power Board 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Control Board 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Control Board 6-27. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Control Board 6-29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Display Board 6-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Display Board 6-30. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Display Board 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6Control

Table of Contentsviii


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Replacing the Operator Panel 6-33. . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Operator Panel 6-33. . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Operator Panel 6-35. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Control Assembly 6-36. . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Control Assembly 6-37. . . . . . . . . . . . . . . . . . . . . . .

Installing the Control Assembly 6-39. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Tank RTD or Thermostat 6-40. . . . . . . . . . . . . . . . . . .

Removing the Tank RTD or Thermostat 6-40. . . . . . . . . . . . . . . .

Installing the Tank RTD and Thermostat 6-42. . . . . . . . . . . . . . . .

5. Illustrated Parts List 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . .

Vista Controller Assembly Parts List 6-44. . . . . . . . . . . . . . . . . . . . . .

1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Overview of the Tank 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Tank and Manifold Replacement 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Tank and Manifold 7-2. . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Tank and Manifold 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Illustrated Parts List 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frame Assembly Parts List 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Assembly Parts List 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ground Stud Assembly Parts List 7-12. . . . . . . . . . . . . . . . . . . . . . . .

Manifold Assembly Parts List 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Assembly Parts List 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7Tank and Manifold

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Manual 41-TM4-MA-01

1. Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running the Applicator Safely 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Pressure 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Maintenance Procedures 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduling Maintenance 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing a Manifold Filter 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning a Manifold Filter 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Removable Nozzles 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the System 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flush the System With Adhesive 8-15. . . . . . . . . . . . . . . . . . . . . .

Flush the System With a Flushing Material 8-17. . . . . . . . . . . . . .

Flush the System With Type R Fluid 8-21. . . . . . . . . . . . . . . . . . .

Restoring the Applicator After Flushing the System 8-24. . . . . . . . .

1. Introduction 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Use of Wiring Diagrams 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic TM4 Applicator Schematic 9-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic for TM4 Applicators With Optional Equipment 9-4. . . . .

Basic TM4 Applicator Wiring Diagram 9-6. . . . . . . . . . . . . . . . . . . . .

Wiring Diagram for TM4 Applicators With Optional Equipment9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8Maintenance

Section 9Wiring and Schematics

Table of Contentsx


237 500EIssued 9/05

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Issued 11/94 A1EN−02−[XX−SAFE]−4

Section 1

Safety

Safety1-0


Issued 11/94A1EN−02−[XX−SAFE]−4

Safety 1-1



Section 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

Safety1-2



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 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

Safety1-4



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 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

Safety1-6



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 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 any ma-terial.

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.

8. Cleaning

Safety1-8



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


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 2

Description

Description2-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Description 2-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 2Description

TM4 applicators may be used only to melt and pump adhesive. They arenot intended for use with polyurethane-reactive adhesive material. Usethe applicators only as described in this manual.

This manual describes how to install, operate, and service an applicator.It also explains how the applicator works with other major components ofa hot melt system.

This section of the manual describes the key parts of the applicator andhow it works. The following topics are discussed here:

� Functional Description� Major Components� Control System� Specifications

NOTE: The applicator illustrations in this product manual are generallyrepresentative of TM4 applicators. Your applicator may differ slightly.

Variations that may occur include:

Options

� number of adhesive hoses that the applicator can support (4 or 6)� adhesive tank capacity� pattern control capability

Accessories

� low adhesive level indication� remote input/output control for the Vista control system

Information regarding PATTERN CONTROL has been presented brieflyin this product manual. The Vista control system operator panel with thePATTERN CONTROL option is illustrated only when specificallydiscussing pattern control requirements during equipment installation,operation, and other related topics.

1. Introduction

2. Overview

Description2-2


237 500EIssued 9/05

Manual 41-TM4-MA-01

The applicator is the main component of your hot melt system: it meltsadhesive and pumps it to other parts of the system that direct the flow ofthe melted adhesive and apply it to the work surface.

Figure 2-1 shows a typical applicator along with other key parts of a hotmelt system.

4107001

Fig. 2-1 TM 4 Hot Melt System

During sequential startup, when the clock timer or an operator turns thesystem on, the tank and hoses begin to heat first. After temperatures ofthe tank and hoses are all within 19.5 �C (35 °F) of their setpoint(operating) temperatures, the guns begin to heat. When the tank, hoses,and guns are within 3 °C (5 °F) of their setpoint temperatures, a timedelay begins. The time delay provides additional time for the material inthe tank to melt. At the end of the time delay, the green READY lightturns on and the pump is automatically enabled. The ability to heat allzones simultaneously is also available.

3. Functional Description

Sequential Startup

Description 2-3


237 500EIssued 9/05

Manual 41-TM4-MA-01

When you trigger a gun, the pump draws in the melted adhesive andtransfers it through a manifold and filter to the hose and gun where it isdeposited on to the work surface. Figure 2-2 shows the components of atypical hot melt system and the path that melted adhesive follows whenbeing pumped through the system.

4107002

ÇÇÇÇ

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

3

2

5

4

6

7

8

9

11

12

1

10

Fig. 2-2 Adhesive Flow Path of a Typical Hot Melt System

1. Air piston2. Air cylinder3. Pump4. Air pressure regulator and gauge

with air filter 5. Hydraulic plunger 6. Tank

7. Crossover tube8. Manifold9. Manifold filter

10. Automatic gun11. Hose12. Drain valve

Routine Operations

Description2-4


237 500EIssued 9/05

Manual 41-TM4-MA-01

The major mechanical and electrical components of the applicator arebriefly described in the following pages.

4107003

1

2

3

4

Fig. 2-3 Major Components of a Typical TM4 Applicator(Shown without options.)

1. Pump2. Tank

3. Manifold filter4. System controller

4. Major Components

1

24103991

4107004

Description 2-5


237 500EIssued 9/05

Manual 41-TM4-MA-01

A PTFE-coated aluminum tank holds adhesive. Heating elements castinto the walls of the tank melt the adhesive so that it can be pumped tothe rest of the system.

For tank adhesive capacity refer to Specifications given later in thissection .

Fig. 2-4 Typical l Tank

1. Aluminum with PTFE coating2. Cast-in heaters

A 14:1 piston pump equipped with an air motor drive transfers meltedadhesive from the tank to the work surface.

Fig. 2-5 14:1 Piston Pump

Tank

Pump

4130002

Description2-6


237 500EIssued 9/05

Manual 41-TM4-MA-01

A manifold directs the flow of melted, filtered adhesive to as many as fourhoses. The manifold has a 45-degree face for easy hose routing, andconnecting elbows allow hoses to be positioned either horizontally orvertically. In addition, a pressure-relief valve transfers melted material tothe tank when system pressure exceeds 10.4 mPa (1500 psi).

4103982

5

1

4

3

2

Fig. 2-6 Typical Manifold (shown with standard filter)

1. Inlet for adhesive2. Hose ports3. Drain

4. Standard filter5. Pressure-relief valve port

The manifold filter has a 0.15 mm (0.006 in.) mesh screen that trapsforeign matter, keeping it from being pumped through the system.

Fig. 2-7 Standard Filter

Manifold

Manifold Filter

4130015

Description 2-7


237 500EIssued 9/05

Manual 41-TM4-MA-01

The air-pressure regulator allows you to adjust system pressure. Thegauge indicates air pressure to the pump. The filter cleans the air ofcontaminants.

Fig. 2-8 Typical Air-PressureRegulator and GaugeWith Air Filter

The control system regulates all temperature settings and controls howthe applicator functions. The operator panel allows you to program thesystem to meet changing needs:

� Heated zones are controlled individually, giving you more flexibility insetting up your system.

� With the seven-day clock feature, you can tailor operations for a weekat a time, with different schedules for each day of the week.

� Optional pattern programming in either time or distance applicatorsprovides flexibility of bead pattern.

Air-Pressure Regulator andGauge With Air Filter

5. Control System

Description2-8


237 500EIssued 9/05

Manual 41-TM4-MA-01

The operator panel of the control system is divided into four functionalareas:

� System Status� Displays� System Setup� System Controls

4103925

1

2

3

4

Fig. 2-9 Operator Panel

1. System status2. Displays

3. System setup4. System controls

Features of the Operator Panel

Description 2-9


237 500EIssued 9/05

Manual 41-TM4-MA-01

The System Status area of the operator panel gives you a quicksummary of the status of your system. The FAULT and READY lights letyou know if the system is prepared for operation.

4103926

1 2

Fig. 2-10 System Status

1. FAULT light 2. READY light

FAULT Light

The red FAULT light turns on to indicate:

� an overtemperature condition in a zone� an open or shorted RTD in a zone� a fault-code between F1-F9

READY Light

The green READY light turns on to indicate:

� all zones are +/- 3 °C (+/- 5 °F) of the setpoint temperatures� system-ready time delay has elapsed� no faults exist

System Status Area

Description2-10


237 500EIssued 9/05

Manual 41-TM4-MA-01

The Displays area of the operator panel gives detailed information aboutthe status of your system. When running the system, it shows the statusof each operating zone. When customizing the system, it shows thecurrent system setup.

4130011

1 2 3

46 5

Fig. 2-11 Displays

1. Selector display2. Multipurpose display3. Actual temperature display

4. Enter key5. Up and Down keys6. Up key

Selector Display and Up Key

The Selector display allows you to access information about the status ofyour system during operation and system setup. The display shows the:

� selected zone number when used with TEMPERATURE and whenscanning

� day when used with CLOCK

� feature number when used with SYSTEM SETTINGS

� currently active pattern when used with PATTERN CONTROL

The Up key, which is located below the Selector display, changes thevalue of a setting.

Displays Area

Description 2-11


237 500EIssued 9/05

Manual 41-TM4-MA-01

Multipurpose Display and Keys

During normal operation, the Multipurpose display shows the setpointtemperature for a selected zone. This allows you to compare the actualtemperature of the displayed zone with its targeted temperature.

Actual Temperature Display

The Actual Temperature display shows the actual temperature of theheated zone. When the scan mode is enabled, each zone is displayed insequence. When the scan mode is disabled, only the temperature for theselected zone is displayed.

Enter Key

The Enter key saves the number shown in the Multipurpose display.

The System Setup area of the operator panel allows you to customize thesystem to your needs. From this area you can control:

� the temperature at which each zone operates (TEMPERATURE)

� how the applicator operates (SYSTEM SETTINGS)

� when the system operates (CLOCK)

� the pattern of adhesive that the system applies (PATTERNCONTROL)

To customize system controls, use the keys in the System Setup area inconjunction with the keys in the Displays area.

System Setup Area

3

1

2

USE

LINE

STORE

SPEED

1

2PATTERN CONTROL

4

5

6

4130287

Description2-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

Up and Down Keys

The Up and Down keys select features within the System Setup area,allowing you to tailor the system to your needs. You can select thefollowing features using the Up and Down keys:

� SETPOINT temperature� STANDBY temperature� SYSTEM SETTINGS� SET TIME� ENTER STANDBY� EXIT STANDBY� HEATERS ON� HEATERS OFF� Output 1� Output 2� LINE SPEED� STORE� USE

NOTE: Pressing the Up key enables you to move from feature to featurein increments of one.

Fig. 2-12 System Setup

1. Up and Down keys2. Right key3. TEMPERATURE area4. SYSTEM SETTINGS area5. CLOCK area6. PATTERN CONTROL area

Right Key

The Right key selects features within the System Setup area, allowingyou to tailor the system to your needs. You can select the following usingthe Right key:

� INTERNAL zone� HOSE zone� GUN zone� INTERVAL 1� INTERVAL 2� Bead position

NOTE: Pressing the Right key enables you to move from feature tofeature in increments of ten.

Description 2-13


237 500EIssued 9/05

Manual 41-TM4-MA-01

TEMPERATURE Area

The TEMPERATURE area of System Setup allows you to program thesetpoint or standby temperature for three types of heated zones: internal,hose, or gun.

When used in the TEMPERATURE area:

� The Up and Down keys select SETPOINT or STANDBY.

� The Right key selects the zone (internal, hose, or gun) for theselected temperature (standby or setpoint).

SYSTEM SETTINGS Area

From the SYSTEM SETTING area, you can customize or check thesettings of the following system features:

� password enable� system-ready time delay� overtemperature setpoint� Celsius or Fahrenheit applicators� global temperature bands� individual temperature bands� sequential startup or simultaneous startup� display heater proportioning� warning or power notification� ready or pump notification� auto-energize pump� auto-energize heaters� time with heaters on� fault log display� auto-energize pump temperature setting

Description2-14


237 500EIssued 9/05

Manual 41-TM4-MA-01

CLOCK Area

From the CLOCK area you can program the system to turn heaters on oroff or to place the system in standby or operating mode at a time that youselect. The clock stores two sets of times referred to as intervals. Eachinterval stores four settings as shown in Table 2-1.

Table 2-1 Interval Settings

INTERVAL 1 INTERVAL 2

Standby Settings Enter

Exit

Enter

Exit

Heater Settings On

Off

On

Off

PATTERN CONTROL Area

The PATTERN CONTROL is an option and it is located on the operatorpanel. It allows you to customize the bead patterns for a fixed-speedproduction line. Each of the two separate outputs consists of two beadsentered in either time (milliseconds) or distance (inches or millimeters).From this area you can:

� Set the location of each bead.� Define the length of each bead.� Define the pattern in either time or distance applicators.� Store or recall different patterns.

Description 2-15


237 500EIssued 9/05

Manual 41-TM4-MA-01

To customize the bead patterns, use the keys in the System Setup areain conjunction with the keys in the Displays area.

4130286

1

4

3

2

5

Fig. 2-13 PATTERN CONTROL Lights

1. Bead position lights2. Output 1 and output 2 lights3. LINE SPEED light

4. STORE light5. USE light

4130219

1

2

3

4

5

6

7

8

Description2-16


237 500EIssued 9/05

Manual 41-TM4-MA-01

The System Controls area of the operator panel allows you to controlbasic system operations and override programmed controls. The lights inthis area tell you whether a feature is on or off. Using the keys andswitches in this area, you can:

� Monitor the status of a particular zone, or scan each zone to check itsstatus.

� Take the system into or out of standby.

� Turn the heaters on or off.

� Turn the clock feature on or off. (This is useful when you do not wantthe system to startup automatically.)

� Turn the pump on or off.

� Run a system test to determine whether a fault that the system hasdetected was corrected.

� Turn the Pattern Control feature on or off.

� Turn main power to the applicator on or off.Fig. 2-14 System Controls

1. MONITOR/SCAN key and light2. STANDBY key and light3. HEATERS key and light4. CLOCK key and light5. PUMP key and light6. CLEAR FAULTS key7. PATTERN CONTROL key and

light8. POWER switch

System Controls Area

Description 2-17


237 500EIssued 9/05

Manual 41-TM4-MA-01

MONITOR/SCAN Key and Light

Pressing the MONITOR/SCAN key places the system in the scan modeor monitor mode.

� In the scan mode:

- The system scans each heated zone, displaying each zone’stemperature in sequence.

- If the system-ready time delay feature is active, the system showsthe number of minutes remaining until the system is ready foroperation.

- The MONITOR/SCAN light turns on and stays on.

� In the monitor mode:

- The system displays the temperature of only the zone currentlyselected.

- If the system-ready time delay feature is active, the system showsthe number of minutes remaining until the system is ready foroperation.

- The MONITOR/SCAN light stays on.

STANDBY Key and Light

Pressing the STANDBY key takes the system into or out of the standbymode. When the standby feature is active:

� The STANDBY light turns on.

� The READY light turns off.

� The pump is turned off.

� Temperatures on all zones drop until the temperature of each zonereaches the preselected standby temperature.

Description2-18


237 500EIssued 9/05

Manual 41-TM4-MA-01

STANDBY Key and Light (contd)

When the standby feature is disabled,

� The STANDBY light turns off.

� The heaters turn on and all zones begin heating.

� If the auto-energize pump feature is active, the pump turns on.

� After all zones have reached their preselected setpoint temperature,the READY light turns on.

HEATERS Key and Light

Pressing the HEATERS key turns power to the heaters on and off. Theheaters must be turned on for the applicator to operate.

The HEATERS light turns on when this feature is active.

NOTE: If the system is set for auto-energize heaters, the heaters areautomatically enabled and the HEATERS light turns on when thePOWER switch is turned on.

NOTE: Feature number 34 allows the heater’s on/off feature to turn thepump on or off. On gear pump applicators, this starts and stops theelectric motor remotely, while on piston pump applicators it activates anddeactivates the pump solenoid valve remotely.

CLOCK Key and Light

Pressing the CLOCK key turns the seven-day clock on and off. Whenthe clock is on, the system is controlled by the settings for ENTERSTANDBY, EXIT STANDBY, HEATERS ON, and HEATERS OFF.

The CLOCK light turns on when this feature is active.

Description 2-19


237 500EIssued 9/05

Manual 41-TM4-MA-01

PUMP Key and Light

Pressing the PUMP key turns the pump on and off. The PUMP lightturns on when this feature is active.

NOTE: If the system is set for auto-energize pump, the pump isautomatically enabled when the tank reaches the desired temperature.

CLEAR FAULTS Key

Pressing the CLEAR FAULTS key runs a system test. The test lasts fiveseconds and verifies that the problem causing a system fault wascorrected. If the problem was corrected, the FAULT light in the SystemStatus area of the operator panel will turn off once the test is completed.If the problem was not corrected, the FAULT light will stay on.

PATTERN CONTROL Keys and Lights

The PATTERN CONTROL light on the operator panel gives you a quicksummary of the status of the pattern controller. The PATTERNCONTROL key turns the pattern controller on or off. The correspondinglight is on when the feature is active.

Two TEST keys allow the guns to be manually fired. This function isavailable only when the pattern controller is OFF and is not remotelydisabled.

The three lights in this area assist you in troubleshooting.

Table 2-2 Pattern Control Lights

Light Status

Sensor Blinks each time the product travels by the productsensor.

Output 1 Blinks each time the gun attached to output one fires.

Output 2 Blinks each time the gun attached to output two fires.

Description2-20


237 500EIssued 9/05

Manual 41-TM4-MA-01

PATTERN CONTROL Keys and Lights (contd)

4130285

3

1

2

Fig. 2-15 PATTERN CONTROL Keys and Lights

1. TEST keys2. OUTPUT lights3. SENSOR light

POWER Switch

Pressing the POWER switch turns power to the applicator on or off.

Description 2-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 2-3 Specifications of TM4 Adhesive Applicator

Item Specification Notes

General

Electrical service 400/230 VAC with neutral, single or three phase, 50 Hz

Hoses (maximum) 4

Hydraulic pressure(maximum while running)

14:1 piston pump at 621 kPa (90 psi) - 8.7 mPa (1260 psi)

Melt rate 3.6 kg/hr (8 lb/hr)

Noise level 64 dB(A) at maximum pump speed A

Weight of empty applicator 33 kg (72 lb)

Workplace temperature range 0-40 °C (32-104 °F)

Controls

Control temperature range 38-232 °C (100-450 °F)

Temperature control accuracy +/- 0.5 °C (+/- 1°F)

Pump

Air consumption at 415 kPa (60 psi)and maximum pump speed

14:1 piston pump - 46 l/min (1.6 standard ft3/min)

Air pressure while running 70-621 kPa (10-90 psi)

Displacement (maximum) 14:1 piston pump - 7.2 ml/stroke (0.44 in3/stroke)

Output rate (maximum) 0.54 kg/min (1.2 lb/min) B

Speed (maximum) 14:1 piston pump - 90 strokes/min

Viscosity 800-30,000 mPa•s (up to 30,000 cps)

Tank

Capacity 3.6 kg (8 lb)

Opening 140 x 125 mm (5.50 x 4.91 in.)

Volume 3.7 liters (230 in3)

NOTE A: The noise level is measured at a distance of 1 m from the surface of the unit and at a height of 1.6 m from theaccess platform.

B: The pumping rate is based on material density of 0.84 g/ml (0.03 lb/in3) and a specific gravity of 0.84.

6. Specifications

Description2-22


237 500EIssued 9/05

Manual 41-TM4-MA-01

4107005

ÎÎÎÎÎÎÎÎÎÎÎÎ

AB

C

D

E

F

G

H

I

J

KL

Fig. 2-16 Dimensions of TM4 Adhesive Applicator

A. 207 mm (8.16 in.), to remove filter assemblyB. 315 mm (12.41 in.), to open control end frameC. 286 mm (11.26 in.), to remove the electrical enclosureD. 466 mm (18.35 in.), to remove pump enclosure

E. 477 mm (18.9in.)F. 381 mm (15.0 in.)

G. 335 mm (13.9 in.)H. 249 mm (9.80 in.)

I. 296 mm (11.65 in.)J. 560 mm (22.06 in.)K. 65 mm 2.55 in.)L. 62 mm (2.44 in.)

6. Specifications (contd)


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 3

Installation

Installation3-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installation 3-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 3Installation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

This section describes how to install the TM4 applicator and the differentkinds of hoses and guns that can be used with it. For some of thegun-installation procedures, these instructions refer you to the manualshipped with the gun.

Besides using normal care, you need no special instructions to unpackthe applicator or the equipment you purchased with it. All hoses andguns are shipped in separate packages.

After unpacking the equipment, examine all surfaces for damage, suchas dents and scratches, that may have occurred during shipping.Examine all fasteners and mechanical connectors for tightness.

Report any damage to your Nordson representative.

1. Introduction

2. Unpacking

3. Inspection

4103952

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Carefully select the location for the applicator and its associated gunsand hoses. Make sure that the location meets the followingrequirements:

� An operator can reach all controls.

� Maintenance personnel have room to service and repair the unit.

� Installers can route the hoses without kinking them.

� Any wires are routed away from AC power lines, solenoid outputlines, and electrical equipment such as motors, contacts, and relays.

� Connections are made with only the length of wire needed. (A longwire run can act as an antenna.)

� The mounting surface can support 40 kg (88 lb)

� The mounting surface is level.

� The mounting surface is raised for draining adhesive.

� The drain projects over the edge of the mounting surface.

� There is enough room to open the lid, open the manifold drain valve,remove the filter assembly, lift off the pump enclosure, and makeelectrical connections for the hoses.

Figure 3-2 illustrates the space requirements of the applicator.

To install a applicator, you will need an area that is at least:

� Dimension 1: 1040 mm (41 in.) high� Dimension 2: 865 mm (34 in.) long� Dimension 3: 635 mm (25 in.) wide

Fig. 3-1 Clearance Required forDraining Adhesive

4. Equipment Location

Installation 3-3


237 500EIssued 9/05

Manual 41-TM4-MA-01

4107007

1

2

3

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 3-2 Space Requirements for Operation and Maintenance

1. Height consideration: removing pump enclosure2. Length considerations: opening the operator panel and connecting hoses3. Width consideration: removing the manifold filter

Installation3-4


237 500EIssued 9/05

Manual 41-TM4-MA-01

Before connecting any hoses or guns to your applicator, determine themaximum power consumption of your applicator and of the hoses andguns you will install. Certain combinations of hoses and guns canexceed the power capacity of the system and keep the applicator fromoperating.

To determine the maximum power consumption of your system, use thisthree-step procedure, or ask your Nordson representative for assistance.

Refer to Table 3-1 to determine the total wattage for all components.

Example: The applicator and the following hoses and guns will beconnected.

Power RatingHose 1 − 4 foot 100 wattsGun 1 − H201 T 140 watts2-channel total 240 watts

Hose 2 − 4 foot 100 wattsGun 2 − H201 T 140 watts2-channel total 240 watts

Total for all hoses and guns 480 watts

Refer to Table 3-2. Compare the total wattage of each two-channelcombination (calculated in step 1) to the maximum stated in Table 3-2.No two-channel combination can have a total wattage exceeding themaximum. If necessary, modify the hose/gun configuration or choosedifferent components.

In the example, no single channel exceeds the maximum of 1000 wattsand no two channels exceed the maximum of 1200 watts.

1. From Table 3-3, select the nominal line voltage connected to theapplicator.

2. Find the number of hoses/guns on the applicator in column 1. Thenumber of system hoses and guns may be listed several times in thiscolumn. To determine the correct row, move horizontally to column 2,and locate the specific electrical connection of the system.

3. Moving right, read the “Combined Hose/Gun” in column 3. This is themaximum allowable wattage for all hoses and guns combined. Themaximum is 4000 watts. The total in the preceding example is 480watts, which does not exceed the maximum.

5. Maximum System PowerConsumption

Step 1

Step 2

Step 3

Installation 3-5


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 3-1 Individual Component Power in Watts

Individual Component 400/230 VAC,with neutral

Auto Hose (1.2 m, 4 ft) 100



Auto Hose (3 m, 10 ft) 265

Auto Hose (3.6 m, 12 ft) 315

H201 Gun (T or T-L) 140

H202 Gun (T or T-L) 210

H204 Gun (T or T-L) 260

PL � PN � �ELEN�

2

Notes: Actual line voltage in a plant may vary from nominal voltage byas much as ± 15 percent. To calculate the actual power requirementsat other line voltages, use the formula:

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

Table 3-2 Maximum Total Wattage of Control Components

400/230 VAC,with neutral

Maximum Individual Hose or Gun 1000

Maximum Combination of a Hose & Gun Pair 1200

Maximum Combination of two Hose and Gun Pairs 2000

Table 3-3 Power and Current Rating at 230 VAC 1∅ and 400/230 VAC 3∅ with Neutral Operation(TM4 only)

Current

No. of Hosesand Guns

Type Power CombinedHose/Gun

(watts)

Tank ControlPower (watts)

System PowerMaximum

(watts)

1 ∅ (AMPS)230 VAC

3 ∅ (AMPS)400/230 VACwith Neutral

24

1, 3∅1, 3∅

20004000

17231723

37235723

1625

917

Installation3-6


237 500EIssued 9/05

Manual 41-TM4-MA-01

Install the applicator according to the following procedure.


1. Remove the bolts that secure the applicator to the shipping pallet.Save the bolts for later use.

2. For installation within the European Community, find the packet ofadhesive-backed, local-language warning tags that was shipped withthe unit. Overlay the non-English language part of the tags alreadyon this applicator, with the tags from the packet in your own language.Carefully follow the instructions in the packet for the correctplacement of the tags.

CAUTION: Lifting by the mounting feet can damage theapplicator. Lift the applicator by the base only.

3. Using a suitable lifting device that is capable of lifting 33 kg (72 lb), forthe applicator. Position the applicator on the mounting surface. Liftthe applicator by the base, not the mounting feet.

4107008

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Fig. 3-3 Safe Lift Points

6. Mechanical Installation

4107010

Installation 3-7


237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Check to see that the applicator is level. Provide shims as needed.

5. Using the mounting feet as a guide, drill four holes in the mountingsurface for 8 mm (5/16-in.) mounting bolts.

6. Secure the applicator to the mounting surface with the bolts youremoved in step 1.

4107009

Fig. 3-4 Securing the Applicator to the Mounting Surface

1. Install the air-pressure regulator, gauge, and filter that were shippedwith your applicator.

Fig. 3-5 Installing the Air-pressureRegulator, Gauge, andFilter

Connecting the Air Supply

4130016

4130013

Installation3-8


237 500EIssued 9/05

Manual 41-TM4-MA-01

2. Turn the regulator fully counterclockwise (off).

Fig. 3-6 Turning the Air-PressureRegulator Off

NOTE: Nordson recommends installing a shutoff valve with a lockoutin the air-supply line to isolate the applicator from the air supply formaintenance procedures.

