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1. See Chapter 7 for detailed drawings of printed circuit boards and modules g PAGE INDEX a 2 PAGE 1 POWER BOARDS 24 5 PAGE 2 POWER SUPPLY CONFIGUR a o g 5 PAGE 3 CONTROLLER BOARD
2. OPERATOR PANEL er eve ai a 2 E E 9 C DYNATEC ONLY 13 a eu 39 M 2 Bl x e 2 s 78 z l 1 98 arr 23 ud zd 2x D o co dH dn o X Om om Om gt z L J fm IS Je em Ig le E Bee 2 4 gt m a bad LS P eve P PN 115893 lt m Bel B lo le lo gt ln 8 FROM RED POWER PN sese sese eee Sees BEBE SUPPLY COM ERES ERRE ERRE ERRE BREE elle Ble BP G9 RATE G9 G9 G9 G9 bd 000 0000 HOO bpooo eooo zog lt Cum A 7 xo x3 x4 X X6 X X10 24V ae OUTPUT OUTPUT l i V6 TEMP16 115735 V6 BASE4 PN 115734 POS N l l l l l 1 1 I INPUT MOT DRIVER gt gt u s z922259 8888 ea rg 982520 OUT1 5 OUT6 10 OUT11 15 22222 2 oof Fog VT 2zo0o0 4 Y m O OUT16 A EEN TER 60696909 506969069 0 11600 600960600909 69690909 PUMP PEE E ENABLE Y n PISTON Ka PUMP T jh emm uw a
3. gua 50 5 1 99 5 amp Seis 5 os a 9 Mrs 3 E oo e t i LT g r LI y zt E x e 127 5 502 508 5 20 02 Description amp Specifications Page 2 7 Revised 4 12 210 0 20 39 Installation amp Clearance Dimensions DM 5810 10 kg 20 Ib Hopper Capacity Page 2 8 Description amp Specifications ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Amperage Calculation The Amperage Calculation chart assumes standard ITW Dynatec equipment Applicator head air heater width is typically equal to the applicator s service block width For non standard equip ment read the amperage from the equipment s data tag or consult with ITW Dynatec s Customer Service Dept Wire gauge calculation assumes wire ratin
4. Component Illustration PN 115881 Sheet Metal Assembly Page 10 4 Component Illustrations Revised 6 13 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 115898 Electronics Assembly Piston Pump Item 4 5 6 9 10 11 12 13 15 16 17 18 19 21 22 23 24 25 26 29 PN 115729 115808 115823 115732 115738 115733 115734 115735 117382 117479 680159 115719 105162 106328 117143 117477 105251 105252 117370 105256 115015 Qty NN HB HB B B QU N B BN HB Description Din Rail Power Board Bracket Disconnect Switch Assy Main Power Board Power Supply 24vdc Auxiliary Power Board V6 Base Module V6 Temperature Module V6 Ethernet Module Option Phillips Pan Hd M4x8 Black w Wshr V6 LCD Control Assy Screw M3x6 Phillips SHC Screw M4x16 Zinc Signal Isolator V6 Option Level Sensor Control Assy Blk Term Dual Wk4e U 10a Endplate for 105251 Swirl Trigger Board Assy Option End Stop Din Rail ES35 Screw FH CR M4x0 7x10 Blk Revised 6 13 Component Illustrations Page 10 5 DYNAMELT S ASU Manual 20 59P ITW Dynatec c 2012 gt 78 IPR Eu f lt x J J 2 Q 22 G Component Illustration PN 115898 Electronics A
5. rwDynatec Llum ve TEMP PN 115738 PN 117382 S N xooooxx WO ITW Dynetec 117382 Rev x RoHS 5 SWIRL KIT OPTION PUMP ENABLE HAND APPLICATOR L 22 gt WHT RED TRIGGER SWITCH 6 X235 25 52 WHT BK HS TRIGGER PCB ur HAND APPLICATOR 1 22 2 gt WHT RED 117240 TRIGGER SWITCH 5 X 25 2 3 52 WHT BK pe uu ar I SOLENOID EE gt H4 COM 5 8015 TRGS HAND APPLICATOR 22 2 gt WHT RED E lici TRIGGER SWITCH 4 1235 2 5 x WHT BK nem come SOLENOID L VALVE 4 H3 Toi Q gos HAND APPLICATOR 122 225 mez Oe SOLENOID TRIGGER SWITCH 3 125525 2 WHT BK Q 1 VALVE 3 M 220 H2 TRGI SOLENOID HAND APPLICATOR 292 1 gt WHT RED 8 VALVE 2 TRIGGER SWITCH 2 X235 25 WHT BK H1 SOLENOID 1 VALVE 1 APPLICATOR 1 22
6. 4 1 Defining DynaControl Temperature Control Terms 4 1 DynaControl V6 Display During Normal Operating Mode 4 3 Error Indication Alarms 0 4 3 Optional System Status Stack Lights 4 5 Settings for a Typical Operation 034 4 5 System Values that are Factory Programmed not customer accessible 4 6 Customer Programmable System Values Preset at the Factory 4 6 Page iv Table of Contents ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Default Settings of the DynaControl Controller 1 4 7 Optional Line Speed 4 8 Helpful Tips for the User uy ur e ete RU et PU unten IC NRI UR E a CRUS 4 8 Controller Features J usss ee pere re rele ne e rre elec once koe eg 4 8 Chapter 5 Programming of DynaControl Controller DynaControl V6 LCD Interface 2 5 1 IrixGen ral ku ga rine xcii RERO P REOR Def REL ie REPRE OR REGEL ES Ee IU 5 1 Overview Screen Reference
7. 655 0 25 79 633 0 24 92 368 0 14 19 285 5 11 24 50 5 199 OW m e e 8 at 5 94 e 0 5 20 0 0 79 324 0 12 76 127 5 5 02 508 5 20 02 10 0 20 39 Description amp Specifications Page 2 5 Revised 4 12 Installation amp Clearance Dimensions DM SRO5 5 kg 10 Ib Hopper Capacity Page 2 6 Description amp Specifications ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P gt TR gt e re ZW OK 351 6 13 84 e 344 0 PE 375 8 14 79 388 1 15 28 37 5 1 48 862 5 33 96 699 5 27 54 186 4 7 34 Installation amp Clearance Dimensions DM 5810 10 kg 20 Ib Hopper Capacity ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P e 368 0 14 19 285 5 11 24 655 0 25 79 633 0 24 92
8. 4 5 2 Status Line 2 s deban hg re no t sob ge antes gr ete 5 3 Temperature Zone 1 5 4 5 3 Bar Graplis et Rn We ER HE acera 5 4 2 ER RS abe x SENS ATE SIE Qu We EA TS 5 4 To Navigate Away from Overview Screen 5 4 Setup Your System Parameters 5 5 Temperat re Zones 2 5 RR xe oe RR RR RE Ree UR dm uwa 5 5 Pump Settings E ss ML Ab bs hou ud hoste 5 7 Standard Piston Pump ASU 5 7 ASUs with Optional Line Speed Tracking 5 7 Main 5 9 Recipe Management 5 Ee e ace eds e au Su 5 9 Standby Setback een da see ta dre ra D esa whe d E erit e eats 5 10 Setpoint Locking ever Rer me ed Gh wh VE EM ESTHER Via E eee tate eee 5 11 7 Day Sched ler Rune Sb RICE RUP Rb S ER e Reed 5 12 Current Time of Day and 5 13 NfO SCLER ss n esr etu ease ait IRURE eee ees EE QS 5 14 System Configuration Menu 5 15 Accessing the Parameters 5
9. L Special or customized versions 000 Standard version available on request E External autozero inches OUTPUT SIGNAL 4 20mA E VERSION Rigid stem 0 Rigid stem flexible 1 With thermocouple 2 Exposed capillary 3 CONNECTOR Standard 6 pin 6 8 pin 8 ACCURACY CLASS 0 25 FSO 4 ranges 100 bar 1500 psi 0 5 FSO M RANGE bar psi 35 B35U 500 PO5C 50 B05D 750 P75D 70 B07D 1000 PO1M 100 BO1C 1500 P15C 200 BO2C 3000 350 B35D 5000 P05M 500 B05C 7500 P75C 700 B07C 10000 P10M 1000 B01M 15000 P15M Examples Magnetic autozero FLEXIBLE LENGTH Standard WE0 0 none Standard WE1 WE2 D 457mm 18 E 610mm 24 F 760mm 30 Standard WE3 L 711mm 28 Available on request A 76mm 3 B 152mm 6 C 300mm 12 RIGID STEM LENGTH mm inches Standard WE1 WE2 4 153mm 6 5 318mm 12 5 Standard WE3 0 none Available on request 1 38 1 5 2 50mm 2 3 76mm 3 6 350mm 14 7 400mm 16 8 456mm 18 max combined stem flexible length is 914mm 36 THREAD Standard 1 1 2 20 UNF 4 18 1 5 WE2 6 M B07C 1 4
10. 11 9 Appendix Pressure Transdueer RR ce ene E eC MERE nacre ee yrs Appendix 1 Signal Isol atOF zs Meer s ett eet eo Re oe td ae es d air co ccu Appendix 5 ITW Dynatec c 2012 ALL MODELS All operators and service personnel must read and understand this manual before operating or servicing equipment Safety Page 1 1 Revised 8 13 Chapter 1 SAFETY PRECAUTIONS All maintenance and service on this equipment must be performed by trained technicians Safe Installation amp Operation Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections To avoid possible failure of hoses make sure all hoses are routed to avoid kinking tight radius turns 8 or less and abrasive contact Hot melt hoses should not have prolonged contact with heat absorbing surfaces such as cold floors or metal troughs These heat absorbing surfaces can alter adhesive flow and cause incorrect calibration Hoses should never be covered with materials that prevent heat dissipation such as insulation or sheathing Hoses should be spaced apart from each other not making direct contact Do not use adhesive that is dirty or that may be chemically contaminated Doing so can cause system clogging and pump damage When adhesive hand held applicators or other movable applicators are used never point them at yourself or at
11. TO BASE TO POWER TO POWER TO POWER MODULE MODULE 1 MODULE 2 MODULE 3 Page 7 10 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P V6 Power Module PN 115732 The V6 POWER module provides controlled power to the heater of the first five zones It receives its control signals from the V6 TEMP module The Power Module also has protected outputs for the DC power supply and motor drive Fuses under Connect to protective cover V6 TEMP Module V6 POWER PN 115732 Head 2 Heater EN Hose 2 Heater 3 Voltage Configuration Connector Head 1 Heater o Hose 1 J TT Heater i gt Power supply for additional power boards Hopper Heater Trigger L1 gt Motor Drive 4 gear pump lt models N Trigger N DC Power gt supply Main Voltage Supply from main On Off switch ITW Dynatec c 2012 Troubleshooting Page 7 11 DYNAMELT S ASU Manual 20 59P Revised 4 12 V6 Power Module cont Fuses The fuses of the POWER Module are located underneath a protective cover The cover should only be removed after the ASU is switched Off and disconnected from the main power supply After checking or replacing fuses the cover must be re installed Heater and motor driver circuits are fused on both
12. Input Options Output Input Opt Output NOTE It is also possible to set the dip switches using the wizard of the configuration software following the procedure described in the section Configuration by PC until the step 6 and clicking on Switch DIP SWITCH CONFIGURATION TABLES TAB 1 Settings Input Output Options swi Sw1 Sw1 1234 96 5 Out BARR BRR 20 B Direct BARR o 20mA JAR 4 20mA Reverse 4 20ma o 10v 10 li 2 10 v RBBR 2 10 v OSV MIN 5v NOTES If the dip switches SW1 1 4 are all set in the position 0 Default the device will follow the configuration programmed by PC Input and output type and options Eventual wrong dip switches settings will be signalled by the blinking of the led PWR
13. Accuracy 1 H lt 0 25 FSO 100 1000 bar M lt 0 5 FSO 35 1000 bar Resolution Infinite Measurement range 0 35 to 0 1000bar 0 500 to 0 15000psi Maximum overpressure without degrading performances 2xFS 1 5 x FS above 500bar 7500psi Measurement principle Extensimetric Power supply 10 30Vdc Maximum current absorption 32mA Insulation resistance at 50Vdc gt 1000 MOhm Output signal Full Scale FSO 20mA Zero balance 4mA tollerance 0 25 FSO Zero signals adjustment tollerance 0 25 FSO Autozero function Span adjustment within 5 FSO See Manual Maximum allowed load See diagram Response time 10 90 FSO 4ms Output noise RMS 10 400Hz lt 0 025 FSO Calibration signal 80 FSO Output short circuit ingress and reverse YES polarity protection Voltage spike protection gt 2KV burst test to EN61000 4 4 CE conformity 89 336 direttive EMC Emissions EN61000 6 3 Immunity EN61000 6 2 10V m Compensed temperature range 0 85 C Operating temperature range 30 105 Storage temperature range 40 125 Thermal drift in compesated range Zero Calibration Sensibility lt 0 02 5 Diaphragm maximum temperature 315 C Zero drift due to change in process temperature zero lt 0 04 bar C Zero drift temperature for Autocompensated version SP wi
14. gt WHT RED TRIGGER SWITCH 1 X 255 2 5 WHT BK 1 RED BLK V6 BASE P MODULE 1 TOMAINPOWER SUPPLY INPUT N z SEE PAGE 1 BLK T z22222 m Sida 222222 590909090909 69690690909 19090 L ume z T power SUPPLY PS2 ONLY REQUIRED FOR SWIRL KITS 2 PS3 g wl gt m gt 5 POWER SUPPLY PS3 ONLY PUMP wae p REQUIRED WHEN MORE ENABLE Bx 352 SD Z THAN 4 SWIRL KITS ARE ano 23 connected NOTE CHANGE ACCEL DECELERATION PARAMETERS C1 01 C1 02 to 1sec HARTING CONNECTOR OPTION ks RELAY1 RD 2 RDY 3 RELAY2 ALARM 4 s 5o o0 RELAY3 AUX N e 6 24V 6 6 8 GND x Tu 9 INT STAND BY ETE 10 IN2 TBD Q 9 14 IN3 TBD W2 j IN6 PUMP START Han M10B BULKHEAD MOUNT WITH Han C DD INSERTS L1 L2 L3 Schematics DM SR5 10 Control Modules PN 115894 Rev E page 5 of 5 Page 11 8 Schematics ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59 SEE SCHEMATICS FOR TERMINATION AT THE UNIT Audible Alarm Green GASKET STACKLIGHT BASE CINCLUDED WITH ITEM 2 242526 Item No PN Qty
15. s ls gt ls gt s N N N m Ne w r N ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Wattage Chart Description amp Specifications Page 2 9 Revised 4 12 The Wattage Chart shows the maximum current of the power service and the main power switch size Use it to determine the adequate power service for your ASU Hopper Hose amp Head Hose amp Head 1 2 3 4 SR05 102 Hoses SR05 10 4 Hoses SR10 6 Hoses Main Switch 3PH 400V Wye SR05 102 Hoses 20 Amp PN 116879 SR05 10 4 Hoses 20 Amp PN 116879 SR10 6 Hoses 30 Amp PN 116879 The PN 115823 main switch 63 amp is used for all models Main Switch 3 PH 240V Delta 20 Amp PN 116879 30 Amp PN 116879 50 Amp PN 116879 Hose amp Head 5 6 Main Switch 1 PH 240V 30 Amp PN 116879 50 Amp PN 116879 Page 2 10 Description amp Specifications ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Dynamelt SR X N X XXXX X X XXXXXXXXX HOPPER SIZE 221 5 5kg 10 Ib 1 10kg 20 Ib NO DROP IN GRID N A drop in grid is not available for 5 amp 10 liter units NUMBER OF HOSES 2 4or 6 PUMP P12 Piston pump 12 1 standard PL12 Piston pump 12 1 oil or lotion GGS Gear pump 0 15cc single SHS Gear pump 8 5cc single high accuracy GGD Gear pump 0 15cc dual ZLS Gear pump 0 160cc single high accuracy GAS Gear pump 1 5cc single ZDS Gear pump 0 297cc single hi
16. e pie eos e eo Ho 2 9 DYNAMELT Model Designation Matrix 2 10 Chapter 3 Installation amp Start Up Components of the DYNAMELT ASU 3 1 Mounting the DYNAMELT 5 3 2 Lifting thie ASU y tea Dep beue mee ee mead de pes d elena sd Aa pires 3 2 lnstallatiGr ae REN de uui dae REO e Rue 3 3 Voltage Configuration Connector Schematics 3 5 Customer Electrical Connections 4 3 6 Adding AdhesiVe eere ERR reve om grece en et Sree ARR ene eine 3 7 Changing the Adhesive Formula 3 7 Repositioning the HMI Controller 3 8 Operation and Calibration of the Level Sensor 3 9 Field Installation of Controller Options 3 10 Typical Start Up and Shut Down Procedures 3 11 Storage and Disposal of the Application System 3 12 Chapter 4 DynaControl Controller Set Up Temperature Control Functions in General
17. 1 2 3 4 5 6 m gt N mS HOSE b MOT DRIVER gt gt 1 RD ORANGE d 3 T STAT V6 BASE MODULE mb _ h 2 ovr 29859 455248 i 99 oooooo 9090909 099 fans Ex OVT z200 C Li O HEAD s2 za 696969 69 w rs zy sk FIR H2 S52 2 2 L BLU Ex o1 U V 122 RED PN117143 N ol 6 5 ORANGE x Ei INPUT 19 x _ BLK LINE SPEED HOSE Cmm Ee BLK S o S VD OUTPUT 2 7 RED INPUT us SIGNAL ISOLATOR 5 m NOTE PLACE SHUNT JUMPER ON TEMP MODULE JTAG HEADER PIN 9810 v ha QR S SIGNAL ISOLATOR PN 2AVDC 117143 HOPPER LOW LEVEL DETECTION LINE SPEED INPUT INPUT CONTACT CLOSURE 567 WHEN LOW LEVEL Input Output n SW1 SW1 Out 3 5 Output LEVEL SENSOR 1234 5678 4 20 ASSEMBLY 117477 e ee GHn Zi o 20ma AADA HT Tm VE BASE CAL SW SW2 4 20 0 10 V P MODULE 7 boars 7 9 010 V DEFAULT lgg222g m 88335 be 7 SET SIGNAL ISOLATOR S I peeeeg 558999 1 2 10V DIP SWITCHES TO 0 10V INPUT 3 ae Z RP 0 5 V 4 20mA OUTPUT ENABLE O VP TRANSDUCER P N 117808 NOTE CHANGE PUMP TYPE TO VARIABLE S DIGITAL PRESSURE READOUT OPTION TRIGGER SWITCH PUMP ENABLE j STACK LITE OPTION SINGLE APPLICATOR RED ALARM V6 BASE JF 7 P MODULE BLUE CUSTOM LOW LEVEL V6
18. 135 C 275 F Adhesive VISCOSITY us Sed Maa wel RR AER e RA A EA Bs 500 to 50 000 centipoise Warm up time full hopper approximately 30 40 minutes Adhesive delivery rate open line 0 91 kg min 2 Ib min 12 1 piston pump 0 38 kg min 0 83 Ib min 4 5cc gear pump Adhesive pressure up to 68 bar 1000 psi maximum DynaControl V6 Temperature Control Power board scr strud 5 zones per board modular construction Auxiliary board 5 zones per board modular construction Display type sa eo COO ol ORC X ede c d o Ras ean aes liquid crystal LCD Temperature control zones 5 15 triac output FUSES c ete arulius 13 on main power board 10 on each auxiliary power board 10 Amp Other Display languages English German Spanish French Japanese Operator interface LCD graphic display with rotary knob controller with simple icons Temperature standby C deere cl xs aede x RE aot ped tele qve yes High and low temp alarms eo eere ieee US rr yes Readyinterlock LOUER EA SS au Oe yes PassWOrd provection 99999403 xf op So or Bose ad tis Arb one os deu es uu rae yes Sequential heating yes hopper hose he
19. 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Error Indication Alarm Display Examples solid Non Active outlined bar graphs Zones bar graphs lt Zone has Zone is cold no sensor Zone is at lower tolerance Zone is near setpoint Zone is just under setpoint Zone is cold Zone is exactly at setpoint Zone has a sensor fault Zone is slightly above setpoint Active Zones Zone is over heating Operator Response to Error Indication Alarms If an alarm occurs during operation the controller will switch off the internal power to the heaters and an appropriate error indication display will appear Pressing the RETURN button resets the error If several zones display alarms each must be ac knowledged by pressing RETURN The alarm display is switched off The operator must either switch OFF the indicated temperature zone s via the DynaControl keypad or troubleshoot to correct the problem Low temperature alarms will not open the main contactor and are only indicated on the bar graph display and auxilary alarm output contacts A sensor failure is displayed as a on the bar graph and power is switched off to the zone When the actual temperature exceeds the setpoint limitation plus a tolerance of a few degrees a I is displayed the bar graph and heater power is switched off ITW Dynatec c 2012 Controller Setup Page 4 5 DYNAMELT S ASU Manual 20 59P Revised 4 12 Optional System Status Stack Lights
20. Black RE dible al Stack lights ease remote monitoring of the system s status On the basic four color stack light the lower clear light illuminates when the system is Red turned ON The green light indicates that the system has warmed up to tem alarm perature setpoints ready The upper red light illuminates only in an Blue alarm condition and is accompanied by an audible alarm The audible alarm userconfigured is housed within the upper black section of the stack The blue light is user Green configurable system ready Clear Other setups are possible for example the alarm may be wired to indicate System Dn low adhesive level standby or open shorted sensor Settings for a Typical Operation Note The values given here are approximate settings for a typical packaging application The val ues you choose will be based on the type of equipment and adhesive you are using and the nature of your particular operation If Application Temperature is 177 C 350 F Hose and head temperature 177 C 350 F Hopper setpoint temperature 163 C 325 F Hi Lo limit deviation 12 C 20 F ASU operating range 149 C to 177 C 300 F to 350 F Standby condition temperature deviation 30 C 50 F Hopper over temperature setpoint 177 C 350 F Mechanical thermostat for the hopper over temperature 219 C 425 F For most operations temperature fluctuations will be very small a
21. L2 N B A Ex 10 WHT Xt um P N 117500 xa L3 3 10 P N 05861 x10 0 2 6 PE 1 e Schematics DM SR5 10 Voltage Configuration PN 115894 Rev E page 2 of 5 10 WHT AUX PWR 3 PHASE 400V WYE L1L2L3 N 115768 EMI d PIN 115726 OR YELLOW 2 9 MAIN SWITCH mE 10WHT XS BOARDZ i 10 YEL 3 NE P N 115769 O WH x3 L2 rH 10 BLK L3 5 O 2 G 4 N 10 BLU PIN N05861 PE Schematics Page 11 5 ITW Dynatec c 2012 Revised 12 12 DYNAMELT S ASU Manual 20 59
22. PRESSURE 4 20mA OPTION PRES n order to monitor the actual pump speed RPM reading device is connected to this terminal for gear pump models only COM OXOXO RPM READOUT PROX 01V tS NS In order for a gear pump to follow the line speed of a parent ma chine a 0 10VDC voltage is required This input voltage is connec ted to these terminals The input is polarity sensitive ITW Dynatec c 2012 Troubleshooting Page 7 9 Revised 5 12 DYNAMELT S ASU Manual 20 59P V6 Temperature Module PN 115735 The V6 TEMP module is mounted to the right of the V6 base Module on the din rail It requires 24VDC supply voltage It is responsible for the temperature control of all heated temperature zones The RTD temperature sensors connect to this module and the TEMP module provides cor responding output signals to the power boards Depending on the configuration of the ASU the RTDs can be PT100 or NI120 Each of the maximum 15 zones has a status LED which shows its heating status in the following manner if the zone is switched off the LED is Off if the zone is heating the LED is On if the zone is near or at the setpoint temperature the LED blinks 24VDC POWER SUPPLY Temperature Sensors RTD Inputs x2 x x7 xs V6 TEMP PN115735
23. 9 16 18 MANIFOLD ASSY TABULATION HOSES QTY 101624 QTY 101625 2 2 9 4 4 7 6 6 5 NOTES 1 ITEM 2 LUBE O RING WITH 001V078 TORQUE TO 10 15 FT LBS 2 ITEM 3 amp 4 TORQUE TO 10 15 FT LBS 3 FILTER ASSY LUBE ALL O RINGS ITEMS 7 8 amp 9 WITH 001V078 APPLY ANIT SEIZE COMPOUND 107324 TO M45 THREADS TORQUE FILTER CARTRIDGE HAND TIGHT TORQUE FILTER NUT TO 15 20 FT LBS 4 ITEM 10 APPLY ANTI SEIZE COMPOUND 107324 TO THREADS TORQUE TO 8 10 FT LBS 5 ITEM 20 TORQUE TO 3 5 FT LBS 6 ITEM 21 APPLY ANTI SEIZE COMPOUND 107324 TO THREADS TORQUE TO 5 7 FT LBS 7 ITEMS 14 amp 15 APPLY THERMALCOAT 001V061 PRIOR TO INSTALLATION 8 TORQUE ALL M4 FASTENERS TO 5 7 FT LBS ITW Dynatec c 2012 Component Illustrations Page 10 9 DYNAMELT S ASU Manual 20 59P Revised 4 12 3 0 x 6 DL AN K 10 3 e o y 18 59 9 11 13 Component Illustration Manifold Asy PP Page 10 10 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 116857 Piston Pump Drive Item No PN Qty Description 1 105134 4 Spacer 33id X 500 Thk 2 1 5 Liter Hopper Assembly shown for reference 3 115704 1 Manifold Seal Tube Assembly 4 115715 1 Piston Pump Manifold Assembly 5 115816 1 Piston Pump Guard 6 115891 1 Piston Pump Manifold Insulator 7 115865 1 Regulator Gauge Assembly 8 11
24. D 000 Melt pressure transmitter with type J thermocouple 4 20mA output 6 pin connector 1 2 20UNF thread 700 bar full scale 0 5 accuracy class 153 mm 6 rigid stem 457mm 18 flexible capillary WSPMO 6 M P03M 1 4 0 000 Melt pressure transmitter autocompensated version rigid stem 4 20mA output 6 pin connector 1 2 20UNF thread 3000 psi full scale 0 596 accuracy class 153 mm 6 rigid stem GEFRAN reserves the right to make any kind of design or functional modification at any moment without prior notice GEFRAN DTS_WE_0807_ENG ITW Dynatec c 2012 Appendix 5 DYNAMELT S ASU Manual 20 59P Revised 4 12 PN 117143 Signal Isolator V6 GENERAL DESCRIPTION The isolated converter DAT 4531 D is able to measure voltage and current signals In function of programming the measured values are converted in a current or voltage signal The device guarantees high accuracy and performances stability both versus time and temperature The programming is made by the dip switch located in the window on the side of the enclosure By means of dip switches it is possible to select the input type and range and the output type without recalibrate the device Moreover by Personal Computer the user can program all of the device s parameters for his own necessity The 1500 Vac galvanic isolation on all ways input output and power supply eliminates the effects of all ground loops eventually existing and
25. Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Manual Mode Adjustments In Manual Mode turn the Input Wheel to increase or decrease the pump speed percentage Or press F5 to scroll through the pre set speed shortcuts The presets are 30 60 or 90 Press F5 again until desired pre set is selected No entry confirmation is necessary Auto Mode Adjustments The ASU s pump must be programmed with a minimum and maximum percent of full maxim um speed when Auto mode is used The maximum speed is used as a scaling factor between the input signal for example a PLC and the percent of full speed value of the pump The minimum speed is necessary to keep the pump moving in order to maintain a minimum amount of adhesive pressure through the hose and applicator head For instance if the input signal is TOVDC at 100 meters per minute and the pump percent of full speed is 10096 maximum speed but the system is putting out too much adhesive adjusting the MAX value to 50 will allow the pump to slow down and adhesive output will decrease by 5096 To Adjust Press the F5 button once to open the minimum percent of speed input field Turn the Input Wheel to select desired minimum speed Press the Enter Knob to confirm Press F5 again to open the maximum percent of speed field Turn the Input Wheel to select desired maximum speed Press the Enter Knob to enter the value Press the RETURN button to return to the Overview Screen
26. Dynatec c 2012 Installation Page 3 9 DYNAMELT S ASU Manual 20 59P Revised 6 13 Operation and Calibration of Level Sensor The level of adhesive in the hopper is monitored by a sensor mounted in the wall ofthe hopper and accessed from within the electronics cabinet which informs the operator of a low adhesive level via a system status message illustrated below on the controller s Overview Screen HOPPER EMPTY PRESS After a Hopper Empty message is displayed the operator must press the controller s RETURN but tonto acknowledge the message and then replenish the glue in the hopper Ifthe glue is not replen ished within ten minutes the alarm will repeat Calibration Thelevel sensor has been calibrated atthe ITW Dynatecfactory If re calibration is necessary follow the following sequence 1 Openthe electronics cabinet door as described on page 8 1 Locatethe level sensor housing with its calibration button on the side of the hopper 2 Fill the hopper with adhesive and turn the unit On 3 Pump adhesive out of the hopper until the adhesive reaches the top of the sensor This is the level that will activate the Hopper Empty message 4 On the level sensor housing press and hold the calibration button for five seconds 5 Turn Off the ASU close the cabinet and re fill the hopper Note in the event removal of the hopper shroud is required the level sensor housing will need to be removed also it is attached by two screws gr
27. Half Volume Full Pressure 1 UP STROKE J Upper Check Valve Closed Lower Glue Flow Chamber Full Volume Lower Check Valve Open Lower Glue Flow gt 2 AL lt 4 Y A A m Lower A A Chamber 1 2 Volume Upper Check Valve Open 94 9 Lower Check Valve Closed L d p 44 glue flow Full Volume Full Pressure Lower Glue Flow Troubleshooting Page 7 27 Revised 4 12 Step 3 lower right drawing UP STROKE Lower Chamber Full Volume Lower Check Valve Open EE AA glue flow Adhesive Flow through the Piston Pump Once both chambers are full the adhesive pressure is con stant on both the upward and downward strokes with the downward strokes having ap proximately half the volume of the upward stroke Upper Check Valve Closed Page 7 28 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Troubleshooting the ASU Pump NOTE Before troubleshooting your pump first determine if your DYNAMELT ASU is equipped with a piston pump or a gear pump This chapter contains separate Troubleshooting Guides for each No special tools are needed for working on the ASU
28. Module c If head to hose and hose to ASU plugs and sockets are okay head sensor may have an intermittent short or open circuit Examine connections inside the service block area of the head and monitor head sensor resistance with an ohmmeter while flexing sensor leads Repair or replace an inoperative sensor Check each Hose Head circuit on the system ITW Dynatec c 2012 Troubleshooting Page 7 21 DYNAMELT S ASU Manual 20 59P Revised 4 12 Hose Head No Not Heating Sensor Circuit Open 1 Disconnection between hose and ASU 1 Visually examine connector for proper contact and seating If pins or housings are damaged repair or replace hose or hose harness in ASU 2 Hose sensor harness un plugged from Power or Aux Power Module 2 Verify that affected hose is properly connected to Power or Aux Power Module Replace or repair damaged hose harness as necessary Disconnection between Power or Aux PCB and the Temperature Module 3 Verify that all PCBs are properly inserted in their connections on the Temperature Module Hose Head sensor circuit 4 Replace head sensor if resistance inoperative does not comply with resistance table Use hose schematic to check hose sensor resistance at ASU socket repair or replace hose hose harness Power or Aux Power Module as appropriate Hose Head No Not Heating Sensor Circuit Shorted 1 Debris at connection betw
29. V6 Base Module The main control module of the system It controls and communicates with the temperature control module the operator interface and all auxiliary modules and 1 0 devices V6 Temperature Module Monitors temperature signals from all heated zones and provides control signals to the Power and Auxiliary PCBs modules DynaControl V6 LCD Display During Normal Operating Mode System Status Time of Day 7 Day Scheduler Keypad Status Status Pump Status Tran Dyna Status REA DY Line c JfeeeeeeHee mmm nmm Pump Z Tu Information On Off Zone Im Symbols ON OFF F1 F2 F3 F4 F5 Toggle On Off selected functions Error Indication Alarms The following illustration shows the display screen that will be activated when one or more er ror indication alarm conditions occur The conditions that will trigger an alarm are When a hopper hose or head has exceeded its selected over temperature setpoint which is the setpoint plus its Hi Lo alarm setting or when it is below its selected under temper ature setpoint which is the setpoint minus its Hi Lo alarm setting When a hopper hose or head sensor has an open circuit When an alarm condition occurs the current display will be interrupted only if a sensor failure occurs If more than one alarm condition occurs simultaneously all alarm conditions will be dis played sequentially Page 4 4 Controller Setup ITW Dynatec c
30. at your hardware store Spe cialty fasteners are available by contacting Dynatec s Customer Service Page 10 2 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 115881 Sheet Metal Assembly Piston Pump Item PN Qty Description 1 115730 1 Base Frame Assy 2 115744 1 Electronics Backplane 3 115760 1 Electronics Cabinet Door Assy 4 115762 1 Hopper Shroud Assy 5L 115814 1 Hopper Shroud Assy 10L 5 115764 1 Shut Off Access Door 5L 115731 1 Shut Off Access Door 10L 6 115770 1 Main Top Molded 7 115776 1 Hopper Collar 8 115777 1 Lid Liner 9 115785 1 Front Panel Assy 10 115789 1 Bracket Access Panel Mount 11 115836 1 Stiffener Plate Main Top 13 115840 1 Manifold Drip Tray 14 115790 1 Pump Access Panel PP 15 115835 1 Hose Connector Plate DynaControl 115839 1 Hose Connector Plate NDSN 16 115778 1 Lid Hinge Rod 17 115838 1 Incoming Power Access 18 115833 1 Regulator Panel PP 19 115772 1 Lid Top 22 680159 40 Pan Hd Scr M4x8 w Wshr Black 24 115896 1 Raceway Cover 25 115849 1 Power Blank Off 26 101156 4 Scr SHC M6x20 Stl Blk 27 115719 1 Control Panel Assy LCD 28 107389 9 Scr Php M4 0 7x8 Zinc w Washer 29 117268 1 Gasket Hopper Collar Revised 4 12 Component Illustrations Page 10 3 DYNAMELT S ASU Manual 20 59P ITW Dynatec c 2012 USE NINE 9 107389 SCREWS TO ASSEMBLE ITEMS 7 amp 8
31. base plate No belts or hooks should be used Never allow anyone to stand on the ASU Pre Installation CAUTION An appropriate power cord and overload protection must be provided by the customer as part of the ASU installation To determine if your electrical system has the correct circuit breaker size and wire gauge for the installation of this hot melt system including the ASU hoses applicator heads and air heaters see the amperage calculation chart on page 2 8 before proceeding Installation Note Re read Chapter 1 Safety Precautions before performing any installation procedures All installation proced ures must be performed by qualified trained technicians After the DYNAMELT S SERIES ASU has been properly mounted the following general sequence should be followed for installation Refer to the component drawings on page 3 1 for orientation and location of described items 1 Make sure that incoming line power to the ASU is disconnected and the unit s Main Power Switch is turned OFF DANGER HIGH VOLTAGE Disconnect and lock out input power to the application system before starting any installation procedures Make sure there is no electrical power on the leads you will be connecting ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Installation Page 3 3 Revised 4 12 2 Loosen the latch screws on the top and bottom of the electrical cabinet access door Select a power cord sized correctly for your ASU s amp
32. be independently programmed If hopper temperature is above ready temperature when the ASU is turned ON the hose and applicator se quence is bypassed and they will be turned ON Sequential heating is restored after Standby is turned from ON to OFF Sequential heating is not needed for most applications and can delay total system warm up time Setpoints The temperatures that you have selected and programmed for each of the temperature zones Setpoint Limitation This is a universal maximum temperature for all zones The programmer cannot program a tem perature setpoint higher than the setpoint limitation If the actual temperature of any zone climbs higher than the setpoint limitation all heaters will shut down Standby Condition The system condition where the ASU hose and head temperatures are maintained at predeter mined reduced temperature values Standby temperatures are set lower than setpoint temperat ures in order to reduce adhesive degradation and energy consumption when the system is tem porarily inactive and to permit rapid system warm up when run condition is selected When standby mode is activated the controller will display STANDBY ITW Dynatec c 2012 Controller Setup Page 4 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 Temperature Zone Enable The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not appear on the controller s display and heating is switched OFF
33. function when the pendant controller is disconnected Page 7 4 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Handling DynaControl Modules and Printed Circuit Boards PCBs The Dynamelt ASU and DynaControl controller utilize several modules and printed circuit boards PCBs These boards are extremely sensitive to electrostatic charges When working near or with these components the following procedures must be followed to avoid damage to them DANGER HIGH VOLTAGE Before unplugging connectors from the modules or I O PCBs ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the assembly when you are removing and replacing connectors CAUTION Modules and printed circuit boards PCBs should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is not available frequently touch a bare metal part of the ASU unpainted frame mounting screw etc to safely discharge any electrostatic buildup on your body 2 Handle a by its edges only Don t grip a PCB across its surface 3 When removed from the ASU each PCB must be individually packaged inside a metallized static drain envelope Do not place the removed PCB on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or
34. ie the ASU melter and its hoses and applicators is listed as one of the following HEAT UP No faults present zones are heating but haven t reached their setpoint window READY No faults present and all zones are within the setpoint window ALARM At least one zone is outside the setpoint window over or under temp STANDBY The system is in standby mode OVER TEMP The hopper is in over temperature condition all power circuits are shut off FAULT A temperature zone has a fault and all power circuits are shut off HOPPER EMPTY Adhesive in the hopper is low and must be replenished Pump Status The status of the adhesive pump is listed as of the following RUN Pump has start signal and is actually running STOP Pump is in Stop mode HOLD Pump is in Run mode but a low temperature condition prevents it from running Temperature Zone Symbols Each temperature zone is represented by a symbol on the display as follows MIN 12234 ASU s Hoses Applicator Heads Hopper up to 6 up to 6 ASU s Filter Block Manifold Page 5 4 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Bar Graphs The temperature status of each zone is shown by a bar graph A solid bar graph indicates that the temperature zone is activated An outlined bar graph indicates a temporarily de activated temperature zone A question mark indicates that the zone s RTD sensor is not valid An exclam ation mark
35. pump See Chapter 8 of this manual for disas sembly assembly procedures for the ASU pump and Chapter 10 for locating pump parts on the component illustrations exploded view drawings Piston Pump Priming Start Up WARNING HIGH PRESSURE To avoid accidental splashing of hot melt adhesive always relieve pressure by opening the filter drain on the pump manifold before working on the pump WARNING Observe manufacturer s procedures for selecting and using cleaning solvents Be sure to read and comply with the safety procedures outlined in Chapter 1 of this manual before proceeding particularly the section entitled Preventing Explosions and Fire The pump is self priming Before starting the pump make sure a hose is attached with an open line WARNING HOT ADHESIVE Use a stable deep container to collect hot melt adhesive while priming the pump Begin with ASU electrical power OFF and the Air Control Filter Unit adjusted to zero air pressure Turn the ASU power switch ON and slowly increase air pressure to the pump and the Air Control Filter Unit Increase air pressure until the pump begins to stroke very slowly By allowing the pump to stroke very slowly it will gradually purge itself of air As the pump begins to run smoothly gradually in crease the air pressure to normal operating pressure 1 4 to 5 4 bar or 20 to 80 PSI ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Piston Pump Troubleshooting Guide
36. pump enable to make sure there has been enough time for the adhesive to rise to the hopper setpoint temperature Verify that adhesive selection and hopper setpoint temperature are compatible and that both are appropriate for your application Remove the shaft and piston from the pump See Chapter 8 for dis assembly assembly procedures Verify that piston diameter is correct 19 63mm to19 66mm 0 773 to 0 774 and that piston is tightly assembled to end of shaft Inspect system for open filter drain disconnected or ruptured hose or disconnected head Repair as necessary Clean inlet check valve This may be possible without removing the pump by cleaning debris through the pump inlet hole at bottom of hopper Run Calibration Procedure 2 then Calibration Procedure 1 See page 7 15 for details ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Problem Troubleshooting Page 7 31 Revised 4 12 Pump Motion on the Forward Stroke shaft moving into pump is very slow or stopped Pump Quick Strokes on the Reverse Stroke shaft moving out of pump Low or Inconsistent Adhesive Output Outlet check valve Inlet check valve Adhesive Leak at Filter Drain 1 Outlet check valve is blocked closed 1 Outlet check valve is blocked open 1 Outlet filter is clogged 2 Adhesive used is too viscous 3 Blocked hose 4 Blocked applicator heads 5 Pressure re
37. systems use electrical power that can be life threatening and hot melt adhesives that can cause serious burns Re read Chapter 1 Safety Precautions before performing any troubleshooting or repair procedures All troubleshooting and repair procedures must be per formed by qualified trained technicians CAUTION Printed circuit boards PCBs are prone to damage from static electrical charges during handling Read the section on Handling Printed Clrcuit Boards before handling or attempting service on Dynamelt s PCBs The Dynamelt s DynaControl includes malfunction self diagnostics alerts and error indication alarms The error indication alarms the alarms displayed on the DynaControl readout are triggered whenever there is a sensor failure and whenever there is an over temperature condi tion The operation of the error indication alarms is described in Chapter 4 of this manual Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 The ASU is supplied with power 3 The ASU is supplied with pneumatic air if applicable 4 Pneumatic and electrical connections are correct 5 Adhesive is in the hopper Error Messages The controller indicates an error by displaying the word FAULT or ALARM in either the System Status or the Pump Status fields of the HMI BA EME System Status Display Pump Status See examples of controller error messages in the Troubleshooting Guides section of this chapt
38. temperature difference Press the Enter Knob again to highlight the temperature difference value Then turn the Input Wheel to program your desired value Confirm your choice by pressing the Enter Knob Standby Time Delay and Activation The standby time delay is the programmed number of minutes until standby takes place after activation by either an external contact for example a PLC or an external switch or by a pump stoppage The default time delay is 0 minutes immediately The programmable range of the standby time delay is 0 150 minutes Turn the Input Wheel to select the time delay parameter ie Standby X min After Press the Enter Knob Turn the Input Wheel again to select your desired minutes value Confirm your choice by pressing the Enter Knob Now turn the Input Wheel to select the After Ext Contact After Pump Stop field Press the Enter Knob and then turn the Input Wheel to highlight your choice of activation Confirm your choice by pressing the Enter Knob Sleep Mode After Standby Sleep mode shuts the ASU off after it has been in standby for a programmed length of time This length of time can be from one hour to 99 hours Or you can choose to program the unit to have no sleep mode by programming When the unit is in sleep mode the Main Screen displays System Off Switch On with Enter Knob Turn the Input Wheel to select the Sleep Mode After Hrs In Standby field Press the Enter Knob to highlight the hours val
39. the regulator valve clockwise To decrease pressure turn the regulator counter clockwise The recommended pressure is 0 7 to 6 8 bar 10 to 100 psig 6 Nine hydraulic hose connection ports are located on the filter manifold These ports are posi tioned to allow for up to six hoses to be routed either from the back of the unit or from the right hand side It is recommended that you use a 45 fitting available from ITW Dynatec when using the three ports located on the corner of the filter manifold ITW Dynatec recommends that hoses be connected to the bottom ports first then the middle ports and finally the top ports 7 The hydraulic pressure gauge can be installed either in one of the hose ports or in the dedicated gauge port The gauge port is not filtered by the unit s secondary filter WARNING HOT SURFACE Do not remove the high temperature insulating foam cover from the filter manifold This cover should remain in place during operation in order to prevent burns and maintain the temperature of the filter manifold Replace the foam cover if it becomes damaged or dirty Adding Adhesive CAUTION Using adhesive with viscosity over 50 000 centipoise could cause motor stall and or pump failure The adhesive level in the melt tank should be maintained at 25mm to 100mm 1 to 4 from the top of the hopper Where applications demand a high output volume of adhesive add small amounts of adhesive frequently Adding large amounts of
40. will Switch Off at 4 30pm Daily Program 3 On Saturdays the ASU will Switch On at 8 15am and Switch Off at 12 15pm Set Current Time of Day and Day of Week While in the 7 Day Scheduler Set Up screen press the Configuration button to set the cur rent time and day SCHEDULER SET UP SET TIME DAY 12 07 MONDAY CONF IRM Press F5 to confirm your changes Turn the Input Wheel to select the item to be changed Press the Enter Knob Turn the Input Wheel to the desired time day and press F5 to confirm your entry Page 5 14 Controller Programming ITW Dynatec c 2012 Revised 5 12 DYNAMELT S ASU Manual 20 59P LCD Info Menu F5 The info screens contain details about the hot melt system and can aid in troubleshooting Info Screen 1 The first Info Screen lists temperature zone and pump configuration It also provides the revision level of the controller s modules the elapsed time on the Dynamelt S ASU s controller and the number of strokes that the piston has performed Press F5 to go to the next Info Screen LCD REEU HOPPER BASE REU FIL BLOCK HOSE ELAPSED PUMP STROKE Press F5 to go to the next Info Screen Info Screen 2 The second Info Screen lists each temperature zone individually Scroll through the zones using the Input Wheel The zone s description ie HOPPER actual temperature and location of its cor responding RTD sensor is given The screen also shows the physical loc
41. wrist of that person to eliminate any electrostatic charge before you hand the PCB to him 5 When unwrapping a PCB from its static drain envelope place the envelope on a grounded non metallic surface 6 To cushion modules or PCBs for shipment use only static drain bubble pack Do not use foam pea nuts or bubble pack not known to be static draining The following pages detail the Dynamelt SR Series modules and PCBs Troubleshooting Page 7 5 ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P V6 Base Module PN 115734 The V6 Base Module is the main control module of the DynaControl V6 controller Most of the in ternal and external components are connected to the Base module The Base module is always the left most module on the DIN rail O Q OPERATOR TO TEMP SUPPLY linca MODULE za HMI COM RELAY OUTPUT POWER ON HMI COM rp a 24V IN ON ERR m V6 BASE PN 115734 80 TEMP Ssnnaa 000006 Bo OHC VHC OHOH O 5 MOTOR ENABLE TRIGGER PISTON PUMP RPM ENABLE OV TEMP READOUT SOLENOID T STAT PROX MOTOR PRESSURE DRIVE TRANSDUCER OPTION cont Page 7 6 Troubleshooting I
42. 15 Temperature Unit Celsius or 5 16 Eang age Selectlon w ete ste he Rn A ee D ERA Te Ron eR AUR dte 5 16 Zone Configuration o e sto ae DUI E RA RR RE UE CR OR Ug 5 16 Pump Configuration 1 2 5 16 Setpoint LIMITATION ari Ce Salty x ce e ld e pa os q lna 5 16 Hi IEo Alarm Tolerantce 5 trem RE Ud EU RR DU RUNE 5 17 Standby Configuration 5 17 Level Detectiori 1 52 eua Uer es 5 18 Heat p Sequence zuo atii Rio OR oet webs dr PR CROCO Ce et EQ daas 5 19 hvo Lcieop ICD 5 19 Temperature Offset ves er cc wine hey Galak ety p ede pL Cea oa S RE S 5 19 Customer Zone 2 5 20 Logbook Fault 41 5 21 Power On Configuration 0 5 22 Global Setpoliits oi 5 23 Chapter 6 Preventive Maintenance General GCleanirig s eR ORE RR CE ei AU C ERAT ee eR ACH n 6 1 Purging the Filter Manifold of Adhesive and Pressure 6 2 Preventive Maintenance Schedule 4 6 4 OUT
43. 2 3 N PE 1 9 9 10 WHT AUX PWR 3 PHASE 230V DELTA Lus PIN 115767 10 WHT 5 Ee af x9 1 2 3 N MAIN SWITCH PIN 118725 0O CO 3 9 MENS 10 BLK VIOLET Q 10 WHT xh mE L1 3 10 BLK x4 gt 117500 or x3 L3 10 BLK P N 05861 x10 Too IN PE UM 10 WHT AUX PWR 3 PHASE 400V WYE ova 796 BoM ELEEES N C PIN 115768 jo Wir x3 f P N 115726 Q Q YELLOW x9 9 MAIN SWITCH m 10 WHT x AER L1 e x 10 BLK 10 YEL E L2 z 10 BLK P N 115769 10WHT m M ah xo O 0709 09 10 BLU N amp P N 05861 PE 1 Voltage Configuration Connector Schematics Page 3 6 Installation Revised 4 12 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P 4 At installation the customer must make the following terminal connections into the ASU s main power ON OFF switch and modules The modules do not need to be removed from the ASU in order to make connections Refer to the detailed layout drawings of these components in Ch 7 if needed Required connections for standard 240VAC 1 phase ASU Input Power from Main Power 240VAC Ground Required connections for 240VAC 3 phase Delta ASU Input Power from Main Power 240VAC Ground Required connections for 380 400VAC 3 phase WYE ASU Input Power from Main Power 380VAC Neutral 380VAC Ground Non essential connections connect if feature is installed RELAY R
44. 31 Volunteer Drive OPERATIONS amp SERVICE MANUAL Hendersonville TN 37075 USA Manual 20 59P Telephone 615 824 3634 Fax 615 264 5222 Revised 8 1 13 Email dynatec itwdynatec com Web www itwdynatec com IT Dynatec minnovation mservice mreliability The Next Level of Technology DYNAMELT S V6 SERIES ADHESIVE SUPPLY UNIT with Piston Pump and LCD Controller 5 10 OPERATIONS AND SERVICE MANUAL Software Version 6 00 and up IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT It is the customer s responsibility to have all operators and service personnel read and understand this information Contact your ITW Dynatec customer service representative for additional copies NOTICE Please be sure to include the model serial number and software version of your application system each time you order replacement parts and or supplies This will enable us to send you the correct items that you require ITW Dynatec Service Parts Direct Dial 1 800 538 9540 ITW Dynatec Technical Service Direct Dial 1 800 654 6711 Page ii Revised 4 12 ITW Dynatec c 2012 SAFETY INSTRUCTIONS GENERAL CONSIDERATIONS 1 Read and follow these instructions Failure to do this could result in severe personal injury or death 2 Additional safety instructions and or symbols are located throughout this manual They serve to warn maintenance personnel and operators about potentially hazardous situation