3. Connect a supply of clean, dry air to the input air fitting or shutoffvalve. The applicator requires a minimum air supply of 103-620 kPa(15-90 psi).

Fig. 3-7 Connecting the Input AirLine

Connecting the Air Supply (contd)

Installation 3-9


237 500EIssued 9/05

Manual 41-TM4-MA-01

CAUTION: Make certain that you do not exceed the maximumpower consumption of your system. Otherwise, the applicatorwill not operate. Refer to the procedure Maximum SystemPower Consumption given earlier in this section.

Install each automatic gun in your system onto the parent unit, makingmechanical connections only. Follow the instructions in the manualshipped with the gun to complete the following procedures:

� Mount the automatic gun onto the parent unit.� Connect air to the gun.� Install the gun solenoid.� Connect a triggering device to the solenoid.

Instructions for electrically connecting the hose to the applicator are givenlater in this section.

CAUTION: Make certain that you do not exceed the maximumpower consumption of your system. Otherwise, the applicatorwill not operate. Refer to the procedure Maximum SystemPower Consumption given earlier in this section.

First mechanically connect the hose to the automatic gun following theinstructions in the manual shipped with the gun. Then connect the hoseto the applicator following this procedure.

CAUTION: Failure to connect the first hose to the rear-mostunused port creates a dead end where char builds up, causingdowntime.

4107011

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

4 3 2 1 1 2 3 4

Fig. 3-8 Correct Sequence for Hose Installation

Installing Automatic Guns

Installing Hoses

4103382

4103398

Installation3-10


237 500EIssued 9/05

Manual 41-TM4-MA-01

WARNING: Hose ports that are unused must be closed by aplug. Removing plugs can cause hot adhesive to spray or flowfrom the port and injure operators.

1. Remove the plug from the rear-most unused hose port on theapplicator. Keep the plug for use during servicing and maintenance.

Fig. 3-9 Removing the Plug of theRear-Most Hose Port

2. Apply an antiseize compound to the threads of the hose-connectionfittings that were shipped with the unit. Thread the fitting into thehose port.

Fig. 3-10 Threading theConnection Fitting intothe Hose Port

Installing Hoses (contd)

4103397

5920023

Installation 3-11


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Tighten the connection with a wrench.

Fig. 3-11 Tightening theConnection Fitting

4. Tighten the hose to the fitting, by selecting the two wrenches given inTable 3-4. Follow the instructions for their use as shown in Figure 3-12.

Table 3-4 Wrench Sizes Needed to Tighten Hose Connections

Hose Size(Internal Diameter)

ConnectorWrench Size

Hose-FittingWrench Size

8 mm (5/16 in.) 16 mm (5/8 in.) 18 mm (11/16 in.)

Fig. 3-12 Correct and IncorrectWays to Tighten a Hose

5. Route the hose from the applicator to the application area. Makesure that the hose does not contact sharp or abrasive surfaces.Follow the guidelines on routing hoses shown in Figure 3-13.

6. Install any additional hoses by repeating steps 1-5. Be sure toconnect a second hose next to the first, working from right to left.

Installation3-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

5920010

P/N 111 940

X=13 mm (0.50 in.)

R=203 mm (8.00 in.)

P/N 271 486 − 8 mm (5/16 in.)P/N 274 174 − 16 mm (5/8 in.)

X

Fig. 3-13 Hose Routing Guidelines

Installing Hoses (contd)

Installation 3-13


237 500EIssued 9/05

Manual 41-TM4-MA-01

WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform installationprocedures. Observe all high voltage indicators.

Your body carries a certain amount of static electricity. Dry weather andfriction caused by walking across a floor can cause static electricity tobuild up. Touching certain objects discharges this buildup.

A discharge of static electricity can destroy circuit boards, making yourapplicator inoperable.

To prevent damage from electrostatic discharge, follow theseprecautions:

� Minimize a buildup of electrostatic energy by transporting and storingparts that are electrostatic sensitive in static-safe containers.

� Keep electrostatic sensitive parts in their containers until they arriveat static-free workstations.

� Ground yourself and place parts on a grounded surface beforeremoving them from static-safe containers. Refer to the procedureEnsuring a Proper Ground, given in this section.

� Avoid touching pins, leads, or circuitry, when possible.

Use one or more of the following grounding methods when handling orinstalling electrostatic-sensitive parts:

� Use a wrist strap connected by a ground cord to a properly groundedunit.

� Use conductive service tools.

� Use a static-dissipating work mat.

� If you do not have the suggested equipment for proper grounding,have a Nordson representative perform the installation.

7. Circuit Board Protection

Preventing ElectrostaticDischarge

Ensuring a Proper Ground

Installation3-14


237 500EIssued 9/05

Manual 41-TM4-MA-01

To provide a proper ground and protect your applicator from damagecaused by electrostatic discharge, follow this procedure when workingwithin the applicator’s electrical enclosure.

WARNING: Risk of electrical shock. Failure to observe canresult in personal injury, death, or equipment damage. Due torisk of electrocution, never wear a static strap when working onan applicator that is still connected to a power source, includingI/O lines.

CAUTION: Risk of equipment damage. Failure to observe canresult in damage to electrical components. To dissipate staticelectricity, always wear a static strap when installing or handlingany printed circuit board.

1. Wrap the copper end of the wrist strap securely around the groundlug of an applicator that is properly grounded.

2. Wrap the other end of the strap snugly around your wrist.

3. After you have completed the electrical repair or installation, removethe strap from the ground and your wrist, taking care not to touch anypins, leads, or other circuitry while securing the electrical enclosure.

Using an ElectrostaticDischarge Wrist Strap

4107012

ÏÏÏÏÏÏÏÏ

Installation 3-15


237 500EIssued 9/05

Manual 41-TM4-MA-01

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

This section includes procedures that require installing wiring or makingelectrical connections. Before making any electrical connections, firstmake the required mechanical connections. Refer to MechanicalInstallation described earlier.

Follow this procedure to connect hose and gun cordsets.

1. Connect the gun to the electrical connector at the end of the cordset.

2. Connect the hose plug to its corresponding electrical receptacle.Hose 1 connects at the bottom receptacle. Hose electricalreceptacles are sequentially numbered from bottom to top.

3. Connect any other hoses and guns to your system by repeatingsteps 1-2.

Fig. 3-14 Connecting a HoseCordset to the Unit

8. Electrical Installation

Connecting Hose and GunCordsets

4110132

4107013

Installation3-16


237 500EIssued 9/05

Manual 41-TM4-MA-01

WARNING: Risk of electrical shock. Failure to disconnectpower can result in personal injury or death.

CAUTION: When working on or near circuit boards, lock out allpower to the applicator and wear a static strap to protect theapplicator from electrostatic discharge. Otherwise, circuitboards can be damaged.

To connect output contacts and main power contacts, first access themain control board following this procedure.

1. Check to make sure that power to the applicator is off and locked out.

Fig. 3-15 Locking Out Power

CAUTION: Take care when removing the electrical enclosurelid. Lifting the lid more than 127 mm (5 in.) from the applicatorcan disconnect electrical wiring.

2. Remove the four screws on the lid of the electrical enclosure. Lift thelid approximately 127 mm (5 in.) above the applicator.

Fig. 3-16 Removing the ElectricalEnclosure Lid

Opening the ElectricalEnclosure

4107042

ÎÎ

Installation 3-17


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Disconnect the ground wire attached to the electrical enclosure lid.Remove the lid from the applicator.

Fig. 3-17 Electrical EnclosureGround Wire

4. Retaining screws secure the operator end panel in position. Insert athin blade screwdriver through the frame’s access hole. Unscrew thepanel retaining screw from the control panel. Carefully lower thepanel.

4107014

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 3-18 Accessing the Power Board

Installation3-18


237 500EIssued 9/05

Manual 41-TM4-MA-01



5. When working in the electrical enclosure, use a static wrist strap tokeep circuit boards from being damaged. Refer to the procedurePreventing Damage to Circuit Boards given earlier in this section.

6. To continue making electrical connections, go to the next procedure,Connecting Output Contacts.

Output contacts allow your applicator to communicate withcustomer-supplied equipment, enabling operators to monitor theapplicator from a remote location or enabling the applicator toautomatically activate other equipment.

The following procedure describes how to make output contactconnections.

NOTE: The contacts are rated for 250 VAC at 2 A maximum. See theelectrical schematic in Wiring Drawings and Schematics, Section 9.

1. Decide which contacts to connect by referring to the following table.If you decide to install none of the contacts, skip to the nextprocedure, Connecting Electrical Service.

Table 3-5 Description of Standard Output Contacts

Output Contact Function

System Warning/Power ONNotification

(See Note.)

This contact is used to alertoperators of a warning conditionor to let them know that power issupplied to the applicator.

System Fault This contact is used to alertoperators of a system faultcondition. It is typically used toturn on a light or to sound analarm at a remote location alertingoperators of a fault condition.

Opening the ElectricalEnclosure (contd)

Connecting Output Contacts

Installation 3-19


237 500EIssued 9/05

Manual 41-TM4-MA-01

Output Contact Function

System Ready/Pump Notification

(See Note.)

This contact is used to alertoperators that the applicator isready for operation. Typically thiscontact is used to send a readysignal to a production line so thatthe line turns on only when theapplicators ready to pumpadhesive.

NOTE: More information on the flexibility of this output contact isgiven in Table 3-9

2. If you have not already done so, access the power board by referringto the procedure, Opening the Electrical Enclosure, given earlier inthis section.

3. Remove the plug on the back panel of the unit.

4107015

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 3-19 Removing the Plug for Output Contacts

4103340

Installation3-20


237 500EIssued 9/05

Manual 41-TM4-MA-01

CAUTION: Use 1 mm2 (18 AWG) wire. Contacts are rated for250 VAC, 2 A. maximum. Do not use a smaller gauge wirethan recommended or equipment can be damaged.


Fig. 3-20 Typical Strain Relief

4. Install a strain relief to support the output contact wires.

NOTE: Table 3-8 provides strain relief information.

5. Route the output contact wires through the strain relief.

4107016

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 3-21 Routing Wires of the Output Contacts (Wires shown for all outputcontacts.)

Connecting Output Contacts (contd)

Installation 3-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

4130465A

2

3

1

4

Fig. 3-22 Routing of Standard and Accessory Contact Wiring

1. Standard outputs2. Input/Output accessory board

3. Ferrites4. Terminate I/O wiring at terminal block

Installation3-22


237 500EIssued 9/05

Manual 41-TM4-MA-01

6. Find the six-position terminal block (labeled TB2) at the bottom of thepower board.

4107017

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 3-23 Terminal Block (TB2) for Output Contacts

7. Hold the terminal block’s receptacle with one hand, and carefully pullthe block’s plug with your other hand until the two parts separate.

4107018


Fig. 3-24 Removing the Terminal Block Plug


4103966

Installation 3-23


237 500EIssued 9/05

Manual 41-TM4-MA-01

WARNING: Use the proper length of wire. Excess wiring canbe pinched when opening and closing the operator panel,causing equipment damage, personal injury, or death.

8. Make sure that the wires reach the receptacle on the power boardeven when the operator panel is opened. See Figure 3-26.

9. Make appropriate connections at terminal block 2 (TB2). Refer toTable 3-6.

Fig. 3-25 Connecting All ThreeOutput Contacts to theTerminal Block Plug

Table 3-6 Electrical Connections for Output Contacts

Output Contactas Labeled on

Status of Applicator and ContactPosition on TB2as Labeled on

Power Board Applicator Power Off Applicator Power OnPosition on TB2

(see Note A)

Ready Contact Open Open (not ready) Closed (applicatorready)

5 and 6

No Fault Contact Open Closed (no fault) Open (fault) 3 and 4

No WarningContact

Open Closed (nowarning)

Open (warning) 1 and 2

NOTE A: The contacts are not polarity sensitive. You may insert the two wires of each contact into either TB2position listed for the contact.

Installation3-24


237 500EIssued 9/05

Manual 41-TM4-MA-01

10. Carefully position the plug over the receptacle and push the plug intoplace.

4107019


Fig. 3-26 Connecting All Three Output Contacts

11. If the applicator has the Pattern Control option, contact your Nordsonrepresentative for setup and connection.

If your applicator does not have the Pattern Control option, go to theprocedure Connecting Electrical Service.


Installation 3-25


237 500EIssued 9/05

Manual 41-TM4-MA-01

1. If you have not already done so, access the power board by referringto the procedure, Opening the Electrical Enclosure, given earlier inthis section.

CAUTION: Operate the applicator only when connected to theline voltage specified on the identification plate located on thehose end of the applicator.

2. Check that the line voltage you are using matches the voltagespecified on the voltage label of the applicator’s identification plate.Refer to Table 3-7.

Table 3-7 Electrical Service Requirements of Voltage Options

VOLTS (AC) Label Electrical Service Requirements

3/N/PE AC 400/230V 400/230 VAC with neutral, single-or three-phase


Connecting Electrical Service

Installation3-26


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Use the following power source:

Power Source Wiring

230 single-phase service Use two 6 mm2 (10 AWG) wiresto make main electrical serviceconnections and a ground wire forchassis ground. The ground wireis typically green or green/yellow.

4107021


Fig. 3-27 Electrical Service Supply Access


Connecting Electrical Service (contd)

4103340

Installation 3-27


237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Refer to Table 3-8, and install a strain relief in the electrical servicesupply access hole to support electrical wires.

5. Route the main power lines through the strain relief and secure thewires using a plastic collar provided in the kit taped to the unit.

Table 3-8 Strain Reliefs Used With Knockouts

Size of Knockout Size of Strain Relief

23 mm (29/32 in.) I/O Lead Opening PG 16

38 mm (1 1/2 in.) Main Power Opening PG 29

Fig. 3-28 Typical Strain Relief


6. Make sure that the wires will reach terminal block TB1 on the powerboard and the ground connector on the heatsink adjacent to TB1,even when the operator panel is opened.

NOTE: You will need a slightly longer wire for the ground connection.

4107022


Fig. 3-29 Routing and Securing the Main Power Lines

4107049

L1 L2 L3 N

L1 L2 L3 N

A

B

PEGND

PEGND

TB1

TB1

Installation3-28


237 500EIssued 9/05

Manual 41-TM4-MA-01


CAUTION: Connecting the ground wire to position N on TB1will cause equipment failure.

7. See Figure 3-30 and make appropriate connections to terminal blockTB1 on the power board and to the ground connector located on theheatsink adjacent to terminal block TB1.

Fig. 3-30 Electrical ServiceConnections

A. 400/230 VAC with neutral,three-phase service

B. 400/230 VAC with neutral,single-phase service

4107050

X3X4

L1 L2 L3 N

PEGND

Installation 3-29


237 500EIssued 9/05

Manual 41-TM4-MA-01

NOTE: All systems are shipped with a default set for three-phaseelectrical service. Verify that the voltage plug (X3 and X4) is correctfor the electrical service to the unit. Refer to steps 9−11 if usingsingle-phase electrical service.

8. Refer to the input power label on the inside of the electrical enclosure.

� In the V∅ column, go down to the voltage and phase of service tothe unit.

� Verify that the existing plug’s part number, found in the X3column, matches the unit’s electrical service requirement.

9. If single-phase service is required, verify that the X3 and X4 plug inthe install kit is for single-phase service. See the input power label onthe inside of the electrical enclosure.

10. Remove the existing voltage plug from connector X3 and X4 andreplace it.

Fig. 3-31 400/230 VAC WithNeutral, Single-phaseConnection

4130612

Fig. 3-32 Voltage Plug for Power Board Connector X3 and X4

NOTE: If your applicator requires single-phase service and has thepattern control option, contact your Nordson representative forspecific electrical service connection requirements.

11. Go to the next procedure, Securing the Electrical Enclosure.

4107023

Installation3-30


237 500EIssued 9/05

Manual 41-TM4-MA-01

CAUTION: When working on or near circuit boards, lock out allpower to the applicator and wear a static strap to protect theapplicator from electrostatic discharge. Otherwise, circuitboards can be damaged.

Once you have connected main power and the output contacts, followthis procedure to secure the electrical enclosure:

1. Lift the operator panel back into place. Screw the retaining screwsinto the operator end panel holes.

2. Place the lid of the electrical enclosure into place on top of the unit,ensuring that the ground wire removed during the procedure Openingthe Electrical Enclosure is re-installed.

3. Install the four screws removed during the procedure Opening theElectrical Enclosure, given earlier in this section.

4. Remove the lock out and turn on power to the system.

Fig. 3-33 Installing the ElectricalEnclosure Lid

Securing the ElectricalEnclosure

Installation 3-31


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 3-9 SYSTEM SETTINGS Features

FeatureNo.

Feature Description DefaultSetting

Optional Settings

0 Password Provides a password if the password enable feature isturned on. The password (321) cannot be changed.

321 none

1 Password Enable Turns the password enable feature on or off. Whenthe password enable feature is on, operators can viewthe settings for TEMPERATURE, SYSTEMSETTINGS, or CLOCK. To change the settings,operators must enter the correct password (321).When the feature is off, operators can change allsettings without entering a password.

0

(off) 1 (on)

2 System-ReadyTime Delay

Specifies the amount of additional time needed for theadhesive to melt after all zones have reached theirsetpoint temperatures. At the end of the time delay,the READY light turns on.

18 (minutes) 0−60 (minutes)

3 OvertemperatureSetpoint

Specifies the maximum temperature any zone canreach before the system initiates a fault condition.This setting should be at least 14 �C (25 �F) abovethe highest operating setpoint. The system will notallow you to set the overtemperature setpoint lowerthan this, or the operating setpoint higher. (See Note A.)

218/425

(�C/�F)

52−246/125−475

(�C/�F)

4 Celsius/Fahrenheit

Displays temperature measurements in Celsius orFahrenheit.

F (Fahrenheit) C (Celsius)

5 GlobalTemperatureBand

Specifies the degree to which a temperature maydeviate from any zone before the system indicates anout-of-band warning. (See Note B.)

17/30

(�C/�F)

6−28/10−50

(�C/�F)

6−19 IndividualTemperatureBands(See Note D.)

Specifies the degree to which a temperature maydeviate for an individual zone before the systeminitiates a warning. (See Note C.)

17/30

(�C/�F)

6−28/10−50

(�C/�F)

20 Sequential orSimultaneousStartup

Specifies whether the system will perform a sequentialstartup (internal zones and hose zones heat first, thengun zones) or simultaneous startup (all zones heat atonce).

1

(sequential)

0 (simultaneous)

21 Display HeaterProportioning

Displays the heater proportioning (a flashingINTERNAL, HOSE, or GUN light).

0

(no display) 1 (show display)

22 System Warningor PowerNotification

Changes the System Warning output contact to alertremotely located operators that a system warning hasoccurred or that power is on.

1

(warning)

0 (power)

23 System Ready orPump Notification

Changes the System Ready output contact to alertremotely located operators that the system is ready(up to temperature) or that the pump is on.

1

(ready)

0 (pump)

NOTE A: The overtemperature setting should be at least 42 �C (75 �F) below the flash point temperature.

B: If entering a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint.

C: If entering a new setting for this feature, the new setting is immediately entered for the individual zones (FeatureNos. 6−19). However, it is not saved as the setting for Feature No. 5. Feature No. 5 always returns to the defaultsetting of 6 �C (10 �F).

D: Feature No. 6 = tank, Feature No. 7 = grid, Feature Nos. 8−13 = hoses 1−6, Feature Nos. 14−19 = guns 1−6.

Continued on next page

SYSTEM SETTINGS

Installation3-32


237 500EIssued 9/05

Manual 41-TM4-MA-01

FeatureNo.

Feature Description DefaultSetting

OptionalSettings

24 Auto-energizePump

Piston pump units only: Allows the auto-energize pump feature tobe turned on or off. If this feature is on, the system turns thepump on automatically once the tank reaches the presettemperature of Feature No. 32. If the auto-energize pump featureis off, you must turn the pump on by pressing the PUMP key untilthe PUMP light turns on.

1

(on)

0 (off)

1 (on)

25 Auto-energizeHeaters

Turns the auto-energize heaters feature on or off. If the feature ison, the system turns heaters on automatically once the POWERswitch is turned on. However, if you have programmed thesystem to turn heaters on and off automatically using the clockfeature, your clock settings override the auto-energize heatersfeature. If the auto-energize heaters feature is off, you must turnheaters on manually or allow any clock settings you haveprogrammed to turn heaters on or off.

1

(on)

0 (off)

1 (on)

26 Time WithHeaters On

Displays the total time (in hours) that the heaters have beenrunning to assist with servicing and maintenance. Refer toChecking Run Time of Heaters in Maintenance, Section 8.

See Note A none

27 Fault Log (mostrecent)

Displays the cause of the most recent system fault. Refer toChecking the Warning or Fault Log in Control, Section 6 for a listof fault codes.

See Note A none

28 Fault Log(second mostrecent)

Displays the cause of the second most recent system fault. Referto Checking the Warning or Fault Log in Control, Section 6 for alist of fault codes.

See Note A none

29 Fault Log (thirdmost recent)

Displays the cause of the third most recent system fault. Refer toChecking the Warning or Fault Log in Control, Section 6 for a listof fault codes.

See Note A none

30 & 31 Auto StandbyTimeout and InStandbyTimeout

These features are available only on units with an I/O board.

32 Auto-energizePumpTemperatureSetting

Piston pump units only: Determines when the pump automaticallystarts if using the auto-energize pump feature (Feature No. 24).The pump can start either when the system reaches the READYcondition or when the tank reaches a specified temperature. (SeeNote B.)

0 (ready) 0 (readycondition) or

1−232/1−450

(�C/�F)

34 Remote PumpEnable/RemoteHeaters On

This feature is available only on units with an I/O board.

35 Warning Log(most recent)

Displays the cause of the most recent system warning. Refer toChecking the Warning or Fault Log in Control, Section 6 for a listof fault codes.

See Note A none

36 Warning Log(second mostrecent)

Displays the cause of the second most recent system warning.Refer to Checking the Warning or Fault Log in Control, Section 6for a list of fault codes.

See Note A none

37 Warning Log(third mostrecent)

Displays the cause of the third most recent system warning.Refer to Checking the Warning or Fault Log in Control, Section 6for a list of fault codes.

See Note A none

38 Lose Ready onRemote Enable

Allows the user to decide whether or not the control systemshould lose ready status when a cold zone is enabled through theenhanced I/O board.

0 (off) 0 (off)1 (on)

NOTE A: Features 26−29 and 35−37 are always ON. There is no default setting.

B: If entering a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint.

SYSTEM SETTINGS (contd)


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 4

Operation

Operation4-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Operation 4-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 4Operation


This section describes how to:

� Prepare the TM4 applicator for operation by programming systemcontrols.

� Run the applicator after programming the system to yourspecifications.

You can control and monitor your applicator’s operations using the Vistacontroller’s operator panel.

1. Introduction

Operation4-2


237 500EIssued 9/05

Manual 41-TM4-MA-01

4103925

1

2

3

4

Fig. 4-1 SYSTEM SETTING Keys

1. System Status2. Displays

3. System Setup4. System Controls

1. Introduction(contd)

4103985A

Operation 4-3


237 500EIssued 9/05

Manual 41-TM4-MA-01

Before running the applicator, customize system operations by followingthe procedures in this section for programming the system. The Vistacontrol system simplifies programming system functions: all programmingis done from the System Setup area of the operator panel.

From the System Setup area of the operator panel, you can control:

� how the applicator operates (SYSTEM SETTINGS)

� the temperature at which each zone operates (TEMPERATURE)

� when the system operates (CLOCK)

� the type of adhesive pattern the system applies to your product(PATTERN CONTROL), if the pattern control option is available

Fig. 4-2 System Setup Area of theOperator Panel

Before you begin programming the system, take a few minutes to removethe system settings forms found in Records of System Settings at the endof this section.

2. System ProgrammingProcedures

Keeping a Record of SystemSettings

4103986

Operation4-4


237 500EIssued 9/05

Manual 41-TM4-MA-01

1. To begin programming system controls, first turn power on to theapplicator by pressing the POWER switch. The following occurs:

� The system scans each heated zone, displaying each zone’stemperature in sequence.

� The Multipurpose display shows four dashes (- - - -) for each zoneuntil a setpoint temperature is entered. After a setpoint is entered,the display will show the setpoint that was entered as the defaultwhen power is turned on.

� The Actual Temperature display shows the room temperaturebecause no heat has been applied to the zones.

2. Customize the system to your operations by completing theprocedures listed below. Refer to Table 4-1 for a summary of all thefeatures that you can customize.

� Programming SYSTEM SETTINGS Controls� Programming TEMPERATURE Controls� Programming CLOCK Controls� Programming PATTERN CONTROL functions (for applicators with

pattern control options)� Programming Optional Features

Fig. 4-3 Turning Power On

Programming System Controls

Operation 4-5


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-1 Summary of Features to Customize

Control Area Features to Customize

SYSTEM SETTINGS From SYSTEM SETTINGS, you can customize the following features:

� Password� System-Ready Time Delay period� Overtemperature Setpoint� Celsius or Fahrenheit display� Global Temperature Band setting� Individual Temperature Bands setting� Sequential or Simultaneous Startup� Display Heater Proportioning� Warning or Power notification� Ready or Pump notification� Auto-Energize Pump� Auto-Energize Heaters� Time With Heaters On� Fault Log

TEMPERATURE SETPOINT Temperature: This feature sets the temperature that a zone willmaintain during normal operation.

STANDBY Temperature: This feature sets the desired temperature to which azone will be reduced when the system is in the standby mode.

CLOCK SET TIME: This feature keeps the current day and time. The clock must be onbefore you can use the features HEATERS ON, HEATERS OFF, ENTERSTANDBY, and EXIT STANDBY.

ENTER STANDBY and EXIT STANDBY: This feature sets the time that you wantthe system to automatically enter and exit the standby mode.

HEATERS ON and HEATERS OFF: This feature sets the time that you wantheaters to automatically turn on and off.

PATTERN CONTROL 1. This feature allows you to control how output channel 1 will apply a line ofadhesive.

2. This feature allows you to control how output channel 2 will apply a line ofadhesive.

LINE SPEED: This feature works with output channels 1 and 2 to allow you toprogram the speed of your line so that the pattern control accurately appliesbeads of adhesive to your product.

STORE: This feature allows you to store as many as 99 adhesive patterns in thesystem memory. Once a pattern is stored, it can be used at any time.

USE: This feature allows you to use a stored pattern.

OPTIONAL FEATURE If you have selected optional features for your applicator, refer to the appropriateoperating instructions.

Operation4-6


237 500EIssued 9/05

Manual 41-TM4-MA-01

1. If you have not already done so, turn power on to the applicator bypressing the POWER switch.

2. Press the Up and Down keys until the SYSTEM SETTINGS lightturns on. When you select SYSTEM SETTINGS, the following occurs:

� The values in the Displays area change.

� The number in the Selector display changes to a feature number.

� The Multipurpose display changes to the current value for thefeature selected.

4103988

1

2

Fig. 4-4 Selecting the SYSTEM SETTINGS Feature

1. Up key 2. Down key

WARNING: Risk of fire. The default for the overtemperaturesetpoint is 218 �C (425 �F). When using adhesives with aflashpoint below 218 �C (425 �F), reset the overtemperaturesetpoint. Otherwise, a fire can occur.

3. Check the Material Safety Data Sheet of the adhesive that you use. Ifthe MSDS gives a flashpoint that is below 218 �C (425�F), be sure toreset the overtemperature setting to at least 42�C (75 �F) below theflashpoint.