45. 339 116023 116024 116877 L16569 116855 116876 116026 116028 117205 117191 116068 N06006 116067 116614 116072 116073 116031 117193 117204 A69x134 N03812 117173 108700 108669 116619 115816 107389 N00175 06006 Qty Q LB IB S N B BS S gt 20 A R N N Description Body Piston Pump Inlet Check Valve Asy Seat Inlet Check Valve Ball Bearing 5 8 Dia Spring Compression Retainer Spring Rtng Ring Int Inv Lug 813 Bore Shaft Asy Shaft Pin Asy Pump Ball Bearing 5 16 Dia Spring Compression Seat Outlet Check Viv Retaining Ring Ext 5103 56 Seal Cartridge Asy Retainer Seal Cart Asy Scr SHC M5 0 8 X 12 Tie Rod Cylinder M6 Spacer Tube Lower Cyl Head Asy 5 16 Tube Cylinder Head Lower 5 16 Tube Seal Rod O ring 224 Viton Piston Asy Piston Magnet Asy Seal Piston Wear Ring Piston Cylinder Tube Composite Transfer Tube 5 16 Elec Encl Upp Cyl Head Asy 5 16 Tube O ring 128 Viton O ring 125 Viton Scr SHC M6 1 0 X 25 Zp Lube TFE Pre pack Threadlocker Hi temp Lube Piston Seal Magnalube g Cover Pump Shaft Scr MA 0 7 X 8 Sems O ring 008 Viton O ring 224 Viton ITW Dynatec c 2012 Component Illustrations Page 10 13 DYNAMELT S ASU Manual 20 59P Revised 4 12 Component Illustration PN 116125 Electronic Pi
46. 4 0 58 0 016 1 19 TA 0 75 E E Ch 19 8 amp 27 5 0 307 e IE Hex 3 4 ese 928 1 10 Capillare esposto NOTE 09 0 357 Exposed capilla en D1 1 2 20UNF dimensions refer to 161006462 305 rigid stem length option 0 An 4 153 mm 6 an 414 412 m 10 52 10 46mm LT A 125 120 WARNING e 51 3 18 3 05mm N For installation use a mas 2217219818 2 2 8 08 7 92mm maximum tightening gt cat torque of 56 Nm 20 6mm 500 102 idi s ITW Dynatec c 2012 Appendix 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 ELECTRICAL CONNECTIONS CURRENT OUTPUT 4 20mA two wires MAGNETIC EXTERNAL AUTOZERO AUTOZERO 6 pin 8 pin 6 pin 8 pin COMO ER A B umet A n c C A Signal Signal amp 20m B 4 20m 0 E n c D C n c D C Calibration shunt E n F E Autozero T E F E _ F 6 pin connector VPTO7RA10 6PT2 PTO2A 10 6P Shield drain wire is tied to connector via cable clamp LOAD DIAGRAM AUTOZERO FUNCTION 42 1 65 2 1 657 Autozero function is activated through a magnetic contact exter nal magnet supplied with the sensor See the manual for a complete Au
47. 6 HEAD SENSOR RED 18 AWG 7 7 HEAD HEATER ORANGE 18 AWG 8 8 HEAD HEATER BLUE 20 IL 1 9 HOSE SENSOR PT100 RTD SENSOR m BLUE 20 AWC 10 HOSE SENSOR BLACK 18 AWG 11 HOSE HEATER WHITE 18 AWG 120V APPLICATOR END MEDIE WIRE YELLOW 18 AWG 200V ASU END VIOLET 18 AWG 240V ix GSE ENER dL GREEN YELLOW 16 AWG dL GROUND HOSE CORE GROUND NOTES 1 ALL WIRING IS ROUTED THROUGH THE HOSE 2 WIRE SIZES SHOWN ARE FOR NO 6 AND NO 8 HOSES UP TO 24 FT IN LENGTH FOR LARGER DIAMETER AND LONGER HOSES HEATER LEAD WIRES ARE 16 AWG OTHER WIRE SIZES AND COLORS MAY BE CHANGED IN SPECIAL HOSES PER CUSTOMER REQUEST DynaControl Hose Schematic PN 101082 Rev G ASU to Applicator ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59 3d IH VV VV VV VV VV VV V Schematics Page 11 3 Revised 12 12
48. 6125 1 Piston Pump Assembly 9 680159 2 Scr Php M4 0 7x8 Blk w Washer 10 117156 3 Scr SHCS M10x110 Zinc 11 117376 1 Ftg Blkhd 1 4tubx1 4fpt Brs 12 111898 1 Grom 38id 50dx 09 Rbr 13 105061 4 Stud M8x50 Allen Head 14 105126 4 Nut Lock Insrt M8x1 25 15 NOO688 4 Wshr 312 Plain 688 O 16 107389 2 Scr Php M4 0 7x8 Zinc w Washer NOTES 1 ITEMS 13 APPLY 102289 THREAD PRIMER AND 108669 THREAD LOCKER TO THREADS THAT INSTAL INTO THE HOPPER ASSEMBLY TIGHTEN M8 STUDS TO 6 7 FT LBS TIGHTEN M8 NUTS TO 6 7 FT LBS 2 ITEMS 10 APPLY 107324 ANIT SEIZE COMPOUND TO THREADS TIGHTEN TO TORQUE OF 6 7 FT LBS 3 ITEM 3 LUBRICATE O RINGS WITH 0010002 OR 001078 4 TIGHTEN ALL M4 SCREWS TO MAXIMUM OF 8 4 IN LBS ITW Dynatec c 2012 Component Illustrations Page 10 11 DYNAMELT S ASU Manual 20 59P Revised 4 12 Pneumatic Pressure D 20 Z 9 __N00187 O ring 020 01010 O ring 021 Component Illustration PN 116857 Piston Pump Drive Page 10 12 Component lllustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 116125 Electronic Piston Pump Assembly Item No 01 02 02a 02b 02 02d 02e 03 03a 03b 03c 03d 03e 04 05 06 07 08 09 09a 09b 09 10 10 10b 10c 11 12 13 14 15 16 17 18 19 20 21 22 23 PN 116854 116033 116032 00004 N04483 L16532 N06967 116025 116875 111
49. BASE MODULE INPUT H g22222 pm B8 38 di GREEN READY MOTDRVER wm es p TST soo o 26 999690 eeeeeej B 21 Hj ovr 550055 Jati E 2 CLEAR POWER ON uz E 1 fac A 2 a zee 2 600000 9 60 69 69 69 69 I PUMP s ENABLE 0 24 Q x H1 1 CLR 1 1 1 WHT RED HAND APPLICATOR 268 ti tj ti e _ TRIGGER SWITCH Xa 2 5 WHT BLK ob dU w EN TRANSDUCER N ae 8 1 1 i 4 20ma 7 fe BLU gan 5 2 35 2 3 BRWN CALIBRATION V6 BASE MODULE NOTE CHANGE ACCEL DECELERATION PARAMETERS C1 01 C1 02 to 1sec page 4 of 5 Schematics DM SR5 10 Voltage Configuration PN 115894 Rev E Schematics Page 11 7 ITW Dynatec c 2012 Revised 12 12 DYNAMELT S ASU Manual 20 59 rrv Dynatec Lon nu s OS PENDANT CONTROL OPTION J2 RS232 ON DISPLAY PCB ON BASE MODULE LENGTH 13ft 4m PN 117238 EtherNet IP O EtherNet IP PTION RED 24V BLACK
50. D gt PN115733 x iw SI Schematics DM SR5 10 Power amp Heater Circuits 115894 Rev E page 1 of 5 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59 Page 11 4 Schematics Revised 12 12 x1 VOLTAGE AUX POWER BOARD CONFIGURATION WIRING LEE iau 14 WHT AUX PWR SINGLE PHASE 230V L1L2L3 N P N 115766 Lx S mas 14 WHT ji Fee x3 3 x MAIN SWITCH PIN 115724 x9 0 2 9 AUX PWR L1 L 9 om D X5 BOARD2 BLK L2 N 3 E P N 115766 14 WHT M P N 042X036 x3 3 E X10 1 2 3 N PE 1 9 3 9 tower AUX PWR 3 PHASE 230V DELTA zt 4 ncm d c PIN 115767 10 WHT xi ERES HH MAIN SWITCH 116125 2 24 AUX PWR L1 5 5 10 BLK VIOLET 2c m BOARD
51. D FROM PROG 1 Press the Main Menu button then press F1 Recipe Management Turn the Input Wheel to LOAD FROM PROG Press the Enter Knob to enter 2 Select the desired recipe by turning the Input Wheel until its recipe number is highlighted Press F5 to confirm the selection Notes 1 Recipes that contain temperature zones that do not show valid RTD sensors ie zones with 2 in their bar graphs will be turned Off after re loading because the controller assumes those zones will not be used 2 If you have loaded a recipe any changes you make to the temperature or motor settings are not automatically stored in that recipe If your changes need to be stored go to the Recipe Man agement Screen and follow the steps to SAVE TO PROG Standby F2 In Standby mode the temperatures of all active temperature zones will decrease by a pre defined amount and the pump will stop Note the pre defined amount is programmed on page 2 of the System Configuration Menu System is in System is in Standby Mode Normal Mode Press the Main Menu button then press F2 to toggle between Normal mode setpoints and pump are active and Standby mode setpoints are lowered and pump is stopped Confirm Standby mode by pressing F2 again After making a change a screen message will indicate Standby ON or Standby Off Notes Standby can also be activated via an external contact closure or via the 7 Day Scheduler See also Standby Configur
52. Description Item No PN Qty Description 36 042x007 5 FT WIRE TFE 18GA 1000V WHT 18 01144 2 EA CONDUIT LOCKNUT 1 2 35 042X025 5 WIRE TFE VIOLET 18 260 17 0487093 2 EA CGB CABLE GRIP 25 38 34 042X233 5 FT WIRE TFE ORANGE 186A 260 16 048J024 10 FT SLVG BLK SILICONE 3 8 33 09830 5 FT WIRE TFE 18GA BLU 260 15 105327 2 EA WSHR LOCKJNT TOOTH M3 32 042X016 16 75 FT WIRE TFE 18GA RED 14 103405 2 EA SCR M3X0 5X6 SHC 31 042X021 7 FT WIRE TFE 18CA BLK 13 115738 1 EA PWR SUPPLY 24V 0 240V IN 30 03246 5 FT WIRE TFE T8GA LT BLUE 12 048H415 1 EATRELAY 2PDI 24VDC AU BI 29 NO6989 5 FT WIRE TFE 18GA GRN YEL 11 078 089 2 EA FLAT WASHER 12 SAE 28 04229 2 EA FERRULE UNINSUL 14 AWG 10 078D018 2 10 32 HEX NUT 27 04228 4 EA FERRULE UNINSUL 16 AWG 9 04302 2 EA WSHR LOCK EXT 10 26 02992 2 EA NUT HEX 06 32UNC SM_PAT 8 01735 2 EA SCR PAN 0 10 32 X 0 375 25 06236 2 EA WSHR LOCK EXT TOOTH M4 7 105256 2 END STOP DIN RAIL ES35 24 N05238 2 EA SCR CAP SOC HD 46 32X1 5 6 103440 041 FT JMPR BAR 70 FOR 048F154 23 16841 1 EA LT AS W G B R ALARM 24V 5 105254 1 EA ENDPLATE FOR 105253 22 N06946 12 EA TERM SPADE 22 18GA f 06IN 4 105253 2 EA BLK TERM SINGLE RK254 20 21 02537 1 22 18 8 INSUL 3 048F104 187 ET RAIL TERM MOUNT H32 20 078 021 2 EA SPACER 88x1 0x 13L ALUM 2 116847 1 EA PANEL MACH 6x6 19 048J018 2 EA BUSH PLAS
53. Dynatec recommends that the following procedure for relieving adhesive pressure be utilized in conjunction with the air controlled relief valve 9 P Purge Valve 1 Ensure that the motor is OFF and the ASU is at operating temperature ITW Dynatec c 2012 Maintenance Page 6 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 2 Locate the purge valve screw on the side of the filter manifold The purge valve is the bot tom most port on the manifold 3 With a 5mm allen wrench slowly loosen the purge screw Do not attempt to remove the purge screw Allow the pressure and adhesive to drain 4 After adhesive pressure has been relieved re tighten the purge screw Page 6 4 Maintenance ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Preventive Maintenance Schedule The Dynamelt S requires periodic maintenance to function reliably The Elapsed Hours feature of the controller on Info Screen 41 see Chapter 5 can aid in determining a maintenance schedule The ASU parts that require regular periodic maintenance are as follows Output Filter The output pump filter cartridge should be replaced monthly during the first few months of op eration After you gain experience with your system you can determine how often you need to replace it The output filter is located on the output filter manifold on the hose connection panel of the ASU See illustration EZ Spin Filter
54. ITW Dynatec c 2012 Controller Programming Page 5 9 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Main Menu Press the Main Menu button on the Overview Screen to go to the following functions F1 Recipe Management F2 Standby Mode F3 Setpoint Locking FA 7 Day Scheduler F5 Info Menu To select a function press its F button or turn the Input Wheel to highlight the desired func tion and then press the Enter Knob to select MENU F1 Recipes F3 Setpoint Locking F5 Info F2 Standby Setback FA 7 Day Scheduler Recipe Management F1 A recipe or program is a set of temperature setpoints and parameters which the user has programmed and stored in the controller for future use Up to four recipes may be stored in the DynaControl controller PROGRAMZRECIPE SELECTION e LOAD FROM PROG Fi n np np mpm Recipe F5 Confirm Page 5 10 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD To Save a Recipe SAVE TO PROG 1 Program the controller as you wish it to be setup for a recipe Program the following paramet ers temperature setpoints and zone On Off settings 2 Press the Main Menu button then press F1 Recipe Management Turn the Input Wheel to SAVE TO PROG Press the Enter Knob to enter Turn the Input Wheel to select a program number up to four recipes may be created and stored Press F5 to confirm To Load a Stored Recipe LOA
55. LT S ASU Manual 20 59P Revised 4 12 TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Safe Installation and Operation 1 1 Eye Protection amp Protective 1 1 Electrical P do NE ce cedes de det EA rM d 1 2 High Temperatures 42 25 ed DRE rete RE IEEE ERREUR Mee FCR CERE TES 1 2 High PFESSURCS nts u Mid e be ene Xe Rb Pade Olea Nein us NR 1 2 ProtectiVe COVers oes PERI EE eet ete tbe a ey rat dee nd 1 2 Treatment for Burns From Hot Melt Adhesives 1 3 SerViCe RN EC e a 1 3 Explosion Fire Hazard iere ay casein eat ee Medo dera hele C ERU 1 3 Lockout Tago t i Eee CR ash uya u u CREDE ITs ile BATE REESE NUUS 1 3 Use of PURAdhesives 1 3 Safety Symbols in this Manual 1 1 3 Chapter 2 Description amp Specifications Description RR 2 1 Specifications gt no odes doo de RO Rs 2 2 Installation Dimensions eee tie eid CER RES HE EM e IVO WEE ERES i eed e 2 4 Amperage Calculatiori 22 PEPPER V EC UE e o Qa e 2 8 Wattage Chart stesse aub bec e ead
56. NI U Filter Manifold Page 8 6 Disassembly ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P To Access Electrical Components 1 Turn the unit Off 2 Open the electrical cabinet door 3 Press the release button under the top cover to release the main top cover Open the main top cover all the way Note the electrical cabinet door may be removed by opening it 45 and lifting it straight up and off of the unit Main ON OFF Power Switch The switch body is mounted to the center divider panel with two M4 Phillips head screws Fuse Replacement There are several fuses on both the Main Power PCB and the Auxiliary Power PCB All fuses are beneath a protective cover see below To access the fuses lift the fuse cover up off the retain ing standoffs then slide the cover out of the unit Control panel assembly Power supply 24VDC Motor speed control p Ns Release tab Power IN Neutral connection Main power board Auxiliary power board Fuses Fuse cover ITW Dynatec c 2012 Disassembly Page 8 7 DYNAMELT S ASU Manual 20 59P Revised 4 12 Power Supply Replacement The power supply is attached to the center panel with two M3 screws Printed Circuit Board or Module Replacement When removing the unit s PCBs or modules all connectors must be removed therefore it is im portant to label or use the illustrations in Chapter 7 to note t
57. Nut O ring PN 812616 O ring PN A69X133 O ring PN 00187 EZ Spin Filter Cartridge 40 mesh kit PN 117145 80 mesh kit PN 117146 100 mesh kit PN 117147 150 mesh kit PN 117148 200 mesh kit PN 117149 for details see pg 9 1 WARNING PPE REQUIRED Failure to wear a face shield or safety glasses could result in severe eye injury during this procedure Protect yourself from potential burns by wearing insulated gloves and arm guards HIGH PRESSURE Use the output filter manifold s drain valve to relieve adhesive pressure before performing any pump filter maintenance See the section titled Purging the Filter Manifold of Adhesive and Pressure for detailed instructions HOT ADHESIVE Avoid splashing hot adhesive The filter cartridge will be covered with hot adhesive and must be handled with proper tools Position a heat resistant container under the manifold s drain valve before proceeding ITW Dynatec c 2012 Maintenance Page 6 5 DYNAMELT S ASU Manual 20 59P Revised 4 12 1 The system should be at operating temperature before starting this procedure 2 Before proceeding verify that the pump is OFF 3 Position a heat resistant container below the drain valve discharge chute Remove the mani fold insulator to prevent adhesive from accumulating on its surface 4 Wearing insulated gloves arm guards and a face shield use a flat tip screwdriver to open the purge screw within the
58. Overview Screen at any time by pressing the RETURN button twice Temperature Unit P1 After turning the Input Wheel to select the Temperature Unit parameter toggle between de grees Fahrenheit or degrees Celsius by pressing the Enter Knob Language Selection P1 After turning the Input Wheel to select the Language parameter press the Enter Knob The cur rent language will flash Turn the Input Wheel to select a language from the ones listed Confirm your choice by pressing the Enter Knob Zone Configuration P1 This menu configures the controller s temperature zones by listing the number of each type of zone Zone configuration is typically done at the ITW Dynatec factory and does not require pro gramming by the user Pump Configuration P1 This menu configures the ASU s pump by listing pump type Most pump parameters are setup at the ITW Dynatec factory The only user serviceable pump parameter is the pump enable tem perature Pump Enable Programming The Pump Enable Temperature serves as a low limit value The controller will not allow the pump to come on until its enable temperature is achieved By doing so it protects the pump and pump shaft After pressing the Enter Knob to select the Pump Enable parameter turn the Input Wheel to in crease or decrease the pump enable temperature Confirm your choice by pressing the Enter Knob Setpoint Limitation P2 This parameter sets the maximum temperature zone setpoint The set
59. PUT FING Ryo ar tae T D C asuy kuqa coe o ee e ee cate EE LAC Rn 6 4 8S sos PD 6 5 Fasteners ofa oce ROM sa Mast souder 6 5 Primary Filter Cleaning u L py E C E Cae ene 6 6 ITW Dynatec c 2012 Table of Contents Page v DYNAMELT S ASU Manual 20 59P Revised 4 12 Summary of Preventive Maintenance Schedule 6 7 Fl shingthe System Ls asa See he wan ae ben Rind ceed Feed b SI oed 6 8 Chapter 7 Troubleshooting General Troubleshooting Notes zo ocrni ss pa asna eee hr 7 1 Eocation f Components a wie He Se ee EE EAM ER He Ee VETE wg RR 7 2 High Temperature Redundant Overtemp Thermostat 7 3 p pss u ban m a n s eh Heelies Meade Ner eL EN Heg ede ds 7 3 Dynacontrol Vo Modules nur cad bed nv Heme Cha USE RAS 7 3 Handling Modules amp Printed Circuit Boards 1 7 4 V6 Base Module he qi ae Esp DES UR QE ER T d 7 5 V6 Temperature Modul e 7 9 V6 Power Modu le 32252522 qos oix bed kins Ue Ede 7 10 V6 AUxK Power Module e Dag U usu a Sa Wiehe eae Dag EG ern 7 12 Optional Printed Circuit Boards 2 2 7 13 Piston
60. Page 9 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 9 OPTIONS amp ACCESSORIES Service Kits Filter Kits Each filter kit contains three o rings size 127 124 and 020 one easy spin filter cartridge and silicone lubricant PN 117145 Service Kit containing a 40 mesh filter PN 117146 Service Kit containing a 80 mesh filter PN 117147 Service Kit containing a 100 mesh filter PN 117148 Service Kit containing a 150 mesh filter PN 117149 Service Kit containing a 200 mesh filter Hopper Manifold Sensor Kit DCL PN 117152 Hopper Manifold Sensor Kit NDSN PN 117416 Service kit contains a manifold sensor assembly and a ceramic terminal block Manifold Heater Kit PN 117154 Service kit contains a manifold heater assembly and a ceramic terminal block Manifold Rebuild Kit requires Filter Kit also PN 117201 Service kit contains both a manifold heater and sensor assembly o rings pump seal ceramic ter minal block and an electrical cover gasket Piston Pump Repair Kit PN 117257 Service kit contains the following items needed to rebuild the 12 1 piston pump Description s Description 116569 Bearing amp Shaft Seal Assy N03812 O ring 125 108700 Lube Seal 1 4 oz A69X134 O ring 128 116033 Inlet Check Valve Assy 116023 Spring Outlet Check 116024 Seat Outlet Check 111339 Ball SST 0 312 dia 116877 Ring Retaining Ext Piston Pump Airmotor Repair Kit PN 117256 Service kit contains seals wear ring and
61. Pump Control Board amp Calibration 7 14 Heater and Sensor Resistance Values 7 16 Resistance Tables o EIL e qu cb A ey eal arri Red ee e CERE E 7 17 Error Indication Alarm Troubleshooting Guide 7 18 Controller Messages Troubleshooting Guide 7 23 Pneumatic Pressure Relief Valve Operation 7 25 Operation of the ASU s Pump 0 7 26 Piston Pump Flow Diagram 7 27 Troubleshooting the ASU 1 4 7 28 Pump Troubleshooting Guide 7 29 Chapter 8 Disassembly amp Re assembly Procedures Disassembly amp Procedures 8 1 Open amp Remove the Electronics Cabinet Door 8 1 To Remove the Hopper Lid Assembly 8 2 To Remove the Hopper Cover 4 8 2 Overtemp Thermostat Replacement 8 2 To Remove the Pump i ere AI e
62. S EI lt CASS PAGE 4 amp 5 OPTIONS AND VARIATIONS kekk agl PAGE 6 BOARD INTERCONNECTIONS B B2 2 8 E 2 9 os 5 MUT BER z 2 g 2 i K Ke v 7 9 ie ew g les Km Egret 5 ssl K BEBE L 3SOH d IH LOAD 25 HE i Fit 85 _ Songz jg WI 7 7 c 2 5 Y Tr5m7s o 5 N5823 mm s ke 2 OV3H mx om wow gom 2 3S0H 59 Rabe z b RE EQ Ble s ofo of S 6 ojo 6 d o o yx SX 9X z 9 spes es pese gig BHE xam 223 G9 d a MAIN POWER BOARD x i gka PN115732 E gt x 2 o gt x x s L 4 4 2 2 ml ms 29 000 58 CI ooo 3 m ono 8 NE E ym YIH 8778 B H D 8 g z L L K 572 E 5 gt QV3H zi zr Y Qv3H Gam m wow sm 3SOH Y 35 5 i ooo ol pX SX ox Q 55 YILT AUX POWER BOARD E 2 115733 Smp x 8778 8 H D 8 2 L 4 4 4 BS 5 MEG X ET E Y G QV3H zi zi 9 QV3H G ULH u TI lo mr m In um S 35 9 3SOH 228 HE T T O Sj 6 956 oob o RIPE E x X SX x 9 Ell BE E Bie gif sg EE 9149 LT3AdHd a 3 my Kuy ENSE AUX POWER BOAR
63. Status OFF F5 Zone Off Advance to the temperature zones display to see which zone is affected The two status linesshown above will alternate in this mode As seen above the question mark is placed on the zone with the faulty sensor ie Head 1 After troubleshooting the fault reference the Error Indication Alarm Troubleshooting Guide on the previous pages of this chapter and solving the problem with the sensor press the RETURN button Or if Head 1 is not in use press F5 to turn the zone Off ITW Dynatec c 2012 Troubleshooting Page 7 25 DYNAMELT S ASU Manual 20 59P Revised 4 12 Pneumatic Pressure Relief Valve Operation For location of the pneumatic pressure relief valve see the exploded view drawing in Chapter 10 Valve Operation The Dynamelt S ASU is equipped with a pneumatic pressure relief valve that has two functions It controls output adhesive pressure during pump operation and also lowers adhesive pressure when the pump is switched off The pneumatic pressure relief valve regulates adhesive pressure proportional to air pressure sup plied to the pump The relief valve operates at a 14 1 adhesive to air pressure ratio Ten psi of air pressure will regulate the adhesive pressure to a maximum of 140 psi The valve is designed to de liver a maximum adhesive pressure of 1000 psi When air pressure is cut off from the relief valve the valve will open and dump adhesive pressure by relieving adhesive ba
64. T CAP 1 2 COND 1 116846 1 EA ENCL MACH 6x6 Optional System Status Lights Stack Lights Assembly PN 116848 Rev A ITW Dynatec c 2012 Schematics Page 11 9 DYNAMELT S ASU Manual 20 59 Revised 4 12 ZERO CAL Item No PN Qty Description 9 048J036 933 FT TUBING HTSHK 1 78 135C BK 8 104226 EA FERRULE UNINSUL 20 AWG 105199 EA CABLE CLAMP STRAIN RELIEF 6 115838 EA PLATE POWER CONNECTOR 5 042 158 1 EA CABLE ASY PR XDCR 25 FT 4 O78A164 2 SCR HWH 10 24X1 2 1YPE 5 115827 EA BRKI MIG PRSR XDCR SNGL 2 00182 EA O RING 015 75DURO VITON 1 812340 EA XDCR PR 4 20 BSP 9 NHG Optional Pressure Transducer Kit PN 116878 Rev B Page 11 10 Schematics ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59 IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Appendix 1 Revised 4 12 PN 812340 Pressure Transducer Cil Filled Melt Pressure Transmitters WE Series Output 4 20mA Au The WE series of Gefran are pressure transmitters for using in High temperature environment The main characteristic of this series is the capability to read temperature of the media up t
65. T S ASU Manual 20 59P Revised 4 12 Primary Filter Cleaning 9 PLIA EC Access Cover S ASS QIK PSS gee TS Primary Filter 41 Horizontal knob position closed OFF shown Vertical knob position open ON 1 Pump all the adhesive out of the hopper Then shut off the pump 2 Lower the temperature of the application system to the adhesive s softening point WARNING HOT SURFACE The ASU will still be hot when this procedure is being done Use insulated gloves and protective clothing when removing the primary filter 3 Remove the orange access cover by loosening the captive screw and lifting the panel off of the base rail 4 Wearing gloves unscrew the filter retaining nut and pull the primary filter out of the hopper 5 Immerse the clogged filter in flushing fluid PN L15653 to loosen contaminants Remove filter from fluid and use a hot air gun if necessary and rags to clean all contaminants from the filter 6 Apply a coat of anti seize compound onto the threads of the filter retaining nut and re install into the hopper 7 Note the orientation of the filter shut off knob When the knob is rotated to the left flow is cut off to the pump 8 Replace the orange access cover and restore the ASU to normal operation ITW Dynatec c 2012 Maintenance Page 6 7 DYNAMELT S ASU Manual 20 59P Revised 4 12 Summary of Preventive Mai
66. T S V 6 SERIES Model Designation Matrix ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Components of the DYNAMELT S ASU Installation Page 3 1 Revised 4 12 Chapter 3 INSTALLATION Hopper Lid Hinged Access Cover Access Panel Mounting Point Control Panel Air Regulator Gauge Electronic Cabinet Access Door Wireway Access Mounting Point Main Power Switch ON amp OFF Front View Hose Head Electrical Connections Motor Pump Access Panel Mounting Point Filter Manifold Filter Nut Filter Rear Wireway Access Gauge Port Pre Filter ith Di Hopper Drain Plug with Discharge Chute Pressure Relief Valve Mounting Point 1 4 Air Inlet Fitting Hose Head Adhesive Connections Back View Page 3 2 Installation ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Mounting the DYNAMELT S ASU The DYNAMELTIS SERIES ASU can be mounted on most flat surfaces on either an open or a solid frame Four mounting thru holes have been provided in the base of the unit Electrical power and serial communications may be routed through the wire raceway under the unit from either the left or right side of the unit For installation dimensions and required clearances see illustrations in Chapter 2 Lifting the ASU WARNING The unit must be lifted by two persons using proper lifting technique one person at either end Securely hold the unit under its