Programming SYSTEMSETTINGS Controls

Operation 4-7


237 500EIssued 9/05

Manual 41-TM4-MA-01

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before thesystem will allow you to change any SYSTEM SETTINGS features.

4. Determine which SYSTEM SETTINGS feature to customize. Refer toTable 3-9 in Installation, Section 3 for a list of defaults and options forcustomizing each feature.

5. Press the Up key below the Selector display until the number of thefeature you want appears on the display. As the feature numberchanges, the Multipurpose display changes to show the setting ofeach feature selected.

4130012

2 3

4 5

1

Fig. 4-5 Changing the Setting of a Selected Feature

1. Up key2. Selector display3. Multipurpose display

4. Up and Down keys5. Enter key

6. Press the Up or Down keys below the Multipurpose display to changethe setting. The display flashes.

7. Press the Enter key to save the new setting. The display stopsflashing.

8. Record your setting in the forms provided at the end of this section.Refer to Keeping a Record of System Settings given earlier.

9. Repeat steps 4 through 8 for each feature you wish to change.

Operation4-8


237 500EIssued 9/05

Manual 41-TM4-MA-01

From the operating panel you can heat each of the system’s majorcomponents at a temperature specific to your needs. For programmingpurposes, each heated system component (tank, hose, and gun) isreferred to as a zone.

In addition to being able to heat each zone individually, you can assigntwo different temperature settings to each active zone: a setting for thesetpoint (operating) temperature and one for the standby temperature.

Table 4-2 Types of Temperature Settings

Setting Description

Setpoint Temperature Desired temperature of a zoneduring normal operation.

Standby Temperature Temperature to which a zone willbe reduced when the system is inthe standby mode.

If you do not enter a standby temperature, the standby default of OFF willremain in effect for each zone and the heaters will turn off if you activatethe standby feature. If you make the standby temperature equal to thesetpoint, pressing the STANDBY key will have no effect on thetemperatures, but it will turn the READY light off and disable the pump.

NOTE: The default setting for all zones is OFF (less than 38 °C or100 °F). To turn a zone on, set the setpoint temperature to 38 °C (100 °F)or higher.

Because your system can use more than one hose and gun, channelnumbers identify possibilities for programming the temperature of eachhose and gun. When programming TEMPERATURE settings, the numberin the Selector display represents a particular channel number.

Programming TEMPERATUREControls

Operation 4-9


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-3 Heated Zone and Channel Numbers

ChannelNumber

ZoneNumber

INTERNAL HOSE GUN

0 Set All 1

1 Tank Hose 1 Gun 1

2 Hose 2 Gun 2

3 Hose 3 Gun 3

4 Hose 4 Gun 4

5 2 Hose 5 Gun 5

6 2 Hose 6 Gun 6

1 Use Set All to set all zones to the same temperature. Onlyzones that are turned on are affected.

2 Not all applicators are equipped to accept more than fourhoses and guns.

Temperature Settings Guidelines

Follow these guidelines when programming temperature settings:

� Check the Manufacturer’s Safety Data Sheet for the recommendedoperating temperature of the adhesive that you will use.

� For a zone to be on, the operating temperature must be set at 38 °C(100 °F) or higher.

� Set the standby temperature 56 °C (100 °F) lower than the operatingtemperature.

� Before programming any temperature settings, make sure that theovertemperature setpoint is at least 14 �C (25 �F) higher than thehighest operating setpoint used. Refer to Feature No. 3 in Table 3-9 in Installation, Section 3.

Operation4-10


237 500EIssued 9/05

Manual 41-TM4-MA-01

Temperature Settings Guidelines (contd)

Use this suggestion to program temperature settings quickly:

Setting Procedure

All zones to the sametemperature

Follow the procedure To ProgramAll Zones to the SameTemperature.

Most zones to the sametemperature

1. First, follow the procedure ToProgram All Zones to the SameTemperature.

2. Then, follow the procedure ToProgram Setpoint and StandbyTemperatures Individually tochange the settings that youwish.

Program All Zones to the Same Temperature

Follow this procedure to set all zones to the same temperature. Also usethis procedure along with Program Setpoint and Standby TemperaturesIndividually to set most zones to the same temperature.

Only zones that are turned on are affected.

NOTE: For a zone to be on, the setpoint temperature must be set at38 °C (100 °F) or higher.


2. In the System Setup area, press the Up and Down keys until theSETPOINT or STANDBY light turns on. The system defaults to theinternal zone and the INTERNAL light turns on.

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before thesystem will allow you to change any of the temperature settings.

Operation 4-11


237 500EIssued 9/05

Manual 41-TM4-MA-01

4130305

1

2

4

3

Fig. 4-6 Customizing the Setpoint Temperature of a Zone (System SetupArea)

1. Zone lights2. Up key

3. Down key4. Right key

3. In the Displays area, press the Up key below the Selector display until0 appears on the display. All three zone lights turn on and theMultipurpose display shows a default temperature.

4. Press the Up or Down keys below the Multipurpose display to changethe temperature. The Multipurpose display flashes.

5. Press the Enter key to save the setting. The display stops flashing.

6. Record your setting in the forms provided at the end of this section.Refer to Records of System Settings.

Operation4-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

Program Setpoint and Standby Temperatures Individually

Follow this procedure to set the setpoint and standby temperatures foreach zone.


2. In the System Setup area, press the Up and Down keys until theSETPOINT or STANDBY light turns on. The system defaults to theinternal zone (the tank) and the INTERNAL light turns on. (See Figure4-6.)

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before thesystem will allow you to change any of the temperature settings.

3. Select a zone (internal, hose, or gun) to customize.

Zone Procedure

Internal (tank) zone Go to step 5.

Hose or Gun zone Press the Right key until the lightbeneath the zone you want to setturns on.

4. In the Displays area, press the Up key below the Selector display untilthe channel number you want appears on the display. (Refer toTable 4-3.) The Multipurpose display changes to show the currenttemperature setting for the zone you selected.

4103931

2 3

4 5

1

Fig. 4-7 Using the Displays Keys to Set the Temperature of a Zone(Displays Area)

1. Selector Up key2. Selector display3. Multipurpose display


4103934

2

1

Operation 4-13


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. In the Displays area, press the Up or Down key below theMultipurpose display to change the temperature. The display flashes.

NOTE: Pressing the Up or Down keys in the Displays area oncechanges the number shown in increments of one. Pressing andholding the key changes the number in increments of five.


7. Record your setting in the forms provided at the end of this section.Refer to Record of Systems Settings.

8. Press the Up key below the Selector display to select the nextchannel number for the zone that you wish to customize, and repeatthis procedure until you have set temperatures for all zones.

The seven-day clock feature turns the heaters on and off or takes theapplicator into and out of the standby mode at preset times that youprogram. This feature works in conjunction with the clock on theapplicator, which keeps the correct day and time. It does not matterwhether you set the current day and time first, or set the standby andheater times. However, both features must be set for the heaters to turnon and off correctly.

NOTE: If you experience a power outage, the applicator’s internal clockwill continue to keep time. Once power is restored and the applicator isturned on, the applicator will resume normal operations. You do not needto reprogram any features controlled by the clock.

Set the Clock

Follow this procedure to set the clock for the current time and day.

NOTE: The clock uses a seven-day, 24-hour format.


2. In the System Setup area, press the Up and Down keys until the SETTIME light turns on.

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before thesystem will allow you to change the clock settings.

Fig. 4-8 Selecting SET TIME

1. Up and Down keys2. SET TIME light

Programming CLOCK Controls

Operation4-14


237 500EIssued 9/05

Manual 41-TM4-MA-01

Set the Clock (contd)

3. Check the Selector display. The display flashes a numberrepresenting the day of the week as shown in Table 4-4.

Table 4-4 Selector Display Codes Shown When Clock Feature is Activated

Day Code Day of Week

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

4103935

1 2 3

6 5 4

Fig. 4-9 Setting the Correct Day and Time

1. Day code2. Hours3. Minutes

4. Enter key5. Up and Down keys6. Selector Up key

4. Check that the day code is correct.

Correct? Action

Yes Press the Enter key to save thesetting.

No Press the Up key below theSelector display until the correctcode appears on the display, andthen press the Enter key to savethe setting.

Operation 4-15


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. When you press the Enter key, the Selector display stops flashingand the hour shown in the Multipurpose display begins flashing.Check that the hour shown in the Multipurpose display is correct.

Correct? Action

Yes Press the Enter key to save thesetting.

No Press the Up key below theSelector display until the correcthour appears on the display, andthen press the Enter key to savethe setting.

6. When you press the Enter key, the hour shown in the Multipurposedisplay stops flashing and the minutes shown begin flashing. Checkthat the minutes shown in the Multipurpose display are correct.

Correct? Action

Yes Press the Enter key to save thesetting

No Press the Up key below theSelector display until the correctminutes appear on the display,and then press the Enter key tosave the setting

NOTE: Once the clock is set, all displays stop flashing.

Activating the Seven-day Clock

The seven-day clock is enabled/disabled by pressing the CLOCKselection key on the left side of the operator panel.

4103936

1

2

Operation4-16


237 500EIssued 9/05

Manual 41-TM4-MA-01

Set Standby and Heater Times

The seven-day clock feature turns the heaters on or off, or takes theapplicator into and out of the standby mode at preset times. Using aseven-day, 24-hour format, the clock can store two sets of times, referredto as intervals, for each day of the week. Each interval can store four timesettings:

� one to enter standby� one to exit standby� one to turn the heaters on� one to turn the heaters off

Fig. 4-10 Selecting Standby andHeater Times

1. Up and Down keys2. INTERVAL lights

Follow this procedure to set times for entering and exiting standby and forturning heaters on and off.

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before the systemwill allow you to change any SYSTEM SETTINGS features. Refer to theprocedure Programming SYSTEM SETTINGS Controls in this section.

1. In the System Setup area, press the Up and Down keys until the lightnext to the feature you wish to set turns on.

NOTE: When you select any of the standby or heater on/off settings,the applicator selects an interval. The INTERVAL 1 light turns on as adefault.

2. Check the Selector display. The display flashes a number (the daycode) representing the day of the week as shown in Table 4-5.

Table 4-5 Selector Display Codes Shown When Clock Feature is Activated

Day Code Day of Week

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

Operation 4-17


237 500EIssued 9/05

Manual 41-TM4-MA-01

4103935

1 2 3

6 5 4

Fig. 4-11 Setting the Correct Day

1. Day code2. Hours3. Minutes

4. Enter key5. Up and Down keys6. Selector Up key

3. Press the Up key below the Selector display to select the day codefor the day that you want to set a time.

4. Press the Enter key to save the day code setting. The Selectordisplay stops flashing and the hour shown in the Multipurpose displayflashes.

5. Press the Up or Down keys below the Multipurpose display until thehour for which you want to set a time appears in the display.

6. Press the Enter key to save the hour setting. The hour shown in theMultipurpose display stops flashing and the minutes flash.

7. Press the Up or Down keys until the minutes for which you want toset a time appear on the Multipurpose display.

8. Press the Enter key to save the minutes setting. All displays stopflashing.


10. Set a second time for the same day, by pressing the Right key untilthe INTERVAL 2 light turns on. Press the Enter key to save the dayand repeat steps 5 through 9.

Operation4-18


237 500EIssued 9/05

Manual 41-TM4-MA-01

Change a Standby or Heater Set Time

To change a set time, follow Set Standby and Heater Times given earlier.

Delete a Standby or Heater Set Time

Follow this procedure to delete a standby or heater set time.

1. From the System Setup area, press the Up and Down keys until thelight next to the feature you wish to change turns on.

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before thesystem will allow you to change the clock settings.

2. Check the Selector display. The display flashes the day coderepresenting a day of the week.

3. Refer to Table 4-5, and press the Up key below the Selector displayuntil the day code of the day that you want to change appears in theSelector display.

4. Press the Enter key to save the setting. The Selector display stopsflashing and the hour shown in the Multipurpose display flashes.

5. Press the Up or Down keys below the Multipurpose display until fourdashes (- - - -) appear on the display. (The dashes indicate that nosetting has been entered.)

6. Press the Enter key to save the setting. All displays stop flashing.


Operation 4-19


237 500EIssued 9/05

Manual 41-TM4-MA-01

Delete Times for an Entire Day

To delete times for an entire day, follow Delete a Standby or Heater SetTime. Turn the clock off for each feature: entering standby, exitingstandby, turning heaters on, turning heaters off.

An Example of How to Use the Seven-day Clock Feature

At one company, the production line runs for two shifts each day andshuts down on weekends. Both shifts shut down for 45 minutes each day:once at 1200 for lunch and again at 1800 in the evening for dinner. Byusing the clock feature, the company can have the applicator start andstop by setting the clock feature to

� Put the applicator into the standby mode (ENTER STANDBY) at 1200(INTERVAL 1) and again at 1800 (INTERVAL 2).

� Take the applicator out of the standby mode (EXIT STANDBY) at1230 (INTERVAL 1) and at 1830 (INTERVAL 2), allowing 15 minutesfor the system to reach application temperature.

� Turn the heaters on (HEATERS ON) Monday through Friday30 minutes before the start of the first shift (INTERVAL 1).

� Turn the heaters off (HEATERS OFF) Monday through Friday at theend of the second shift (INTERVAL 1).

NOTE: The clock is not set for Saturday or Sunday when the company isclosed.

WARNING: Allow only qualified personnel to operate theapplicator.

This section describes how to prepare the applicator for its first operation.

3. System Preparation

Operation4-20


237 500EIssued 9/05

Manual 41-TM4-MA-01

The applicator’s pump operation can be controlled in three ways:

� manually activated using the PUMP key on the operator panel

� automatically activation through the auto-energize function (seeProgramming System Settings Controls in this section)

� pump operation can be stopped by the applicator going into StandbyMode, either automatically or manually selected. Standby Mode canbe selected remotely through optional remote inputs/outputs.

WARNING: When flushing the applicator, ensure that pumpactivation is controlled through the operator panel.

NOTE: When troubleshooting pump operation, ensure that the pump isactivated through the operator panel and that no fault condition existsthat could disable pump operation.

WARNING: Before continuing, refer to General Hot MeltMaterial Processing Instructions at the beginning of this manual.

1. If you have not already done so, set the system controls for yourapplicator. Refer to System Programming Procedures earlier in thissection.

2. Open the tank lid.

WARNING: Use a metal or plastic scoop to fill the tank withadhesive. Never use your bare hands.

3. Use a metal or plastic scoop and fill the tank with adhesive until thematerial is 25 mm (1 in.) below the top of the tank.

4. Close the tank lid.

5. As the system scans through the system settings, check that alltemperatures are set as recommended by your adhesive supplier.

6. Go to the next procedure, Flushing the System.

Pump Operation

Filling the Tank with Adhesive

4103287

4130016

Operation 4-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

Before operating your applicator for the first time, flush the system bypumping adhesive through it to remove trapped air and other impuritiesthat are left over from factory testing. Follow this procedure to flushimpurities from the system.

WARNING: Trapped air may still be in the hoses and guns.Shield the area and operator from splashing adhesive.

1. Place a drain pan beneath each nozzle, and remove all gun nozzles.

2. Turn main power on by pressing the POWER switch. Allow theapplicator to reach operating temperature.

Fig. 4-12 Removing Gun Nozzles

3. Check that the applicator’s air pressure is set to 0, with the regulatorturned fully counterclockwise (off).

Fig. 4-13 Turning the Air-pressureRegulator Off

Flushing the System

4103997

4107056

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Manual 41-TM4-MA-01

WARNING: Hot! Risk of burns. Wear safety goggles andheat-protective gloves.

4. Place a suitable container beneath the manifold drain valve. Openthe drain by turning the drain valve counterclockwise.

Fig. 4-14 Draining a TypicalManifold

5. Press the PUMP key. The PUMP light turns on and the pump starts.

Fig. 4-15 Pump Key

6. Remove trapped air, by gradually increasing air pressure to the pumpand allow adhesive to flow.

7. Reduce pump air pressure to 0 by turning the air pressure regulatorfully counterclockwise.

8. Press the PUMP key. The PUMP light turns off and the pump stops.

9. Remove and clean the manifold filter following the instructions inMaintenance, Section 8.

NOTE: Ensure that the manifold drain valve is closed (turned fullyclockwise) before continuing with this procedure.

Flushing the System (contd)

4103993

Operation 4-23


237 500EIssued 9/05

Manual 41-TM4-MA-01

10. Turn the air pressure regulator clockwise to increase the gun airpressure to 240 kPa (35 psi).

WARNING: Trapped air may still be in the hoses and guns.Shield the area and operator from splashing adhesive.

NOTE: Gun air pressure may require adjustment depending on theviscosity of the adhesive and the gun response.

Fig. 4-16 Remove the ManifoldFilter for Cleaning

11. Press the PUMP key to turn the pump on.

12. Trigger the guns, keeping them open so that no pressure builds up.

13. Gradually increase air pressure to the pump by turning the airpressure regulator clockwise and allowing adhesive to flow out of theguns until all trapped air, cleaning solution, and impurities are flushedout of the system. If the pump slows noticeably or stops, increasepump air pressure slightly.

14. Stop triggering the guns.

15. Reduce the pump air pressure to 0 by turning the air pressureregulator fully counterclockwise.


17. Trigger the guns momentarily to relieve trapped hydraulic pressure.

18. Attach the nozzles to the guns.

19. Turn the air pressure regulator clockwise until pump air pressure is at140 kPa (20 psi).

20. Record the initial operation setting on the form provided at the end ofthis section.

21. Refer to the gun product manual for additional setup information forthe specific gun.

The system is ready for routine operation.

4103532

25mm50%

Operation4-24


237 500EIssued 9/05

Manual 41-TM4-MA-01

Some of the following routine operating procedures can be performedfrom the Vista operator panel:

� Start up the applicator.� Shut down the applicator.� Check the temperatures on all zones.� Check the time remaining before the system is ready for operation.� Check the system status.� Enter or leave the standby mode.� Check programmed settings.� Check the amount of time that the system has been operating.� Run a system test.

The following procedures describe how to perform routine operations.

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

WARNING: Use a metal or plastic scoop to fill the tank withadhesive. Never use your bare hands.

1. Check the tank to see if you need to add more adhesive. Refill thetank before the level drops below 50% of its holding capacity. Ifnecessary, use a metal or plastic scoop and add material up to25 mm (1 in.) below the top of the tank.

WARNING: Adhesive vapors may be released when the tanklid is opened. Breathing vapors can cause discomfort. Exposingthe material to air can accelerate the curing process, causingmaterial to char.

Fig. 4-17 Filling the Tank WithAdhesive

2. Close the lid immediately after filling.

3. Begin daily operations by referring to the appropriate procedure.

� Manually Starting Up the applicator� Automatically Starting Up the applicator

4. Operating Procedures

Checking the Adhesive Level

Operation 4-25


237 500EIssued 9/05

Manual 41-TM4-MA-01

If you do not use the seven-day clock feature to automatically start up theapplicator, you will need to follow the procedure below to start up yourapplicator. If you set the applicator to start automatically, there will still beoccasions when you may need to start the applicator manually:

� when you want to turn the applicator on before it is time for automaticstartup to occur

� when you want to start the applicator on a day for which the clockfeature is turned off (by having - - - - as the entry)

� when you need to start the applicator because the CLOCK key wasnot turned on

In any of the situations listed above, follow this procedure:

1. If the POWER switch is off, turn it on.

2. Press the HEATERS key. The HEATERS light will turn on and theapplicator will begin to heat up.

3. Turn on the operating air for the guns.

4. Turn on the applicator air pressure and adjust it to the setting thatworks best for your system.

5. Check to see if your temperature settings are correct.

6. Activate the pump by pressing the PUMP key on the operator panel.

The system is ready for routine operation.

When the seven-day clock and auto-energize pump features areenabled, the heaters turn on automatically and the pump starts once thetank reaches its preset temperature.

Manually Starting Up theApplicator

Automatically Starting Up theApplicator

4756077

Operation4-26


237 500EIssued 9/05

Manual 41-TM4-MA-01

You can use this procedure to shut the applicator down at any time.

1. Press the PUMP key. The PUMP light will turn off and the pump willstop.

2. Relieve system pressure by triggering all guns in your system.

3. Turn off gun operating air.

4. Press the HEATERS key. The HEATERS light will turn off.

Fig. 4-18 Relieving SystemPressure

If the CLOCK light is on (and the system is set for the heaters to turn offautomatically), the system will shut itself down.

NOTE: The seven-day clock activates this feature.

Manually Shutting Down theApplicator

Automatically Shutting Downthe Applicator

Operation 4-27


237 500EIssued 9/05

Manual 41-TM4-MA-01

The control system allows you to check the temperatures of all zones insequence (to scan) or to continuously monitor the temperature of a singlezone (to monitor).

The scan mode activates and the MONITOR/SCAN light turns on whenthe system is powered up. In this mode, the applicator scans through theheated zones and monitors each zone in sequence. Pressing theMONITOR/SCAN key takes the applicator out of the scan mode. Thelight stays on, and the applicator monitors only the selected zone.

NOTE: Selecting a setting in the System Setup area takes the applicatorout of the monitor/scan mode. The MONITOR/SCAN light turns off.Pressing the MONITOR/SCAN key at this time puts the system back intothe monitor/scan mode. If no action is taken after two minutes, the controlsystem automatically switches back to the monitor/scan mode.

Follow this procedure to manually place the system in standby.

1. Press the STANDBY key.

2. Wait for the STANDBY light to turn on and the READY light to turn off.The pump will be disabled, and temperatures will drop to standbysetpoints.

To return from standby to normal operation, press the STANDBY key. TheSTANDBY light will turn off and the system will heat each active zone toits operating setpoint.

This section includes procedures that are used infrequently.

If you did not keep a record of the system settings, follow this procedureto check the settings that have been programmed for your system.

1. Press the Up and Down keys until the SYSTEM SETTINGS lightturns on.

2. Find the feature number of the feature you want to customize. Forthe feature number, refer to Table 3-9 in Installation, Section 3.

Checking Temperatures

Placing the System in Standby

Removing the System FromStandby

Checking ProgrammedSYSTEM SETTINGS

Operation4-28


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Press the Up key below the Selector display until feature number forthe item you want to check appears in the display.

4. Check the Multipurpose display to find the setting for the feature.

To change the setting of the feature, refer to Programming SYSTEMSETTINGS Controls.

After you have corrected a problem causing the system to register a fault,press the CLEAR FAULT key to run a system test. During the test, whichlasts 5 seconds, the following occurs:

� All lights on the control panel will turn on.� Information in the Displays area will change.

Problem Corrected? Result

Yes The FAULT light will turn off oncethe test is completed, and thesystem will begin scanning eachzone.

No The FAULT light will stay on oncethe test is completed.

NOTE: Refer to the Troubleshooting tables in this manual for moreinformation on faults and warnings.

Follow this procedure to check the total number of hours that the heatershave been running for servicing or maintenance purposes.


2. Press the Up key below the Selector display until feature number 26appears in the display.

3. Check the displays above the Multipurpose keys and above the Enterkey. Reading from left to right, the displays show the total number ofhours that the heaters have been running, up to 999,999 hours ofoperation.

NOTE: After 999,999 hours of operation is reached, the systemautomatically resets the count of hours to zero.

Checking ProgrammedSYSTEM SETTINGS (contd)

Running a System Test

Checking Total Hours HeatersHave Been Running

Operation 4-29


237 500EIssued 9/05

Manual 41-TM4-MA-01

Contact your adhesive supplier about the compatibility of the old and newmaterials. If the old and new adhesives are compatible, add the newadhesive to the tank. If the new material is not compatible with the oldone, ask your supplier for an acceptable flushing material to thoroughlyclean the system.

Follow the steps listed below when changing adhesives.

1. Pump as much of the old adhesive as possible from the system usingone of the following methods:

Method of Draining Description

Gun Place a suitable containerbeneath each gun nozzle.Remove each nozzle from its gunand pump the adhesive outthrough the gun.

Manifold Place a suitable containerbeneath the manifold drain valveand pump the adhesive outthrough the manifold.

Hose Disconnect a hose from its gun.Replace the dust covers, whichwere removed during installation,over the electrical receptacle.Position the hoses over a suitablewaste container and secure them.Pump the adhesive out throughthe hose.

4103998

Fig. 4-19 Methods of Draining the Applicator

1. Draining through the gun 2. Draining through the manifold 3. Draining through the hose

Changing Adhesives

Operation4-30


237 500EIssued 9/05

Manual 41-TM4-MA-01

2. Flush the system with a flushing material recommended by youradhesive supplier. Refer to Flushing the System with a FlushingMaterial or to Flushing the Material with Type R Fluid in Maintenance,Section 8.

3. Check the Manufacturer’s Safety Data Sheet for the recommendedoperating temperature of the new adhesive.

4. If the recommended operating temperature of the new adhesive isdifferent than that of the adhesive you were using, reprogramtemperature settings. Refer to the procedures given in Table 4-6.

Table 4-6 Recommended Temperature Settings

Setting Procedure

Overtemperature setpoint Programming SYSTEM SETTINGSControls

SETPOINT or STANDBYtemperature

Programming TEMPERATUREControls

The applicator is ready for operation. Refer to the procedure OperatingProcedures given earlier in this section.

If you have selected accessories for your applicator, refer to their specialoperating instructions.

Use these forms to record your system settings. The record will beuseful if you ever need to reprogram the system.

Changing Adhesives (contd)

5. Optional Features

6. Records of SystemSettings

Operation 4-31


237 500EIssued 9/05

Manual 41-TM4-MA-01

Store the forms in a convenient place. You may want to give a copy toothers in your workplace who need the information.

Table 4-7 Record of SETPOINT (Operating) Temperatures for INTERNAL (Tank) Zone

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ChannelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint(See Note A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Range of Setpoints(See Note B)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised Setpoint

ÁÁÁÁÁÁÁÁÁÁ

1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: Four dashes (- - - -) show that the heaters for this zone have not been programmed.

B: For a zone to be on, the operating temperature must be set at or above 38 °C (100 °F).

Table 4-8 Record of SETPOINT (Operating) Temperatures for HOSE ZonesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ChannelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hose

(SeeNote A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note B)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Range of Setpoints

(See Note C)


Revised Setpoint


1ÁÁÁÁÁÁÁÁ

1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁ2ÁÁÁÁÁÁÁÁ2

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ- - - -

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFrom 38 °C to 232 °C (100 °F to 450 °F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


3ÁÁÁÁÁÁÁÁÁÁÁÁ

3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁ4 ÁÁÁÁÁÁÁÁ











From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: Not all applicators are equipped to handle more than four hoses and guns.

B: Four dashes (- - - -) show that the heaters for this zone have not been programmed.

C: For a zone to be on, the operating temperature must be set at or above 38 °C (100 °F).

Table 4-9 Record of SETPOINT (Operating) Temperatures for GUN Zones


ChannelÁÁÁÁÁÁÁÁÁÁÁÁ

Gun

(SeeNote A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note B)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Range of Setpoints

(See Note )CÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised Setpoint


1ÁÁÁÁÁÁÁÁÁÁÁÁ


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

















ÁÁÁÁÁ6ÁÁÁÁÁÁÁÁ


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




Records of OperatingTemperature Setpoints

Operation4-32


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Manual 41-TM4-MA-01

Table 4-10 Record of STANDBY Temperatures for INTERNAL (Tank) Zone

ÁÁÁÁÁÁÁÁÁÁÁÁ

ChannelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note B)


Revised Setpoint

ÁÁÁÁÁÁÁÁ1


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFrom 38 °C to 232 °C (100 °F to 450 °F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: Four dashes (- - - -) show that the heaters for this zone have not been programmed.