67. TEFLON TAPE TO ALL PIPE THREADS WITHOUT PRE INSTALLED SEALANT 2 TIGHTEN TO FOLLOWING TORQUE 1 8 NPT TIGHTEN 3 7 5 2 FT LBS 1 4 NPT TIGHTEN TO 8 1 9 6 FT LBS ITW Dynatec c 2012 Component Illustrations Page 10 19 DYNAMELT S ASU Manual 20 59P Revised 4 12 AIR OUT TO PUMP AIR INLET Component Illustration PN 115865 Air Regulator Assembly Page 10 20 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Schematics Page 11 1 DYNAMELT S ASU Manual 20 59 Revised 4 12 Chapter 11 SCHEMATICS PLUG HEAD 7 BROWN 22 BROWN 22 GND GRN YEL 18 SOLCS ACTIVATES HEAD Notes 1 ALL WIRE MIL W 22759 10 OR 12 MINIMUM 600 VOLTS 260 DEG C 2 SOLENOID S VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION 3 RTD WILL BE PLATINUM 100 OHM DynaControl Head Schematic PN 103117 Rev B Page 11 2 Schematics ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59 WHT RED 20 AWG 1 1 TRIGGER WHT BLK 20 AWG 2 2 TRIGGER WHT BLU 20 AWG 5 5 HEAD SENSOR WHT YEL 20 AWG 6
68. TEM 10 NOT SHOWN TO BE LEAD WIRES OF SENSOR ASSY ITEM 7 ACHED TO ITW Dynatec c 2012 Component Illustrations Page 10 7 DYNAMELT S ASU Manual 20 59P Revised 6 13 Component Illustration 5 10 Liter Hopper Assembly Page 10 8 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 115715 Manifold Assembly Piston Pump DCL Bill of Materials for PN 117447 Manifold Assembly Piston Pump NDSN Item No PN Qty Description 1 115714 1 Manifold Piston Pump 2 01703 4 Ftg Skt Plug 4 O Seal 3 101624 SeeTab Ftg Adptr Str G1 4 6 Stl 4 101625 See Tab Ftg Plg G1 4 6mm Soc Stl 5 814018 1 Nut Filter DMS Easy Spin 6 9 1 1 Filter Cartridge 7 812816 1 O ring 127 75 Duro Viton 8 A69X133 1 O ring 124 75 Duro Viton 9 N00187 1 O ring 20 70 Duro Viton 10 115540 1 Valve Asy Pneu Prv Cp 208 11 115822 1 Discharge Chute Assy 13 808344 2 Scr SHC M4 0 70x12 Zp 14 117083 1 Assy Htr Sr PP Manifold 15 117081 1 Assy Snsr Sr Manifold Block DynaControl 117414 1 Assy Snsr Sr Manifold Block NDSN 16 107881 2 Term Blk 2 Pos Ceramic 17 115851 1 Harness Mnfld Htr 18 117055 1 Gasket Manifold Htr 19 100908 2 Scr SHC M4 7x25 Zinc Pl 20 104852 1 Scr SS M10x12 Cone Relief 21 101833 1 Scr Tmpr Pnhd 10 32x 5 22 106328 5 Scr SHC M4 0 7x16 Zp 23 107389 1 Scr Php M4x8 w Wshr 24 078D022 1 Nut Jam
69. TOR POSITION Assembled View without Cover Component Illustration PN 117204 Electrical Enclosure Assembly Page 10 16 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 115540 Pneumatic Pressure Relief Valve Item PN Qty Description 01 115532 1 Valve Body 02 115437 1 Seal Stem 03 115534 1 Seal Retainer 04 115533 1 Stem Valve 05 115539 1 Spring Compression 06 115535 1 Piston Lower 07 115537 1 Piston Seal 08 115536 1 Retainer Piston Seal 09 00184 1 O ring 017 Viton 10 115538 1 Cap Valve Body 11 115438 1 Ftg 90 M5 X 1 4 Tube 12 01601 1 O ring 908 Viton 13 N05733 1 Backup Ring 012 Split Ptfe 14 00179 1 O ring 012 Viton 15 108700 A R Lube TFE Pre pack ITW Dynatec c 2012 Component Illustrations Page 10 17 DYNAMELT S ASU Manual 20 59P Revised 4 12 Component Illustration PN 115540 Pneumatic Pressure Relief Valve Page 10 18 Component Illustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 115865 Air Regulator Assembly Item No PN Qty Description 1 115842 1 Valve Reg Sol Asy 24VDC 2 115846 1 Gauge 40mm Panel Mnt 3 N06436 1 Ftg El 1 8npt X 1 4 Tube 4 115713 1 Ftg Conn 1 8fpt X 1 4 Tube 5 N06412 2 Ftg El 1 4npt X 1 4 Tube 6 115833 1 Bracket Regulator Solenoid 7 N07677 0 333 Tubing TFE 25 OD 125 ID NOTES 1 APPLY N02937 THREAD SEALANT OR 111457
70. TW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P V6 Base Module cont Description of Components The following items are referenced to the illustration on page 7 5 Item 1 controller runs on standard 24VDC The supply voltage coming from the 24VDC power supply is connected to this terminal The input is polarity sensitive Item 2 operator s panel connects to this header via a ribbon cable There are several types of operator s panels available They are interchangeable Item 43 This connector provides customer accessible relay contacts There are three pairs of dry contacts which are designed for maximum 240 VAC 1A The default functions of the relays are Relay 1 Ready Signal This contact closes once the system is in ready condition ready condition all active temperature zones are within their tolerances and there is no other alarm message pending Normally open Relay 2 Alarm Signal This contact opens whenever a critical situation arises A critical situation could be a defective temperature sensor an over or under temperature situation a motor driver fault etc Normally closed Relay 3 Hopper Empty Signal This contact closes when the adhesive level in the hopper drops below a certain level It can be used to indicate this situation via an external light or an audible alarm Normally open Note Depending on the controller s settings one or more of the relay outputs may be re pro grammed for differen
71. Troubleshooting Page 7 29 Revised 4 12 WARNING HOT SURFACE amp ADHESIVE Some of the procedures in the following Troubleshooting Guide require working near hot adhesive Be sure to wear protective gloves safety glasses and clothing and use proper tools for handling hot melt components Problem Pump Will Not Stroke Piston pump assembly Electrical connection Air operated Lig SL pressure hel relief valve o Solenoid valve Air pressure gauge Air regulator 1 No air pressure 2 Hopper or filter block temperature is below ready setpoint 3 2 way solenoid valve is closed Air inlet 4 Fault in compressed air fitting on ASU 5 Pump is switched Off at the control panel 6 ASU has not reached setpoint temperature 7 f pump status shows RUN then 1 Verify system has been provided with at least 0 5 SCFM of air at 10 100 psi 014 std cubic meters minute at 6 8 bar 2 Air valve cannot pass air until hopper has reached ready condition Verify that hopper has reached ready Re program hopper operating setpoint 3 Verify that valve is properly con nected electrically inside ASU Verify that valve is properly con nected to Air Control Filter Unit Disconnect valve electrical leads and verify that air is passed through when 24VDC is applied to the valve terminals Replace valve if defective 4 Inspect the system for impro
72. able ALLOWING PUR ADHESIVE TO CURE IN A UNIT OR ITS COMPONENTS VOIDS ITW DYNATEC S WARRANTY Safety Symbols In This Manual WARNINGS and CAUTIONS are found throughout this manual WARNINGS mean that failure to observe the specific instructions may cause injury to personnel CAUTIONS mean that failure to observe the specific instructions may damage the equipment Page 1 4 Safety ITW Dynatec c 2012 Revised 4 12 ALL MODELS IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Description amp Specifications Page 2 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 2 DESCRIPTION amp SPECIFICATIONS Description The DYNAMELT s Series adhesive supply unit ASU is a computer controlled hot melt supply unit designed on metric standards Its all icon control panel with choice of display languages is in ternationally operator friendly It is available for 240V 1Ph 240V 3Ph Delta or 400V 3Ph Wye service A transformer kit is available for 400V 3Ph Delta and 480V 3Ph Delta Available in two hopper sizes and with a choice of piston or gear pump the Dynamelt S ASU uses a microprocessor temperature control to closely control the temperature of hot melt adhesive for up to six hoses and six heads Temperature setpoints are operator selected for up to 16 zones and the system automatically provides warnings and alarms for operator errors and system malfunc tions The Dy
73. ad staged heating Sensor open an ec Sca teh Ed JUS Ses e Uu ga HS cae Bae 7 yes EtherNet IP communications capable yes Seven day scheduler e VE ule RR Ue Gd OOS e ae re Need ess yes Adhesive level SerSOf iae diced atia m rr Siar Bom ic Reti Rea le cl Du Boas eii yes Page 2 4 Description amp Specifications ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P 351 6 13 84 __ N 2 2 e 10 e 37 5 1 48 344 0 13 54 375 8 14 79 388 1 15 28 S 59 S 3 lt o e n od 5 9999 H L 1864 7 34 Dimensions are expressed as mm inch Installation amp Clearance Dimensions DM SRO5 5 kg 10 Ib Hopper Capacity ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P
74. adhesive to an almost empty hopper will lower the temperature of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint Changing the Adhesive Formula If a different adhesive formulation from the one being currently used is needed the system will have to be flushed if the two formulations are incompatible See Chapter 6 of this manual for the proper flushing procedure When in doubt about adhesive compatibility flush your system Page 3 8 Installation ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Repositioning the HMI Controller The control panel HMI may be rotated 90 from its standard location for the convenience of the operator DANGER HIGH VOLTAGE Disconnect and lock out input power to the application system before starting repositioning procedures Procedure 1 Remove the top cover from the unit a Open the electronics cabinet door b Release the top latch and open the top cover Loosen and remove the four screws that attach the top cover to the hinges see illustration 2 Remove the HMI by removing the four screws holding it in place 3 Drill four 1 4 holes in the locations shown below and re attach the HMI at these holes 4 Re install the top cover and close the cabinet door 5 Plug the three visible holes on the top cover with hole plugs Hinge Screws 1 of 4 HMI Screws Top Cover Drill 1 4 holes in these four pockets ITW
75. all of the other zones However to do so it must be appropriate for all your hoses to be programmed to one setpoint and for all your applicator heads to be programmed to one setpoint After turning the Input Wheel to select the Global Setpoints parameter press the Enter Knob to turn Global Setpoints On Off YES NO SYSTEM CONFIGURATION CUSTOMER ZONE NAMES NO LOGBOOK FAULT HIST E E we TN GLOBAL SETPOINT HOSE HOPPE HEAD HOPPE On the Global Setpoints menu you set up simple mathematical relationships increases between the hopper setpoint and the setpoints of the hoses and applicator heads Pressing the Input Knob increases the temperature of the hose or head by 5 degrees or if you press again by 10 degrees press again for 15 degrees and press again for 20 degrees Once setup all of the hoses will increase over the hopper setpoint by the same amount 0 5 10 15 or 20 degrees and likewise all of the heads will increase over the hopper setpoint by the same amount as you program here Once Global Setpoints are setup you simply program the hopper as described on page 5 5 and your hoses and heads will automatically be programmed to the increases you specified on the Global Setpoints menu For example If you setup a Global Setpoint increase of 10 degrees for Hoses and 15 degrees for Heads and you program your Hopper setpoint to 290 degrees then the controller will automat ically prog
76. allows the use of the converter in heavy environmental conditions found in industrial applications The DAT 4531 D is in compliance with the standard 89 336 CEE on the Electromagnetic Compatibility It is housed in a plastic enclosure of 12 5 mm thickness suitable for DIN rail mounting in compliance with EN 50022 and EN 50035 standards USER INSTRUCTIONS The converter must be powered by a direct voltage applied to the terminals Q and R The input channel measures the value from the sensor connected to the terminals I L and G and transmits the output measure on the terminals N and M The input and output connections must be made as shown in the section Connections It is possible to configure the converter on field by dip switch or Personal Computer as shown in the section Programming The configuration by dip switches can be made also if the device is powered note after the configuration the device takes some seconds to provide the right output measure LIGHT SIGNALLING LED STATE DESCRIPTION BLINKING Wrong dip switches setting cont Appendix 6 ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P PROGRAMMIN CONFIGURATION BY DIP SWITCHES 1 Open the suitable door on the side of the device Refer to TAB 1 2 Set the input type by the dip switch SW 1 1 4 12345678 3 Set the output type by the dip switch SW 1 6 8 12345678 4 Set the options by the dip switch SW1 5 Ex of configuration SW1
77. aminants also 2 Switch ON the Main Switch The controller display will come on and the ASU will begin to heat up 3 Allow adequate time approximately 20 30 min for the adhesive to melt and the temperat ures of the heated zones to stabilize The display will indicate when the unit reaches operating temperature The LCD panel will display READY in the upper left hand corner when all zones are within their hi lo tolerance range of the setpoint temperature More information about the display can be found in Chapters 4 and 5 4 When temperatures are ready the piston pump is enabled to pump adhesive and will begin pumping Ready display Shut Down Procedures 1 Turn OFF the Main Switch TWDynatec However if the 7 Day Scheduler is in use the unit should be turned ON and OFF by the Scheduler On Off a Press Menu b Press 7 Day Scheduler F4 c Press F2 for Sleep Mode Off To cancel Sleep Mode press the Input knob F wap button Input J turn Enter button push Page 3 12 Installation ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Storage and Disposal of the DYNAMELT S Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN L15653 following the instructions detailed in chapter 6 of this manual 2 Relieve residual adhesive pressure 3 Clean or replace both the outlet filter and the primary filter following the instr
78. any other person Never leave a hand held applicator s trigger unlocked when not actually in use Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until the adhesive s temperature is within the operating range Severe damage could result to internal parts and seals Never attempt to lift or move the unit when there is molten adhesive in the system Eye Protection amp Protective Clothing WARNING EYE PROTECTION REQUIRED PROTECTIVE CLOTHING REQUIRED It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment Wear a face shield conforming to ANSI Z87 1 or safety glasses with side shields which conform to ANSI Z87 1 or EN166 Failure to wear a face shield or safety glasses could result in severe eye injury It is important to protect yourself from potential burns when working around hot melt adhesive equipment Wear protective gloves and long sleeved protective clothing to prevent burns that could result from contact with hot material or hot components Always wear steel reinforced safety shoes Page 1 2 Safety Revised 4 12 Electrical DANGER HIGH VOLTAGE Dangerous voltages exist at several points in this equipment To
79. ation in this chapter ITW Dynatec c 2012 Controller Programming Page 5 11 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Setpoint Locking F3 When Setpoint Locking is on temperature and motor setpoints and the System Configuration Menu are locked and cannot be changed But even when locked the pump can be stopped and the setpoints can be monitored When Setpoint Locking is on a small key symbol can be seen on the Overview Screen near the time of day display If setpoints are unlocked and you desire to lock them press the Main Menu button then press F3 twice The controller s access code must be keyed in to unlock setpoints To do so press the Main Menu button press F3 then enter your access code using the F1 thru F5 buttons For example if your access code is 2453 press the sequence F2 F4 F5 F3 Note setup an access code on page 3 of the System Configuration Menu The Dynamelt S ASU is shipped from ITW Dynatec with a default access code of 1111 Keypad is unlocked gt 4 Keypad is locked press F3 to lock it enter access code to unlock it 7 Day Scheduler F4 The 7 Day Scheduler allows the user to program the ASU to automatically switch on or off at pre programmed times and days of the week Up to three daily programs may be setup Each daily program can have two on periods with a standby period between them Time to Switch Switch Off Stand by Switch On Switch Off Sched
80. ation of the RTD connectors of the temperature module This information can help in troubleshooting errors in wiring All zones are shown here even those that are not in use on the ASU RTO INPUTS TEMP HMODLLE 1 ZOME HOPPER HCT 138F HORE Info Screen 3 The next Info Screen provides set up information for the unit s optional communication module If that module is installed on your ASU the set up info is provided on a supplemental CD If the module is not installed the Info Screens end here Press RETURN to exit the Info screens and press RETURN again to return to the Overview Screen ITW Dynatec c 2012 Controller Programming Page 5 15 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 System Configuration Menu Press the System Configuration Menu button on the Overview Screen to program the following parameters Temperature Unit Fahrenheit or Celsius Language Selection English German Spanish French or Japanese Zone Configuration typically configured by ITW Dynatec Pump Configuration typically configured by ITW Dynatec Setpoint Limitation sets a limit on the maximum setpoint Hi Low Tolerance the high and low temperature window which defines the Ready temperature Standby Configuration amount of temperature difference time delay activation method and sleep mode for the standby function Level Detector activates or de activates the low adhesive level detector Heat up Sequence simultaneous or sequential
81. attages A suspected head heater problem can be isolated by measuring head heater resistance and compar ing it to the resistance for the appropriate wattage of your system The Nominal Hopper Heater Resistance table gives heater resistance for the hopper heaters of each Dynamelt S Series model and for the optional drop in grids DANGER HIGH VOLTAGE Before unplugging connectors from the PCBs ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the PCB assembly when you are removing and replacing connectors ITW Dynatec c 2012 Troubleshooting Page 7 17 DYNAMELT S ASU Manual 20 59P Revised 4 12 Temperature Resistance F Ohms Hose Length Resistance 32 0 Meters Feet in Ohms 466 544 279 326 236 275 189 221 155 181 118 137 77 90 Nominal Hose Heater Resistance for 6 DynaFlex Hoses Resistance in Ohms Temperature Sensor Resistance Nominal Head Heater Resistance 0 00385 PT 100 RTD ASU s Heaters Hopper Filter Manifold Resistance in Ohms for each heater 71 96 80 65 66 3 82 3 Nominal Heater Resistance Note Resistance is measured at ambient temperature 20 C 68 F Page 7 18 Troubleshooting Revised 4 12 Error Indication Alarm Troubleshooting Guide ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P The operation of error indication alarms is described in Chapter 4 When checki
82. avoid personal injury do not touch exposed connections and components while input ITW Dynatec c 2012 ALL MODELS power is on Disconnect lockout and tag external electrical power before removing protective panels A secure connection to a reliable earth ground is essential for safe operation An electrical disconnect switch with lockout capability must be provided in the line ahead of the unit Wiring used to supply electrical power should be installed by a qualified electrician High Temperatures WARNING HOT SURFACE Severe burns can occur if unprotected skin comes in contact with molten adhesive or hot application system parts Face shields preferred or safety glasses for minimum protection gloves and long sleeved clothing must be worn whenever working with or around adhesive application systems High Pressure WARNING HIGH PRESSURE PRESENT To avoid personal injury do not operate the equipment without all covers panels and safety guards properly installed To prevent serious injury from molten adhesive under pressure when servicing the equipment disengage the pumps and relieve the adhesive system s hydraulic pressure e g trigger the heads hand held applicators and or other application devices into a waste container before opening any hydraulic fittings or connections IMPORTANT NOTE Even when a system s pressure gauge reads 0 psig residual pressure and trapped air can r
83. b to select the new character 6 Press the Input Knob to confirm the new character 7 Repeat steps 3 through 6 to spell desired zone name 8 Press the Return button J to select another zone to program Repeat steps 1 through 6 for each zone desired 9 Press Return again when all temperature zone name programming is completed Logbook Fault History P4 The Logbook provides a read only history of the last 250 maximum controller faults and events Controller faults include sensor or temperature errors or motor faults Examples of an event include switching the ASU on off or System Ready The most recent event is recorded at the top of the list No 1 Day Time and Event are listed for each item in the Logbook This information can be valuable when troubleshooting controller problems After turning the Input Wheel to select the Logbook parameter press the Enter Knob to display the Logbook Turn the Input Wheel to scroll through the list LOGBOOK 7 FAULT HISTORY 1 is most recent entry gt ERROR 2 4 TOR FAULT STEM READ Page 5 22 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Power On Configuration P4 Two start up parameters are programmed at the Power On Configuration screen and they are set by choosing YES or NO Power On Motor Stop At the Power On Motor Stop parameter you decide if you prefer the the motor to be stopped when the ASU is turned on if so ch
84. ck to the hopper Air pressure may be cut off from the relief valve by per forming any or all of the following actions Turning Off the pump at the ASU s control panel Switching the ASU s main power Off or Shutting Off air supply to the ASU Adjustment Air pressure supplied to the pneumatic relief valve is adjusted by turning the pressure regulator built into the front of the ASU with clockwise to increase pressure or counter clockwise to de crease pressure Maximum adhesive pressure can be determined by reading the air pressure from the built in gauge and multiplying by 14 For example if the air pressure gauge reads 25 psi then adhesive pressure will be limited to 350 psi Page 7 26 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Operation of the ASU s Piston Pump The pump is double acting and provides constant pressure However the pump does not provide the same volume of adhesive with each piston stroke When operating the pump shaft will move more slowly during the forward stroke into the pump body and more quickly during the reverse stroke out of the pump body During the forward stroke of the pump the piston s movement forces the input check valve to close The pressure generated by the piston opens the output check valve During the forward stroke the adhesive pressure is uniform within the pump and in the output During the reverse stroke the piston moves to the left and low pressu
85. d decreases the total stroke length Turning R1 clockwise lowers the bottom switching point until the bottom stop is reached or the pump stalls If you cannot make the pump stroke upward 1 Check the air pressure and air supply tubes 2 Check the DOWN solenoid valve a Listen for the solenoid to go on and off b Check the voltage 24V c Manually shuttle the solenoid valve push the poppet and see if the pump moves 3 Replace the pump controller PCB Page 7 16 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Heater and Sensor Resistance Values The resistance values given in the four tables on the following page will aid in troubleshooting when a sensor or heater malfunction is suspected The Temperature Sensor Resistance table gives values for various temperatures If you know the approximate temperature of the suspected sensor you can check to see if the sensor resistance approximates the value given in the table by unplugging the affected head or hose connection and measuring resistance across the affected pins see wiring diagram in Chapter 11 for pin numbers The Nominal Hose Heater Resistance table gives the heater resistance for hoses A suspected hose heater problem can be quickly isolated by measuring hose heater resistance and comparing it to the correct resistance for your hose length and voltage as shown The Nominal Head Heater Resistance table gives values for several different head w
86. d into another ASU socket If the new hose number is then displayed as malfunc tioning the problem is in the hose that was moved Repair or replace hose or head or ASU hose head harness as appropriate 2 Verify that the hose harness is properly inserted into its Power or Aux Power Module plug Check for loose leads debris and proper contact 3 Visually inspect wiring inside head Verify that cartridge heater leads are properly connected in the service block area 4 Use an ohmmeter to measure resis tance of head cartridge heater Refer to resistance table for resistance values Infinitely high resistance indi cates an open heater Replace cartridge heater as appropriate 5 f a fuse is found to be blown do not replace it without first finding cause Look for a short circuit to ground in the head heater circuit particularly inside the head at the connections in the service block area If replaced fuse also blows Power or Aux Power Module may be the cause However fuse failure is usually due to a problem in the head heater circuit not the Power or Aux Power Module 6 Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate an open wire in head heater cir cuit Repair or replace ASU hose har ness or other ASU wiring as necessary ITW Dynatec c 2012 Troubleshooting Page 7 23 DYNAMELT S ASU Manual 20 59P Revised 4 12 Controller Messages Troubleshooting Guide The following are exampl
87. de Adi as ath aot 1 5 cc rev or 4 5 cc rev standard Enclosure styled durable metal and high temp polymer dust and splatter resistant Hoseconnections standard universal 15 pin Amphenol connectors at ASU wrench secured fluid fittings 6 JIC optional NDSN 12 pin rectangular electrical connectors Hopper tank capacity DM 505 4 7 kg 10 Ib DM S10 9 5 kg 20 Ib Hopper construction welded aluminum cast in heaters Hopper coating ies ceu rS RRR eG weds ceramic nano composite FilttatiORc aee eo o bac tte en ro e Ha RE hopper filter shut off valve filter manifold large pleated pump outlet filter Weights emptyss do e oe eee bt eI DM 505 58 5 kg 129 Ib DM S10 62 6 kg 138 Ib Adhesive TOR sr qepa satu Ce stb e vau A accepts most forms Electrical Service Requirements 200 240 VAC ASUs 50 60 Hz see also Wattage Chart 380 400 VAC ASUs 50 60 Hz see also Wattage Chart Power consumption system maximum 200 240 VAC system DM S05 DM S10 7200 watts 380 400 VAC system DM S05 DM S10 9650 watts Power consumption hopper 240 380 VAC system DM 505 DM S10 1500 watts Hopper heater type sc Beals eas EP EXE eee Gla Re EO cast in tubular Temperature control microprocessor based proportional in
88. drain valve A small amount of adhesive will pop out of the drain valve relieving stored pressure in the manifold Allow the adhesive to drain into the container Close the drain valve purge screw after pressure has been relieved 5 After all pressure has been drained from the manifold remove the filter nut and the attached filter cartridge with a 25mm 1 wrench 6 All the o rings and the filter cartridge are attached to the filter nut To loosen and remove the filter cartridge turn it to the right relative to the filter nut Note the threads that attach the fil ter cartridge to the filter nut are left handed 7 Inspect the filter nut and o rings for damage and replace as necessary When replacing o rings lubricate the new o ring with o ring lubricant prior to installation 8 Install a new filter cartridge onto the filter nut Turn it to the left to thread it onto the stud 9 Re install the filter assembly into the manifold Tighten the filter nut to 15 20 ft lbs being careful not to damage the o ring seal Note when correctly installed the filter nut sits below the top surface of the manifold Replace the manifold insulator Hose Fittings All hose fittings should be checked for tightness after every three months of operation Fasteners Check that all fasteners are tight after the first ten hours of operation Re check all fasteners after every three months of operation ITW Dynatec c 2012 Page 6 6 Maintenance DYNAMEL
89. ds recommended by ITW Dynatec or your adhesive supplier only Flash points of cleaning compounds vary according to their com position so consult with your supplier to determine the maximum heating temperatures and safety pre cautions Lockout Tagout Follow OSHA 1910 147 Lockout Tagout Regulation for equipment s lockout procedures and other impor tant lockout tagout guidelines Be familiar with all lockout sources on the equipment Even after the equipment has been locked out there may be stored energy in the application system par ticularly in the capacitors within the panel box To en sure that all stored energy is relieved wait at least one minute after removing power before servicing electrical capacitors Use of PUR Polyurethane Adhesives PUR adhesives emit fumes MDI and TDI that can be dangerous to anyone exposed to them These fumes cannot be detected by the sense of smell ITW Dyna tec strongly recommends that a power vented ex haust hood or system be installed over any PUR sys tem Consult with your adhesive manufacturer for specifics about required ventilation CAUTION Because of the nature of PUR adhesives to strongly bond in the presence of moisture care must be taken to prevent them from curing inside Dynatec equipment If PUR adhesive solidifies in a unit the unit must be replaced Always purge old PUR adhesive from the system per your adhesive manufacturer s instructions and time t
90. e cH Voltage Supply from Power Board Head3 5 gt Heater Hose3 5 Heater Heater Premelt Grid Filter Block Troubleshooting Page 7 13 ITW Dynatec c 2012 Revised 5 12 DYNAMELT S ASU Manual 20 59P Optional Printed Circuit Boards Wiring diagrams and other details on the following optional PCBs can be found on the main ASU schematic PN 115894 in Chapter 11 Adhesive Level Sensor hopper low level detection Stack Lite system status lights Signal Isolator gear pump models auto mode Line Speed Following piston pump models line speed tracking Trigger Switch Pump Enable hand held applicators swirl kits EtherNet IP communications protocol Page 7 14 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Piston Pump Control Board PN 115801 The PN 115801 printed circuit board controls the air motor piston pump via an electronic shift ing mechanism Its electronics are factory calibrated and normally do not need service However if the PCB or other parts of the air motor assembly are replaced it may be necessary to re adjust the board The board is located within the top compartment of the piston pump Based on the position of the piston inside the air motor cylinder the control board activates one of the two solenoid valves that control the up and down movement of the piston Th
91. e compressed air input Piston pumps are available for either hot melt or lotion applications A gear pump is also available to assure a smoother and higher precision flow The single or dual pump is driven by a single drive The Dynamelt s hopper accepts adhesive in all popular forms including pellets slugs and blocks The ASU can accommodate air actuated automatic applicators heads electric applicators hand held applicators and or special applicators Among the options available are pressure gauge pendant control stack lights and line speed tracking Page 2 2 Description amp Specifications ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Specifications Environmental Storage shipping temperature 40 C to 70 C 40 F to 158 F Ambient service temperature 7 C to 50 C 20 F to 122 F NOISC CMISSION rs m ries de ree Qs BO Geen eh Re XU d 60 dbA at 1 meter Physical Dimension Sese ieee Reh C a buka ER see dimensional layouts on following pages Number of heads hoses 2 4 or 6 heads hoses Number of hopper temperature ZONES 10r2 Number of pumps 3 535 ns pisipas aga hap iwa pis a ca Paes 1 Piston PUMP ALO reme ebur ngos esee ee Rom UE Rol f oe HD wey RU 12 1 Gear PMP ada aw atl scarcer ng
92. e F5 button or the Pump button on the Overview Screen ASUS with Optional Line Speed Tracking On units utilizing the line speed tracking option adhesive output is adjusted automatically through a parent machine The Dynamelt S Pump Screen allows you to change the pump mode Manual stop or Automatic and the pump scaling factor a minimum and maximum percentage of full pump speed Selecting Pump Mode AUTO Mode the pump will be started and stopped by a parent machine production line MANUAL MANU Mode the pump will be started and stopped manually by an operator STOP Mode the pump is stopped until AUTO or MANUAL is selected To select a pump mode a Use the function buttons F2 MANUAL Mode F3 STOP or F4 AUTO Mode or b Use the Input Wheel If Auto or Stop modes are desired simply turn the Input Wheel to highlight that function However to select Manual mode press the Input Wheel before turning the wheel Pressing the Input Wheel here toggles between mode selection and percentage of full speed selection Once you are in Manual mode and you have highlighted the percentage selection turn the Input Wheel to your desired percentage value PUMP SETTINGS G5 4501 Ku AUTO MAX 80 0 MANUAL Mode is selected AUTO Mode is selected speed is 45 of maximum pump speed speed is 80 of maximum pump speed STOP AUTO 30 60 90 EE NS NR Page 5 8 Controller Programming ITW
93. e position of the switching points can be adjusted using the two trim potentiometers R1 and R2 ON BOTTOM Y ADJUSTMENT pown PE N DYNATEC ONLY TOP NC _ DOWN ADJUSTMENT LES UP LED d ND _ DOWN LED N a 24V J2 VALVE DOWN VALVE Before starting be sure there is pressurized air connected to the ASU and that the ASU and the pump are switched On Open the electronics cover Depending on the status of the pump follow these procedures 1 Pump is not stroking Check the pump status in the display a If status shows STOP the pump is switched off Go to the pump screen and switch the pump On b If status shows HOLD the ASU may not be ready Wait for the temperature zones to reach setpoint lower the setpoint or widen the temperature tolerance Hopper zones are below Wait for hopper to reach pump enable temperature lower the pump enable temperature the pump enable temperature or raise the hopper setpoint and wait c If status shows RUNNING no LED is lit The PCB has no power Check connection to the Base module ITW Dynatec c 2012 Troubleshooting Page 7 15 DYNAMELT S ASU Manual 20 59P Revised 4 12 UP LED is lit Perform Calibration Procedure 1 DN LED is lit Perform Calibration Procedure 2 2 Pump is stroking but may need calibratio
94. eady Output Signal OUTPUT1 contact closes when ready RELAY Alarm Output Signal OUTPUT2 contact opens when alarm RELAY Hopper Low Level Signal OUTPUT3 contact closes when glue level is low Main ON OFF Switch L1 L2 Ground Lug Main ON OFF Switch L1 L2 L3 Ground Lug Main ON OFF Switch L1 L2 L3 Terminal on Main Switch Ground Lug V6 BASE Module top side Sa AGOOO RELAY OUTPUT 1 Standby IN2 Recipe Selection 1 IN3 Recipe Selection 2 INA not applicable IN5 not applicable IN6 External Pump Start Stop activate to start pump V6 BASE Module bottom side OOODOOQOQ Line Speed Tracking Voltage 0 10V V6 BASE Module bottom side BENE G l or L I Line Speed Tracking Signal with Signal Isolator option Installed at the left of the Base Module Refer to schematic for details ITW Dynatec c 2012 Installation Page 3 7 DYNAMELT S ASU Manual 20 59P Revised 4 12 5 The air pressure regulator gauge and solenoid valve assembly located in the base frame on the front of the unit are pre installed Connect a one quarter inch 1 4 air line to the female 1 4 NPT fitting on the right side of the unit located in the base frame Air supplied to the unit must be regulated clean and dry Recommen ded supply pressure is 10 to 100 psig 0 7 to 6 8 bar To increase pressure use a flat tip screw driver to turn
95. ec c 2012 Controller Programming Page 5 5 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Setup Your System s Parameters System Parameter Setup refers to the process of programming the controller to meet the specif ic temperature requirements of your production Temperature setpoints for each temperature zone must be programmed as well as a standby temperature and high low alarm tolerances Choices must be made for program selection and pump If desired temperature zone offsets and or a temperature zone enable may be selected The following is a step by step procedure for setting up the DynaControl with your system s parameters Temperature Zones Selecting Temperature Zones From the Overview Screen turn the Input Wheel slowly to view each temperature zone As the wheel is turned you will see the names of the individual temperature zones on the top line of the display To select a zone simply stop turning the wheel when the desired zone s name appears example below HEAD 1 To the right displayed on the top line is this zone s programmed setpoint ex SET 320 F and the actual current temperature of the zone ex ACT 319 F Below the zone s name is the bar graph with the selected zone highlighted Below the bar graph you can see that this zone is 41 of the system s applicators At the far right of the display you can see that this zone is turned ON Head 1 zone is selected Head 1 s Setpoint Head 1 s Actual current Tempera
96. ecise monitoring of system pressure It is also useful for troubleshooting and main tenance Pressure Transducer Kit PN 116878 contains PN 812340 Xducer 4 20 BSP A pressure transducer is an electronic probe that allows the melted adhesive s pressure to be processed by the ASU s control system They are used to monitor system operating pressures and their limits They troubleshoot clogged nozzles and filters Norsdson NDSN Compatible ASU This adhesive supply unit is a drop in replacement for Nordson units It is built with Nordson hose and head compatible harnesses and utilizes Nickel Iron RTD sensors in the hopper and manifold ITW Dynatec c 2012 Options Page 9 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 ASU Roll Cart PN 108838 A gray enamel flush top cart of welded steel construction 24 x 30 1800 Ib capacity Includes two rigid and two swivel locking 5 casters Flow Control PN 104890 The flow control valve installed between the outlet filter manifold and the hose adjusts adhesive output resulting in a more even flow Harting Connector Set PN 115879 The addition of a Harting connection provides dedicated hardware for making terminal connec tions The male and female 18 pin connector simplifies installations and makes them safe and reli able and provides one connection for all electrical devices Piston Pump Line Speed Tracking PN 117144 The assembly controls line speed changes and adjusts adhesive volume output
97. een hose head and ASU 1 Visually inspect hose connector and ASU socket for cleanliness and proper contact and seating of pins 2 Debris at connection between hose head harness and Power or Aux Power Module 2 Visually inspect that the affected hose connector at Power or Aux Power Module is clean and properly installed 3 Hose Head sensor circuit 3 Using the hose schematic check hose inoperative sensor resistance at ASU socket An ohmmeter can also be used to isolate a pinched wire in the hose harness When cause is isolated repair or replace sensor hose hose harness Power or Aux Power Module as appropriate Check each Hose Head circuit on the system Page 7 22 Troubleshooting Revised 4 12 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Problem 1 Disconnection between hose head and ASU Hose Head No Not Heating Heater Circuit Open 2 Disconnection between hose head harness and Power or Aux Power Module 3 Disconnection between cartridge heater and cable assembly inside head 4 Open head heater element 5 Head fuse on Power Module or Aux Power Module inoperative 6 Open wiring inside ASU Check each Hose Head circuit on the system 1 Visually examine affected hose head plug and ASU socket for cleanliness and proper contact and seating Refer to wiring diagram for pin identifica tion The problem can be isolated by plugging the affected hose hea
98. ely 30 seconds the controller will automatically return to the Overview Screen Page 5 2 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Overview Screen Reference System Status Time of Day Pump Status 7 Day Scheduler Keypad Status Status Status gt REA DY Line sa Zone Information Bar Graph ON or OFF Zone Symbols F1 F2 F3 F4 F5 Toggle On Off selected functions or Go To selected screens Toggle Pump On Off Configuration Menu e 10 Input Wheel Return to Previous Screen ain vienu Press Knob to Enter The Overview Screen gives a comprehensive view of the status of each of the temperature zones and the system as a whole It gives the status running or stopped of the pump The pump may be started or stopped by pressing either the F5 button or the Pump button on this screen ITW Dynatec c 2012 Controller Programming Page 5 3 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Status Line The status line is the top line of the display It always lists the System Status the Time of Day and the Pump Status It can also include the status of the Keypad if locked and the 7 Day Scheduler if active An example of an Overview Screen status line is seen below System Status Keypad is locked 1 7 Day Scheduler is active Pump Status System Status The status of the system
99. emain within it causing hot adhesive and pressure to escape without warning when a filter cap or a hose or hydraulic connection is loosened or removed For this reason always wear eye protection and protective clothing Either of the two High Pressure symbols shown may be used on ITW Dynatec equipment Protective Covers WARNING DO NOT OPERATE WITHOUT GUARDS IN PLACE Keep all guards in place To avoid personal injury do not operate the application system without all covers panels and safety guards properly installed ITW Dynatec c 2012 ALL MODELS Treatment for Burns From Hot Melt Adhesives Burns caused by hot melt adhesive must be treated at a burn center Provide the burn center s staff a copy of the adhesive s M S D S to expedite treatment Care should be used when working with hot melt adhesives in the molten state Because they rapidly solidify they present a unique hazard Even when first solidified they are still hot and can Safety Page 1 3 Revised 4 12 cause severe burns When working near a hot melt application system always wear safety gloves safety glasses and long sleeved protective clothing Always have first aid information and supplies available Call a physician and or an emergency medical technician immediately Service Refer all servicing to qualified personnel only Explosion Fire Hazard Never operate this unit in an explosive environment Use cleaning compoun
100. er Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunction does not move with the applicator and hose the problem is probably in the ASU Before disconnecting a hose or applicator always turn its temperature zone OFF at the controller This will avoid controller alarms and possible system shutdown Page 7 2 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Operator Panel PCB Assembly Piston Pump Disconnect lt Fx V6 Base Module V6 Temperature Module Power PCB Primary Filter Auxiliary Power PCB s Over temp Thermostat push to re set Location of Components ITW Dynatec c 2012 Troubleshooting Page 7 3 DYNAMELT S ASU Manual 20 59P Revised 5 12 High Temperature Redundant Overtemp Thermostat The Dynamelt S Series ASU includes a mechanical redundant overtemp thermostat that acts as a safety backup If the ASU s hopper temperature should exceed 232 C 450 F the thermostat will cause the ASU s power relays to open and power to the hopper and all hoses and heads will be cut off The mechanical thermostat m
101. er Knob Standby Configuration P2 There are four ways to activate standby mode 1 Manually at the Main Menu s F2 2 Automatically via the 7 Day Scheduler 3 Remotely via an external contact program as described below or 4 Automatically after a pump stop program as described below Standby Configuration allows you to select 3 or 4 and program other standby parameters Program a standby time delay STANDB CONFIGURATION Program a standby temperature STAM DB TEMF DIFF ET difference STANDBY AFTER EXT CONTRCT Toss to choose after External SLEEP MODE AFTER 2 hrs IM STANDBY Program a sleep mode after standby time delay Page 5 18 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Standby Temperature Difference In Standby mode the temperatures of all active temperature zones decrease by a programmed amount and the pump s stop pumping adhesive The programmed decrease in zone temperatures is the standby temperature difference The standby temperature difference applies to all zones once standby is activated For example if the difference temperature is 80 F and setpoints are 300 F then all zones will reduce to 220 F 300 80 220 when standby is activated After turning the Input Wheel to select Standby Configuration press the Enter Knob to advance to the screen Press the Enter Knob to select the first parameter ie
102. erage Run the power cord through the wireway to the hole in the bottom of the base plate Attach the power cord at the main switch s connectors Secure the cord with a strain relief Attach a ground wire to the ground lug provided in the base plate Piston Pump Disconnect 24VDC Power Supply V6 Base Module V6 Temperature Module C EN Totg 1 Insert power cord through wireway access gt Main ON OFF Switch Main Power Module WS cm Auxiliary Power Module Jj Top Latch Release Main Power Installation amp Internal Components cont Page 3 4 Installation ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P conducting wire as earth ground is incorrect and may cause damage to the 1 CAUTION Grounding conductors never carry electrical current The use of a neutral DYNAMELT controller 3 A voltage configuration connector plug appropriate for your order has been
103. es of System Status or controller display error messages and solutions EXE ub HOLD 55 The jumper connection from IN6 to COM or IN6 to 24V is not made on the Base Module 2 MOTOR FAULT This fault could be caused by one of the following problems a there may be a motor short circuit solution replace the motor b there may be a faulty motor drive solution replace the motor drive c there may be a motor overload contact ITW Dynatec Technical Service SYSTEM FAULT This fault seen on the controller display will result if the V6 modules on the din rail are not connec ted properly A bus connector near the rail connects one module to the next Modules can become disconnected during transport or during repair procedures 4 FAULT CONFIRM WITH lt A fault such as this indicates an over temperature or an RTD sensor fault The solution is not simply to press the RETURN button to confirm The solution is to troubleshoot and solve the problem which caused the fault and then confirm with the RETURN button to production AFTER problem is solved 5 TEMP ALARM 55 lt restorer The alarm shown above can occur on any screen Its question mark indicates a problem with the RTD sensor the Head 1 zone After about 20 seconds the following display is shown Page 7 24 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P HEMD1 SWITCH ZONE OFF lt
104. ff time or a Standby time then press the Enter Knob to highlight it As above turn the Input Wheel to program your desired time in hours and minutes then press the Enter Knob In the same manner if desired program another Switch On time and or Switch Off time To Program Additional Daily Programs Turn the Input Wheel to the second or third set of Days of the Week to program Switch On and Switch Off times for Daily Program 2 or 3 Program in the same manner as above To Choose Activate Deactivate or Sleep Mode Once the 7 Day Scheduler s Daily Programs are setup press F4 to Activate This is indicated by the clock symbol in the status line To deactivate the scheduler press F4 again Press F2 to put the ASU into SLEEP MODE indicated below In this state the ASU will be activ ated at the next programmed Switch On time of the scheduler or it can be manually started Symbol f System OFF BS aie Knob i 7 Day Scheduler Examples as shown on the illustration on the previous page Daily Program 1 On Mondays Tuesdays Wednesdays and Thursdays the ASU will Switch On at 6 00am It will go into Standby at 12 00 noon It will come out of Standby at 1 00pm and Switch Off at 6 00pm cont ITW Dynatec c 2012 Controller Programming Page 5 13 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Daily Program 82 On Fridays the ASU will Switch On at 5 30am It will go into Standby at 12 30pm It will come out of Standby at 1 00pm and