B: For a zone to be on, the operating temperature must be set at or above 38 °C (100 °F).

Table 4-11 Record of STANDBY Temperatures for HOSE Zones


ChannelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Hose

(SeeNote A)


Default Setpoint

(See Note B)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note C)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised Setpoint


1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁ2 ÁÁÁÁÁÁÁÁÁÁ


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ













ÁÁÁÁ6ÁÁÁÁÁÁÁÁÁÁ6


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFrom 38 °C to 232 °C (100 °F to 450 °F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




Table 4-12 Record of STANDBY Temperatures for GUN Zones

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ChannelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Gun

(SeeNote A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note B)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Setpoint

(See Note C)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised Setpoint


1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 38 °C to 232 °C (100 °F to 450 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ













ÁÁÁÁ5ÁÁÁÁÁÁÁÁÁÁ


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁ6ÁÁÁÁÁÁÁÁÁÁ6


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFrom 38 °C to 232 °C (100 °F to 450 °F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




Records of STANDBYTemperature Setpoints

Operation 4-33


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-13 Record of Settings for Automatically Turning Heaters On and OFF

Day Code Default Times Range of TimesRevised Times

Day Code(Day)

Default Times Range of Times(see Note A) INTERVAL 1 INTERVAL 2(Day)

Interval 1 Interval 2(see Note A)

On Off On Off

1(Monday)

On at0600

Off at1700

- - - - - - - - and 00:01 to 24:00

2(Tuesday)

On at0600

Off at1700

- - - - - - - - and 00:01 to 24:00

3(Wednesday)

On at0600

Off at1700

- - - - - - - - and 00:01 to 24:00

4(Thursday)

On at0600

Off at1700

- - - - - - - - and 00:01 to 24:00

5(Friday)

On at0600

Off at1700

- - - - - - - - and 00:01 to 24:00

6(Saturday)

- - - - - - - - - - - - and 00:01 to 24:00

7(Sunday)

- - - - - - - - - - - - and 00:01 to 24:00

NOTE A: Four dashes (- - - -) show that the Heaters On feature has not been programmed for the indicated dayof the week.

Record of Set Times forHEATERS ON and HEATERSOFF

Operation4-34


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-14 Record of Settings for Automatically Entering and Exiting Standby

ÁÁÁÁÁÁÁÁÁÁDay Code

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDefault Times

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRange of Times

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised TimesÁÁÁÁÁÁÁÁÁÁ

Day Code(Day)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Default Times ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Range of Times(see Note A)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁINTERVAL 1

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁINTERVAL 2ÁÁÁÁÁ


(Day) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Interval 1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Interval 2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

(see Note A) ÁÁÁÁÁÁÁÁÁÁÁÁ

EnterÁÁÁÁÁÁÁÁÁÁÁÁ

ExitÁÁÁÁÁÁÁÁÁÁÁÁ

EnterÁÁÁÁÁÁÁÁÁÁÁÁ

Exit

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1(Monday)


Enter at1200

Exit at1300


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





2(Tuesday)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Enter at1200

Exit at1300


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





3(Wednesday)


Enter at1200

Exit at1300


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





4(Thursday)


Enter at1200

Exit at1300


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





5(Friday)


Enter at1200

Exit at1300


- - - -ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





6(Saturday)


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00 ÁÁÁÁÁÁÁÁÁÁÁÁ



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


7(Sunday)


- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

- - - - and 00:01 to 24:00 ÁÁÁÁÁÁÁÁÁÁÁÁ



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: Four dashes (- - - -) show that the Standby feature has not been programmed for the indicated day ofthe week.

Record of Set Times forEntering and Exiting Standby

Operation 4-35


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-15 Record of Customized SYSTEM SETTINGS

SystemSetting

Feature Default Options Available(Programming Code)

Revised Setting

0 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Password Entry ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


321 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ1 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁPassword ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁOff (0) ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁOn (1) ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

System-Ready TimeDelay

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

18 minutesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 0 to 60 minutesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

OvertemperatureSetpoint


218 °C (425 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 52 °C to 246 °C(From 125 °F to 475°F)


4ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCelsius/Fahrenheit

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFahrenheit

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCelsius

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Global TemperatureBand


6 �C (10 °F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

From 6 °C to 28 °C(From 10 °F to 50 °F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ6−19 ÁÁÁÁÁÁÁÁ


Individual TemperatureBands


6 �C (10 °F) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ20 ÁÁÁÁÁÁÁÁ


Sequential orSimultaneous Startup


Sequential (1) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Simultaneous (0) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ21 ÁÁÁÁÁÁÁÁ


Display HeaterProportioning


No display (0) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Show display (1) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ22 Warning or Power

NotificationWarning (0) Power (1)

23 Ready or PumpNotification

Ready (1) Pump (0) or


Auto-energize PumpÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

On (1) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Off (0) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ25 Auto-energize Heaters On (1) Off (0)

32 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Auto-energize PumpTemperature Setting


100 °F ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Record of CustomizedSYSTEM SETTINGS Features

Operation4-36


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 4-16 Record of System Faults


Fault Code(See Note A)


DayOccurred


Action Taken ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Additional Notes



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ










ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ









































































ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: Fault Code 0 = No fault occurred.Fault Code 1 = Zone below setpoint temperature.Fault Code 2 = Open RTD.Fault Code 3 = Shorted RTD.Fault Code 4 = Zone overtemperature.Fault Code 5 = Control board bad.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Fault Code 6 = Brown out occurred.Fault Code 7 = Faulty PATTERN CONTROL board.Fault Code 8 = Faulty gun circuitry.Fault Code 9 = Control system can notcommunicate with pattern control.

Record of System Faults


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 5

Hydraulics

Hydraulics5-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Hydraulics 5-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 5Hydraulics


This section provides hydraulic system problem troubleshootinginformation including:

� a brief description of the TM4 applicator’s hydraulic system

� troubleshooting information

� procedures for repairing the system

If after trying all the suggestions in this section assistance is required insolving hydraulic system problems, call your Nordson representative.

Refer to the following sections of this manual for additional information onthe hydraulic system:

� Description, which includes pump specifications

� Installation, which gives procedures for installing the input air line

1. Introduction

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Manual 41-TM4-MA-01

See Figure 5-1. Two major assemblies make up the hydraulic system:an air-driven piston pump and a manifold. The pump assembly includesa hydraulic section, an air motor, and an actuator. The manifoldassembly, which is indirectly heated by the tank, includes an aluminummanifold with hose ports, a filter assembly, a drain valve, and a pressurerelief valve.

4131138A

1

2

3

4

Fig. 5-1 Key Parts of the Hydraulic System(shown with a typical tank and manifold)

1. Air motor2. Pump hydraulic section

3. Manifold4. Actuator

2. Overview of theHydraulic System

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237 500EIssued 9/05

Manual 41-TM4-MA-01

These troubleshooting tables describe the kinds of adhesive applicationand pump-operation problems you may encounter and provide correctiveactions for handling those problems. When necessary, the tables refer tomore detailed diagnostic procedures. Refer to the appropriatetroubleshooting table for the type of problem you are experiencing:

� Adhesive Application Defective� Pump Not Working

Problem Possible Cause Corrective Action

1. Little or no adhesive output Applicator not at operatingtemperature

Wait for the time delay to expire andthe READY light to turn on.

Adhesive level too low Keep the tank at least half full ofadhesive. Refer to Filling the TankWith Adhesive in Operation, Section 4.

Adhesive too cold Check the tank, hose, and guntemperature setpoints and adjustthem as necessary.

Clogged manifold filter Clean the manifold filter. Refer toCleaning a Manifold Filter inMaintenance, Section 8.

Blockage in manifold Check for blockage. Refer toManifold Blockage Check given laterin this section.

Cold hose-to-applicator orhose-to-gun joints

Insulate the joints.

Guns not operating properly Refer to the gun manual totroubleshoot gun problems.

Manifold heat exchanger (if applicable) blocked

Check manifold heat exchanger forblockage. Clean if necessary.

2. Wavy beads Adhesive too cold Check the tank, hose, and guntemperature setpoints and adjust asnecessary.

Ambient temperature below freezingor guns subject to draft

Protect the applicator and guns fromfreezing temperature conditions anddrafts.

Nozzles too far from product Position the guns so the nozzles areno more than 13 mm (0.5 in.) fromthe product.


3. Troubleshooting Tables

Adhesive Application Defective

Hydraulics5-4


237 500EIssued 9/05

Manual 41-TM4-MA-01


3. Excessive adhesive atbeginning of bead

Hose and gun temperature setpointsnot properly balanced (for example,hose temperature too low and guntemperature too high)

Check the tank, hose, and guntemperature setpoints and adjustthem as necessary.

Nozzles too far from product Position the guns so the nozzles areno more than 13 mm (0.5 in.) fromthe product.

Filter partially clogged (manifoldfilter, inline filter, etc.)

Clean the filter or filters. To clean themanifold filter, refer to the Cleaning aManifold Filter in Maintenance,Section 8.

4. Adhesive stringing Nozzle too far from product Position the guns so the nozzles areno more than 13 mm (0.5 in.) fromthe product.

Adhesive too viscous Increase the hose or gun temperaturesetpoint or change to a compatiblelower-viscosity adhesive.


Adhesive too old Do not exceed the recommended potlife of the adhesive.

5. Bead lays on product inconcentric circles


Adhesive too viscous Change to a compatiblelower-viscosity adhesive.

6. Adhesive bouncing orsplashing from product

Nozzle orifice too small forapplication, resulting in need for toomuch hydraulic pressure

Change to a nozzle with a largerorifice and decrease hydraulicpressure.

Adhesive too hot Check the tank, hose, and guntemperature setpoints and adjustthem as necessary.

Adhesive not viscous enough Change to a compatiblehigher-viscosity adhesive.


Adhesive ApplicationDefective (contd)

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Problem Corrective ActionPossible Cause

7. Adhesive not penetratingproduct


Special coating on product Increase the temperature setpointsslightly or change adhesives.

Not enough adhesive being applied Change to a higher-flow nozzle,increase operating temperaturesetpoints slightly, or increasehydraulic pressure.

Adhesive too viscous Change to a compatiblelower-viscosity adhesive.

8. Gun spitting intermittently,causing erratic beadplacement

Adhesive level too low (pumpingesting air)

Keep the tank at least half full ofadhesive. Refer to Filling the Tankwith Adhesive in Operation, Section 4.

Because of product form (pellets, forexample) and high viscosity,adhesive bridging as it melts and airnot migrating to surface before beingingested into pump

Change to a compatiblelower-viscosity adhesive or to anadhesive form that is less likely tobridge, or raise the tank operatingtemperature setpoint to make theadhesive less viscous.

Product wet Preheat the product.

9. Adhesive gelling Changing to an adhesiveincompatible with the previousadhesive without first cleaning thesystem

Clean the system. Refer to Flushingthe System in Maintenance, Section 8.

Adhesive heated for too long Clean the system. Flushing theSystem in Maintenance, Section 8. Do not exceed therecommended adhesive pot life.

Adhesive overheated Clean the system. Flushing theSystem in Maintenance, Section 8. Decrease the operatingtemperature setpoints.

10. Adhesive drooling from gun Guns not shutting off properly Refer to the gun manual totroubleshoot gun problems.


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11. Cartons popping open (goodadhesive penetration, butadhesive bond separates

Adhesive not cooling fast enough Decrease hydraulic pressure todecrease the bead size. Decreasethe operating temperature setpointsslightly. Reduce the line speedthrough the compression section.Increase the length of thecompression section. Cool theproduct. Use a stitched bead pattern.

Adhesive open time too long Change to an adhesive with a shorteropen time.

Adhesive deposit shearing Check for twisting or other adversemovement during the compressionsection.

12. Cartons popping open (pooradhesive transfer andpenetration on marriedproduct)

Adhesive cooling too fast Increase the hydraulic pressure toincrease the bead size. Increase theoperating temperature setpointsslightly. Decrease the distancebetween the nozzles and the product.Decrease the distance between beadapplication and bead compression.Heat the product. Use a higher-flownozzle. Avoid stitched bead patterns.Protect the gun or bead from cold air.

13. Adhesive fuming or smoking Adhesive in tank too hot Check the tank operating temperaturesetpoint and adjust it as necessary.

Unstable adhesive Keep the lid closed when theapplicatoris operating. Change to amore stable adhesive.

14. Adhesive charring in tank Adhesive in tank too hot Check the tank operating temperaturesetpoint and adjust it as necessary.

Tank overheating Refer to Solving Zone Faults inControl, Section 6.

Adhesive level too low Keep the tank at least half full ofadhesive. Refer to Filling the TankWith Adhesive in Operation, Section 4.

Adhesive oxidizing in tank Keep the lid closed when theapplicator is operating. Change to amore stable adhesive.

Adhesive ApplicationDefective (contd)

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237 500EIssued 9/05

Manual 41-TM4-MA-01


1. Pump stroking too fast orerratically (inconsistent orno adhesive output)(See Note A)

Adhesive level too low Check the adhesive level. Add adhesiveif necessary. Refer to Filling the Tankwith Adhesive in Operation, Section 4.

Adhesive not melting as fast as it isbeing consumed

Increase the tank temperature setpoint.

Pump siphon ball seat missing orforeign material lodged between balland seat

Check the siphon ball seat. Refer toPump Siphon Ball Seat Check givenlater in this section.

Broken crossover tube O-ring Replace the crossover tube O-ring.Refer to Servicing the Pump given laterin this section.

Pressure relief valve defective Replace the pressure relief valve.

2. Pump not stroking (noadhesive output)

No input air pressure to the pump Check the input air pressure. Adjust ifnecessary.

Adhesive too cold in tank, hose, orguns

Increase the temperature setpoints andmake sure the time delay has expiredand the READY light is on.

Pump solenoid valve failed Check the solenoid valve. Refer toPump Solenoid Valve Check given laterin this section.

Clogged manifold filter or blockage inmanifold

Check the manifold and filter forblockage. Refer to Manifold BlockageCheck given later in this section.

Foreign material or gelled adhesiveblocking pump intake

Clean the tank. Refer to Flushing theSystem in Maintenance, Section 8.

Pump leaking air Locate the leak and replace damagedpiston cups, seals, or O-rings. Refer toPump Air Section Check given later inthis section.

NOTE A: The pump should make two regularly spaced exhaust sounds. If you hear two exhaust soundsfollowed by a pause, the pump is stroking erratically (the hydraulic shaft is moving faster in onedirection than the other).


Pump Not Working

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2. Pump not stroking (noadhesive output) (contd.)

Pump actuator malfunctioning for oneor more of the following reasons:

Check for a malfunctioning actuator.Refer to Actuator Check given later inthis section.

� air valve binding Disassemble and clean the air valve.Refer to Cleaning or Replacing the AirValve given later in this section.

� shifter fork slipped out of position Check the position of the fork andreposition if necessary. Refer toReplacing the Shifter Fork given later inthis section.

� shifter fork installed upside down Check the position of the fork andreposition if necessary. The fork shouldbe positioned with the side stamped UPfacing the air motor. Refer to Replacingthe Shifter Fork given later in thissection.

� shifter fork bent or damaged Replace the fork. Refer to Replacingthe Shifter Fork.

� magnet assembly dirty ordamaged

Clean or replace the magnet assembly.Refer to Magnet Assembly Removal andPump Component Cleaning.

� bumper assembly dirty ordamaged

Replace the bumper assembly.

� shifter fork magnet loose Replace the fork. Refer to Replacingthe Shifter Fork.

Pump Not Working (contd)

4103143

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Use these procedures as directed in the Pump Not Workingtroubleshooting table to further diagnose hydraulic system problems.

WARNING: System or material is pressurized. Releasepressure. Failure to observe may result in serious burns.

1. Reduce pump air pressure to 0.

2. Trigger all guns to relieve the residual system pressure.

Fig. 5-2 Reducing Air Pressure

3. Open the manifold drain valve.

4103144

A B C

Fig. 5-3 Different Manifold Drain Valves

Troubleshooting TestProcedures

Relieving System HydraulicPressure

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Manifold Blockage Check

1. Reduce the pump air pressure to 0.

2. Place a container under the manifold drain valve or valves.

3. Standard manifold filter: Open the drain valve.

Reverse-flush manifold filter: With the manifold filter in the RUNposition, open the right-side drain valve.

4. Remove the filter.

5. Slowly increase the pump air pressure and check to see if the pumpis stroking.

Pump Action

Does not stroke There is no blockage in the manifold andthe problem is in the pump. Close the drainvalve and return to the troubleshootingtable.

Strokes The manifold may be blocked. Clean orreplace the manifold filter. Refer toCleaning a Manifold Filter in Maintenance,Section 8.

Pump Siphon Ball Seat Check




3. Turn the pump air pressure regulator clockwise to increase pump airpressure and allow the pump to cycle rapidly for several seconds.This should remove any particles lodged between the siphon ball andits seat.

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237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Check to see if the pump is stroking normally.

Pump strokes Action

Normally Resume operation.

Erratically Remove and clean the pump. Refer toServicing the Pump.

Actuator Check

1. Remove the pump cover.

2. Grasp the top of the air valve with a long-nosed pliers and alternatelypress down and pull up on the valve to manually shift it.

� If the air valve does not move, refer to Pump actuatormalfunctioning for one or more of the following reasons, underPump not stroking in the Pump Not Working troubleshooting table.

� If the pump strokes when the air valve is shifted but will not strokeon its own, refer to Pump actuator malfunctioning for one or moreof the following reasons, under Pump not stroking in the PumpNot Working troubleshooting table.

� If the pump does not stroke, then the pump is leaking air or isjammed. Refer to Pump Air Section Check to check for air leaks.If an air leak is not the problem, then the pump is jammed. Referto Servicing the Pump to clean the pump air or hydraulic section.

Hydraulics5-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

Pump Solenoid Valve Check

1. Be sure the applicator is turned on and the READY status light on.



4. Disconnect the air input line from the pump.

5. Slowly increase pump air pressure.

6. Check the disconnected air input line for air flow.

Condition Action

Air flows The solenoid valve is functioning properly.Reduce the air pressure to 0, reconnect theair input line, and return to the Pump NotWorking troubleshooting table.

Air does not flow Go to the next step.

Testing Solenoid Voltage

Test the solenoid voltage using the following procedure.

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.

CAUTION: Take care when removing the electrical enclosurelid. Lifting the lid more than 76 mm (3 in.) from the applicatorcan disconnect electrical wiring.

1. Open the electrical enclosure. Refer to Opening the ElectricalEnclosure in the Installation, Section 3.

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237 500EIssued 9/05

Manual 41-TM4-MA-01

4107028

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 5-4 Opening the Electrical Enclosure

2. Locate connector J9 on the main control board.

3. Measure the voltage at positions 1 and 2 while the pump is enabled.(Verify that the pump is enabled by observing that the pump ON/OFFswitch is illuminated.)

NOTE: The voltage at the solenoid is polarity insensitive. Yourreadings may indicate a negative (–) reading or a positive (+) readingdepending on which meter probe is connected to which pin of J9.

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237 500EIssued 9/05

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Voltage Measurement Action

22.8–25.2 V DC Replace the solenoid. Refer to theprocedure Replacing the Solenoid Valve inthis section.

Greater than 25.2 V DCor less than 22.8 V DC

Replace the main control board. Refer tothe procedure Replacing the Main ControlBoard in Control, Section 6.

4107029

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ+

Fig. 5-5 Measuring Voltage of Connector J9 on Main Control Board

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Pump Air Section Check



3. See Figure 5-6. Slowly increase pump air pressure and check for airleaks

� at the actuator’s top or bottom exhaust port

� at the top of the hydraulic shaft

� between the air motor cylinder head and the air cylinder orbetween the air cylinder and the pump mount

4131137A

3

2

1

Fig. 5-6 Checking for Pump Air Section Leaks

1. Between air motor cylinder headand air cylinder or betweenair cylinder and pump mount

2. Top of hydraulic shaft3. Top and bottom exhaust ports

4130039

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Manual 41-TM4-MA-01

4. Take appropriate action based on the source of the leak.

Air is Action

Not leaking Replace the pump cover and return to thePump Not Working troubleshooting table.

Leaking from theactuator’s top or bottomexhaust port

Replace the piston cups and washers.Refer to the appropriate procedures inServicing the Pump.

Leaking around theshaft at the bottom ofthe air motor

Replace the U-cup. Refer to theappropriate procedures in Servicing thePump.

Leaking between the airmotor cylinder head andthe air cylinder orbetween the air cylinderand the pump mount

Replace the air cylinder and pump mountO-rings. Refer to the appropriateprocedures in Servicing the Pump.

Use these procedures to service and repair the piston pump. Refer tothe Parts section for the part numbers of any components that need to bereplaced. You can also use the pump parts list illustration as a guide toperform the following procedures.

Use these procedures to disassemble the pump, to clean or replacepump components, and to reassemble the pump.

Preparation for Pump Removal

1. Make sure the applicator is at operating temperature.

2. Turn the POWER switch off.

Fig. 5-7 Turning Off Power

4. Pump Repair Procedures

Servicing the Pump

Hydraulics 5-17


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Manual 41-TM4-MA-01


4. Open the drain valve or trigger the guns to relieve hydraulic pressure.Refer to Relieving Hydraulic Pressure given earlier in this section.


6. Disconnect the air input line from the actuator.

Pump Removal

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

1. If you have not already done so, complete Preparation for PumpRemoval.

2. Remove the screws and washers that secure the pump to theapplicator.

3. Make sure the adhesive around the pump is melted (the READY lightshould be on).

4. Rotate the pump slightly to break the suction and pull the pumpstraight up to remove it. Lay the pump on a clean, flat work surface.

NOTE: To install the pump and actuator assembly, go to PumpInstallation.

Hydraulics5-18


237 500EIssued 9/05

Manual 41-TM4-MA-01

To replace the air valve, it is necessary to remove the actuator and aircylinder assembly from the pump body. These components are part ofthe upper pump assembly.

Actuator and Air Cylinder Assembly Removal

1. Remove the four hex-head cap screws and washers from the aircylinder head.

4131113A

1

2

4

5

3

Fig. 5-8 Removing the Actuator and Air Cylinder

1. Air cylinder head2. Air cylinder head O-ring3. Actuator and air cylinder assembly

4. Can5. Hex-head cap screw and lock

washer

2. Remove the air cylinder head from the actuator and air cylinderassembly.

3. Check the O-ring on the air cylinder head for damage. Replace ifnecessary.

4. Remove the actuator and air cylinder assembly from the pump mountby lifting up on the assembly and pulling the can of the air cylinderaway from the fork.

Replacing the Air Valve

Hydraulics 5-19


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Manual 41-TM4-MA-01

Magnet Assembly Removal

1. Remove the two socket-head screws securing the can to the actuator.

4131120A

Fig. 5-9 Removing the Can from the Magnet Assembly

2. Pull the can straight off of the actuator.

3. Pull the magnet assembly away from the upper detent.

4. Place a suitable tool into the small hole at the top of the magnetassembly to prevent it from rotating.

4131118A

Fig. 5-10 Removing the Magnet Assembly from the Actuator

4131119A

12

3

5

6

9

8

7

4

Hydraulics5-20


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Manual 41-TM4-MA-01

5. Loosen the valve spool nut from the top of the valve assembly.

NOTE: When loosening the nut from the top of the valve assembly,the magnet assembly may loosen before the valve spool nut does. Ifthis occurs, simply unscrew the magnet assembly and set it aside.

6. Remove the valve spool nut and bumper assembly from the top of thevalve assembly.

7. Place a wrench on the flats of the valve spool to prevent it fromrotating.

8. Unscrew the magnet assembly and set it aside.

Valve Spool and Sleeve Removal

CAUTION: Stand the air manifold vertically to remove thespool. Failure to observe may result in equipment damage.

1. See Figure 5-11. Stand the air manifold vertically and carefully slidethe valve spool from the top of the assembly. Set the valve spoolaside on a clean cloth or towel.

2. Remove the two socket-head screws securing the upper detent to theair manifold.

3. Remove the upper detent and spring.

4. Remove the socket-head screws from the flange on the top of the airmanifold.

5. Press the sleeve out of the air manifold with a socket or similar objectagainst the bottom of the sleeve.

NOTE: The valve spool and sleeve are a matched set and cannot beexchanged with parts from another air valve assembly. If replacementis needed, they must both be replaced.

Fig. 5-11 Removing the Air Valve

1. Valve spool nut2. Bumper assembly3. Valve spool and sleeve assembly4. Flange5. Air manifold6. Spring7. Upper detent8. Magnet assembly9. Can

Hydraulics 5-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

6. Inspect the sleeve and spool for wear.

7. If the spool lands are nicked, gouged, deeply scratched, or corroded,replace the valve assembly. If they are not damaged, but coveredwith contaminants, clean the assembly and set it aside on a cleancloth or towel.

4131121A

1

2

3

Fig. 5-12 Air Valve Components

1. Spool lands2. Spool

3. Sleeve

NOTE: Do not to scrape the spool or sleeve. Clean them withmineral spirits or any non-chlorinated cleaning solvent and a softcloth. Do not use abrasives such as sandpaper or emery cloth. Donot round off the sharp edges of the spool lands.

8. Remove the O-rings from the sleeve.

9. Clean the sleeve and wipe the valve parts thoroughly with a cleancloth or rinse them with denatured alcohol.

Hydraulics5-22


237 500EIssued 9/05

Manual 41-TM4-MA-01

Valve Spool and Sleeve Installation

1. Install the upper detent. Fasten with screws and tighten to 1.82−2.27N�m (16−20 in.-lb).

2. Install the spring.

3. Remove the valve spool from the sleeve. The valve spool can fall outduring assembly and become damaged.

4. Apply O-ring lubricant to the new O-rings and install them on thesleeve.

NOTE: The top of the air manifold has two screw holes and thebottom has four screw holes.

5. Lie the flange over the sleeve and press the sleeve into the top of theair manifold.

6. Install the flange. Fasten with screws and tighten to 3−4 N�m (28−36in.-lb).

7. Apply one drop of oil to each spool land. Use only Nordson SPlubricating oil.

CAUTION: Carefully guide the spool into the sleeve. Do notapply pressure. Applying pressure to the valve spool candamage the valve assembly.

8. Position the air valve vertically and reassemble the valve spool intothe sleeve.

9. Check that the valve spool slides freely in the sleeve. If it does not,replace the valve assembly.

10. Check the bumper assembly for wear. Replace if necessary.

11. Place the bumper assembly on the top of the valve assembly andsecure it with the valve spool nut.

Hydraulics 5-23


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Manual 41-TM4-MA-01

Actuator and Air Cylinder Assembly Installation

1. Holding the valve spool in place, screw the threaded end of themagnet assembly into the valve spool until it seats.

2. Place a suitable tool into the small hole at the top of the magnetassembly to prevent it from rotating.

3. Holding the magnet assembly in place, tighten the valve spool nut.Tighten to 9−11 N�m (81−99 in.-lb).

4. Hold the bumper assembly against the flange and install the can.The cut-out side of the can should face the circular part of the airmanifold.

5. Secure the can in place with screws. Tighten to 3−4 N�m(28−36 in.-lb).

NOTE: Refer to Replacing the Piston Cups to remove the upperpiston cup before installing the actuator and air cylinder assemblyonto the pump. This prevents damage to the upper piston cup. Oncethe air cylinder and actuator are in place, return the upper piston cupand washer to the assembly.

6. Remove the upper piston cup, washer and nut.

7. Install the air cylinder and actuator assembly on the pump.

8. Install the upper piston cup, washer and nut.

9. With the valve spool end centered in the opening of the cylinder head,install the cylinder head. Secure with screws and tighten to 5−6 N�m(45−55 in.-lb).

This procedure must be performed with the actuator and air cylinderremoved. If the actuator and air cylinder assembly are still installed onthe pump, refer to Actuator and Air Cylinder Assembly Removal.

1. Check to be sure the fork is at the top of its stroke.

2. Place a wrench on the flats of the piston to prevent it from turning.

Replacing the Piston Cups

Hydraulics5-24


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Manual 41-TM4-MA-01

3. Loosen the nut above the piston cups and remove the two pistoncups, two piston cup washers, and the piston seal washer from thepiston.

4. Install one piston cup washer, one piston cup, and the piston sealwasher onto the piston in the proper order. The curved edge of thepiston cup should be pointing down.

4131116A

3

2

3

2

1

Fig. 5-13 Piston Cups, Piston Cup Washers, and Piston Seal Washer

1. Piston seal washer2. Piston cup

3. Piston cup washer

5. Carefully align the actuator and air cylinder assembly with the shifterfork and slide the assembly into place on the pump.

6. Install the remaining piston cup and piston cup washer onto thepiston. The curved edge of the piston cup should be pointing up.

7. With a wrench placed on the flats of the piston, install the nut, andtighten to 11.30−13.56 N�m (100−120 in.-lb).


Replacing the Piston Cups (contd)

Hydraulics 5-25


237 500EIssued 9/05

Manual 41-TM4-MA-01

The actuator and air cylinder assembly must be removed in order toreplace the shifter fork. If they are not already removed, refer to Actuatorand Air Cylinder Assembly Removal.

1. Make sure the shifter fork is in the lower half of its stroke.

4131115A

1

2

Fig. 5-14 Removing the Shifter Fork

1. Shifter fork 2. Clamping screw and washer

2. Remove the clamping screw and washer from the shifter fork.

3. Slide the fork toward the air motor and off the piston.

4. Slide the new shifter fork onto the piston until it sits on the shoulder.The side stamped UP must face the air motor.

5. Insert the screw and apply torque of 8-10 N�m (71−89 in.-lb).

6. Move the piston up or down until the shifter fork is in the center of thepump mount.

7. Replace the actuator and air cylinder assembly. Refer to Actuatorand Air Cylinder Assembly Installation.

Replacing the Shifter Fork

Hydraulics5-26


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Manual 41-TM4-MA-01

The actuator and air cylinder assembly and the shifter fork must beremoved in order to access the pump body. If they are not alreadyremoved, refer to Actuator and Air Cylinder Assembly Installation andReplacing the Shifter Fork.

1. Straighten the lock tab on the tab lock washer.

411117A

Fig. 5-15 Removing the Lock Tab Nut and Washer

2. Loosen the locking nut and slide the nut and the tab lock washeraway from the pump body.

3. Pull the pump mount off of the pump body.

4. Set the locking nut and the tab lock washer aside.

5. Inspect the U-cup seal and the O-ring and replace if necessary.

4103255

1

2

3

Fig. 5-16 Pump Mount Components

1. O-ring2. U-cup seal

3. Retaining ring

Cleaning or Repairing thePump Body

4131148A

1

2

3

4

Hydraulics 5-27


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Manual 41-TM4-MA-01

Hydraulic Piston Components Removal

CAUTION: Risk of equipment damage. Do not scratch thehydraulic piston or the inside of the pump body. Scratches cancause the pump to leak.

1. Use a retaining ring tool to remove the retaining ring at the top of thepump body.

2. Manually stroke the hydraulic piston up and down to loosen thewasher and pump seal.

3. Remove the seal and washer. Inspect the seal and replace ifnecessary.

4. Secure the pump body by placing an adjustable wrench on thewrench slots of the pump body or by placing the pump body into avise.

5. Remove the crossover tube. Inspect the O-ring and backup ring.Replace if necessary.

Fig. 5-17 Hydraulic ShaftComponents

1. Retaining ring2. Washer3. Pump seal4. Hydraulic piston

4103181

1 2

3

4

Fig. 5-18 Crossover Tube, O-Ring, and Backup Ring

1. Crossover tube2. O-ring

3. Backup ring4. Pump body

Hydraulics5-28


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Manual 41-TM4-MA-01

Siphon Ball and Pressure Ball Components Removal

1. Unscrew the siphon ball seat from the pump body.

2. Pull the siphon ball seat and its cage from the pump body.

4103198

1

2

3

Fig. 5-19 Siphon Ball Cage, Siphon Ball, and Siphon Ball Seat

1. Siphon ball cage2. Siphon ball

3. Siphon ball seat

3. Pull the piston out of the pump body.

4. Remove the pressure ball seat and the pressure ball from the pistonby unscrewing the seat from the piston.

4130113

1

2

3

Fig. 5-20 Pressure Ball Seat and Pressure Ball

1. Hydraulic piston2. Pressure ball

3. Pressure ball seat

Hydraulics 5-29


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. Inspect both the pressure and siphon balls and their seats for wear ordamage. Replace if necessary.

WARNING: Do not heat Type R solvent with an open flame orin an unregulated heating device. Do not heat Type R solventabove 246 �C (475 �F).

6. Heat a container of Type R solvent to the melting temperature of theadhesive being used. Clean all components of the pump.

Cleaning Pump Components

If necessary, follow this procedure to clean the pump components.

WARNING: Risk of fire or explosion. Do not heat NordsonType-R cleaning fluid above 246 °C (475 °F). Do not heatcleaning fluid with an open flame or in an unregulated heatingdevice.

1. Use one of the following methods to clean the components:

� Place the components, except for O-rings, in a container ofType-R cleaning fluid and heat the fluid above the melting point ofthe adhesive.

� Use a flameless heat gun to heat the components, except forO-rings.

2. Scrub the components with a fine-bristled brush and wipe them with aclean, dry cloth.

4131122A

1

2

Hydraulics5-30


237 500EIssued 9/05

Manual 41-TM4-MA-01

Siphon Ball and Pressure Ball Components Installation

1. Insert the pressure ball into the plunger end of the piston.

2. Apply Loctite to the threads of the pressure ball seat and screw it onto the piston. Tighten the seat to 4.07−6.78 N�m (3−5 ft.-lb).

3. Insert the piston into the pump body.

4. Place the siphon ball onto the siphon ball seat.

5. Attach the siphon ball cage to the seat. If the cage does not fitsecurely, bend the legs of the cage slightly inward by hand.

6. Apply Loctite to the threads of the seat and screw it into the pumpbody.

Pump Components Installation

1. Put the backup ring and O-ring on the crossover tube. Apply NeverSeez lubricant to the threads of the crossover tube and screw it intothe pump body.

NOTE: All adhesives must be removed from the seal cavity and theretaining-ring groove in the pump body before the seal is installed.

2. Apply O-ring lubricant to the pump seal. Pull the piston up throughthe top of the pump body.

3. Put the pump seal (with the groove facing the pump body) on thepiston then put the washer on the piston.

4. Slide the piston down to help guide the seal and washer into place inthe pump body.

5. Use a retaining-ring tool to snap the retaining ring into place.

6. If the U-cup is being replaced, insert the U-cup into the upper face ofthe pump mount with the groove facing up and install a new retainingring to hold the U-cup in place.

Fig. 5-21 Pump Body andHydraulic Shaft

1. Pump body2. Hydraulic piston

Hydraulics 5-31


237 500EIssued 9/05

Manual 41-TM4-MA-01

7. Place the O-ring over the air cylinder mount on the upper surface ofthe pump mount.

8. Guide the upper part of the pump body and the piston through thebottom hole in the pump mount.

NOTE: The piston must be inserted through the tab lock washer andthe locking nut before it passes through the top hole in the mount.

9. Secure the pump body to the pump mount with the locking nut. Donot tighten. There is a “stop” in the bottom of the pump bracket.Rotate the pump body clockwise until it rests against the “stop.”

10. Install the shifter fork onto the piston. Refer to Replacing the ShifterFork.

11. Install one piston cup washer, one piston cup, and the piston sealwasher onto the piston in the proper order. The curved edge of thepiston cup should be pointing down. Refer to Replacing thePiston Cups.

NOTE: To prevent damage to the upper piston cup, do not install theupper piston cup and washer before installing the air cylinder andactuator assembly on the pump.

12. Install the actuator and air cylinder assembly onto the pump. Refer toActuator and Air Cylinder Assembly Reassembly.

13. Install the upper piston cup, washer and nut.


15. Install the pump in the applicatorand resume normal operation.

Hydraulics5-32


237 500EIssued 9/05

Manual 41-TM4-MA-01

Pump Installation

NOTE: If you are replacing an old pump with a new pump and your oldpump has a pump cover bracket, remove the bracket and install it on thenew pump.

1. Make sure the pump pan is positioned correctly.

2. Lower the pump into the applicator until the crossover tube seats inthe manifold.

3. Secure the pump to the applicator with the screws and washers youremoved earlier. Tighten to 12.20−13.56 N�m (9−10 ft-lb).

4. Connect the air input line to the actuator.

System Restoration

1. Replace the pump cover.

2. Place the circuit breaker in the ON position and wait for the READYlight to turn on.




5. Increase pump air pressure until clean adhesive flows from the drainvalve. This will purge the system of trapped air.


7. Close the drain valve.

8. Return the air pressure to the normal operating setting and resumeoperation.

Hydraulics 5-33


237 500EIssued 9/05

Manual 41-TM4-MA-01

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 dash in this column (–) means the part cannot be orderedseparately.

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 perapplicator, assembly, or subassembly. The code AR (As Required) isused if the part number is a bulk item ordered in quantities or if thequantity per assembly 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. Illustrated Parts List

Using the Illustrated Parts List

Hydraulics5-34


237 500EIssued 9/05

Manual 41-TM4-MA-01

The Uptime pack for the SP30 14:1 piston pump gives you parts thatshould be replaced as a part of routine maintenance.


— 164 601 Uptime Pack 1

1 940 111 � O-ring, Viton, 0.301 in. Internal Diameter x0.070 in.

4

2 940 332 � O-ring, Viton, 2.00 in. x 2.125 in. x 0.063 in. 2

3 984 092 � Nut, Hex Head, M6, Steel 1

4 983 409 � Washer, Lock, M, Split, M6, Steel 4

5 163 039 � Cup, Piston, SP30 2

6 986 331 � Retaining Ring, Internal, 100, Push-on 1

7 952 100 � Cup, U, Viton 1

8 986 602 � Retaining Ring, Internal, 81, Inverted 1

9 273 138 � Washer, 0.799 in. Outside Diameter, 0.543 in.Internal Diameter, 0.034 in.

1

10 273 139 � Seal, Pump 1

11 940 133 � O-ring, Viton, 0.426 in. InternalDiameter x 0.070 in.

1

14:1 Piston Pump Uptime Pack

Hydraulics 5-35


237 500EIssued 9/05

Manual 41-TM4-MA-01

4130141

8

9

10

3

5

2

6

7

2

1

4

11

Fig. 5-22 14:1 Piston Pump Uptime Pack

Hydraulics5-36


237 500EIssued 9/05

Manual 41-TM4-MA-01


— 161 424 Pump, piston, 14:1, SP-30

1 1005247 � Bracket, cover, pump, SP, 14:1, 6:1 1

2 982 059 � Screw, socket-head, M4 x 8 2

3 983 402 � Washer, flat, narrow, M4 2

4 983 403 � Washer, lock, split, M4 2

5 1006027 � Valve assembly, SP 1

6 900 493 � Lubricant, Parker, hi-temp AR

7 333 560 � Spring, wave, SP pump 1

8 155 057 � Detent, upper, SP 1

9 166 880 � Fork, magnetic, assembly 1

10 164 606 � Actuator, magnetic, assembly, SP 1

11 155 068 � Can, SP 1

12 155 067 � Detent, lower, SP 1

13 986 714 � Retaining ring, internal, 156, bowed 1

14 155 059 � Piston pump, 14:1, SP 1

15 985 302 � Pin, roll, 0.125 x 0.500 in. 1

16 900 000 � Ball, 440 stainless, 0.375 in., 50 1

17 503 709 � Seat, ball, pressure 1

18 900 470 � Adhesive, threadlocking, Loctite 272 AR

19 503 696 � Cage, ball, siphon 1

20 288 031 � Tube, crossover, pump 1

21 900 344 � Lubricant, Never Seez, 8 oz can AR

22 954 013 � Backup ring, single, 7/16 x 9/16 in. 1

23 940 133 � O-ring, Viton, 0.426 ID x 0.070 in. wide 1

24 503 695 � Seat, ball, siphon 1

25 900 001 � Ball, 440 stainless, 0.500 in., 50 1

26 288 028 � Body, pump, hydraulic 1

27 973 402 � Plug, pipe, socket, flush, 1/8 in. 1

28 288 030 � Mount, pump, machined, 6:1 and 14:1 1

29 983 184 � Washer, lock, bearing, W-08, 1

30 984 545 � Nut, lock, bearing, PN-08 1

31 982 135 � Screw, hex-head, cap, M6 x 30 1

32 983 410 � Washer, flat, narrow, M6 1

33 940 332 � O-ring, Viton, 2.000 x 2.125 x 0.063 in. 2

34 952 100 � U-cup, Viton 1

35 986 331 � Retaining ring, internal, 100, push-on 1

36 309 822 � Manifold, air, SP 1

37 984 092 � Nut, hex, lock, torque, M6, class 10 1

38 333 137 � Head, cylinder, SP, machined 1

39 983 445 � Washer, piston seal, SP 1

40 983 446 � Washer, piston cup, SP 2

41 163 039 � Cup, piston, SP 2

14:1 Piston Pump Parts List

Hydraulics 5-37


237 500EIssued 9/05

Manual 41-TM4-MA-01


42 986 602 � Retaining ring, internal, inverted 1

43 273 138 � Washer, 0.799 OD x 0.543 ID x 0.034 in. thick 1

44 273 139 � Seal, pump 1

45 982 147 � Screw, hex-head, cap, M6 x 120 4

46 983 409 � Washer, lock, split, M6 4

47 982 028 � Screw, socket-head, M5 x 20 4

48 211 228 � SP lubricating oil AR

49 982 308 � Screw, pan-head, M4 x 10 2

50 940 181 � O-ring, Viton 4

51 984 090 � Hex, nut lock 1

52 1014 650 � Bumper assembly 1

AR: As Required

4601190A

38 45

46

42

43

44

27

26

20 21

22 23

3132

9

14

15

17 1816

19

25

24

28

34 6

37

40

41

39

40

41

33

35

30

29

13

12

11

47

10

8

7

493

4

1

6

47

5

36

48

33

2

51

50

52

Fig. 5-23 14:1 Piston Pump Parts

Hydraulics5-38


237 500EIssued 9/05

Manual 41-TM4-MA-01


— 165 871 Regulator/filter assembly, 90 psi (4 hose applicators) —

— 165 872 Regulator/filter assembly, 90 psi (6 hose applicators) —

1 165 735 � Regulator, filter, air, 1/4 NPT 1

2 973 490 � Nipple, brass, 40, 1/4 in., 2.50 in. (4 hose applicators) 1

2 973 491 � Nipple, brass, 40, 1/4 in., 5.00 in. (6 hose applicators) 1

3 901 258 � Gauge, air, 1/8 NPT, 90 psi 1

4 165 870 Service kit, filter element 1

5 165 878 Service kit, filter bowl 1

4103139

3

1

4

5

2

Fig. 5-24 Air Pressure Regulator Parts

Air Pressure Regulator PartsList


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 6

Control

Control6-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Control 6-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 6Control


This section covers the following topics:

� overview of the control system� troubleshooting information� procedures for repairing the system

This section includes procedures for replacing the power board, controlboard, display board, operator panel, and control assembly. Instead ofreplacing a single circuit board or the operator panel, you may decide tosave time by replacing the entire control assembly.

Refer to the following sections of this manual for additional information onthe control system:

� Description, which gives an overview of each of the functional areasof the control-end frame.

� Installation, which gives procedures for installing output contacts andmain power.

� Operation, which gives procedures to help you customize controlsystem settings for your specific needs.

� Wiring Diagrams and Schematics, which includes the TM4 applicatorwiring diagrams and schematics.

1. Introduction

Control6-2


237 500EIssued 9/05

Manual 41-TM4-MA-01

The Vista control system is made up of the following major componentsthat are connected by a wire harness and ribbon strip:

� power board� control board� display board� control-end frame� operator panel� I/O board is an option (not shown in Figure 6-1)

4130076

1

+

1

2

3

45

Fig. 6-1 Vista Control System

1. Power board2. Control board3. Display board

4. Control-end frame5. Membrane panel

2. Overview of the ControlSystem

Control 6-3


237 500EIssued 9/05

Manual 41-TM4-MA-01

If your applicator does not power on, use the troubleshooting table givenbelow.

WARNING: Risk of equipment damage, personal injury, ordeath. Some troubleshooting procedures require you toperform work inside the electrical enclosure with the power on.Follow electrical safety procedures and observe all high-voltageindicators.


Displays do not illuminate

or

displays illuminate butapplicator will not power onand no faults are displayed

No input power Make sure the power is turned on atyour branch circuit disconnect switchand that your power supply is supplyingthe proper voltage to the unit. Checkthe voltage at TB1 on the power board.If necessary, check your electricalconnections at TB1. Refer toConnecting Electrical Service inInstallation, Section 3.

Defective POWER switch Check the POWER switch. Refer toChecking the POWER Switch inTroubleshooting Procedures.

Blown fuse or fuses Use an ohmmeter to check fuses F9 andF10 on the power board. Replace blownfuses.

Contactor K1 on power board notengaging

While pressing the unit’s HEATERS keyon and off, listen for the K1 contactor toengage. You can also open theapplicator and visually examine thecontactor to see if it engages. SeeFigure 6-2 for the location of K1 on thepower board. If K1 is not engaging,replace the power board. Refer toReplacing the Control Board orReplacing the Control Assembly givenlater in this section.

Power board not properly connectedto control board

Make sure the power board is properlyconnected to the control board at XP1.The pins from the control board shouldextend through XP1 on the power board.

Defective power board or controlboard

Replace the control assembly. Refer toReplacing the Control Board orReplacing the Control Assembly givenlater in this section.

Applicator Not Powering On

Control6-4


237 500EIssued 9/05

Manual 41-TM4-MA-01

4131111A

TB1

L1 L2 L3 NJ2

TB2123456

J4

X2

X1

XS2 XS1J9

Q17

X3

X4

XP1

XS4XS3

X3H

XS2H

XS1H

X2H

X2C

J2C

J1C

X1C

XS4A XS4B XS4C

XS3A XS3B XS3C XS3D

XS2A XS2B

XS1AL1

L2

L3

1 3

4

X1H

2

XP6

XP4A

XP1

XP5

XP3

XP2

K1

Fig. 6-2 Location of Connectors on Boards in the Applicator

1. Power board2. Control board

3. 5/6 hose/gun board 4. Contactor board

Applicator Not Powering On (contd)

Control 6-5


237 500EIssued 9/05

Manual 41-TM4-MA-01

When a warning condition occurs, the melter continues to functionnormally. When a fault occurs, the red FAULT light turns on, the meltershuts down, and the selector display, in combination with the INTERNAL,HOSE, or GUN light, shows a number that represents the problem zone.Refer to Table 6-1 to determine which zone is represented in the selectordisplay. Refer to Table 6-2 to troubleshoot warnings or faults.

NOTE: Each heated component (each hose, each gun, the grid, and thetank) is referred to as a zone.

610400028

2

1

3

4

5

Fig. 6-3 Fault Indicators

1. FAULT light2. Selector display3. Multipurpose display

4. Actual-temperature display5. INTERNAL, HOSE, and GUN

lights

Table 6-1 Determining the Affected Zone

ZoneNumber inSelectorDisplay

(See Note A)

Affected Zone

INTERNALLight On

HOSELight On

GUNLight On

1 Tank Hose 1 Gun 1

2 Grid Hose 2 Gun 2

3 Hose 3 Gun 3

4 Hose 4 Gun 4

5 Hose 5 Gun 5

6 Hose 6 Gun 6

NOTE A: For example, if the Selector display shows the number 3 andthe GUN light is on, then the affected zone is gun 3.

Control System Indicating aWarning or Fault

Control6-6


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 6-2 Determining the Warnings and Faults

Warning orFault

FAULTLight Status

SelectorDisplay Status

MultipurposeDisplay Status

Cause of Warning or Fault Corrective Action

Out-of-band warning

Off Shows zonenumber (referto Table 6-1)

Shows thesetpointtemperature ofthe affectedzone

The actualtemperature of theindicated zone isout-of-band. See Note B.

Wait to see if thetemperature stabilizesat the setpoint. Youmay want to change theout-of-band temperaturesetpoints.

Under-temperature warning

Off Shows zonenumber (referto Table 6-1)

Flashes UT

(See Note B)

The indicated zone’sactual temperature ismore than19.5 �C (35 �F)below the setpointtemperature.

Refer toTroubleshooting Under-temperature Conditionsunder TroubleshootingProcedures.

Over-temperature fault

On Shows zonenumber (referto Table 6-1)

Flashes OT

(See Note B)

A zone’s actualtemperature hasreached theover-temperaturesetpoint entered inFeature 3. Thedefault setting is218 �C (425 �F).

Refer toTroubleshooting Over-temperature Conditionsunder TroubleshootingProcedures.

RTD fault On Shows zonenumber (referto Table 6-1)

Flashes RTD

(See Note B)

The RTD or RTDcircuit of the indicatedzone is open orshorted.

Refer to Checking anRTD or RTD Circuitunder TroubleshootingProcedures.

Fault-codefault

On Shows theletter F

Shows thenumber 2

The power boardscrews are loose, causing a faultyground connection.

Tighten the power boardscrews.

NOTE A: If the melter is in scan mode when an out-of-band temperature warning occurs, the control system willstop scanning and freeze up the zone that is out-of-band. Press the MONITOR/SCAN key to resumescanning.

B: You can choose the degree to which a zone’s temperature may deviate from its temperature setpoint(Features 5−19) and still stay within the temperature band setpoints. You should base your out-of-bandtemperature setpoints on your adhesive application requirements. Refer to System ProgrammingProcedures in Installation, Section 3. to program out-of-band temperature setpoints.Procedures in Installation, Section 3. to program out-of-band temperature setpoints.

C: An under-temperature condition is logged into the warning log as an out-of-band warning and causesthe warning output contact to open. It is also logged into the fault log, but it is not a fault condition.

D: Refer to Programming Temperature Settings in Section 4, Setup, to program over-temperaturesetpoints.

E: If the RTD is open, the actual-temperature display will show 260 �C (500 �F). If the RTD is shorted, theactual-temperature display will show 0 �C (0 �F). When the control system detects an RTD problem, itactual temperature display will show 0 C (0 F). When the control system detects an RTD problem, itlogs a warning in the warning log, opens the warning output contact, and starts a 2-minute countdown.If the RTD problem disappears before the 2-minute countdown ends, the warning disappears and thecountdown stops. If the RTD problem still exists after the 2-minute countdown ends, the control systemlogs a fault in the fault log, opens the fault output contact, and shuts the the melter down. Nordsonoffers two test plugs that simplifies troubleshooting the RTD faults. These test plugs help you quicklydetermine whether there is a component RTD problem or a control system problem. Refer to OptionalAccessories in Section 12, Parts, for the kit part number.

Control System Indicating aWarning or Fault (contd)

Control 6-7


237 500EIssued 9/05

Manual 41-TM4-MA-01

Warningor Fault

FAULTLight Status

SelectorDisplay Status

MultipurposeDisplay Status

Cause of Warning orFault Corrective Action

Fault-code On Shows theletter F

Shows thenumber 1, 2, 3,5, or 6

The control board isdefective.

Turn the melter off, thenback on again to see ifthe problem recurs. If itrecurs, replace thecontrol board or replacethe control assembly.Refer to Replacing theControl Board, orReplacing the ControlAssembly given later inthis section.


Shows thenumber 4

There is a brownoutcondition.

(See Note F)

Correct the cause of thebrownout.


Shows thenumber 7

The seven-day clockbattery is dead.

(See Note G)

Replace the controlboard or the controlassembly. Refer toReplacing the ControlBoard, or Replacing theControl Assembly givenlater in this section.


Shows thenumber 8

Memory (RAM) testfailure

Replace the Vistafirmware chip or thecontrol assembly. Referto Replacing the ControlBoard, or Replacing theControl Assembly givenlater in this section.


Shows thenumber 9

Memory (ROM) testfailure

Replace the Vistafirmware chip or thecontrol board. Refer toReplacing the ControlBoard, or Replacing theControl Assembly givenlater in this section.

F: A brownout occurs when the power supply voltage falls below the voltage needed to maintain systemoperation. When this happens, the control system stops normal operation. The system will resumenormal operation once the brownout condition is corrected.

G: If the melter and the clock are turned on and the clock battery dies, the CLOCK light will flash. If themelter is then subject to a power cycle or power interruption, the displays will indicate fault code 7.However, if the clock is not turned on and the clock battery dies, the melter will not indicate a fault.When the clock battery is dead, the melter will continue to operate normally except for any automaticfunctions.

Control6-8


237 500EIssued 9/05

Manual 41-TM4-MA-01

Use these procedures as directed in Troubleshooting Tables to furthertroubleshoot control system problems.

Follow this procedure to troubleshoot under-temperature (UT) warnings.

WARNING: Risk of equipment damage, personal injury, ordeath. Some troubleshooting procedures require you toperform work inside the electrical enclosure with the power on.Follow electrical safety procedures and observe all high-voltageindicators. Refer to Electrical Safety During Troubleshootingand Opening and Closing the Electrical Enclosure beforeperforming any troubleshooting procedure.

1. Press the CLEAR FAULTS key and wait for the system to return tothe system-ready state.

2. If the warning disappears and the melter appears to be workingagain, the voltage to the melter may have temporarily sagged or youmay have an intermittent problem. Repetitive warnings in the samezone indicate a problem with the circuitry in that zone or anintermittent RTD failure. Take the following steps to troubleshootintermittent under-temperature warnings:

a. Check for a change in environmental conditions, such as addedventilation or sources of drafts. A cold draft can keep your melter,hoses, and guns from heating.

b. Make sure the power is turned on at your branch circuitdisconnect switch and that your power supply is supplying theproper voltage to the melter.

c. Check all hose and gun electrical plugs. Make sure theconnections are tight and free of corrosion.

d. Check your operating temperature setpoints to make sure theyhaven’t been changed. Refer to Records of System Settings inInstallation, Section 3.

3. TroubleshootingProcedures

TroubleshootingUnder-Temperature Conditions

Control 6-9


237 500EIssued 9/05

Manual 41-TM4-MA-01

e. If the affected zone is a hose or gun, replace the hose or gun witha hose or gun that is known to be good. If the warningdisappears, replace the defective hose or gun. If the warning stillappears, continue to the next step.