105. g of 75 C CAUTION The customer is responsible for providing appropriate over current protection Amperage Calculation Chart DM S V6 STEP 1 DM S 05 10 95 Enter 9 5 Amps Total Length of All Hoses Feet 12 24 36 48 60 72 sa 96 108 120 1 144 156 168 180 15 3 45 6 75 9 105 12 13 5 15 165 18 195 21 225 STEP 2 Add up all hoses Enter Amps Total Width of All Applicator Heads STEP 3 Add up all applicators Enter Amps Total Width of All Air Heaters finches 0 2 4 6 10 12 14 16 18 20 22 24 26 28 o 51 102 152 203 256 305 356 406 457 508 559 610 660 711 o 25 5 75 10 125 15 175 20 225 25 27 4 34 32 5 35 STEP 4 Add up all air heaters Enter Amps STEP 5 Add up total amps STEP 6 Recommended Wire Gauge and Over Current Protection for Your Power Source Find the column SINGLE PHASE AC INPUT VOLTAGE SPECIFICATIONS Total Current for SINGLE PHASE AC Input Voltage with your total single phase Amp amperage in chart at left a 2 s al u o o s s 2K fta 240V STEP 7 59 Contact Dynatec J Wire Gauge Select your b AC input EJ SS 5 Wire Gauge corresponding maximum Amp 3PH amperage and 400V wire gauge PHASE 400VAC INPUT VOLTAGE SPECIFICATIONS Wire Gauge z 0 P gt
106. gh accuracy GBS Gear pump 3 2cc single ZES Gear pump 0 584cc single high accuracy GCS Gear pump 4 5cc single ZFS Gear pump 1 168cc single high accuracy GAD Gear pump 1 5cc dual ZGS Gear pump 2 92cc single high accuracy GBD Gear pump 3 2cc dual ZLD Gear pump 0 160cc dual high accuracy GDD Gear pump 0 55cc dual ZED Gear pump 0 584cc dual high accuracy GDS Gear pump 0 55cc single ZFD Gear pump 1 168cc dual high accuracy GES Gear pump 10cc single SGD Gear pump 2 92cc dual high accuracy GFS Gear pump 20cc single ZDD Gear pump 0 297cc dual high accuracy FILTER MESH ae i 4 240 52150 8 80 2 200 1 100 standard VOLTAGE 2 200 240V 1 phase 3 380 400V 3 phase WYE 4 200 240V 3 phase DELTA 5 480V 3 phase DELTA 6 400V 3 phase DELTA without neutral OPTIONAL ACCESSORIES A LCD HMI M Ethernet I P B LED HMI N Nordson hose connectors C Water resistant kit hose connection covers O Motor enable gear pump only D Digital pressure control LCD only P Pendant controller E Pneumatic dump valve gear pump only W Swirl kit 2 hose 240v G Analog pressure gauge WW Swirl kit 4 hose 240v K Signal isolator Y Pressure dump kit PRV 2 Tank recirculation kit EXAMPLE SR1N2P1212 AG Dynamelt SR ASU with 10 liter hopper no drop in grid 2 hoses piston pump 100 mesh filter 240VAC 1 PH with LCD controller and analog pressure gauge DYNAMEL
107. he re connection points Note the only replaceable components on the PCBs are the fuses There are no replaceable components on the modules For any other failure the PCB or module must be replaced Main or Auxiliary Power Board Replacement To Remove 1 Unplug all connectors on the PCB noting re connection points 2 Loosen the two M4 screws at the front of the board 3 Tilt the board up approximately 5 degrees and pull it straight back out of the unit To Replace 1 Engage the lip on the heat sink plate to the hold down bar in the back of the unit 2 Tilt the board down to lock against the hold down bar 3 Tighten the two M4 screws at the front of the board 4 Plug in all connectors Module Replacement To Remove 1 Unplug all connectors on the module noting re connection points 2 Slide the module to the right to disengage the communication buss Note you may have to move adjacent modules out of the way 3 Using a flat blade screwdriver unlatch both the top and bottom orange catch on the module and pull the module off of the DIN rail To Replace 1 Snap the module onto the DIN rail 2 Slide the module to the left until it is flush 3 Slide any modules that were re positioned during removal until flush 4 Plug in all connectors Page 8 8 Disassembly ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Control Panel Replacement The entire control panel and shell is replaced as a unit To remo
108. heat up of temperature zones Access Code setup an access code to prevent un authorized programming Temperature Offset fine tuning allows compensation for temperature gradients Customer Zone Names allows personalization of the temperature zone s names Logbook Fault History records the time and date of controller events and faults Power On Configuration allows custom settings for pump motor and heaters at startup Global Setpoints allows easy one temperature programming of setpoints Accessing the Parameters There are four pages of configuration parameters Four parameters are on each page Turn the Input Wheel to select the parameter to be programmed The slider graph on the left indicates the page of the System Configuration Menu Once you select highlight your desired parameter many parameters can be changed simply by pressing the Enter Knob SYSTEM CONFIGURATION Page 1 P 1 indicator x Page 1 of 4 Pages of Parameters Slider Graph Selected parameter is unlocked and may be programmed SYSTEM CONFIGURATION eee 2 ZONE CONFIGURATION Enter knob PUMP CONFIGURATION ie Selected parameter is locked and cannot be programmed without the access code Page 5 16 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD You may also progress through the pages by using the Configuration button J When in the System Configuration Menu pages you may return to the
109. hermostat Tighten the screws and re attach the terminals 6 Close the orange shutoff access cover To Remove the Piston Pump 1 Turn the unit off 2 Remove the orange shutoff access cover Turn the filter shutoff to the OFF horizontal posi tion 3 At the rear of the unit remove the piston pump guard 4 Remove three M6 socket head cap screws that secure the piston pump to the filter manifold 5 Lift the pump straight up and out of the filter manifold 6 Unplug the circular electrical connector disconnect the air tubing and remove the pump from the unit Piston pump assembly Pump snout Piston pump guard Hose head electrical connection plate Filter manifold Page 8 4 Disassembly ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Piston Pump Seal Replacement A piston pump seal kit is available from ITW Dynatec See details in Chapter 9 Remove the upper and lower o rings from the piston pump s snout and replace Hopper Sensor Replacement A Hopper Sensor Repair Kit is available from ITW Dynatec See details in Chapter 9 1 Remove the hose head electrical connection plate via four screws The sensor is located be hind the hole in the sheet metal panel 2 Pull the sensor out and disconnect it from the terminal block Discard the old sensor 3 Crimp ferrules onto the two wires of the replacement RTD sensor and insert them into the
110. inside a solid bar graph means that the temperature of the zone is significantly out side its setpoint window solid Non Active outlined bar graphs Zones bar graphs T Zone has Zone is cold no sensor Zone is at lower tolerance Zone is near setpoint Zone is just under setpoint Zone is cold Zone is exactly at setpoint Zone has a sensor fault Zone is slightly above setpoint Active Zones Zone is over heating Scan Mode Scan Mode allows the operator to watch the currently active temperature zones scroll one at a time on the Overview Screen Each zone is displayed with its name programmed setpoint actual temperature and bar graph To activate Scan Mode On the Overview Screen push the input knob To stop Scan Mode Turn the input wheel To Navigate Away from the Overview Screen Press This Button To System Configuration to the System Configuration Menu to program the temperature unit language setpoint limitation hi low tolerance setback temperature level control heat up sequence pump enable temperature access code temperature offset customer zone names power on configuration or view the logbook Menu Go to the Main Menu screen to program recipes set back mode keypad locking and the 7 day scheduler or to go to the Help Screen Pump Go to the Pump screen to program pump Return Return to the previous screen F1 F2 F3 FA F5 Go to the temperature zones use as shortcuts ITW Dynat
111. installed in your ASU Before proceeding verify that this connector is correct for your operating voltage CAUTION Using the incorrect power configuration connector may cause serious damage to the unit The voltage configuration connector is installed on the DynaControl V6 Power Module see module illustration below For location of the module see Main Power Installation amp Internal Components illustration on preceding page There are three different voltage configuration connectors available 240V Single phase P N 115724 Black 240V Three phase P N 115725 Violet 400V Three phase P N 115726 Yellow For reference the schematics of each voltage configuration connector is printed on the next page V6 POWER x7 PN 115732 104F ZONES 10AF Verify Voltage Configuration Connector poer xar wd according to your voltage 5 240V Single phase Black ol 1 l 240V Three phase Violet i X9 400V Three phase Yellow o ww J 20 2 a ets c I La X10 wel DA 5 ZONE r 11 10 11 o Lx MOTOR DR AL oar X1 AY Cae 1 LL 03 POWER SUPPLY fT LOL j dE od L1 L2 L3 N SS Connect to Main ON OFF Switch according to your voltage see chart on next page LC JC DynaControl V6 Power Mod
112. legs with a 10AF fuse The output for the DC power supply has a 1A fuse Always replace fuses with the same type of fuse Voltage Configuration Connector The appropriate voltage configuration plug must be installed for the machine to operate properly Three different connectors plugs are available PN 115724 240V single phase black PN 115725 240V three phase Delta violet PN 115726 400V three phase Wye yellow Page 7 12 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P V6 Aux Power Module PN 115733 The V6 AUX module provides controlled power to the heater of the additional five zones It re ceives its control signals from the V6 TEMP module Depending on the configuration of the ASU there could be one or two of these modules in the system The fuses of the AUX Module are located underneath a protective cover The cover should only be removed after the ASU is switched Off and disconnected from the main power supply After checking or replacing fuses the cover must be re installed All heater circuits are fused on both legs with a 10AF fuse Always replace fuses with the same type of fuse Fuses under protective cover O lt Connect to Head 4 6 V6 TEMP Module Heater ar ee o Hose 4 6 lt L m Heater Q ZONE 9 14 X7 zx 10AF Sx rx
113. lief valve in outlet block is opening 1 Filter drain valve not tightly closed 2 Filter drain valve blocked open 1 1 1 5 Clean outlet check valve Clean outlet check valve Remove and inspect outlet filter Clean or replace as necessary See Chapter 6 Preventive Maintenance for procedure Verify that system components are at proper temperature and that selected adhesive is correct for your application Inspect hose for kinks internal plugs of debris or char degraded adhesive Clean or replace hoses as required Inspect heads for plugged nozzles proper air valve operation or plugged filters Clean or repair heads as needed Verify that air supplied to pump is less than 6 8 bar 100 psi If relief valve is opening with air pres sure less than 6 8 bar 100 psi adjust or replace pressure relief valve Close and tighten filter drain valve Remove filter plug assembly from pump Disassemble plug assembly clean and re install Page 7 32 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Adhesive Leak at Pump 1 Pump seal out of proper 1 Remove seal and bearing assembly Shaft Seal position inside seal and from pump Verify that all compon bearing assembly ents are correctly assembled 2 Seal inoperative 2 Remove seal from pump and inspect it Replace worn or damaged seal Be sure there are no burrs or other sharp edge
114. low blow Power PCB Printed Circuit Boards amp Modules 115719 115733 115732 115734 115735 117265 Filter Replacements 117147 117145 117146 117148 117149 814018 115717 HMI Assembly Aux Power PCB V6 Power PCB V6 Base Module V6 Temperature Module V6 Pump Control PCB Replacement Kit Filter Service Kit 100 mesh standard Filter Service Kit 40 mesh option Filter Service Kit 80 mesh option Filter Service Kit 150 mesh option Filter Service Kit 200 mesh option Filter Nut ES Filter Shutoff 5 10 Options Page 9 5 Revised 8 12 HL H HH N N N I B Page 9 6 Options ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Component Illustrations Page 10 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 10 COMPONENT ILLUSTRATIONS amp BILLS OF MATERIAL WARNING All parts must be periodically inspected and replaced if worn or broken Failure to do this can affect equipment s operation and can result in personal injury Chapter Format This chapter contains the component illustrations exploded view drawings for each assembly of the DYNAMELT S SERIES ASU These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Note most common nuts bolts and fasteners can be obtained locally
115. lubricant for the piston pump s airmotor Piston Pump Master Repair Kit PN 117258 Master service kit contains both the Airmotor Repair Kit and the Piston Pump Repair Kit contents listed above Page 9 2 Options ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Solenoid Valve Replacement Kit PN 117264 Service kit contains a three way 24 VDC solenoid valve assembly mounting screws and instruc tions for pump stroke re calibration Pump Control Printed Circuit Board Replacement Kit PN 117265 Service kit contains the pump s control PCB mounting screws and instructions for pump stroke re calibration Pump Electrical Enclosure Service Kit PN 117266 Service kit contains a piston pump enclosure assembly see pages 10 14 and 10 15 for contents and illustration and instructions for pump stroke re calibration Pneumatic Pressure Relief Valve Repair Kit PN 116326 Contains the following items needed to repair the PN 115540 Pneumatic Pressure Relief Valve Description Description 108700 Lube Seal 1 4 oz 115438 Fitting 90 deg M5x1 4 NOO179 O ring 012 115537 Piston Seal N05733 Backup Ring 012 Split 115539 Compression Seal 01601 O ring 908 115437 Stem Seal 00184 O ring 017 Analog Pressure Gauge Kit PN 101175 An optional analog pressure gauge can be mounted on the outlet filter manifold either pre or post filter Reading the adhesive pressure at the manifold rather than in line on a hose allows for more pr
116. n OV TEMP EK go CONTROLLER X8 iil xD XT i TSTAT 422 AUX INPUTS CUSTOMER S CONNECTION MAIN POWER AUX POWER AUX POWER Eom mec et E GEAR PUMPONLY BOARD BOARD 1 BOARD 2 PISTON uen PN 115732 PN 115733 PN 115733 BLU WH pote EM 1 5 T BM I lt X I I BLU 9 86 o ORANGE 2 cry S O gt I l AM RS PUMP SOLENOID RED 24VDC Schematics DM SR5 10 Control Modules 115894 Rev E page 3 of 5 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59 Page 11 6 Schematics Revised 6 13 NORDSON COMPATIBLE RECEPTACLE SIGNAL ISOLATOR OPTION FOR GEAR PUMP LINE SPEED FOLLOWING FOR PISTON PUMP TE T V6 BASE MODULE
117. n Check the UP and DN LEDs a UP LED is lit The controller is attempting to move the piston to the upper most position but has not reached the upper shift point Perform Calibration Procedure 1 and then Procedure 2 b DN LED is lit The controller is attempting to move the piston to the lower most position but has not reached the lower shift point Perform Calibration Procedure 2 and then Procedure 1 Calibration Procedure 1 1 Turn the R2 trim potentiometer ten turns counter clockwise 2 Turn the R2 trim potentiometer clockwise until the pump strokes downward without hitting the upper mechanical end stop Notes Turning R2 clockwise lowers the top switching point and also decreases the total stroke length Turning R2 counter clockwise raises the top switching point to the point where the upper stop is reached or the pump stalls If you cannot make the pump stroke downward 1 Check the air pressure and the air supply tubes 2 Check the UP solenoid valve a Listen for the solenoid to go on and off b Check the voltage 24V c Manually shuttle the solenoid valve push the poppet and see if the pump moves 3 Replace the pump controller PCB Calibration Procedure 2 1 Turn the R1 trim potentiometer ten turns clockwise 2 Turn the R1 trim potentiometer counter clockwise until the pump strokes upward without hit ting the lower mechanical end stop Notes Turning R1 counter clockwise raises the bottom switching point an
118. n the hopper lid 2 Using a Phillips head screwdriver remove the four button head retaining screws located in the corners of the lid assembly 3 Lift the lid assembly up and off of the hopper cover Hopper cover Hopper lid assembly Pump access Hopper gasket cover Hose connector Access cover Hopper Lid Assembly Filter shutoff shown in Off position Removal Over temp thermostat To Remove the Hopper Cover 1 Remove the orange shutoff access cover located on the front of the unit 2 Using a 2 5mm Phillips head screwdriver loosen the four button head retaining screws which secure the hose connector plate to the hopper cover 3 Rotate the top of the hose connector plate away from the ASU and pull it up to disengage the mounting tabs 4 Remove the two Phillips head screws from the base of the hopper collar 5 Remove the two Phillips head screws from the top side of the back wall of the electronics cabinet 6 Gently pull the hopper cover up and off the ASU Overtemp Thermostat Replacement 1 Remove the orange shutoff access cover located on the front of the unit 2 Remove the two screws and slip the terminals off of the thermostat ITW Dynatec c 2012 Disassembly Page 8 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 3 Remove the old thermostat 4 Apply thermal paste to the back side of the new thermostat 5 Install the new t
119. namelt system provides accurate proportionate temperature control for the hopper filter manifold hoses and applicators Sequential heating delays may be programmed to enable hoses and heads A standby temperature may be programmed so that the temperature zones can be maintained at a lower temperature when the ASU is not in active use enabling rapid return to normal operation A seven day scheduler and adhesive level sensor are standard features With these flexible temperature programming features the Dynamelt system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time The temperature control can interlock with a parent machine using pre selected adhesive temper atures so that production automatically begins when adhesive temperatures are correct for the application All system temperature values can easily and quickly be programmed Digital readout of system conditions is provided Optional external audible signals or lights which alert the operator to alarm conditions may be wired in A security code can restrict access to sys tem programming and parameters The CPU monitors the electronic circuitry and provides alarms for error conditions The Dynamelt S ASU uses an extremely dependable constant pressure piston pump This air oper ated pump ensures a high pressure adhesive output from a low pressur
120. nd of short duration For these reasons the settings above are recommended Page 4 6 Controller Setup ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P System Values That Are Factory Programmed not customer programmable Minimum setpoint value 10 C 50 F Maximum setpoint value Setpoint limitation 218 C 425 F Maximum alarm deviation 50 C or F Minimum alarm deviation 5 C or F Maximum standby temperature 150 C or F less than setpoint Minimum standby temperature 30 C or F less than setpoint Actual temperature indication range O C to 260 C 32 F to 500 F Customer Programmable System Values Preset At The Factory ITW Dynatec can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the DynaControl controller at the factory They may be changed by reprogramming through the controller These are not the default settings see following section Applicator head and hose setpoints 177 C 350 F Hopper setpoint 150 C 300 F All zones are switched off except for the hopper and the manifold Motor rpm 0 in the Manual mode Standby 66 C 150 F under setpoint Hi and low alarms 20 C 36 F from setpoint Pump enable temperature 135 C 275 F ITW Dynatec c 2012 Controller Setup Page 4 7 DYNAMELT S ASU Manual 20 59P Revised 4 12 Default Settings of the DynaCont
121. ne s e ie es ee ea 8 3 Pump Seal Replacement ere tnm tne e re ee b eR rect dete regen 8 4 Hopper Sensor Replacement 2 4 8 4 Note on the Cast In 4 8 4 Filter Manifold RTD Sensor and Heater Replacement 8 5 To Access the Electrical Components 8 6 Main On Off Power Switch Replacement 8 6 Fuse Replacement Je re pes UE soe o REND eR RT a ERU Re le EL HR ge e eae ce e TR RR 8 6 Power Supply Replacement 0 8 7 Printed Circuit Board or Module Replacement 8 7 Main or Aux Power Board Replacement 8 7 Module Replacement susu ato ec nde DRIN AVATAR RR RE lo REL heals TIR e AER a 8 7 Control Panel Replacement 2 8 8 Re assembly Procedures amp Cautions 8 8 Chapter 9 Available Options amp Accessories Service Kits nudo ea hls Cds ae eh ee oe ts XU leto Roe EORR 9 1 9 2 Page vi Table of Contents ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Rec
122. ng for correct equipment operation in the following guide be aware that all heaters will go off immediately after an error indication alarm occurs if the operator takes no action With the exception of the fuses there are no user replaceable parts on the printed circuit boards If there is a non fuse failure on any of the PCBs the PCB must be replaced DANGER HIGH VOLTAGE Some of the procedures in the following Troubleshooting Guide require potentially dangerous electricity to be present Only qualified service personnel should perform these procedures Hopper tank Overtemp Sensor Hopper Filter Block Sensor Open 1 Setpoints have been programmed without enough deviation Hopper sensor inoperative Hopper control triac on V6 Power Module is inoperative Sensor cable has become unplugged from V6 Temperature Module Hopper sensor inoperative Filter block sensor WW O 1 Re program setpoints allowing a larger deviation between the high and low limits Replace hopper sensor if resistance does not comply with the resistance table in this manual If the hopper status LED on the Temp erature Module is Off and the hopper temperature continues to rise the triac on the power module has failed The module must be replaced Verify that hopper and filter block sensor cable is properly connected at X3 on the V6 Temperature Module Replace hopper sensor if
123. nob to display a list of all temperature zones Turn the Input Wheel to select a zone for programming and press the Enter Knob Turn the Input Wheel to program the desired temperature offset for that zone Press the Enter Knob to confirm your selection Page 5 20 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD If desired turn the Input Wheel to select another zone for programming Program this zone as outlined above When all desired zones are programmed press RETURN to go to the System Configuration Menu page 1 then press RETURN again to go to the Overview Screen Customer Zone Names P4 With this configuration parameter the user may personalize the names of the temperature zones with names that are more descriptive for his application That is instead of the factory set zone names of Z01 702 703 etc the customer may prefer temperature zone names such as TANK HEAD 1 FILTER BLOCK SUPPLY HOSE LEFT etc After turning the Input Wheel to select the Customer Zone Names parameter press the Enter Knob to display YES To enter programming mode press F3 Change Text Now by turning the Input Wheel you can scroll through the zones and see their current zone names or numbers These names can be re programmed one at a time Each new name may consist of two lines with a maximum of 12 characters in each line Note the factory set numeric names correspond to RTD inpu
124. ntenance Schedule Monthly Inspect output filter cartridge and replace as required Check for adhesive residue in the manifold drip tray If residue is found inspect and replace the pump seal as required Every Three Months Check all hose fittings Check all fasteners Inspect primary filter Clean or replace the filter as required Page 6 8 Maintenance ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Flushing the System Contaminated adhesive accumulation of residue in the system and hopper or changing the adhes ive formulation may require the system to be flushed To flush the system have at least 6 liters 1 5 gallons of flushing fluid on hand PN L15653 WARNING HOT ADHESIVE The flushing fluid will splash easily Wear protective clothing gloves and a face shield to prevent severe burns 1 Pump out as much of the molten adhesive from the hopper as possible 2 Reduce the ASU s pump pressure to zero Note the hose used in the following process is merely for the convenience of depositing flushing fluid This procedure does not have to be repeated for each hose in the system 3 Disconnect one of the supply hose s adhesive feed from its applicator head Do not disconnect the electrical power to the head since that would disable the pump Put the hose in a secured posi tion within a heat resistant container which will catch the used flushing fluid 4 Add flushing fluid to the hopper and allow ap