3. If the warning still appears after you press the CLEAR FAULTS keyand after you have taken the actions in step 2, take the followingsteps.

a. Check for loose heater connections on the board that supplies theheater power for the affected zone. For example, check theharnesses connected to X1 and X2 on the power board to checkthe heater connections for hoses 1−4 or guns 1−4. See Figure 6-2 for the location of connectors on boards.

b. Use an ohmmeter to check the fuse or fuses on the board thatsupplies the heater power for the affected zone. Refer toFigure 6-9 for fuse locations. Replace the appropriate fuse orfuses.

c. If the affected zone is the tank or grid, make sure the harnessconnected to J2 on the power board is secure or check thethermostat. See Figure 6-2 for the location of J2 on the powerboard. To check a thermostat, refer to Checking a Thermostatgiven later in this section.

d. Check the K1 contactor on the power board. While pressing themelter’s HEATERS key on and off, listen for the K1 contactor toengage. See Figure 6-2 for the location of K1 on the powerboard. If K1 is not engaging, replace the power board. Refer toReplacing the Control Board, or Replacing the Control Assemblygiven later in this section.

e. Check the heater or heater circuit of the affected zone. Refer toChecking a Heater or Heater Circuit in given later in this section.

f. If the warning condition still appears after you have taken all theactions in this step, replace the control assembly. Refer toReplacing the Control Board, or Replacing the Control Assemblygiven later in this section.

Control6-10


237 500EIssued 9/05

Manual 41-TM4-MA-01

Follow this procedure to troubleshoot over-temperature (OT) faults.

WARNING: Risk of equipment damage, personal injury, ordeath. Some troubleshooting procedures require you toperform work inside the electrical enclosure with the power on.Follow electrical safety procedures and observe all high-voltageindicators. Refer to Electrical Safety During Troubleshootingand Opening and Closing the Electrical Enclosure beforeperforming any troubleshooting procedure.

1. Press the CLEAR FAULTS key.

2. If the fault disappears and the melter appears to be working again,you may have an intermittent problem. Repetitive faults in the samezone indicate a problem with the circuitry in that zone or anintermittent RTD failure. Electrical noise from DC-drive motors maycause the triacs that control heater power on the power board toclose independent of the control system. Take the following steps totroubleshoot intermittent over-temperature faults:

a. Check your operating temperature setpoints to make sure theyhaven’t been changed. Refer to Records of System Settings inInstallation, Section 3.

b. To verify that something other than the control system is affectinga heated zone, turn on the Display Heater Proportioning feature(Feature No. 21) for the affected zone. When the display blinkson and off, it means the control system is proportioning heatcontrol to the heater. During proportioning, the temperaturedisplayed for the zone should stay fairly constant, within +/−1 °F.If the temperature continues to rise during proportioning, thensomething other than the control system is closing the triacs onthe power board and causing the heaters to heat. If electricalnoise from DC drives is causing the overheating problem, thenyou may be experiencing problems with other equipment in yourfacility. Take the following steps to solve electrical noiseproblems:

� Install the proper line reactor. Consult with the DC drivemanufacturer for the appropriate line reactor size.

� Electrically ground the hot melt melter to the parent machineusing as short a length of twisted cable as possible.

TroubleshootingOver-Temperature Conditions

Control 6-11


237 500EIssued 9/05

Manual 41-TM4-MA-01

� If the triacs continue to close after the hot melt melter isgrounded to the parent machine, install a line filter on eachinput power line to the hot melt melter. Connect the filterline-to-line. Refer to Parts for the line filter part number. For athree-phase system, order three filters.

c. If the faulted zone is a hose or gun, replace the hose or gun with ahose or gun that is known to be good. If the fault disappears,replace the defective hose or gun. If the fault remains, continue tothe next step.

3. If the fault remains after you press the CLEAR FAULTS key and afteryou have taken the actions in step 2, check the heater or heatercircuit of the faulted zone. Refer to Checking a Heater or HeaterCircuit given later in this section.

4. If the fault remains after you have taken all the actions in thisprocedure, replace the control assembly. Refer to Replacing theControl Board, or Replacing the Control Assembly given later in thissection.

Follow this procedure to check an RTD or RTD circuit.

WARNING: Risk of equipment damage, personal injury, ordeath. Disconnect and lock out electrical power to the melter,including input/output (I/O) lines.

1. Place the melter’s POWER switch in the off position, disconnect andlock out electrical power to the melter at the branch circuit disconnectswitch, and disconnect and lock out electrical power supplied throughany I/O wiring.

2. Open the electrical enclosure. Refer to Opening and Closing theElectrical Enclosure.

3. Check the RTD by measuring its resistance. Refer to Table 6-3.

� If the RTD is defective, replace the RTD. If a hose RTD isdefective, you must replace the hose. To replace a gun RTD,refer to your gun manual. To replace a tank or grid RTD, refer toReplacing an RTD or a Thermostat given later in this section.

NOTE: Flex the hose when you are checking a hose RTD. Somehose RTDs exhibit problems intermittently.

� If the RTD is good, go to the next step.

Troubleshooting an RTD orRTD Circuit

Control6-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 6-3 Measuring RTD Resistance

Quick Methods In-Depth Methods

Using a surface-temperature sensing device, such asa thermocouple, measure the temperature of the RTDat or near the end of the RTD that is accessible. Thenuse an ohmmeter to measure its resistance(see Note A). See Figure 6-4 and compare theresistance reading to the RTD’s normal resistance atthe known temperature.

Let the system cool down to room temperature. Whenthe RTD has had time to reach room temperature, usean ohmmeter to measure its resistance (see Note A).See Figure 6-4 and compare the resistance reading tothe RTD’s normal resistance at room temperature.

Roughly estimate the temperature of the RTD to thenearest 50 �C (100 �F). Use an ohmmeter tomeasure its resistance (see Note A). See Figure 6-4and compare the resistance reading to the RTD’snormal resistance at the estimated temperature.Because RTDs usually fail open or closed, anyresistance reading from approximately 100−400 ohmsstrongly indicates that the RTD is good.

Remove the RTD and heat it to a known temperature byusing an oven or by placing it in boiling water (protectthe wires and hold them above the water). Then use anohmmeter to measure its resistance (see Note A). SeeFigure 6-4 and compare the resistance reading to theRTD’s normal resistance at the known temperature.

NOTE A: If the faulted zone is a hose or gun, measure the RTD resistance at the hose or gun electrical plug.Refer to your hose or gun manual for a diagram of the electrical plug and for procedures for checkingRTD resistance. Because the core elements of a hose are not accessible, you cannot use some of themethods described in this table to measure the temperature of a hose RTD. If the faulted zone is atank or grid, measure the RTD resistance at the control board . For a tank RTD, measure theresistance at pins 33 and 34 of the harness attached to connector XP2 on the control board. For a gridRTD, measure the resistance at pins 21 and 22 of the harness attached to connector XP2 on thecontrol board.

4. Check the continuity of the RTD circuit by measuring the RTDresistance at other points in the circuit. Refer to Table 6-4 for the plugor harness pins for each check. For a gun RTD, you can checkcontinuity at two points: first at the hose electrical plug and then atthe harness connected to XP2 on the control board. For a hose RTD,you can check continuity at the hose electrical plug or at the harnessconnected to XP2 on the control board. See Figure 6-2 for thelocation of XP2 on the control board. For the tank or grid RTD, thereare no further checks you can make: go to the next step.

Troubleshooting an RTD orRTD Circuit (contd)

Control 6-13


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 6-4 Pins for Checking RTD Resistance

Zone withFaulted RTD

Gun ElectricalPlug Pins

Hose ElectricalPlug Pins

Connector XP2Harness Pins

Gun 1 3 and 5 3 and 5 9 and 10

Hose 1 N/A 5 and 8 1 and 2

Gun 2 3 and 5 3 and 5 11 and 12


Gun 3 3 and 5 3 and 5 13 and 14


Gun 4 3 and 5 3 and 5 15 and 16


Gun 5 3 and 5 3 and 5 25 and 26


Gun 6 3 and 5 3 and 5 27 and 28


Tank N/A N/A 33 and 34

Grid N/A N/A 21 and 22

5. If you find a continuity problem in the gun RTD circuit, replace thehose or replace the gun RTD harness inside the melter asappropriate. If you find a continuity problem in the hose RTD circuit,replace the hose RTD harness inside the melter. If you do not find acontinuity problem, go to the next step.

6. Replace the control board or the control assembly. Refer toReplacing the Control Board, or Replacing the Control Assemblygiven later in this section.

Control6-14


237 500EIssued 9/05

Manual 41-TM4-MA-01

�F

5940833

�F (130 )

�C54

�F �F

�C�C�C

(170 )

�C �C77 99 121 143 166 188 210 232�C �C �C

�F (290 )(210 )�F (250 )�F (370 )�F (410 )�F (450 )�F(330 )�F

160

360

340

320

300

280

260

240

220

200

180

140

120

RE

SIS

TAN

CE

IN O

HM

S

(90 )

�C32

(50 )

�C10

Fig. 6-4 RTD Resistance vs. Temperature

Troubleshooting an RTD orRTD Circuit (contd)

Control 6-15


237 500EIssued 9/05

Manual 41-TM4-MA-01

A faulty control board will cause one of the following to occur:

� A channel will not heat.� A channel will overheat.� The control system will not operate at all.

If the control system is not operating at all, call your Nordsonrepresentative for assistance.

To help determine why a channel is not heating or is overheating, use theDisplay Heater Proportioning diagnostic feature. This feature enablesyou to monitor power pulses to the heater zones. Normally, zone lights inthe TEMPERATURE System Setup area identify the zone for which atemperature is being displayed. While Display Heater Proportioning isenabled, the zone light turns on and off as power to the zone’s heatercycles on and off, thereby indicating the lack or presence and frequencyof power to the heater.

Enabling the Display Heater Proportioning Feature

NOTE: If you have activated the Password feature, you will need toenter the password (321) in the Multipurpose display before the systemwill allow you to change any SYSTEM SETTINGS features.


4103988

1

2

Fig. 6-5 Selecting the SYSTEM SETTINGS Feature

1. Up key 2. Down key

Troubleshooting Control BoardFaults

4130146

Control6-16


237 500EIssued 9/05

Manual 41-TM4-MA-01

Enabling the Display Heater Proportioning Feature (contd)

2. Press the Up key below the Selector display until the number 21 (thecode for Display Heater Proportioning) appears in the display. As theSelector number changes, the Multipurpose display changes to showthe setting of the selected feature.

3. Press the Up or Down keys below the Multipurpose display until thenumber 1 appears in the display, activating the Display HeaterProportioning feature. The Multipurpose display flashes.

4130136

2 3

4 5

1

Fig. 6-6 Changing the Setting of a Selected Feature

1. Up key2. Selector display3. Multipurpose display



Fig. 6-7 Using the Display HeaterProportioning Feature toPinpoint Zone Faults(Shown with a fault onthe internal/tank zone.)

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237 500EIssued 9/05

Manual 41-TM4-MA-01

Solving Zone Faults

1. Return to Monitor mode to check the status of the zone lights(INTERNAL, HOSE, or GUN). When the Display HeaterProportioning feature is enabled, the INTERNAL, HOSE, or GUN lightflashes as power is cycled on and off to the selected zone’s heater. Alight that is either continuously on or off helps diagnose the faultcondition.

NOTE: Because the zone light flashes slowly, it may appear to be oncontinuously. After a few seconds, the light flashes.

2. Select the zone you need to troubleshoot, then refer to Table 6-5 todiagnose and correct the cause of the fault.

3. After you are finished, repeat Steps 1-4 above to disable the DisplayHeater Proportioning feature by setting the value of Code 21 to zeroduring Step 3.

Table 6-5 Using the Display Heater Proportioning Feature to Solve Zone Problems

Fault Condition Problem Solution

The zone doesnot heat.

The setpoint temperature ofthe affected zone is lowerthan 37 �C (100 �F).

Set the temperature above 37 �C (100 �F). Refer to theprocedure Programming TEMPERATURE Controls inOperation, Section 4.

Heater circuit of the affectedzone is open.

Replace the heater of the faulted zone. For a hose or gunfault, refer to the manual that came with your hose or gun.For an internal (tank) fault, the cast-in heaters of the tankrequire that you replace the tank. Refer to the procedureReplacing the Tank in Tank and Manifold, Section 7.

A fuse on the power boardhas blown.

Replace the fuses of the faulted zone. Refer to theprocedure Replacing a Board Fuse in this section. (Refer toNote A.)

Control board is damaged. Replace the control board or replace the control assembly.Refer to the procedures Replacing the Control Board, orReplacing the Control Assembly given later in this section.

Connector J2 (thermostatconnector) on the powerboard is not connected.

Connect J2 to the power board. To locate J2, refer to Figure 6-11.

The zoneoverheats.

Heater circuit of the affectedzone is shorted.

Replace the affected zone’s heater.

Control board is damaged. Replace the control board or replace the control assembly.Refer to the procedures Replacing the Control Board, orReplacing the Control Assembly given later in this section.

Power board is damaged. Replace the power board or replace the control assembly.Refer to the procedures Replacing the Power Board orReplacing the Control Board, or Replacing the ControlAssembly given later in this section.

NOTE A: If the fuse blows again, check that the heater is not shorted to the ground.

Control6-18


237 500EIssued 9/05

Manual 41-TM4-MA-01

Use this procedure to check the fault log or warning log. These logs listthe causes of the three most recent warnings or faults. The actualtemperature display shows the length of time the heaters have been onwhen the warning/fault occurred.


2. Press the Up key below the Selector display until the feature numberof the warning or fault you want to check appears in the display.

3. Check the Multipurpose display to determine the warning or faultcode of the warning or fault currently displayed.

Table 6-6 Fault and Warning Log Feature Numbers

Feature No. Fault/Warning Displayed

27 The zone number and fault code for themost recent fault will be displayed in theMultipurpose display.

28 The zone number and fault code for thesecond most recent fault will be displayedin the Multipurpose display.

29 The zone number and fault code for thethird most recent fault will be displayed inthe Multipurpose display.

35 The zone number and warning code for themost recent warning will be displayed in theMultipurpose display.

36 The zone number and warning code for thesecond most recent warning will bedisplayed in the Multipurpose display.

37 The zone number and warning code for thethird most recent warning will be displayedin the Multipurpose display.

4. Check the Multipurpose display to determine the warning or faultcode of the warning or fault currently displayed.

Checking the Fault or WarningLog

Control 6-19


237 500EIssued 9/05

Manual 41-TM4-MA-01

Table 6-7 Zone Codes for Warning and Fault Logs

# Zone # Zone # Zone

0 Tank 5 Hose 4 10 Gun 3

1 Grid 6 Hose 5 11 Gun 4

2 Hose 1 7 Hose 6 12 Gun 5

3 Hose 2 8 Gun 1 13 Gun 6

4 Hose 3 9 Gun 2

Table 6-8 Meaning of Warning Codes

Warning Code Meaning of Warning Code

2 RTD open

3 RTD short

4 Zone temperature out of band

7 PC power board warning

8 PC microprocessor warning

9 Communication warning

Table 6-9 Meaning of Fault Codes

Fault Code Meaning of Fault Code

0 No fault occurred

1 Zone below the setpoint temperature

2 RTD open

3 RTD short

4 Overtemperature condition in the zone

5 Control board bad

6 Brownout

Control6-20


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. To clear the warning log, pressing the CLEAR FAULTS key.

6. Check the Multipurpose display to determine the code of the warningor fault currently displayed.

4131112A

1 2 3 4

Fig. 6-8 Reading the Fault or Warning Log

1. System Setting2. Zone Number (if any)

3. Fault or Warning Code4. Hours of Use

WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform this task.Observe all high voltage indicators.

WARNING: Disconnect equipment from line voltage. Failure toobserve may cause personal injury or death.

CAUTION: Electrostatic discharge can damage electricalcomponents. Be sure you are properly grounded beforebeginning any electrical repair procedure.

NOTE: Refer to the parts list at the end of this section for the partnumbers of any components to be replaced.

Follow these procedures to replace components of the control system.

To make any electrical repair, you will need to access the electricalenclosure. Refer to the procedures Opening the Electrical Enclosure andSecuring the Electrical Enclosure in Installation, Section 3.

Checking the Fault or WarningLog (contd)

4. Repair Procedures

Safely Accessing ElectricalComponents

Control 6-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

Use this procedure to locate and replace fuses on the main power board,pattern control power board, 5-6 hose/gun board, or contactor board.

1. Be sure that you are properly grounded before beginning thisprocedure. Refer to the guidelines Ensuring a Proper Ground givenearlier in this section.

2. Determine which fuse to replace by referring to Table 6-10. To ordera replacement fuse, refer to Vista Controller Assembly Parts Listgiven later in this section.

Table 6-10 Fuse Specifications

Type of Board Connection Fuse Number Amps

Main power board Hose 1/gun 1 F1/F5 6.3

Hose 2/gun 2 F2/F6 6.3



Tank F11/F12 25

Main power F9/F10 1

Replacing a Board Fuse

4130079

Control6-22


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. If you have not already opened the electrical enclosure to accesscircuit boards, open the enclosure now. Refer to the procedureOpening the Electrical Enclosure in Installation, Section 3.

Locate the fuse to be replaced.

4130070

F1F2

F3F4

F5F6

F7F8F9

F10

F11 F12

Fig. 6-9 Location of Fuses on Boards

4. Remove the fuse from the fuse holder. Refer to Table 6-11.

5. Secure the electrical enclosure. Refer to the procedure Securing theElectrical Enclosure in Installation, Section 3.

Fig. 6-10 Vertical Fuse Holder(Front) and HorizontalFuse Holder (Back)

Table 6-11 Fuse Replacement for Two Connectors

Type of Holder Remove Install

Vertical 1. Press down on the fuse cap and turn itcounterclockwise until you feel the caprelease.

1. Pull the fuse from the cap and replace it with a newfuse.

2. Lift the cap and fuse from theconnector.

2. Insert the cap and fuse into the connector on thepower board. Turn clockwise and press down untilyou feel the cap lock into place.

Horizontal Lift the fuse from its two-station connec-tor on the power board.

Press the replacement fuse into the two-station con-nector on the power board until the fuse snaps intoplace.

Replacing a Board Fuse (contd)

Control 6-23


237 500EIssued 9/05

Manual 41-TM4-MA-01

Follow this procedure to replace the power board.

Removing the Power Board


2. Unscrew the plastic clamps from the bottom of the control-end frameand disconnect main electrical service from connector TB1.

3. Disconnect the following from the power board:

� X1 and X2 (8-position connectors)� XS1 and XS2 (tank heater connectors)� J2 (thermostat connector)� J4 (power switch connector)� J9 (solenoid valve connector)� TB2 (output contacts) if used

4130071A

TB1

L1 L2 L3 NJ2

TB2

123456

J4

X2

X1

XS2 XS1J9

Q17

X3

X4

XP1

Fig. 6-11 Location of Connections on Power Board

Replacing the Power Board

Control6-24


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Power Board (contd)

4. Remove the following from the power board and save them for lateruse:

� X3 jumper plug� two triac clamps and attaching screws� the large tank triac (Q17) attaching screw� the nine screws holding the power board to the control-end frame

4130656

1

24

5

6

3

Fig. 6-12 Power Board Components

1. Connecting screws2. Triac clamp3. Triac clamp screws

4. X3 jumper plug5. Q17 triac screw6. XP1 connector

CAUTION: Do not bend the circuit board plug-in connectorpins. Otherwise, connections can be damaged and the controlsystem will not operate.

5. Starting from the edge opposite the XP1 connector, carefully separatethe power board from the control board. Take care not to bend theXP1 plug-in connector pins, which connect the microprocessor andpower boards.

4130084

1

Control 6-25


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Power Board

CAUTION: Do not bend the circuit board connector pins.Otherwise, connections can be damaged and the controlsystem will not operate.

1. Remove the replacement board from its static-safe package and alignthe board over the control board. Before pressing the board intoplace, be sure that XP1 is aligned with the connector on the controlboard.

Fig. 6-13 Aligning Pins of theBoard Connector

2. Press the board into place, making sure connector pins are properlyinserted into their sockets.

4130120

1

+

Fig. 6-14 Installing the Power Board

3. Once the board is aligned and connector XP1 is secure, replace thenine screws that hold the power board to the control-end frame.Torque to 2.0–2.25 N�m (18–20 lb-in.).

Control6-26


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Power Board (contd)

4. Install the screw for the large triac (Q17), which is to the left of TB1.Torque the screw to 0.8−0.9 N�m (7–8 lb-in.).

5. Install the two triac clamps and torque the securing screws to2.0–2.25 N�m (18–20 lb-in.).

6. Install the jumper plug to connector X3 on the power board.

7. Make the following connections (see Figure 6-11 ):

� X1 and X2� XS1 and XS2 (tank heater connectors)� J2 (thermostat connector)� J4 (power switch connector)� J9 (solenoid valve connector)� TB2 (output contacts) if used

8. Using a Phillips screw driver, fasten the plastic clamps that secure thewire harnesses to the bottom of the control-end frame. Torque to2.0–2.25 N�m (18–20 lb-in.).

9. Connect main electrical service. Refer to the procedure ConnectingElectrical Service in Installation, Section 3.

10. Close and secure the electrical enclosure. Refer to the procedureSecuring the Electrical Enclosure in Installation, Section 3.

WARNING: Risk of electrical shock. Failure to observe canresult in personal injury, death, or equipment damage. Due torisk of electrocution, never wear a static strap when working ona applicator that is still connected to a power source, includingI/O lines.


Follow this procedure to remove and replace the control board.

Replacing the Control Board

Control 6-27


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Control Board


2. Remove the power board. Refer to the procedure Removing thePower Board earlier in this section.

4130080

1

+

Fig. 6-15 Removing the Power Board

Control6-28


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Control Board (contd)

3. Disconnect the following from the control board:

� connector XP2� ribbon strip� the five screws that hold the board to the control-end frame

41300771

12

3

Fig. 6-16 Control Board Connections and Components

1. Connecting screws2. Ribbon strip

3. Connector XP2

4. Carefully separate the control board from the display board. Takecare not to bend the XP4A plug-in connector pins, which join thecontrol and display boards. Be sure to retain the plug-in connector forfuture use.

4130078

1

1

2

Fig. 6-17 Removing the Control Board

1. XP4A 2. Plug-in connector

Control 6-29


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Control Board

1. Remove the replacement board from its static-safe package and alignthe board with the display board. Before pressing the board intoplace, be sure that the pins of connector XP4A are aligned with theconnector on the display board.

2. Once the board is aligned and connector XP4A is secure, replace thefive screws that hold the control board to the control-end frame.Torque to 2.0–2.25 N�m (18–20 lb-in.).

3. Connect the ribbon strip to connector XP1 on the control board.

4. Connect XP2.

5. Install the power board. Refer to the procedure Installing the PowerBoard earlier in this section.




Replacing the Display Board

Control6-30


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Display Board

1. If you have not already opened the electrical enclosure to accesscircuit boards, open the enclosure now. Refer to the procedureOpening the Electrical Enclosure earlier in Installation, Section 3.


4130080

1

+


3. Remove the control board. Refer to the procedure Removing theControl Board earlier in this section.

4130078

1

1

2

Fig. 6-19 Removing the Control Board

1. XP4A 2. Plug-in connector

Control 6-31


237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Remove the four screws holding the display board to the control-endframe.

4130082

Fig. 6-20 Removing the Securing Screws

5. Remove the display board from the control-end frame.

4130118

Fig. 6-21 Removing the Display Board

Control6-32


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Display Board

1. Remove the replacement board from its static-safe package and alignthe board with the control-end frame.

2. Once the board is aligned, replace the 4 screws that hold the board tothe control-end frame. Torque to 2.0–2.25 N�m (18–20 lb-in.).

3. Install the control board. Refer to the procedure Installing the ControlBoard given earlier in this section.

4130121

1

Fig. 6-22 Installing the Control Board

4. Install the power board. Refer to the procedure Installing the PowerBoard earlier in this section.


Control 6-33


237 500EIssued 9/05

Manual 41-TM4-MA-01



Removing the Operator Panel

1. If you have not already opened the electrical enclosure to accesscircuit boards, open the enclosure now. Refer to the procedureOpening the Electrical Enclosure earlier in Installation, Section 3.


4130080

1

+


Replacing the Operator Panel

Control6-34


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Operator Panel (contd)

3. Disconnect the ribbon strip from the control board.

41301021

Fig. 6-24 Disconnecting the Ribbon Strip

4. Lift the control-end frame and screw the retaining screw into thepanel.

4107014

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 6-25 Securing the Control-end Frame

4107043

4130098

Control 6-35


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. Using a flat-blade screwdriver and pliers, pull the operator panel fromthe control-end frame, and guide the ribbon strip through the hole inthe control-end frame.

CAUTION: Mount the operator panel to a surface that is cleanand smooth. Otherwise, the panel can lose contact and causepoor applicator performance. Additional damage can occur ifoperators attempt to run the applicator using a panel that is notsecurely mounted.

6. Remove any adhesive that remains on the control-end frame with acitrus industrial cleaner.

7. Thoroughly clean the control-end frame with denatured alcohol toremove any residue left by the adhesive cleaner.

Fig. 6-26 Removing the OperatorPanel

Installing the Operator Panel

1. Remove the new operator panel from its static-safe package.

2. With clean hands, peel the paper backing from the operator panel.Make certain to thoroughly remove all the paper, especially aroundthe ribbon strip.

Fig. 6-27 Removing Paper Backingfrom the Operator Panel

4130099

Control6-36


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Operator Panel (contd)

3. Connect the plastic ground tab, which is located behind the selectordisplay, by lifting the tab up and pressing it against the adhesivebacking.

4. Insert the ribbon strip through the hole in the control-end frame and,starting from the ribbon strip side of the operator panel, carefully alignthe operator panel to the control-end frame.

5. Firmly press the panel into place with a rubber roller or similar tool.

6. Remove the captive screws to lower the control-end frame. Connectthe ribbon strip to the control board.

7. Install the power board. Refer to the procedure To Install the PowerBoard earlier in this section.


Fig. 6-28 Connecting the GroundTab



Follow this procedure to remove and install the control assembly. Thecontrol assembly includes the following components:

� power board� control board� display board� control-end frame� operator panel

Replacing the ControlAssembly

Control 6-37


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Control Assembly


2. Using a Phillips screwdriver, remove wire harnesses from plasticclamps at the bottom of the control-end frame.

3. Disconnect main electrical service connections, including the groundwire. Refer to the procedure Connecting Electrical Service inInstallation, Section 3.

4. Disconnect the following from the power board:

� X1 and X2 connectors� XS1 and XS2 (tank heater connectors)� J2 (thermostat connector)� J9 (solenoid valve connector)� TB2 (output contacts) if used� X3 (jumper plug)—save the plug for later use.

4130071A

TB1

L1 L2 L3 NJ2

TB2

123456

J4

X2

X1

XS2 XS1J9

Q17

X3

X4

XP1

Fig. 6-29 Location of Connections on Power Board

Control6-38


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Control Assembly (contd)

5. Disconnect XP2 from the control board.

4130089

XP2

1

2

Fig. 6-30 Location of connector XP2 on Control Board

3. Power board 4. Control board

CAUTION: Support the control-end frame before removing thesupport strap or hinge pins from the control-end frame.Otherwise, the panel can fall and injure someone when pins areremoved.

6. Support the control-end frame then remove the strap from the panel.

7. Remove the push nuts from the hinge pins. Remove the controlassembly.

4107045

ÎÎÎÎÎÎ

1

2

Fig. 6-31 Removing Push Nuts and Hinge Pins

1. Push nut 2. Hinge pin

Control 6-39


237 500EIssued 9/05

Manual 41-TM4-MA-01

Installing the Control Assembly

1. Remove the control assembly from the static-safe package.

2. If you have not already done so, support the control-end frame. Thenalign the assembly with the base of the applicator and insert the hingepins through the holes in the control-end frame and applicator base.Take care to install the pins so that the head of each pin is on theoutside of the panel. (See Figure 6-31).

3. Press the push nuts over the hinge pins.

4. Attach the support strap to the panel.

5. Connect XP2 to the control board.

6. Connect the following to the power board:

� X1 and X2 connectors� XS1 and XS2 (tank heater connectors)� J2 (thermostat connector)� J9 (solenoid valve connector)� TB2 (output contacts) if used� X3 (jumper plug)

7. Using a Phillips screw driver, fasten the plastic clamps that secure thewire harnesses to the bottom of the control-end frame. Torque to2.48–2.93 N�m (22–26 lb-in.).

8. Make main electrical service connections, including the ground wire.Refer to the procedure Connecting Electrical Service in Installation,Section 3.

9. Lift the operator panel back into place and secure it. Place the lid ofthe electrical enclosure into place on top of the applicator and secureit. Refer to the procedure Securing the Electrical Enclosure inInstallation, Section 3.

4130087

Control6-40


237 500EIssued 9/05

Manual 41-TM4-MA-01

A faulty RTD or thermostat can cause the tank to overheat or underheat.To replace the RTD, thermostat, or both, follow these procedures.



Removing the Tank RTD or Thermostat

1. Disconnect and lock out electrical power to the applicator beforestarting repairs.

2. Follow the pump enclosure removal procedure described in Checkingfor a Malfunctioning Actuator in Hydraulics, Section 5. Also refer toOpening the Electrical Enclosure in Installation, Section 3.

3. Disconnect the RTD plug or the thermostat plug. The plugs are in theelectrical enclosure.

CAUTION: Do not cut electrical wires or equipment can bedamaged.

Fig. 6-32 Disconnecting the Plug ofthe RTD or Thermostat(Typical plug shown.)

Replacing the Tank RTD orThermostat

4130055

4130069

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Control 6-41


237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Taking care not to cut any electrical wires, cut the ties that bind thetank electrical harness.

5. Pull the RTD or thermostat plug through the access hole in thebottom of the electrical enclosure, along the wire cover on the bottomof the unit, and through the access hole in the bottom of the pumpenclosure.

NOTE: The wire cover underneath the applicator may have to beremoved to route RTD or thermostat wiring during removal andreplacement.

NOTE: RTD and thermostat wiring must be secured to the tankinsulation during reassembly. Observe where the wiring is presentlytaped. The wiring must be taped to the insulation, in the samelocation, during reassembly to avoid electrical interference.

Fig. 6-33 Removing Harness Ties

WARNING: Hot! Risk of burns. Wear heat-protective gloves.Failure to observe may result in personal injury.

6. Fold back the cut-away section of the tank insulation to access theRTD or thermostat.

Fig. 6-34 Accessing the RTD orThermostat

4130067

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Control6-42


237 500EIssued 9/05

Manual 41-TM4-MA-01

Removing the Tank RTD or Thermostat (contd)

7. Remove the RTD or thermostat from the tank.

To Remove the RTD To Remove the Thermostat

1. Remove the two screws thatattach the RTD retaining plateto the tank and remove theplate. Save the screws and theplate for later use.

1. Remove the two screwsholding the thermostat tothe tank and save thescrews for later use.

2. Pull the RTD out of the slot inthe tank wall.

2. Remove the thermostat andprotective rubber boot.

3. Discard the RTD, wires, andplug.

3. Discard the thermostat,wires, and plug.

Fig. 6-35 Removing the RTD(Right) or Thermostat(Left)

Installing the Tank RTD and Thermostat

1. Apply a thermal compound to the new RTD or thermostat.

2. Install the RTD or thermostat.

To Install the RTD To Install the Thermostat

1. Insert the RTD into the slot onthe tank wall.

1. Position the new thermostaton the tank wall.

2. Place the RTD retaining plateover the RTD and secure withthe two screws removed earlier.

2. Secure the thermostat tothe tank wall with the twoscrews removed earlier.

3. Route the RTD or thermostat wires through the access hole in thebottom of the pump enclosure, through the wire cover, and into theelectrical enclosure through its access hole. Prevent wires frombeing pinched, and secure the wiring with new wire ties.

4. Connect the RTD or thermostat plugs.

5. Replace the tank insulation.

6. Tape the RTD and/or thermostat wires, using high-temperature ducttape, to the tank insulation in the same location as found duringinsulation removal.

Control 6-43


237 500EIssued 9/05

Manual 41-TM4-MA-01

7. Replace the pump enclosure and secure it with the four nuts andwashers removed during disassembly.

8. Replace the electrical enclosure cover and secure it with the fourscrews removed during the procedure Opening the ElectricalEnclosure in Installation, Section 3.

9. Remove the lockout and restore power to the system.

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.


The six-digit number in the Part column is the Nordson Corporation partnumber. A dash (–) in this column means the part cannot be orderedseparately.





2 000 000 � � Part 1


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.




Control6-44


237 500EIssued 9/05

Manual 41-TM4-MA-01


− 234 428 Assembly, Control, Vista, (Non PC) Service Kit

1 234 423 Service Kit, Frame, Machined, Controller 1

2 225 458 Membrane Panel, Basic, Vista, (Non PC) 1

3 225 451 Linear Switch, 250 V, 16 A, Panel Mounted 1

4 225 450 Switch Accessory, Boot, Silicone 1

5 982 974 Screw, Hex, Slot, M4 x 12, w/Lockwasher 8

6 230 261 Terminal, Ground, 6-14, AWG 1

7 982 971 Screw, Hex, Slot, M4 x 12, w/Nylon Patch 10

8 939 683 Fuse, 6.3 A, Fast-Acting, 250V 8 A

9 227 569232 617

Plug, 400/230 VAC, Three PhasePlug, 230 VAC, Single Phase

11 B

10 982 975 Screw, Hex, Slot, M4 x 16, w/Lockwasher 6

11 225 446 Clamp, Triac, Retaining 2

12 302 882 Screw, Socket Hd Cap, M3 x 10, w/Nylon Patch 1

13 939 491 Fuse, 25 A, Fast-Acting, 600V 2 C

14 310 904 Fuse, 1 A, 250 V 2 D

15 220 592 Connector, Plug, 6 Position, 5 mm 1

16 234 427 Service Kit, Vista, Power Board 1

17 225 448 Wire Harness, Switch 1

18 232 540 Unshrouded Header, 26-Position 1

19 234 429 Service Kit, Control Board, Vista 1

20 185 092 Unshrouded Header, 0.75 board-spacer, 40-Position 1

21 982 970 Screw, Hex, Slot, M4 x 8, w/Nylon Patch 4

22 234 426 Service Kit, Vista, Basic, (Non PC), Display Board 1

23 225 453 Nut, Spring, Type-U 2

24 234 424 Service Kit, Chip, Vista Software 1

NOTE A: Positions F1 through F8 on the power board.

B: The appearance of the plug will vary slightly according to the voltage used.

C: Fuses for tank heater. Positions F11 and F12 on the power board.

D: Fuses for main power. Positions F9 and F10 on the power board. Fuses for hose/gun pairs.

Vista Controller AssemblyParts List

Control 6-45


237 500EIssued 9/05

Manual 41-TM4-MA-01

14

22

19

16

1112

2

34

1

23

17

21 20

18

5 10

24

9

5

5

8

6

7

15

7

7

75

5

4130426

23

13

5

21

25

Fig. 6-36 Controller Boards

Control6-46


237 500EIssued 9/05

Manual 41-TM4-MA-01


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 7

Tank and Manifold

Tank and Manifold7-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Tank and Manifold 7-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 7Tank and Manifold

This section helps you replace the tank and manifold. The followinginformation is in this section:

� an overview of the tank� procedures for replacing the tank and manifold� a parts list of the tank and frame

Refer to the following sections of this manual for additional information onthe tank:

� Description, which gives specifications of the tank capacity andvolume and gives dimensions of the opening.

� Operation, which gives instructions for loading the tank with hot meltmaterial.

� Maintenance, which gives procedures for cleaning the tank andmanifold and for draining the tank of adhesive.

� Control, which gives procedures for replacing the tank ResistanceTemperature Detector and the tank thermostat.

The PTFE-coated aluminum tank has heating elements cast into itswalls. The tank heaters melt the adhesive so that it can be pumped tothe system’s manifold where it is distributed to hoses.

The temperature of the tank is controlled by a resistance temperaturedetector and a thermostat that are mounted to the tank wall and bysold-state circuitry located in the electrical enclosure.

1. Introduction

2. Overview of the Tank

4110132



237 500EIssued 9/05

Manual 41-TM4-MA-01

NOTE: Refer to the parts list at the end of this section for the partnumbers of any components to be replaced.

Because the tank has no moving parts, you should not need to replace itor the accompanying manifold. However, should you need to replace thetank or manifold for any reason, follow these procedures.

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. Refer to the procedure, Flushing the System inMaintenance, Section 8.


3. Turn the POWER switch off and lock out power to the system.


3. Tank and ManifoldReplacement

Removing the Tank andManifold

4130013

4130133

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ



237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Turn the pump air pressure regulator fully counterclockwise to reducethe pump air pressure to 0. Then disconnect the air line from thepump air regulator.

5. Relieve hydraulic pressure by opening the drain valve until pressureis relieved, then close the valve.

6. Remove the pump enclosure cover. Refer to the procedure inActuator Check in Hydraulics, Section 5.

7. Remove the pump assembly, refer to Pump Removal in Hydraulics,Section 5.

8. If the applicator is secured to a support platform, detach anyanchoring bolts.

9. Remove the tank strainer from inside the tank.Fig. 7-2 Disconnecting the Input

Air Line

10. Disconnect the tank heater leads on the side of the tank nearest theelectrical enclosure.

NOTE: The RTD and thermostat wiring must be secured to the tankinsulation during the reassembly procedure. Make note of the wiringlocation. Not fastening RTD/thermostat wiring in its existing locationmay lead to electrical noise.

11. Remove the RTD, thermostat, and ground wire from the tank. Savethe screws and RTD retaining plate for later use. Refer to Replacingthe Tank RTD or Thermostat in Control, Section 6.

Fig. 7-3 Removing the RTD,Thermostat, and GroundWire from the Tank

4130130



237 500EIssued 9/05

Manual 41-TM4-MA-01

WARNING: Risk of burns. Tank must be free of hot meltadhesive. Wear protective clothing. Failure to observe mayresult in serious injury.

NOTE: Ensure that the four spacers used when mounting the pumpenclosure cover are secured to prevent loss.

12. Tilt the applicator on the pump side and remove the screws thatattach the tank to the base of the applicator.

Fig. 7-4 Removing the Tank fromthe Base

Removing the Tank andManifold (contd)

4130132

1

2

4103200



237 500EIssued 9/05

Manual 41-TM4-MA-01

13. Pull the tank and manifold assembly away from the rest of theapplicator. The three spacers between the tank and manifoldassembly and the base will come loose. Keep the spacers forreassembly.

14. Carefully remove all insulation from the tank and manifold assembly.

15. Separate the tank cover and gasket from the tank and save the coverfor later use.

Fig. 7-5 Removing the TankCover and Gasket

1. Tank cover2. Tank gasket

16. Remove the screws from the bottom of the manifold and separate thetank and manifold.

Fig. 7-6 Separating the Tank andManifold



237 500EIssued 9/05

Manual 41-TM4-MA-01

NOTE: The tank gasket must be replaced anytime the tank cover isseparated from the tank. Manifold O-rings should be replaced anytimethe manifold is removed. Refer to Hydraulics, Section 5 for O-ring partnumbers.

1. Position a new tank gasket in place and secure the tank cover thatyou removed earlier from the tank.

2. Secure the manifold to the bottom of the tank.

3. Connect the wire leads to the tank heater.

4. Wrap the insulation around the tank and manifold assemblies. Usehigh-temperature duct tape to secure the insulation in place.

5. Hold the three spacers in place and attach the base to the tank andmanifold assembly.

6. Set the applicator in the upright position.

7. Install the RTD, thermostat, and ground wire to the tank.

8. Lay the tank strainer in the bottom of the tank.

9. If the applicator was attached to a support platform, anchor it now.

NOTE: Secure the RTD and thermostat leads to the tank insulationwith high-temperature duct tape. The wiring must be attached at thesame locations from which it was removed.

10. Connect the incoming air line to the air regulator and filter.

11. Inspect the tank cover gasket and replace if necessary.

12. Install the pump according to Installing the Pump in Hydraulics,Section 5.

13. After installing the pump and its air line, ensure that the tank coverspacers are mounted between the tank cover and the pumpenclosure. Figure 7-8, Tank Assembly, illustrates the assembly.Replace the pump enclosure, then secure it with the four nuts andwashers removed during disassembly.

14. Remove the electrical lockout and turn the power switch on.

Installing the Tank andManifold



237 500EIssued 9/05

Manual 41-TM4-MA-01

To order parts, call the Nordson Customer Service Center at800-241-8777 or your local Nordson representative. Use this five-columnparts list, and the accompanying illustration, to describe and locate partscorrectly.


The six-digit number in the Part column is the Nordson Corporation partnumber. A dash (–) in this column means the part cannot be orderedseparately.





2 000 000 � � Part 1


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






237 500EIssued 9/05

Manual 41-TM4-MA-01


1 – Enclosure, Tank 1

2 297 528 Handle, Lid 1

3 982 309 Screw, Pan Head, M5 x 10 2

4 983 075 Washer, Locking, M5 2

5 297 523 Lid, Enclosure, Tank 1

6 297 527 Lid, Inner 1

7 106 433 Spacer, 0.218 x 0.375 2

8 983 551 Washer, 0.250 x 0.500 2

9 982 320 Screw, Pan Head, M5 x 16 4

10 984 723 Nut, Hex, Cap, M5 4

11 983 408 Washer, Flat, M5 4

12 297 522 Base, Mounting 1

13 297 520 Frame, Tank 1

14 973 968 Adapter, Bulkhead, 1/4 NPT 1

15 971 265 Fitting, 1/4 NPT x 1/4 Tube 1

16 297 533 Shield, Manifold 1

17 983 064 Washer, Flat, 0.156 x 0.375 x 0.049 2

18 982 950 Screw, Pan Head, M3 x 8 6

19 983 137 Washer, Flat, M4 4

20 984 715 Nut, Hex, M4 4

21 297 524 Channel, Wire 1

22 302 919 Wiremount, Cable Tie Anchor 3 NS

23 982 680 Screw, Hex Head, M5 x 12 8

24 983 422 Washer, Locking, M5 8

25 – Panel, Controller

26 304 456 a Gasket, Left side 1

26 304 455 b Gasket, Top 1

26 304 457 c Gasket, Bottom 1

26 304 460 d Gasket, Right side 1

27 983 047 Washer, Flat, M4 6

28 982 337 Screw, Pan, M4 x 8 4

29 225 454 Strap, Retainer, Controller 1

30 230 027 Cable, Clamp, 0.675 Bun Diameter 1 NS

31 939 110 Strap, Cable, 0.875 Diameter 5 NS

32 225 455 Spc Nut, Push-On, 3/16 Diameter. 2

33 225 456 Rivet, Hinge, 0.187 x 0.625 2

34 – Frame, Electrical 1

35 304 484 Clip, Vista 4

36 304 483 Screw, Vista 16

37 984 715 Nut, Hex, M4 15

38 297 521 Cover, Electrical 1

39 983 137 Washer, Flat, M4 4

40 982 604 Screw, Pan Head, M4 x 12 4

41 304 497 Washer, Flat, 0.20 x 0.75 1

42 973 171 Plug, Dome, PG16, Metal 1

Frame Assembly Parts List



237 500EIssued 9/05

Manual 41-TM4-MA-01

Item NoteQuantityDescriptionPart

43 940 174 O-Ring, Viton, Blk, 0.688 x 0.813 1

44 984 094 Nut, Lock, PG16, Metal 1

NS: Not Shown

4107055

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

23

24

24

15

14

13

16

21

12

17 18

12

3

56

7

89

10

11

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

40

39

38

4137

27

2829

34

32

33

Î

26c

4

25

35

36

27

37

26a

26d

26b 9

23

24

20

19

434241

Fig. 7-7 Frame Assembly



237 500EIssued 9/05

Manual 41-TM4-MA-01


1 971 151 Connector, Male, 1/4 Tube x 1/8 NPT 1

2 – Pump, Piston A

3 288 170 Pan, Piston Pump 1

4 288 311 Gasket, Tank Cover 1

5 304 448 Spacer, 10 mm x 5.3 mm x 10 1

6 982 000 Screw, Panhead, M5 x 10 3

7 304 440 Cover, Tank 1

8 288 309 Gasket, Tank 1

9 100 349 Strainer, Tank 1

10 288 017 Tank, Machined 1

11 274 667 Plate, Retainer, RTD 1

12 982 086 Screw, Pan, M3 x 8 3

13 105 721 Harness, Wire, RTD 1

14 304 429 Wire, Ground 1

15 931 107 Insulation, Tape – NS

16 983 421 Washer, Lock, M4 1

17 230 127 Harness, Wire, Thermostat 1

18 982 170 Screw, Chez Head, M3 x 5 2

19 288 154 Spacer, Manifold, 0.50 in. x 0.546 in. 2

20 – Base, Mounting 1 B

21 983 414 Washer, Flat 6

22 983 404 Washer, Lock, M8 6

23 982 212 Screw, Hex, Cap, M8 x 30 2

24 982 107 Screw, Hex, Cap, M8 x 70 1

25 144 869 Insulation, Tank 1

26 288 148 Spacer, Tank, 0.50 x 2.04 1

27 982 050 Screw, Hex Head, Cap, M8 x 35 3

28 – Lubricant, Never Seez –

29 – Compound, Heat Sink –

30 982 096 Screw, M4 x 8 1

NOTE A: Refer to the Piston Pump Parts List in Hydraulics, Section 5.

B: Refer to the Frame Assembly Parts List in this section.

NS: Not Shown

Tank Assembly Parts List



237 500EIssued 9/05

Manual 41-TM4-MA-01

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

ÎÎÎÎÎÎ

3

4107046

9

21

4

5

7

8

10

19

20

21

22

2322

24

25

1

27

22

21

2

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÌÌÏÏ

12

11

14

29

28

28

30

18

17

16

26

6 28

13 29

Fig. 7-8 Tank Assembly



237 500EIssued 9/05

Manual 41-TM4-MA-01


1 984 129 Nut, Hex Head, Machine, No. 10-32, Brass 5

2 271 221 Lug, 45, Double, 0.250 in., 0.438 in. 7

3 983 120 Washer, Lock, E, Split, No. 10, Steel 5

4 240 674 Tag, Ground 1

5 983 048 Washer, Lock, E, External, No. 10, Stainless Steel 1

6 982 938 Screw, Round Head, 10-32 x 1.500 in., Slotted, Brass 1

7 – Base 1 A

NOTE A: Base shown for reference purposes only.

4130420

ËËËËËËËË

1

3

4

7 6

5

22

Fig. 7-9 Ground Stud Assembly

Ground Stud Assembly PartsList



237 500EIssued 9/05

Manual 41-TM4-MA-01



237 500EIssued 9/05

Manual 41-TM4-MA-01


– 288 020 Manifold Assembly 1

1 288 022 � Pressure Relief Valve, 1600 psi 1

2 983 414 � Washer, Flat, Narrow, M8, Steel 6

3 288 023 � Screw, Special, Hex Head, M8–1.25 in. 5 A

4 973 574 � Plug, O-ring, Straight Thread, 9/16-18 in. 8 A, B

5 940 101 � O-ring, Viton, 0.239 in. Internal Diameter x 0.70 in. 1

6 954 036 � Back-up Ring, Single, 1/4 in. x 3/8 in. 1

7 276 024 � Valve Assembly, Drain 1 A

8 982 096 � Screw, Pan, Slotted, M4 1 A

9 983 403 � Washer, Lock, Split, M4, Steel 1

10 105 432 � Filter Assembly 1 A, C

11 274 569 � Adapter, Filter Bung 1 A, D

12 941 220 � O-ring, Viton, 1.125 in. x 1.313 in. x 0.063 in. 1 E


NOTE A: Apply Never Seez lubricant, part number 900 344.B: Includes O-ring.

C: Refer to Filter Assembly Parts List in this section.

D: Apply retaining cylindrical adhesive, part number 900 419.

E: Apply Parker O-ring lubricant, part number 900 223.

Manifold Assembly Parts List



237 500EIssued 9/05

Manual 41-TM4-MA-01

4130042

1

13

12

11

10

7 4

3

28 9

6 5

Fig. 7-10 Manifold Assembly



237 500EIssued 9/05

Manual 41-TM4-MA-01


– 105 432 Filter Assembly

1 274 578 � Screen, Filter, 0.006 in., 5.38 in, 1

2 981 747 � Screw, Round, 10–32 x 6.250 in., Slotted 1 A

3 274 513 � Bung, Filter 1


5 274 579 � Core, Filter, 5.718 in. Long 1

NOTE A: Apply Never-Seez lubricant, part number 900 341.

4130043

3

4

5

1

2

Fig. 7-11 Filter Assembly

Filter Assembly Parts List


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 8

Maintenance

Maintenance8-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Maintenance 8-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 8Maintenance


This section describes how to maintain your hot melt system. Forinformation on automatic gun maintenance, refer to the automatic gunmanual.

Always observe the following safety warnings when servicing the hot meltsystem.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves. Adhesive may bereleased under pressure.

1. Introduction

2. Safety

Running the Applicator Safely

4110132

Maintenance8-2


237 500EIssued 9/05

Manual 41-TM4-MA-01


During routine operation, pumping and heating the adhesive causespressure to build up in the manifold, hoses, and guns. This proceduredescribes how to relieve pressure in the system before performingmaintenance or repair procedures.


1. Heat the system to operating temperature.

WARNING: Disconnect and lock out power to the systembefore performing maintenance or repair procedures.Otherwise, someone can start a pump while the equipment isbeing serviced, causing hot adhesive to spray or flow from anyopen valve or connection.

2. Turn the POWER switch off and lock out power to the system.

3. Trigger one or more guns in the system until adhesive stops flowing.


Relieving System Pressure

Maintenance 8-3


237 500EIssued 9/05

Manual 41-TM4-MA-01

Performing routine maintenance can extend the life of your applicator anddecrease downtime caused by extensive repairs. The procedures in thissection will help you keep your applicator running properly and reducedowntime.

Table 8-1 lists a recommended schedule for preventive maintenance.Use the table to develop a maintenance schedule for your new applicator.Keep in mind that you may need to adjust how often you performprocedures because of conditions specific to your operations. You mayfind that more or less frequent maintenance is required for someprocedures.

Table 8-1 Recommended Maintenance Schedule

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Frequency

(Time WithHeaters On) 1

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Description of Maintenance

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Daily

(every 8 hours) 2

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean the exterior surfaces of the applicator and guns.

Keep adhesive supply clean and free of contaminants to prevent poor pumpperformance or clogged nozzles.

Check the O-rings and gaskets on hose connectors and plugs for leaks. Refer to theprocedure, Replacing O-rings on Hose Connectors and O-ring Plugs in Hydraulics,Section 5.

Flush the manifold filter. Refer to the procedure, Flushing a Manifold Filter in thissection.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Weekly

(every 40 hours)2

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean the manifold filter. Refer to the procedure, Cleaning a Standard Manifold Filter inthis section.

Clean removable nozzles. Refer to the procedure, Cleaning Removable Nozzles in thissection.


Monthly

(every 160 hours) 2

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Inspect all electrical connections for tightness, including those inside the electricalcabinet.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

As NeededÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean the filter elements of the air regulator.

Clean inside of the electrical cabinet.

Check electrical connections and terminal blocks.

Check hose connections.

Flush the system with a flushing material. Refer to the procedure Flushing the Systemin this section.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE 1: To find out how many hours your system has been running with heaters on, refer to the procedureChecking Total Hours Heaters Have Been Running in Operation, Section 4,.

NOTE 2: Hours are approximate and are based on a 40-hour work week.

3. Maintenance Procedures

Scheduling Maintenance

4107056

4130016

Maintenance8-4


237 500EIssued 9/05

Manual 41-TM4-MA-01

To keep your applicator running properly, it’s important to flush themanifold filter each day. This removes excess dirt and charred materialthat can clog the system and cause poor performance.

Use this procedure to flush the manifold filter.


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


Fig. 8-2 Pump Key

2. Turn the air pressure regulator fully counterclockwise to reduce thepump air pressure to 0.

Fig. 8-3 Reducing Air Pressureto 0

Flushing a Manifold Filter

4103997

4107056

4130003

Maintenance 8-5


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Trigger all guns to relieve trapped hydraulic pressure.

4. Place a container beneath the drain, and turn the valvecounterclockwise to open it.

Fig. 8-4 Opening the Drain Valve


6. Increase the pump air pressure by turning the air pressure regulatorclockwise until a clean, steady flow of adhesive flows from the drain.Drain approximately 0.25 L (8 oz) of material. If char is still present,continue draining until the material is free of char.


Fig. 8-5 Pump Key

8. Close the drain by turning the valve clockwise.

9. Return the pump air pressure to the operating setting.

The applicator is ready for operation.

Fig. 8-6 Closing the Drain

4130016

Maintenance8-6


237 500EIssued 9/05

Manual 41-TM4-MA-01

To keep your applicator running properly, it’s important to clean themanifold filter each week. This removes excess dirt and charred materialthat can clog the system and cause poor performance.

Use this procedure to clean the manifold filter.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves. adhesive may bereleased forcefully.

1. Heat the system to operating temperature.

2. Turn the air pressure regulator fully counterclockwise to reduce pumpair pressure to 0.

Fig. 8-7 Reducing Air Pressureto 0

Cleaning a Manifold Filter

4103997

4107056

4103994

Maintenance 8-7


237 500EIssued 9/05

Manual 41-TM4-MA-01

3. Trigger all guns to relieve trapped hydraulic pressure.

4. Place a container beneath the drain valve, and turn the valvecounterclockwise to open it.



6. Increase the pump air pressure by turning the air pressure regulatorclockwise until a clean, steady flow of adhesive flows from the drainvalve.



Fig. 8-9 Pump Key

9. Loosen the filter with a wrench. A socket-type wrench is best.

Fig. 8-10 Loosening the Filter

4103993

4103999

5940157

Maintenance8-8


237 500EIssued 9/05

Manual 41-TM4-MA-01

10. Pull the filter assembly out of the manifold.

Fig. 8-11 Removing the FilterAssembly

11. Remove the screw in the back of the filter assembly and separate thefilter screen from the assembly.

Fig. 8-12 Separating the FilterScreen from theAssembly

12. Clean the filter screen in heated cleaning fluid, such as Type R fluid,or with an electric heat gun. Scrub with a soft bristle brush.

Fig. 8-13 Soaking the Filter Screenin a Heated CleaningFluid

Cleaning a Manifold Filter (contd)

4130003

Maintenance 8-9


237 500EIssued 9/05

Manual 41-TM4-MA-01

13. Inspect the screen and o-ring for damage. Replace if necessary.

14. Assemble the filter.

4103992

Fig. 8-14 Assembling the Filter

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

16. Slide the filter assembly into the manifold and tighten the assemblyfinger-tight only.

17. Purge the manifold by repeating steps 4 through 7 of this procedure.

18. Close the drain by turning the valve clockwise.

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



Fig. 8-15 Closing the Drain

4107056

4103997

Maintenance8-10


237 500EIssued 9/05

Manual 41-TM4-MA-01

To keep your applicator running properly, it’s important to clean allremovable nozzles each week. This removes excess dirt and charredmaterial that can clog the system and cause poor performance.