125. o 315 C The constructive principle is based on the hydraulic tra smission of the pressure The fluid filled system assures the temperature stability The phisical measure is transformed in a electrical mea ITW Dynatec PN 812340 MAIN FEATURES Pressure ranges from 0 35 to 0 1000 bar 0 500 to 0 15000 psi e Accuracy lt 0 25 FSO H lt 0 5 FSO Oil filling volume WEO 30mm WE1 WE2 40 17 7 PH corrugated diaphragm with GTP coating for ranges below 100 bar 1500 psi GTP advanced protection Coating with high resistance against corrosion abrasion and high temperature AUTOZERO FUNCTION All signal variations in the absence of pressure can be eliminated by using the Autozero function This function is activated by closing a magnetic contact located on the transmitter housing The procedure is permitted only with pressure at zero AUTO COMPENSATES INFLUENCE OF MELT TEMPERATURE Thanks to internal self compensation the WSP series transmitter cancels the effect of pressure signal variation caused by variation of Melt temperature This reduces at the minimum the read error caused by heating of the filling fluid typical of all sensors built with filled technology FSO Full scale output 1 BFSL method Best Fit Straight Line includes combined effects of Non Linearity Hysteresis and Repeatability sure by means the strain gauge technology TECHNICAL SPECIFICATIONS
126. o System Configuration Parameters Press the System Configuration button wrench button on the Overview Screen once to advance to the System Configuration parameters Press it again repeatedly to advance through the pages of parameters Initial Heat up Progress Bar During heat up from a cold start press the Input Wheel Knob for 5 seconds to see a progress bar which graphically tracks heat up until Ready status is attained and production can start The scale shown is 0 to 100 fully heated HEAT Progress Bar Numeric Readout of Progress The ASU illustrated above is one quarter heated If you would like to display the controller s Scan Mode in order to watch the active temperature zones scroll while the unit is heating press the Input Knob once more ITW Dynatec c 2012 Controller Programming Page 5 1 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Chapter 5 PROGRAMMING INSTRUCTIONS PP LCD DynaControl CONTROLLER for PISTON PUMP MODELS 5 10 V 6 00 and Up DynaControl DCL V6 LCD Interface DynaControl V6 controller technology is available as a liquid crystal display LCD which allows an instant overview of temperature zone and pump status and with a combination Input Wheel Enter Knob to facilitate fast programming LCD Input Wheel Press Knob to Enter Return In General Press the Return button to return to the Overview Screen seen above When there is no operator activity on a screen for approximat
127. odule cont Alternative Input Signals STO 15 30V O IN1 Eme Ow er 415 30V iN2 E Pje 1 INS 97 amp l IN4 P 210 a SI 1 ins on O PNP SIG 6 Sm ING zeu re Ge COM Ol e 50 gt lo 27 2 27 24 Dy Ow Q ow 24V G e p On G3 Ou Switch Closure Using Proximity Sensor with Voltage Input with PNP Setting PNP Output Common Ground The first three inputs IN1 IN2 IN3 are designated for default functions Inputs 4 thru 6 are cus tomer programmable Input 1 External Standby Setback Activating this input sets the ASU in Standby Mode In standby mode all temperature zones will lower their temperatures by a programmed amount Opening that contact will return to normal mode Input 2 amp 3 External Program Recipe Selection By activating these inputs it is possible to load one of four programs recipes into the controller The two inputs are coded in the following way Activate input2 while input3 is not activated Load Program 1 Activate inp
128. of the unit and down the rear pa nel Overflow Channel Lid Liner Hopper Collar 9 P Q e I ec je 6 x J Purge Hopper Drain Plug Insulator Drip Tray Page 6 2 Maintenance ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Purging the Filter Manifold of Adhesive and Pressure As a safety precaution the Dynamelt S should be purged of pressure and adhesive before at tempting to change the output filter or before removing any of the hoses or applicators from their manifold ports WARNING PPE REQUIRED Failure to wear a face shield or safety glasses could result in severe eye injury during these procedures Protect yourself from potential burns by wearing insulated gloves and arm guards HIGH PRESSURE During the purging procedure hot adhesive can escape the manifold under high pressure Wear a face shield gloves and protective clothing Stand clear of the ASU until all pressure is relieved HOT ADHESIVE Avoid splashing hot adhesive Position a heat resistant container under the manifold s drain valve before proceeding Purging Adhesive Pressure from a Piston Pump Unit The piston pump equipped Dynamelt S uses an air controlled pressure relief valve that dumps ad hesive pressure back into the unit s hopper whenever the pump or the ASU is turned OFF To ensure operator safety ITW
129. ommended Service Parts List 0 ar unan e 9 5 Chapter 10 Component Illustrations amp Bills of Material Sheet Metal Assembly esteem ee REPRE SEEN sra e A tee ean 10 2 Electronics Assembly 4 10 4 Hopper Assembly ser dre RR rene ee hon e Gadd rra ae era ie e See Bee n 10 6 Filter Manifold Assembly 4 10 8 Pump DriVe du SP 10 10 Piston Pump Assembly 45 die upas sus BE Rp PS RE Re DES PE on ed ak bed e ds 10 12 Electrical Enclosure Assembly 2 10 14 Pneumatic Pressure Relief Valve 4 10 16 Air Regulator Assembly 10 18 Chapter 11 System Schematics amp Engineering Drawings DynaControl Head Schematic all models 11 1 DynaControl Hose Schematic all models 11 2 Dynamelt S ASU Wiring Diagrams 1 11 3 Optional System Status Lights Stack Light Assembly 11 8 Optional Pressure Transducer Kit
130. oose YES or if you prefer that the motor remain in its previ ous mode when the ASU is turned on choose NO Power On Heater Start At the Power On Heater Start parameter you decide if you prefer that the temperature zones start heating automatically when the ASU is turned on if so choose YES or if the heaters should require a manual start when the ASU is turned on choose NO NOTE If you choose NO the heaters will not begin to heat until the Enter Knob is pressed at start up From the System Configuration Menu after turning the Input Wheel to select Power On Config uration press the Enter Knob The first parameter Power On Motor Stop will be highlighted see illustration below Press the Enter Knob to choose YES or NO Turn the Input Wheel to highlight the second parameter Power On Heater Start Press the Enter Knob to choose YES or NO After programming press RETURN twice to return to the Overview Screen Parameter is highlighted programmable Press POWER ON CONFIGURATION POWER ON MOTOR STOP YES selection POWER ON HEATER START NO This parameter may not be programmed until is is highlighted To highlight turn the Input Wheel ITW Dynatec c 2012 Controller Programming Page 5 23 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Global Setpoints P4 Setpoint programming may be simplified by programming Global Setpoints With this paramet er the user programs a hopper setpoint and the controller configures
131. ound wire Afterward the level sensor must be re calibrated Hopper _ gt Pp Sensor housing outside hopper Calibration button recessed Level sensor within hopper EY 9 Glue level required for re calibration Page 3 10 Installation ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Field Installation of Controller Options Customers who choose to modify their adhesive supply unit with ITW Dynatec manufactured op tions should assure that only qualified technicians perform such installations The installation of op tions that require specific procedures and or calibration are outlined in this chapter Before controller options are installed always turn the controller s main power switch OFF In most cases turning the controller OFF will assure thatthe controller will retain its programmed paramet ers and configuration Re booting is not necessary ITW Dynatec c 2012 Installation Page 3 11 DYNAMELT S ASU Manual 20 59P Revised 4 12 Typical Start Up and Shut Down of the DYNAMELT S Piston Pump System The following simplified sequence assumes that the LCD HMI DynaControl V6 Controller has been programmed Start Up Procedures 1 Fill the ASU s hopper with clean hot melt adhesive to within a couple of centimeters inches of the top of the hopper Close the hopper lid immediately to prevent contaminants from falling in Cover your bulk supply of adhesive to prevent cont
132. per connections loose tubing or fit tings or kinked tubing Repair or replace tubing or fittings as necessary 5 If pump status shows STOP the pump is switched off Go to the Pump Screen to switch the pump on 6 Wait for the ASU to reach setpoint temperature or increase temperature tolerance 7 Remove the electrical cover from the top of the piston pump assembly and a If neither LED is illuminated the pump is not receiving power Check the electrical connection with the ASU b If the UP LED is illuminated run Page 7 30 Troubleshooting Revised 4 12 Problem ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P 8 One of the internal pump solenoid valves has failed Pump Quick Strokes in Both Directions 1 No adhesive in hopper 2 Adhesive is too cold to flow into pump R1 potentiometer 3 Adhesive used is too viscous R2 potentiometer 4 Problem with pump shaft Outlet check piston valve Inlet check valve 2 There is a large opening in the system downstream of the pump 1 Inlet check valve is blocked open Pump Quick Strokes on the Forward Stroke Only shaft moving into pump body 2 Pump is out of calibration Calibration Procedure 1 see pg 7 15 c If the DOWN LED is illuminated run Calibration Procedure 2 Replace failed solenoid valve Verify that hopper has an adequate level of hot melt adhesive Check ready temperature of the
133. point limitation is useful for an adhesive with a low melt temperature In this case the maximum selectable setpoint could be lowered in order to avoid over heating the adhesive After turning the Input Wheel to select the Setpoint Limitation parameter press the Enter Knob and then turn the Input Wheel to select your desired setpoint limitation value Confirm your choice by pressing the Enter Knob ITW Dynatec c 2012 Controller Programming Page 5 17 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Hi Lo Tolerance P2 A high and low temperature tolerance can be set for the temperature zones During operation these tolerances activate the error alarms which alert the operator to over temp and un der temp conditions The hi lo tolerance is a range and from the setpoint Thus a setpoint of 150 C which has been programmed with a 10 hi lo tolerance will activate an under temp alarm when the zone s temperature falls below 140 C and will activate an over temp alarm when the zone s temperat ure rises above 160 When this zone s temperature is within the tolerances 140 and 160 it is considered Ready When programming only one value is chosen This value applies to all temperature zones and is both the high and low tolerance After turning the Input Wheel to select the Hi Lo Tolerance parameter press the Enter Knob and then turn the Input Wheel to select your desired tolerance value Confirm your choice by press ing the Ent
134. proportionately It follows a 0 10V or 4 20mA input signal proportional to line speed Signal Isolator PN 117143 A signal isolator conditions a parent machine s production line s DC speed voltage or current refer ence to allow the ASU to track the application s line speed It accepts 0 10 0 5V 4 20mA inputs and outputs a proportional 0 10V signal to DynaControl s electronics Dual PN 117245 and Quad PN 117246 Swirl Kits Used with hand held applicators swirl kits allow quick coverage of a wide area with sprayed ad hesive A dual swirl kit is used with two hand held applicators and a quad swirl kit accommodates four applicators 480V Step Down Transformer Kits PN 115872 2 Hose 115874 4 Hose 115877 6 Hose The kits convert incoming power from 480V Delta without neutral to 240V and can be configured for two four or six hose head zones A maximum of 1800W is available to each set of two hoses and two heads Page 9 4 Options ITW Dynatec c 2012 Revised 5 13 DYNAMELT S ASU Manual 20 59P Controller Options System Status Light Kit PN 116848 Remote monitoring of system status is made easier with this four color stack light Wired into the controller the lights illuminate to indicate Power On Ready and Alarm An audible signal accompanies the Alarm light The alarm may also be wired to indicate either high low temperature low adhesive level or open short sensor Pendant Control Assembly PN 117237 The pendan
135. proximately fifteen minutes for it to reach hopper temperature Carefully stir the flushing fluid to mix with any adhesive remaining in the hopper 5 Slowly increase the pump pressure Pump about half of the fluid through the hopper pump and adhesive supply hose into the flushing container WARNING HOT ADHESIVE Avoid splashing the flushing fluid from the end of the hose 6 Reduce the pump pressure to zero 7 Add new adhesive to the hopper and allow it to reach application temperature 8 Slowly increase air pressure to the pump 9 Actuate each of the heads until all the flushing fluid is removed and a steady stream of new ad hesive flows 10 Remove the output filter and replace the filter cartridge Install a new o ring on the filter nut lubricate the new o ring with o ring lubricant prior to installation and tighten the filter nut Maintenance Page 6 9 ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P 11 Re adjust the pump air pressure for the desired flow 12 Re fill the hopper with adhesive The system is now ready for production Page 6 10 Maintenance ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Troubleshooting Page 7 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes DANGER WARNING HIGH VOLTAGE v HOT SURFACE Dynamelt
136. r ITW Dynatec 31 Volunteer Drive 37075 Hendersonville TN Person residing within the Community authorised to compile the relevant technical documentation Dynatec Engineering ITW Dynatec 31 Volunteer Dr 37075 Hendersonville TN Description and identification of the machinery Product Article Adhesive supply unit Type Serial no Machine number Project number NGSM Project name NGSM Commercial name Dynamelt SR05 SR10 Function Melting and delivery of hot melt adhesives It is expressly declared that the machinery fulfils all relevant provisions of the following EU Directives 2006 42 EG 2006 05 17 Machinery Directive 2006 42 EG 2004 108 EC Electromagnetic compatibility Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC 2006 95 EC Voltage limits Directive of the european Parliament and of the council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits codified version Hendersonville TN 2011 11 14 Place date ff Signature Judson Broome General Manager Page 1 1 ITW Dynatec c 2012 Revised 4 12 IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Table of Contents Page iii DYNAME
137. ram all of the hoses to 300 degrees and all of the heads to 305 degrees When Global Setpoints are turned On YES and a temperature setpoint is changed the display will not show the selected zone s name Instead it will display GLOBAL SET You can still turn individual zones Off and On while using Global Setpoints Page 5 24 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD IT Dynatec minnovation mservice mreliability The Next Level of Technology ITW Dynatec c 2012 Maintenance Page 6 1 Revised 4 12 DYNAMELT S ASU Manual 20 59P Chapter 6 MAINTENANCE Note Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance pro cedures must be performed by qualified trained technicians General Cleaning The DYNAMELT S SERIES ASU enclosure is comprised of both injection molded nylon and epoxy powder coated steel panels The painted steel panels may be cleaned with a variety of industrial cleaners following manufacturers directions The polymer panels may be cleaned with mineral spirits For easy cleaning the hopper collar lid liner and manifold drip tray are coated with the same PTFE release coating used in the adhesive hopper The manifold insulator is replaceable in the event it becomes dirty or is damaged The unit should not be operated without this insulator in place The ASU was designed to channel adhesive overflow out the back
138. rameters To utilize the Setpoint Locking feature of the controller your access code must be keyed in at the Main Menu F3 The Dynamelt S is shipped from ITW Dynatec with a default code of 1111 To re program the ac cess code the current access code must be entered All access codes must be 4 digit numbers using the digits 1 2 3 4 and 5 only After turning the Input Wheel to select the Access Code parameter enter the current access code using the F1 thru F5 numerals Press the Enter Knob Then enter your desired access code using the F1 thru F5 numerals Confirm your choice by pressing the Enter Knob Temperature Offset P3 Temperature Zone Offsets are mathematical factors which compensate for differences in tem perature within components Each temperature zone may be programmed with an offset if de sired Standard equipment does not usually require temperature offsets Note Entering a positive numbered offset will raise the temperature reading of that zone Since the controller attempts to equate setpoint and actual temperature this actually lowers the ac tual temperature by the amount of the offset For example Setpoint and actual temperature both equal 300 F An offset of 10 F is pro grammed Initially the display will read 310 F but the controller will lower the output power un til the actual temperature value is back to 300 F After turning the Input Wheel to select the Temperature Offset parameter press the Enter K
139. re adhesive pushes the in put check valve open and fills the cylinder At the same time the higher back pressure from the pump output holds the output check valve closed SECTION 00000009 T 000000000000000 LH 0000009000000000 n 000000000000000 000000000000000 _ 000000000000 O H H 800000000000008 000000000000008 A 900000000000000 000000000000000 00000000000 00000000 oOoooooQo 0 ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Piston Pump Flow Diagram The illustrations below demonstrate how adhesive flows through the piston pump Step 1 upper drawing On the first priming upstroke of the piston pump the upper check valve closes and the lower check valve opens allowing the plunger to pull adhesive into the lower pump cavity at full volume Step 2 lower left drawing On the downstroke of the piston pump the upper check valve opens and the lower check valve closes forcing adhesive up into the shaft cavity and causing it to escape through the outlet in the shaft The ad hesive then spills into the upper pump chamber at half volume
140. resistance does not match resistance table Replace filter block sensor if resistance does not match resistance table ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Troubleshooting Page 7 19 Revised 4 12 Hopper Filter Block Sensor Short Cartridge Heater mag 1 ger Z Sensor Gasket Ceramic Terminal Blocks Hopper Filter Block Heater Open Heater 72 81 OHMS 1 Short circuit caused by debris where sensor plugs into the V6 Temperature Module 2 Pinched sensor lead wire 3 Hopper Filter Block sensor inoperative 1 Disconnection in hopper heater circuit 2 Disconnection between Power Module and the Temperature Module 3 Open hopper or filter block heater element 2 N 1 Verify that sensor connector is clean and correctly connected at X3 on the V6 Temperature Module Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the sensor lead to the plug at the V6 Temperature Module Repair or replace any damaged wire Replace hopper sensor if resistance does not comply with resistance table Inspect hopper heater wiring for proper connections Verify that all connections are properly made between the Power Module and V6 Temperature Module Remove all lead wires from both hopper and filter block heater elemen
141. rol V6 Controller Language English Setting for Customer Access Code 1111 Standby temperature for all zones 66 C 150 F lower than programmed setpoints Hi lo limit deviation for all temperature zones 20 C 36 F Temperature zone offset 0 C 0 Setpoint limitation 218 C 425 F Pump enable temperature 135 C 275 F Automatic sleep mode Off Sequential heat up Off Power On motor Stop No Power On heater start Yes Global setpoints No Piston Models Equipped with Optional Line Speed Following Minimum Pump Speed 0 of full speed Maximum Pump Speed 100 of full speed Page 4 8 Controller Setup ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Helpful Tips for the User When the ASU is turned ON all temperature setpoints and other operating parameters will be exactly where they were when the ASU was turned off When the ASU is turned ON all system heaters go ON unless they have previously been de activated in which case they will be turned OFF or if sequential heatups have been set However if hopper temperature is above ready temperature when the ASU is turned on all hose and head sequential heatups will be bypassed and hoses and heads will be turned ON Controller Features One button Shortcuts Press the F buttons to go to F1 the Hopper temperature zone F2 the Hose temperature zone F3 the first Applicator temperature zone F5 toggle On Off Shortcut to Advance t
142. s 3 Inspect the machine for unsafe conditions daily and replace all worn or defective parts 4 Keep work area uncluttered and well lit 5 All covers and guards must be in place before operating this equipment For precautions and definitions of safety symbols refer to the Safety Chapter of the service manual SERVICING EQUIPMENT Only trained personnel are to operate and service this equipment Never service or clean equipment while it is in motion Shut off the equipment and lock out all input power at the source before attempting any maintenance Follow the maintenance and service instructions in the manual WARNING LABELS 1 Read and obey all of the warning labels signs and caution statements on the equipment Do not remove or deface any of the warning labels signs and caution statements on the equipment Replace any warning labels signs and caution statements which have been removed or defaced Replacements are available from ITW Dynatec ADDITIONAL CONSIDERATIONS To ensure proper operation of the equipment use specified electrical and or air supply sources Do not attempt to alter the design of the equipment unless written approval is received from ITW Dynatec Keep all manuals readily accessible at all times and refer to it often for the best performance from your equipment EC declaration of conformity according to the EU Machinery Directive 2006 42 EG Annex ll 1 A Manufacture
143. s on pump shaft or on installation tools that could damage the new seal Seal cartridge assembly ITW Dynatec c 2012 Disassembly Page 8 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 8 DISASSEMBLY Disassembly Procedures DANGER WARNING HIGH VOLTAGE v HOT SURFACE Dynamelt systems use electrical power that can be life threatening and hot melt adhesives that can cause serious burns Re read Chapter 1 Safety Precautions before performing any repair pro cedures All troubleshooting and repair procedures must be performed by qualified trained tech nicians Note Use the exploded view drawings in Chapter 10 in conjunction with the instructions outlined in this chapter Read the cautions on page 8 8 before re assembling the ASU To Open and Remove the Electronics Cabinet Door 1 Turn the unit off Loosen the upper and lower door latch screws located below the control pan el with a flat blade screwdriver Turn counter clockwise until the latches stop turning 2 Open the door 3 Press the release button under the top cover to release the main top cover Open the main top cover all the way 4 Open the door 45 and lift it up and off of the unit Main top cover Release button Page 8 2 Disassembly ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P To Remove the Hopper Lid Assembly 1 Ope