Use this procedure to clean removable nozzles.

1. Heat the gun to operating temperature.

2. Press the PUMP key to turn the pump off. The PUMP light goes off.


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

Fig. 8-16 Pump Key

5. Place a container beneath the drain valve, and turn the valvecounterclockwise to open it.

6. Reduce the gun air pressure to 0.


Cleaning Removable Nozzles

4103287

5940157

4204026

Maintenance 8-11


237 500EIssued 9/05

Manual 41-TM4-MA-01

7. Place a container beneath each nozzle, and remove the nozzles.

Fig. 8-18 Removing Nozzles

8. Place the nozzles in a container of cleaning fluid, such as Type Rfluid, and heat the fluid to the melting temperature of the adhesive.

Fig. 8-19 Soaking the Nozzles in aHeated Cleaning Fluid

9. Clean the nozzle bore with the appropriate probe. Insert the probeinto the nozzle in a direction opposite to the flow of adhesive.

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

11. Reassemble the nozzles onto the guns.

12. Close the drain valve.


14. Return the gun air pressure to the normal setting.


Fig. 8-20 Cleaning the Nozzle Bore

4107056

4130016

Maintenance8-12


237 500EIssued 9/05

Manual 41-TM4-MA-01

To keep your applicator running properly, it’s important to flush the entiresystem periodically with adhesive or with a flushing material. Thisremoves excess dirt and charred material that can clog the system andcause poor performance.

You should also flush the system when you switch to a new type ofadhesive that is incompatible with the old material. In this case, youshould flush the entire system before running the new material through it.If you are unsure whether the materials are compatible, contact yourmaterial supplier.

Use this procedure to flush your applicator of char and contaminants.

1. Relieve system pressure by following the procedure Relieving SystemPressure given earlier in this section.

2. Press the PUMP key to turn the pump off. The PUMP light turns offand the pump stops.

Fig. 8-21 Pump Key

3. Turn the air pressure regulator fully counterclockwise to reduce pumpair pressure to 0.

Fig. 8-22 Reducing Pump AirPressure to 0

Flushing the System

Maintenance 8-13


237 500EIssued 9/05

Manual 41-TM4-MA-01

4. Pump as much adhesive from the system as possible using one ofthe following methods:

Method of Draining Description

Gun Place a suitable containerbeneath each gun nozzle.Remove each nozzle from its gunand pump the adhesive outthrough the gun.

Manifold Place a suitable containerbeneath the manifold drain valveand pump the adhesive outthrough the manifold.

Hose Disconnect a hose from its gun.Replace the dust covers, whichwere removed during installation,over the electrical receptacle.Position the hoses over a suitablewaste container and secure them.Pump the adhesive out throughthe hose.

4103998

Fig. 8-23 Methods of Draining the Applicator

1. Draining through the gun 2. Draining through the manifold 3. Draining through the hose

4110132

Maintenance8-14


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. Disconnect each hose in the system from its gun.

6. Clean each gun in the system as needed. Refer to the gun manualfor information on gun disassembly, cleaning, and rebuilding.

7. Remove the lockout and restore power to the applicator.

8. Determine which method of flushing the system is best for youroperation. Refer to Table 8-2.

Fig. 8-24 Removing Power Lockout

Table 8-2 Advantages and Disadvantages of Flushing Procedures

FlushingProcedure

Time Needed

(See Note A)

Best Uses

(See Note B)

Advantages and Disadvantages

Using adhesive About 1 hour Routine cleaningwhen the system isrelatively free of char.

The main advantage of this procedure is that itresults in less downtime. However, it is not asthorough as the other two methods and is bestfor regular cleaning.

Using a flushingmaterialrecommended byyour adhesivesupplier andapproved by yourNordsonrepresentative

From 2 1/2 to5 hours

Occasional cleaningwhen there is somechar buildup.

Although this procedure causes some downtime,it does a good job of cleaning the system fromchar buildup. However, you may need to scrubthe tank to remove char from it. You will alsoneed to purchase and store flushing material,which may have special storage and disposalrequirements.

Using Type R fluid From 3 to13 hours

Thorough cleaningwhen there issignificant charbuildup.

This procedure can cause the most downtime;however, it is the most thorough way to removechar. You may also need to scrub the tank toremove all char. Disadvantages are that youcannot flush Type R fluid through the hoses;accidentally doing so can cause longerdowntime. Type R fluid is expensive if used onlyonce. It can, however, be reused several timesby straining the used fluid into a storagecontainer. The fluid is considered a regulatedwaste.

NOTE A: Time needed varies depending upon how much char must be removed.

B: Because operating conditions vary from plant to plant, you may find that more or less frequentmaintenance is required.

Flushing the System (contd)

4904034

1

2

4107056

Maintenance 8-15


237 500EIssued 9/05

Manual 41-TM4-MA-01

9. Refer to one of the following procedures as appropriate:

� Flush the System With Adhesive� Flush the System With a Flushing Material� Flush the System With Type R Fluid

Flush the System With Adhesive

Before beginning this procedure, first complete the procedure Preparingto Flush the System given earlier.

NOTE: This procedure describes how to flush all hoses at once.However, for maximum cleaning of badly charred hoses, use thisprocedure and flush each hose, one at a time.

1. If you have not already done so, secure the free end of each hose toa container that will be used to collect the adhesive.

2. Using a metal or plastic scoop, place several pounds of fresh, cleanadhesive into the empty tank up to 25 mm (1 in.) of the top of thetank.

3. Wait for the system to reach operating temperature.

Fig. 8-25 Preparing to FlushMaterial Through a Hose

1. Hose2. Waste container


Fig. 8-26 Pump Key

4130017

4130016

4107056

Maintenance8-16


237 500EIssued 9/05

Manual 41-TM4-MA-01

5. Gradually increase pump air pressure by turning the air pressureregulator clockwise to pump adhesive through the system until thematerial is free of char and contaminants.

Fig. 8-27 Increasing Air Pressureto Pump Material

6. Decrease pump air pressure to 0 by turning the valve fullycounterclockwise.

Fig. 8-28 Reducing Pump AirPressure to 0


CAUTION: If the tank will be scrubbed, drain all adhesive fromthe tank.

Fig. 8-29 Pump Key

Maintenance 8-17


237 500EIssued 9/05

Manual 41-TM4-MA-01

CAUTION: Using a metal brush or scraper to clean the insideof the tank can damage the PTFE coating. Use a stiff bristledbrush to clean the inside of the tank.

8. Scrub the PTFE-coated tank with a stiff-bristled, nonmetal brush orsimilar tool. Do not use a metal brush or scraper; these tools candamage the PTFE coating.

9. After scrubbing the tank thoroughly, wipe clean the tank sides andbottom.

NOTE: If this procedure does not remove all the charred material,you may need to replace the tank. Refer to Tank and Manifold,Section 7.

10. Flush the applicator with fresh adhesive.

11. Follow the procedure Cleaning a Manifold Filter in this section.

12. The procedure Restoring the Applicator After Flushing the System,later in this section, describes how to restore the applicator tooperation.

Flush the System With a Flushing Material

WARNING: Use the flushing material at the manufacturer’srecommended temperature, which will be below the adhesive’sflash point. Failure to observe this warning can cause a fire.

WARNING: Never flush your system or clean any aluminumcomponents with halogenated hydrocarbon cleaning solutions.These cleaning solutions are extremely dangerous when usedto clean aluminum components in a pressurized fluid system.

4904034

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2

Maintenance8-18


237 500EIssued 9/05

Manual 41-TM4-MA-01

Flush the System With a Flushing Material (contd)

CAUTION: Do not use this procedure to flush your system withType R fluid. This procedure instructs you to pump flushingmaterial through the hoses. Flushing Type R fluid throughhoses can cause large pieces of char to break off and clog thenozzles during later operation. If you will use Type R fluid toflush your system, refer to the procedure Flushing the Systemwith Type R Fluid.

CAUTION: Certain flushing materials can damage seals ando-rings, resulting in poor pump performance. Be sure that theflushing material you will use has been approved by yourNordson representative.

To determine the best flushing material to use, contact your adhesivesupplier.

Before beginning this procedure, first complete the procedure Flushingthe System given earlier in this section.

NOTE: This procedure describes how to flush all hoses at once.However, for maximum cleaning of badly charred hoses, use thisprocedure and flush each hose, one at a time.

1. If you have not already done so, secure the free end of each hose toa container that will be used to collect the adhesive.



Maintenance 8-19


237 500EIssued 9/05

Manual 41-TM4-MA-01

2. Set the tank and hose temperature to the recommended temperatureof the flushing material. Refer to the procedure ProgrammingTEMPERATURE Controls given in Operation, Section 4.

3. Pour the flushing material into the empty tank up to 25 mm (1 in.) ofthe top of the tank.

4. When the applicator reaches the preset temperature, press thePUMP key. The PUMP light turns on and the pump starts.

5. Gradually increase pump air pressure by turning the air pressureregulator clockwise and pump material through the hoses until theflushing material starts to come out.

6. Decrease pump air pressure to 0 by turning the air pressure regulatorfully counterclockwise.

7. Press the PUMP key to turn the pump off.

8. Allow remaining material to drain from the hoses. Then, remove thehoses from the collecting container, place them over the tank so thatadhesive flows into the tank. Secure the hoses.

9. Press the PUMP key to turn the pump on. The PUMP light turns onand the pump starts.

10. Increase pump pressure by turning the air pressure regulatorclockwise so that the flushing material circulates through the systemwithout splashing out of the tank. Allow the system to circulate for 1.5 to four hours.

11. Press the PUMP key to turn the pump off.

12. Decrease pump air pressure to 0 by turning the air pressure regulatorfully counterclockwise and wait for material to finish draining from thehoses.

4904034

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2

Maintenance8-20


237 500EIssued 9/05

Manual 41-TM4-MA-01

Flush the System With a Flushing Material (contd)

13. Remove the hose from the tank, secure it over a waste container.

14. Press the PUMP key to start the pump. Increase the air pressure atthe regulator and drain the flushing material from the tank into thecontainer.

CAUTION: Verify that all adhesive has completely drained fromthe tank before scrubbing the tank.



CAUTION: Using a metal brush or scraper to clean the insideof the tank can damage the PTFE coating. Use a stiff bristledbrush to clean the inside of the tank.

15. Scrub the PTFE-coated tank with a stiff-bristled, nonmetal brush orsimilar tool. Do not use a metal brush or scraper; these tools candamage the PTFE coating.

16. Wipe the tank walls and bottom to remove any char and debris.

NOTE: If this procedure does not remove all the charred material,you may need to replace the tank. Refer to the procedure forreplacing the tank in Tank and Manifold, Section 7.

17. Using a metal or plastic scoop, place several pounds of fresh, cleanadhesive into the empty tank up to 25 mm (1 in.) of the top of thetank.

18. Set the temperature of the tank to the lowest temperature that theadhesive can be pumped. Refer to the procedure ProgrammingTEMPERATURE Controls in Operation, Section 4.

19. Wait for the system to reach the preset temperature. Then, drainthree-fourths of the adhesive through the hoses into the wastecontainer.

Maintenance 8-21


237 500EIssued 9/05

Manual 41-TM4-MA-01

20. After you have drained three-fourths of the material, press the PUMPkey to turn the pump off.

21. Reduce the pump air pressure to zero by turning the air pressureregulator fully counterclockwise.

22. Place a suitable container beneath the manifold drain valve, turn thevalve counterclockwise, and drain the remaining adhesive through themanifold drain valve.

23. Clean the manifold filter. Refer to the procedure Cleaning a ManifoldFilter given earlier in this section.

24. To restore the applicator to operation, refer to the procedureRestoring the Applicator After Flushing the System given later in thissection.

Flush the System With Type R Fluid

Use this procedure to flush your applicator with Type R fluid.

Before beginning this procedure, first complete the procedure Flushingthe System given earlier in this section.

1. Set the tank temperature 13.9-16.7 �C (25-30 �F) higher than therecommended application temperature of the adhesive. Refer to theprocedure Programming TEMPERATURE Controls in Operation,Section 4.

2. Pour Type R fluid into the empty tank up to 25 mm (1 in.) of the top ofthe tank.

3. Use a clean paint brush or similar tool to apply fluid to areas notsubmerged in the fluid.

4. Allow the fluid to heat in the tank for 2 to 12 hours.

5. As needed, use a wooden or plastic strainer to skim char andadhesive that floats to the top of the tank.

4103997

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Maintenance8-22


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Manual 41-TM4-MA-01

Flush the System With Type R Fluid (contd)

CAUTION: 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.

6. Place a suitable container beneath the manifold drain valve, turn thevalve counterclockwise, and drain the fluid through the manifold drainvalve.

NOTE: You can reuse the fluid if you place a strainer over the top ofthe container used to collect it.

Fig. 8-32 Draining the FluidThrough the Manifold

7. Close the manifold drain by turning the valve clockwise.

8. Using a metal or plastic scoop, place several pounds of fresh,uncontaminated adhesive into the empty tank.

9. Set the temperature of the tank and hoses to the lowest temperaturethat the adhesive can be pumped. Refer to the procedureProgramming TEMPERATURE Controls in Operation, Section 4.

10. Secure the free end of the hose to a container that will be used tocollect the Type R fluid.



4107056

4130017

Maintenance 8-23


237 500EIssued 9/05

Manual 41-TM4-MA-01

11. When the tank and hoses reach their setpoint temperatures, turn thepump on by pressing the PUMP key.

Fig. 8-34 Pump Key

12. Gradually increase pump pressure by turning the air pressureregulator clockwise to pump adhesive through the hoses.

Fig. 8-35 Increasing Air Pressureto Pump Material

13. Continue pumping adhesive into the waste container until a clean,steady stream of material flows from each hose.

14. When material has finished draining, press the PUMP button to turnthe pump off, then reduce the pump air pressure to zero by turningthe air pressure regulator fully counterclockwise.

15. To restore the applicator to operation, refer to the procedureRestoring the Applicator After Flushing the System given in thissection.

Maintenance8-24


237 500EIssued 9/05

Manual 41-TM4-MA-01

After flushing your system with hot adhesive, a flushing material, or TypeR fluid, follow this procedure to prepare your applicator for operation.

1. Disconnect and lock out power to the applicator.

2. Reconnect each gun to its hose both electrically and mechanically.Refer to Mechanical Installation and Electrical Installation inInstallation, Section 3.

3. Remove the lockout and restore power to the applicator.

4. If you have changed the temperature setpoint or the recommendedoperating temperature of the new adhesive is different than theadhesive you were using, reprogram temperature settings. Refer tothe following procedures given in Table 8-3.

Table 8-3 Reprogramming Temperature Settings

Setting Procedure

Overtemperature setpoint Programming SYSTEM SETTINGSControls in Operation, Section 4

SETPOINT or STANDBYtemperature

Programming TEMPERATUREControls in Operation, Section 4

5. Return the pump air pressure to its operating setting.

6. Use a metal or plastic scoop and fill the tank with adhesive. Ifnecessary, refer to Filling the Tank with Adhesive in Operation,Section 4.


Restoring the Applicator AfterFlushing the System


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 9

Wiring Diagrams and Schematics

Wiring Diagrams and Schematics9-0


237 500EIssued 9/05

Manual 41-TM4-MA-01

Wiring Diagrams and Schematics 9-1


237 500EIssued 9/05

Manual 41-TM4-MA-01

Section 9Wiring Diagrams and Schematics

The wiring diagrams contained in this section are based on the voltagecode of your unit. Refer to the following table to determine the voltagecode of your unit; then refer to the appropriate wiring diagram in thissection.

Table 9-1 Unit Voltage Codes and Applicable Wiring Diagrams

UnitVoltageCode

Specification

(See Note A)

Type of service you can connect to the unit: Part of this sectionto refer to:

1 3/PE 200−240 V 200−240 VAC 1∅ (two-wire service without a neutral) Voltage Code 1Wiring Diagram

200−240 VAC 3∅ (three-wire service without aneutral)

NOTE A: This specification is printed in the VOLTS (AC) portion of the identification plate on your unit.

Each wiring diagram is contained on two facing pages. Sometimes awire shown on one page is connected to terminals or components shownon the facing page. In these cases, the connecting wiring is labeled oneach page with the same letters. For example, if you want to trace a wireor harness labeled BL on the left page, look for a wire or harness labeledBL on the right page.

Each wiring diagram shows all of the options or special features the unitcan be equipped with. Options and special features are indicated bydotted lines. To determine the features and options of your unit, refer toExplanation of Configuration Code at the end of the Description section.

NOTE: The wiring diagrams and schematics in this section apply to TM4units. If your unit has optional equipment (for example, hoses 5 and 6and/or I/O signaling) use the wiring diagrams and schematics for unitswith optional equipment.

1. Introduction

2. Use of Wiring Diagrams



237 500EIssued 9/05

Manual 41-TM4-MA-01

CONNECTION

4130613

L2

L1

L3

N

1

4321

56

NO WARNING

NO FAULT

READY

POWER SUPPLY+5VDC

+12VDC-12VDC+24VDC

CONTROL BOARD

DISPLAY BOARD

KEYPAD

POWERK1

X3

X4

XP1

XP3

XP4A

PL1

J2

J9

X2

X1

XS2

XS1

INDICATORPOWER

TB1

SWITCHES

XP2

XP1

J4

TB2

POWER ON/OFF

READY

FAULT/WARNING

F9 F10

TANK HEATER

HOSECONNECTORS

HC1

HC2

HC3

HC4

TANKRTD

CONNECTIONTANK RTD

1234

TB1A

TB1B

TB1C

TB1D

F11

2

45

F12

F1

F2

F3

F4

F5

F6

F7

F8

POWER BOARD

DIGITALPROCESSOR

TANK

PNEUMATIC

OVERTEMPERATURETHERMOSTAT

VALVESOLENOID

TANKTHERMOSTAT

SOLENOID

CONNECTION

Fig. 9-1 Basic System Schematic (1 of 2)

Basic TM4 ApplicatorSchematic



237 500EIssued 9/05

Manual 41-TM4-MA-01

PEGND

GNDPE

4107058

LOAD CONFIGURATION FOR 230V 1 PHASE

TANK

N

L2L3

L1

TB1

1−4H/G

L3TANKN

1−4H/G

LOAD CONFIGURATION FOR 400V/230V 3 PHASE

L1L2

TB1

Fig. 9-2 Basic System Schematic (2 of 2)



237 500EIssued 9/05

Manual 41-TM4-MA-01

CONNECTION

4107059

L2

L1

L3

N

1

4321

56

NO WARNING

NO FAULT

READY

POWER SUPPLY+5VDC

+12VDC-12VDC+24VDC

CONTROL BOARD

DISPLAY BOARD

KEYPAD

POWERK1

X3

X4

XP1

XP3

XP4A

PL1

XP5

XP6

J2

J9

X2

X1

XS2

XS1

INDICATORPOWER

TB1

SWITCHES

XP2

XP1

J4

TB2

POWER ON/OFF

READY

FAULT/WARNING

F9 F10

TANK HEATER

HOSECONNECTORS

PATTERN CONTROLLER OPTION)

HC1

HC2

HC3

HC4

(FOR SERIAL COMM OR

TANKRTD

CONTACTORBOARD

L1

L2

L3

N

XS4

J2C

XS3

XS2

XS1

I/O BOARD

PL2

CONNECTIONTANK RTD

J1CX1C

X2C

1234

TB1A

TB1B

TB1C

TB1D

F11

2

45

F12

F1

F2

F3

F4

F5

F6

F7

F8

POWER BOARD

DIGITALPROCESSOR

5/6

CONTROL

H/G

XS2H

XS1H

X2H

X1HHC5

HC6

X3H

TANK

PNEUMATIC

OVERTEMPERATURETHERMOSTAT

VALVESOLENOID

TANKTHERMOSTAT

SOLENOID

PARTS IN DOTTED LINES ARE OPTIONAL

CONNECTION

Fig. 9-3 TM4 Applicator With Optional Equipment Schematic (1 of 2)

Schematic for TM4Applicators With OptionalEquipment



237 500EIssued 9/05

Manual 41-TM4-MA-01

4107060

LOAD CONFIGURATION FOR 230V 1 PHASE

TANK

PEGND

N

L2L3

L1

TB1

1−4H/G

5&6H/G

L3

TANK

GNDPE

N

1−4H/G

5&6

LOAD CONFIGURATION FOR 400V/230V 3 PHASE

L1L2

TB1

H/G

Fig. 9-4 TM4 Applicator With Optional Equipment Schematic (2 of 2)



237 500EIssued 9/05

Manual 41-TM4-MA-01

HEATER

36

2

3

1

3

1

1

2

CONTROL

F12

F11

F8

F7

F6

F5 123456

8

X2

F4

F3

F2

F1

1

X3

1 3

L1

TB11 2 3 4 65T

B2

NO

WA

RN

ING

NO

FA

ULT

RE

AD

Y

J2

1

2

3

4

GNDPEL2 L3 N

TB

1AT

B1B

TB

1CT

B1D

X4

15

PO

WE

R O

N/O

FF

J4

2

3

4

K1

12345678

X1

POWER BOARD

2

TSTAT

SOLENOID

J9

PNEUMATICSOLENOID

VALVE

TANKOVERTEMP

THERMOSTAT

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

DIGITAL PROCESSORCONTROL

XP

4A

XP2

2

3

1

3

1

2

POWERSUPPLY

PL1

DIS

PLA

Y B

D

7

XP3

XP1

36

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

36

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

BOARD

XS1

XS2

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC1

GUN1

101

4

611859312

27

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC2

GUN2

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC3

GUN3

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC4

GUN4

HG1

HG2

HG3

HG4

CONTROL FRAME G1

TOP COVER G5

G3

GND

4107064

HEATER

RTD

TANK/RESTANK/RES RTD1 1

2 2

XP2B XP2A

5

F9

F10

22A

11A

PO

WE

R

IND

ICA

TO

R

HEATSINK

XP

1

KE

YP

AD

Fig. 9-5 Wiring Diagram for Basic TM4 Applicator (1 of 2)

Basic TM4 Applicator WiringDiagram



237 500EIssued 9/05

Manual 41-TM4-MA-01

4107061

SOURCE WIRE LOCATION

GROUND STACK LIST

CONTROLFRAME

H/G1

H/G2

TANK

TOPCOVER

H/G3

H/G4

G1

HG1

HG2

G3

G5

HG3

HG4

1

2D

3D

3A

2B

2C

3C

LEVEL 5

LEVEL 4

LEVEL 3

LEVEL 2LEVEL 1

A

B

C

D

X4 1

X31

153

X4 1

X31

153

230V 1 PHASE400V/230V 3 PHASE

X3 & X4 CONNECTIONS

Fig. 9-6 Wiring Diagram for Basic TM4 Applicator (2 of 2)



237 500EIssued 9/05

Manual 41-TM4-MA-01

HEATER34

8

36

2

3

1

12

3

1

1

2

CONTROL

F12

F11

F8

F7

F6

F5 123456

8

X2

F4

F3

F2

F1

1

X3

1 3

L1

TB11 2 3 4 65T

B2

NO

WA

RN

ING

NO

FA

ULT

RE

AD

Y

J2

1

2

3

4

GNDPEL2 L3 N

TB

1AT

B1B

TB

1CT

B1D

X4

15

PO

WE

R O

N/O

FF

J4

2

3

4

K1

12345678

X1

POWER BOARD

2

TSTAT

SOLENOID

BC

J9

PNEUMATICSOLENOID

VALVE

TANKOVERTEMP

THERMOSTAT

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

DIGITAL PROCESSORCONTROL

XP

4A

XP2

2

3

1

3

1

2

POWERSUPPLY

PL1

DIS

PLA

Y B

D

7

XP3

XP1

BA

XP

5

J1I/O

XP936

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

36

1

23

45678

910

11121314151617

1819

2021222324252627

2829303132333435

1

2

5

67

1234

5

TB

10 &

TB

20

I/OS

IGN

ALS

BOARD

XS1

XS2

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC1

GUN1

101

4

611859312

27

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC2

GUN2

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC3

GUN3

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC4

GUN4

HG1

HG2

HG3

HG4

BF

BD

CONTROL FRAME G1TOP COVER G5EXPANSION BASE PLATE G6

G3

GND

4107062

HEATER

RTD

TANK/RESTANK/RES RTD1 1

2 2

XP2B XP2A

5

F9

F10

HG5, HG6

PARTS IN DOTTED LINES ARE OPTIONAL

PRESENT WHEN OPTIONAL HOSE/GUN

XP1

KEYPAD

22A

11A

PO

WE

R

IND

ICA

TO

R

HEATSINK

5 AND 6 ARE INSTALLED

Fig. 9-7 Wiring Diagram for TM4 Applicators With Optional Equipment (1 of 2)

Wiring Diagram for TM4Applicators With OptionalEquipment



237 500EIssued 9/05

Manual 41-TM4-MA-01

XS3A,B,C,D

XS2A,B

4107063

BA

L1

L2

L3

N

F1

F2

F3

X1C 1

15

X2C

12

XS4A,B,C

XS1A

K1

J1C J2C

1 2

BC

CONTACTOR BOARD

1 2

1 2

HG5, HG6

101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC5

GUN5

HG5

F3

F4

4321

F1

F2

4321

5 4 1 2 3 X3H

X1H

X2H

XS1H

XS2H

1 2 3 4 5 101

4

611859312

27

HEATER

RTD

HEATER

RTD

5 5

3 34 41 1

2 2G G

HC6

GUN6

HG6

BD

HOSE/GUN BOARD

BF

X1C

1

15

X2C

12

1

230V 1 PHASEX1C

1

15

X2C

12

1

400V/230V 3 PHASE

X1C & X2C CONNECTIONS

SOURCE WIRE LOCATION

GROUND STACK LIST

CONTROLFRAME

H/G1

H/G2

TANK

TOPCOVER

EXP.BASEPLATE

H/G3

H/G4

G1

HG1

HG2

G3

G5

G6

HG3

HG4

1

2D

3D

3A

2B

5D

2C

3C

LEVEL 5

LEVEL 4

LEVEL 3

LEVEL 2LEVEL 1

A

B

C

D

H/G5

H/G6

HG5

HG6

4C

4D

X4 1

X31

153

X4 1

X31

153

230V 1 PHASE400V/230V 3 PHASE

X3 & X4 CONNECTIONS

43

8

7

5

621

1

Fig. 9-8 Wiring Diagram for TM4 Applicators With Optional Equipment (2 of 2)



237 500EIssued 9/05

Manual 41-TM4-MA-01

DECLARATION of CONFORMITY(For CE Certified Adhesive/Sealant Application Equipment)

PRODUCT:

Model TM4/14 Series Hot Melt Application Systems

APPLICABLE DIRECTIVES:89/392/EEC (Machinery Directive)73/23/EEC (Low Voltage Directive)89/336/EEC (Electromagnetic Compatibility Directive)

EN ISO 12100 EN60204-1EN563 EN61000−6−2EN55011

This product has been manufactured according to good engineering practice.

The product specified conforms to the directive and standards described above.

STANDARDS USED TO VERIFY COMPLIANCE:

Nordson Corporation � Duluth, Georgia

DOC006

PRINCIPLES:

Date: 6 September 2005Donald J. McLane, Senior Vice President

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