144. ssembly Page 10 6 Component Illustrations Revised 6 13 Bill of Materials for 5 10 Liter Hopper Assembly ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Item PN Qty Description 1 See Tab 1 Hopper Weldment 2 104166 1 Overtemp T stat 3 115717 1 Filter Shutoff 5 10L 5 107389 3 Screw PH M4x8 w Wshr Zp 7 See Tab 1 RTD Sensor Assy 8 115867 1 Gasket 9 105097 2 SHS Screw M6x30 Blk Ox 10 117415 1 Harness DMSR Hopper Sensor 11 117476 1 Probe Assy Hopper Level Sensor 12 not used 13 001V061 A R Heat Transfer Compound not shown 14 117477 1 Level Sensor Assy 15 107324 Antiseize Compound not shown 16 NO8171 A R RTV Adhesive Sealant not shown HOPPER ASSY DESCRIPTION Item 1 WELDMENT 7 SENSOR 115829 Hopper Assy 5 Liter Base DCL 115809 117081 115868 Hopper Assy 10 Liter Base DCL 115810 117081 117411 Hopper Assy 5 Liter Base NDSN 115809 117414 117412 Hopper Assy 10 Liter Base NDSN 115810 117414 NOTE 1 TEM 2 APPLY 001V061 THERMALCOTE ITEM 13 TO BACK SIDE OF O T THERMOSTAT 2 TEM 3 LUBE O RINGS WITH 001V078 ITEM 14 APPLY 107324 ANTI SEIZE ITEM 15 TO THREADS TORQUE TO 15 20 FT LBS 3 TEM 9 APPLY 107324 ANTI SEIZE TO THREADS TORQUE TO 2 3 FT LBS TEM 7 APPLY 001 061 THERMALCOTE TO RTD SENSOR TORQUE ALL M4 FASTENERS TO 5 7 FT LBS WITH RTV ADH SEALANT ITEM 16 BOND GASKET ITEM 8 TO HOPPER AND SEAL JOINT GASKET SENSOR HARNESS I
145. ston Pump Assembly Page 10 14 Component lllustrations ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Bill of Materials for PN 117204 Electrical Enclosure Assembly a sub assembly of PN 116125 Electronic Piston Pump Assembly Item No PN Qty Description 01 117192 1 Upp Cyl Head Elec Encl 02 117194 2 Viv Sol 3 Way Base Mount 24v 4w 03 116075 4 Scr Fil Hd 2 56 X 3 4 SST 04 110420 2 Muffler Low Profile 1 8 NPT 05 072x529 1 Ftg 1 4tube X 1 8 NPT 06 115801 1 PCB Asy Hall Eff Pstn Pump 07 116497 3 Scr Pan Hd M3x8 Sems 08 116592 1 Cable Clamp M8 09 117202 1 Cable Asy Power Supply 4 Wire 10 100036 1 Viv Sol 3 Way Base Mount 24v 4 11 N03727 1 Backshell Size 11 12 N07432 4 Contact Pin 20 26 Ga Type 3 13 106324 4 Washer Flat M6 Zp 14 116071 4 Nut M6x1 Self Locking 15 116037 1 Cover Enclosure 16 116078 4 Scr Pan Hd M3x10 Zp RED BLACK WHITE WIRE SIDE OF CONNECTOR TOP VIEW IDC CONNECTOR WHITE PN 117204 Wiring Connections ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P A SOLENOID B SOLENOID GROUND CONNECTION HERE Component Illustrations Page 10 15 Revised 6 12 POWER CONNECTION HERE DO NOT CONNECT HERE SOLENOID CONNECTION HERE MATCH A SOLENOID POSITION TO A CONNECTOR POSITION AND B SOLENOID POSITION TO B CONNEC
146. t control option provides keypad mobility via either a 13 or 26 cable The pendant HMI replaces the built in controller of the standard Dynamelt S ASU and has magnets on its back side for mounting Ethernet IP Adapter Kit PN 117381 This kit connects the DMS ASU to an Ethernet network so that all system parameters can be transmitted and received allowing full remote operation of the ASU ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P Recommended Service Parts List DMSR 05 10 Piston Pump 108689 N02937 L15653 116326 115842 116033 115846 06006 812816 69 133 01010 00175 00187 69 134 03812 115891 117201 117264 Electrical 117154 117152 104166 115738 115823 112568 117807 Silicone Lubricant O ring Dow 112 0 25 Thread Sealant Flushing Fluid Kit 1 gallon Pneumatic Pressure Relief Valve Repair Kit Valve Regulator Solenoid Assembly Inlet Check Assy Pressure Gauge 0 100 PSI O ring 224 O ring 127 O ring 124 O ring 021 O ring 008 O ring 020 O ring 128 piston pump snout upper O ring 125 piston pump snout lower Filter Manifold Insulator Manifold Rebuild Service Kit requires Filter Service Kit Solenoid Valve Replacement Kit Manifold Heater Service Kit Hopper Manifold Sensor Service Kit Over Temp Thermostat amp Insulator Power Supply 24V Main ON OFF Disconnect Switch 63 amp Fuse 10AF fast blow Power and Aux Power PCBs Fuse 1AT s
147. t purposes In this case refer to corresponding set up instructions Item 4 This connector is used for a module to module connection It provides the power on signal to the power board through the TEMP board In the case of a critical alarm this 24 VDC sig nal will drop cutting off the heater power on the power boards Item 85 This connector accepts external input signals that can be used to con trol the ASU The inputs require contact closure External voltage is not re quired but if such a voltage signal is used it must be 15 to 30VDC HO J rem lt P N jumper You may choose either NPN sinking or PNP sourcing inputs 010 To make this choice set the P N jumper in its corresponding position For simple switch closure the jumper position is not important however the refer d ence for the switch must match the jumper selection If the jumper is in the position the factory default the inputs must be switched to terminals COM If the jumper position is P the inputs must be switched to terminals 24V When servicing the Base Module the jumper should be returned to its proper position since N6 is used for Motor stop start and the pump will not run without the jumper See illustrations of alternative input signals on the following page ITW Dynatec c 2012 Troubleshooting Page 7 7 DYNAMELT S ASU Manual 20 59P Revised 4 12 V6 Base M
148. tegral derivative PID Temperature lt 100 Ohm Platinum RTD standard 120 Ohm Nickel RTD optional Electrical connectors durable latching connectors Motorer n oL iios dent Do caren inten oes dva ee 1 4 hp alternating current AC motor with variable frequency drive horizontal orientation Maximum power available for each hoseorhead 240 380 VAC system 1200 watts ITW Dynatec c 2012 Description amp Specifications Page 2 3 DYNAMELT S ASU Manual 20 59P Revised 4 12 Pressurized Air Piston Pump Models Air pressure Supply eS I MERECE ELA 0 7 to 7 0 bar 10 to 100 psi Maximum recommended pump speed 60 pump cycles per minute Air consumption at 60 pump cycles per minute 90 normal liters minute 3 2 SCFM at 100 psi Performance Adhesive temperature control range standard models 10 C to 232 C 50 F to 450 F Adhesive temperature control accuracy 1 C 1 F Standby adhesive temperature range up to 80 C 150 F lower than setpoint Hopper ready adhesive temperature deviation factory set field adjustable 20 36 from setpoint Over temperature cutoff for 232 C 450 F Low temperature cutoff for piston pump factory set field adjustable
149. terminal block 4 Plug the new sensor into the hole in the hopper 5 Re assemble the hose head electrical connection plate Note on the Cast in Heaters The two cast in heaters installed in the base of the hopper are not replaceable and will last the life of the ASU Disassembly Page 8 5 ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Filter Manifold RTD Sensor and Heater Replacement 1 Turn the unit Off Wait for the unit to cool or handle wearing protective gloves and sleeves 2 Remove the cap from the top of the filter manifold see illustration on page 8 3 for location by removing two M4 socket head cap screws 3 Gently remove the two ceramic terminal blocks from a pocket located at the top of the mani fold block 4 Check the heater s and or sensor s resistance to determine which component has failed 5 Disconnect the failed component from the terminal block and remove it from the manifold Note the heater cavity has a knockout hole bored through the bottom of the manifold block 6 Coat the replacement component with thermal paste and Install 7 Gently re insert the terminal blocks into the receptacle pocket 8 Ensure that the gasket is in place and that wires are not pinched then secure the cap to the manifold using the two M4 screws Cartridge heater o g Sensor Gasket e P Ceramic b 2 inal 0 x M
150. thin the temperature range 20 C 315 C inclusive the drift temperature of the housing lt 0 005 bar C 100 p lt 500 bar 0 0022 FS C p 500 bar Standard Material in contact with process medium Diaphragm 17 7PH corrugated diaphragm e 17 4 PH Thermocouple model WE2 STD type J isolated junction Protection degree with 6 pole female connector IP65 Appendix 2 ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P 026 5 1 04 p 926 5 1 047 E mE MECHANICAL DIMENSIONS LA 5 Di 1 2 20UNF a ee A 07 8 0 05 f M D2 90 31 0 002 D3 910 5 0 025 97 5 0 307 ial 90 41 0 001 N A io 010 67 a g 04 00 42 FEES o D 3 a D5 012 7 Ds 90 5 A 5 56 0 26 to 0 22 0 01 D5 a B 11 2 ns 0 447 15 74 0 62 FT 4 Ch 16 45 Hex 5 8 D Y e lt ri D1 M18x1 5 se 910 0 05 D2 20 394 0 002 gt 916 0 08 E D3 50 63 0 003 E 026 5 1 04 2 D4 916 0 4 90 63 0 016 18 0 97 5 0 307 DS 90 71 D 6 0 26 A 0 24 001 B 14 8 0
151. tozero func tion explanation LOAD RESISTANCE R 8 pin connector PCO2E 12 8P Bendi X SUPPLY VOLTAGE The diagram show the optimum ratio between the load and supply voltage of the 4 20mA transmitter For a correct use choose any combination of load resistance and supply voltage in the shaded area ACCESSORIES Connectors 6 pin mating connector IP65 protection degree CON300 8 pin mating connector CON307 Extension cables Cable color code 6 pin connector with 8m 25ft cable 08 1 5 Conn Wire 6 pin connector with 15m 5Oft cable C15WLS ar 6 pin connector with 25m 75ft cable C25WLS A Red 6 pin connector with 30m 100ft cable C30WLS B Black C White Other lengths consult factory D Green Accessories E Blue Mounting bracket SF18 F Orange Dummy plug for 1 2 20UNF SC12 Dummy plug for M18x1 5 SC18 Drill kit for 1 2 20UNF KF12 Drill kit for M18x1 5 KF18 Cleaning kit for 1 2 20UNF CT12 Cleaning kit for M18x1 5 CT18 Fixing pen clip PKIT309 Autozero pen PKIT312 Thermocouple for WE2 model Type J 153mm 6 stem TTER 601 Appendix 4 Revised 4 12 ORDER CODE ITW Dynatec c 2012 DYNAMELT S ASU Manual 20 59P 000 Autocompensation SP Standard available for ranges to 100bar
152. ts Selected character E Selected zone Z6 with cursor below it CUSTOMER FONE NAMES Bp Rees 0 SUPPLY HOSE LEFT SIO3 COPY BCLE LINE Zone indicators see below Programmed name Programming keys Customer Zone Name Programming Screen Zi 2223 2425 27677 2829 210211 212 713 714 215 216 Zone numbers s 733 ESTIS lal Zone indicators SUPPLY HOSE LEFT SIDS This line 12 characters This line 11 characters Supply Hose Left Side Zone 6 highlighted zone indicator Using F2 F3 F4 amp F5 Programming Keys F5 press to Clear the entire zone name F2 press to select upper or lower case letters to select numbers or to select special characters amp press to Copy F4 and Paste the name of one zone into another ITW Dynatec c 2012 Controller Programming Page 5 21 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Programming the Zone Names After selecting the Customer Zone Names parameter and pressing the Enter Knob to display YES press F3 Change Text to begin programming 1 Turn the Input Wheel to select desired temperature zone refer to corresponding RTD The selected zone is highlighted 2 Press the Input Knob to confirm zone 3 Turn the Input Wheel to select the character to be re programmed 4 Press the Input Knob to confirm selection The cursor highlights the selected character 5 Turn the Input Kno
153. ts Use an ohm meter to measure resistance across each element Infinitely high resistance values indicate an open heating element which must be replaced Page 7 20 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P Hose Head 1 Hose Head setpoints 1 Re program setpoint to allow a No Overtemp incorrectly programmed larger deviation 2 Hose Head triac on 2 hose or head status LED on the Power or Aux Power Temperature Module is OFF and the Module is inoperative corresponding temperature continues to rise the corresponding triac on its Power Module has failed The module must be replaced Hose Head 1 Disconnection between 1 Verify that Power and Aux Power No Not Heating Power and or Aux Power Module are properly connected to the Module and the V6 Temperature Module Temperature Module 2 Hose Head sensor circuit 2 a Visually examine hose head inoperative socket connections Verify that pins are properly seated If pins or plug housings are damaged repair or replace hose If socket is damaged repair or replace harness b If hose to ASU plug and socket are okay hose may have intermittent short or open circuit Repair or replace hose hose harness Power Module or Aux Power Module as appropriate Alternately problem can be isolated by connecting the affected hose to a different ASU hose socket to determine if the problem is in the hose or in the Power or Aux Power
154. ture Bar Graph of all zones Head 1 is highlighted on the bar graph Page 5 6 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Selecting Temperature Setpoints After selecting a temperature zone press the Enter Knob to highlight the setpoint Turn the In put Wheel to your desired setpoint value To enter the new value press the Enter Knob Contin ue programming by entering a setpoint for each zone Turning a Temperature Zone ON or OFF When a temperature zone is not used it can be de activated turned OFF A zone that is turned off no longer heats and is not monitored by the controller for over or under temperatures Even when a zone is turned off the controller remembers its temperature setpoint and it will be restored when the zone is turned back on To toggle a temperature zone ON or OFF press the Enter Knob Then press F5 You will see the ON OFF switch change position Press the Enter Knob Zone is ON Zone is OFF Setpoint is highlighted Setpoint is displayed as ON or OFF ITW Dynatec c 2012 Controller Programming Page 5 7 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 Pump Settings Return to the Overview Screen if necessary by pressing the RETURN button Standard Piston Pump ASU On a standard piston pump equipped ASU the pump is either turned ON RUN or OFF STOP There are no other pump selections To start or stop the pump toggle either th
155. ture conver sions between degrees Celsius and Fahrenheit Other parameters are independently selected values Defining DynaControl Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained Default Settings The factory set programmable system values that will be in effect if the user does not enter new val ues See page 4 7 for the controller s defaults Error Indication Alarms Controller alarms which indicate that the programmed over temperature values have been ex ceeded for one or more hopper hose or head zones or that a zone temperature has fallen beneath its hi lo tolerance Alarms may also indicate an open or short circuited sensor Main Power amp Aux Power PCBs The Power printed circuit board PCB and Auxiliary PCBs provide power to all the temperature zones in the ASU s system The standard unit s hopper hoses and applicators are controlled by the Power PCB Additional hoses and applicators are controlled by the Aux PCB s Mechanical High Temperature Protection A mechanical redundant thermostat located on the hopper which turns OFF the system at 232 C 450 F or 246 C 475 F for optional high temperature units Microprocessor based Proportional Temperature Control The built in control system that controls monitors and displays all system temperature values Page 4 2 Controller Setup ITW Dynatec c 2012 Re
156. uctions detailed in chapter 6 4 Shut OFF all pressure and power sources 5 Release residual air pressure 6 Remove all residual adhesive and wipe components clean 7 Remove all air lines and all power supply cables 8 Pack the unit in a corrosion proof manner 9 Store the unit in such a way that it is protected from damage Disposal of the Unit 1 Shut OFF all pressure and power sources 2 Relieve residual adhesive pressure 3 Release residual air pressure 4 Remove all residual adhesive 5 Remove all air and adhesive supply hoses and all power supply cables 6 Dismantle all components and sort into mechanical and electrical components 7 Arrange for all components to be recycled ITW Dynatec c 2012 Controller Setup Page 4 1 DYNAMELT S ASU Manual 20 59P Revised 4 12 Chapter 4 DynaControl V6 CONTROLLER SET UP Temperature Control Functions in General The DynaControl microprocessor based proportional temperature control in the ASU performs a number of functions that help to maintain adhesive setpoints in all temperature zones of the DY NAMELT system It maintains permanent system values such as the maximum temperature setpoint It enables the user to program temperature settings and heater on off sequencing that are appro priate to a specific application It displays all programmed values and it includes self diagnostic mal function alerts and failure alarms Note Some DynaControl functions are direct tempera
157. ue Turn the Input Wheel to select your desired hours value Confirm your choice by pressing the Enter Knob Press the RETURN button to return to the System Configuration Menu Level Detection P2 The level detection sensor triggers an alarm when the liquid adhesive level in the hopper falls below a certain level Hopper Empty is the alarm message displayed on the controller s status line ITW Dynatec c 2012 Controller Programming Page 5 19 DYNAMELT S ASU Manual 20 59P LCD Revised 4 12 The level detection parameter allows the user to turn the level sensor function On or Off After turning the Input Wheel to select the level detection parameter press the Enter Knob to change the function from activate to deactivate or vice versa Heat Up Sequence P3 The default heat up sequence is that all system temperature zones heat up simultaneously But in some cases it is preferred that the larger mass of adhesive in the hopper zones including the pre melt hopper and filter manifold get a head start on the other zones the hoses applicators and auxiliary zones Sequential heating is the choice that allows the hopper zones to heat to their ready temperature before the other zones begin heating After turning the Input Wheel to select the Heat Up Sequence parameter press the Enter Knob again to select On YES or Off NO Access Code P3 An active access code prevents unauthorized programming of setpoints and other configuration pa
158. ule Installation Page 3 5 ITW Dynatec c 2012 Revised 12 12 DYNAMELT S ASU Manual 20 59P VOLTAGE AUX POWER BOARD CONFIGURATION WIRING AUX PWR SINGLE PHASE 230V X5 BOARD L1 L2 L3 N P N 115766 kika Er S 14 WHT x3 MAIN SWITCH SATB d x9 0 2 9 AUX PWR L1 L e e 8 BLK BLACK D 14 WHT x5 BOARD 2 8 Ex 10 BLK BLK L2 N E PIN ONDE PIN 115766 e 3 E Urn X10 1
159. uler Days of the Week Active icon Time of Day m nj rr rp x S SCHEDULER SETUR 77 02 15 HTHTFSS ON OFF ST BEY 0 Daily Program 1 3 LEE 6 12 68 15 Daily Program 2 Jg 3H 12 Daily 3 gt S 151l12 151 days and times chosen are examples SLEEP MODE P DIEHCT IU Bl E 5 Sleep Mode status F2 not used indication Daily Programs status F4 Page 5 12 Controller Programming ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P LCD Programming Sequence Set up each Daily Program entirely before moving on to the next Daily Program Up to three Daily Programs may be setup All time selections are based on a 24 hour clock To Program Active Days of the Week Turn the Input Wheel to the Days of the Week Note if you can no longer see the cursor when turning the wheel turn the wheel in the opposite direction The Days of the Week may be toggled Active registers as black on the display or Inactive shown as white by pressing the Enter Knob Each day of the week can only be assigned to one program To Program On Off Times Turn the Input Wheel to select the first Switch On time press the Enter Knob to highlight the time Turn the Input Wheel to program your desired Switch On time in hours and minutes and press the Enter Knob Turn the Input Wheel to select a Switch O
160. ust be manually re set after the hopper temperature falls below 204 C 400 F The overtemp thermostat is located on the front side of the hopper behind the access cover see illustration on previous page To reset turn OFF the ASU s main power switch loosen the captive screw to remove the access cover push the center of the thermostat s insulator to re set restart the ASU Lithium Battery on Operator s Panel Printed Circuit Board The operator display panel s printed circuit board contains a lithium battery which powers the sev en day scheduler s clock The normal life of this battery is about ten years When the battery needs replacement the scheduler s clock does not function but other controller features remain intact Return the board to ITW Dynatec for battery replacement DynaControl V6 Modules The DynaControl V6 control package is built from encapsulated modules that snap onto the DIN rail within the ASU The modules communicate via a proprietary serial communication Each mod ule has a status LED ON ERR This LED shows the module s status as follows ON ERR Blinking green Everything o k Communication is working Solid red Communication fault No Light Module is defective or no voltage supply LED 7 Day Scheduler Use with Pendant Control Units which are controlled via the optional pendant controller must remain connected to the pendant if the 7 Day Scheduler feature is employed The 7 Day Scheduler will not
161. ut3 while input2 is not activated Load Program 2 Activate input2 while input3 is activated Load Program 3 Activate input3 while input2 is activated Load Program 4 Notes the controller loads the new program when the corresponding input is activated Deactivat ing an input does not affect the process It is possible to load a new program manually independent from the input situation Item 86 This output signal provides 24VDC for the piston pump enable solenoid The solenoid valve activates the piston pump when all temperature zones are within tolerance and the custom er has switched the pump into run mode Item 87 This input is connected to the over temperature thermostat on the hopper In the un likely event that that hopper temperature exceeds 450 F 232 C the thermostat will open and cause the power to all the heaters to be cut off A corresponding alarm message will appear on the controller s display The thermostat must be manually re set after the hopper temperature falls below 400 F 204 C cont Page 7 8 Troubleshooting ITW Dynatec c 2012 Revised 4 12 DYNAMELT S ASU Manual 20 59P V6 Base Module cont Item 48 This connects to the motor driver It is used on gear pump models only MB MC Alarm contact indicating driver fault SC S1 Pump start signal A1 AC 0 10V pump speed signal Item 9 If the ASU is equipped with a digital pressure read out it connects to this terminal The transducer type is two wire
162. ve the control panel loosen the four M4 Phillips head attachment screws and unplug the ribbon cable from the V6 Base Module Re Assembly Procedures Unless noted the S Series ASU s re assembly is simply the reverse sequence of the disassembly procedures However the following cautions should be followed whenever they apply for proper re assembly CAUTION In general all O RINGS AND SEALS should be replaced whenever hot melt equipment is re assembled All new o rings should be lubricated with o ring lube PN 108689 CAUTION TAPERED PIPE THREADS are found on air line fittings used with the pump air supply and on the outlet filter manifold Apply thread sealant PN NO2892 whenever tapered pipe threaded parts are re assembled CAUTION SOME FITTINGS used for adhesive on the ASU have straight threads and o ring seals Use of thread sealant is not necessary with these parts but the o ring seals should be clean and lubricated Tighten straight threaded parts and fittings until their shoulders are firmly seated against the pump body or other surface Excessive torque may damage straight threaded parts and the use of power wrenches is not recommended CAUTION HOT MELT RESIDUE should be cleaned from parts before they are re assembled particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts should always be re tightened at operating temperature ITW Dynatec c 2012 Options
163. vised 4 12 DYNAMELT S ASU Manual 20 59P Over Temperature Setpoint The programmable temperatures that will cause alarms to occur when those temperatures are exceeded over temp icon is shown at right Power is not disconnected the READY contact opens and the alarm contact opens If an external alarm has been connected it will activ ate The over temp setpoint is the upper limit of the ready temperature range of each zone Pump Enable Temperature The pump enable temperature protects the pump pump shaft motor and motor control from damage by not allowing the pump to activate until a low limit the programmed pump enable tem perature is achieved RTD Sensors The standard Dynamelt system uses 100 ohm platinum resistance temperature detector sensors for all temperature controls Ready Temperature The programmable temperature which allows the ASU pump to turn ON The default ready tem perature range is a deviation of 20 C 36 F from the setpoint The setpoint minus the devi ation is the low limit of the range and the setpoint plus the deviation is the high limit of the range Sequential Heating The heating sequence which allows the slower heating hopper to reach operating temperature without unnecessary use of electricity for faster heating hoses and applicators Sequential heating is the time period during which the hoses and applicators remain OFF while the hopper and op tional drop in grid heats up Hoses and applicators may

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