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Dynamelt M70/140 AB - Astro Packaging, Inc.

1. AAEM EISE 99 bef dee Immo tor B Ed on On bd B 6 5 5 bd PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP 4 3 2 1 4 3 2 1 DM70 Dual Hopper Temperature Zones DM70 Single Hopper Temperature Zones Zone 1 Grid 1 optional 2500w Zonel Grid 1 optional 5000w Zone2 Grid 2 standard 2500w Zone2 Grid 2 standard 5000w Zone3 Grid 3 optional 2500w Zone3 Hopper standard 10000w Zone4 Grid 4 standard 2500w Zone4 Primary Filter standard 2000w Zone5 Hopper 1 standard 5000w Zone 6 Hopper 2 standard 5000w Zone7 PimaryFilter 1 standard 1000w Zone8 Primary Filter 2 standard 1000w 1991 a Ce e Cte 90 flo B o PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP 4 3 2 1 4 3 2 1 DM140 Single Hopper Temperature Zones DM140 Dual Hopper Temperature Zones Zone 1 Grid 1 optional 5000w Zone 1 Grid 1 optional 2500w Zone2 Grid 2 standard 5000w Zone2 Grid 2 standard 2500w Zone3 Hopper standard 10000w Zone3 Grid 3 optional 2500w Zone 4 Primary Filter standard
2. 2 6 Chapter 3 Installation amp Start Up Placing the DY ASU perpe neos ev s pee edema ew e ad e D 3 1 To Open Close Panel Box Door 3 2 Installation PT 3 2 A ddirig A dfiesl Bele dod Bard d 3 4 Changing the Adhesive Formula 3 4 D ynamelt 70 140 Layout of Pumps amp Hopper Temperature Zones 3 4 Hose Head Electrical amp Adhesive Connections illustration 3 5 Electrical Connections amp Filter M anifold A rrangement M aximum Hose Head Configuration illus 3 5 Adjusting the Pressure 3 6 Pump Enable Ready Thermostat Calibration 3 8 Field Installation of Controller Options 3 8 Installation of the Optional Tach Generator or DC Tracking Signal 3 9 Optional Level Controls sis iein tese ette bcn dae fido dc Pide dd 3 10 Typical Start Up and Shut Down Procedures 3 11 Storage and Disposal of the Application System 3 12 Chapter 4
3. BACKBONE SIZE 4 TABLE WIRE MUST o RUN CONTINUOUS 8 DE 55 14 GND 2 Soc SIDE PLATE LEFT CRN YEL 14AWG BOTTOM PLATE GRN YEL N i TU 5 SCREW STUD e 58 A 58 14 8 gm SIDE PLATE RIGHT GRN YEL 14AWG MOUNTING PLATE GRN YEL 6AWG c Ns x CREW clelolole z 23 SCREW SCREW 544 ET m pz e z 4 2 M TOP PLATE GRN YEL M38 14AWG 8 CABINET GRN YEL 6AWG 3 70 140 210 12AWG m SCREW SCREW 6 DOOR LEFT GRN YEL 12ANG SCREW Q VM DOOR RIGHT GRN YEL 12AWG amp SCREW E 4 o HOPPER COLLAR GRN YEL 14AWG DYNACONTROL POWER BONRDGRN YEL 14AWG S SCREW d SCRE 25 5 F HOPPER COLLAR GRN YEL 14AWG lt gt g MV DYNACONTROL MTR BD _GRN YEL 14AWG E SCREW 8 N e HOPPER COLLAR GRN YEL 14AWG E DYNACONTROL MTR IF BD GRN YEL 14AWG f V VAL m m SCREW ES 4 A 8 JUNCTION BOX COVER _ GRN YEL 5 5 u HEATSINK 1 GRN YEL 14AWG AM m E SCREW o o AF V JUNCTION BOX COVER CRN YEL 14AWG 45 HEATSINK 2 GRN YEL 14ANG SCREW S W e SCREW N 4 5 2 SIDE PLATE LEFT GRN YEL 14AWG 5 a i we M SCREW HEATSINK 5 RN YEL 14AWG eee W
4. 232 C 450 F POOURESIVEVISCOSIUY io teens dote oec UOCE eas Poele ig daha bd a Ped diua 500 to 50 000 centipoise Warm up time full 8 approximately 0 5 hour Typical adhesive melt rate depends on adhesive used DM M70 27 95 kg hr 59 209 Ib hr DM M140 34 115 kg hr 75 253 1b hr Adhesive pressure S cade CITAR RA up to 68 bar 1000 psi maximum Temperature Control EIDanputboard a 4 zones per board modular construction Line Speed plis e eoa notte dod A kcu icd Wid Ao AE D RE 1to4 Temperature control 20 68 32 maximum with solid state relays Power output 55 eee Sae Ca a doa e Op Ca Re C Cu te E hopper 10 000 watt hose 1200 watt applicator head 1200 watt auxiliary 2000 watt Sold State relay THDUC tede t ease e du e eee aerei uet M eta dentes 3 15 VDC Other Op rtat r interface 12 32 EDU a o paite UP a Sede ID adeo PanelView 600 color Teitiperatire Standby s iade dvd xo ec RU E PH ud I ur Pec dA eb n e yes Hish and low temp alatis erie epe ead ERE ETE odo hls PR bordi tae o GR ag yes Ready int erlock daa ewe ultor Sae parteis C oa sequential heating yes hopper hose head staged heating
5. G al V HIN MIN C MIN HL S dNnd dWAd 02 3NOZ 0018M3ll4 v 3NOZ OZ 3NOZ o018N3LI4 3NOZ S jNOZ LI3A 90d 6l 3NOZ NAW 90d jNOZ LI3N 903d 61 3NOZ LISW jNOZ 90Md v MIN C bv MIN XIN C Hl L ML 00 3NOZ MOO 8M3l IJ Y 3NOZ 500883 1l3 04 3NOZ MOOTEYSL TS v 3NOZ 520 TESLA ANOZ LI3A 90d 61 3NOZ LIAW 3NOZ LIAW 90d 61 3NOZ 13N jNOZ 90Md MIN C SIN HL dNnd 1 dnd XIN C MIN lL al dWNd lt 0 JNOZ MOO 1883l1lJ 0 3NOZ 201833LlllJ Y 3NOZ 590 833L1l3 3NOZ NW 90d 61 3NOZ LAW jNOZ LIAW 908d 61 3NOZ LISW 3NOZ v v MH MIN C HIN dW d l d d dWfd L 0 3NOZ 0018931114 bv 3NOZ 520 883L1l4 o o S 3NOZ NW 90Nd 61 3NOZ NAW 90d INOZ LIAN 90Md 6L 3NOZ 90ud 3NOZ IIN 90ud Ml C MIN L 015 Ot L OZN 9u07 sdung
6. 7 2 Pump Enable Thermostat s isai oec edet trae aaa Puedo edo Gackt duck Face 7 2 SLC 500 Power Supply Fuse 7 2 SEC Processor Battery ated e ho cot kh halle ecol t Khi uo ode ade cho 1 2 Handling the SLC 500 s Components 7 3 Model DM M35SLC Module Configuration 7 4 Model DM M 70 140 SLC Module Configuration 7 5 Model DM M210SLC Module Configuration 7 6 DeviceNet Communication 0 2 7 7 DeviceNet Troubleshooting 7 8 SEC Processor CPU Module cao eoe carie 7 10 Input Modules 5 qe pet aet al o bx tue E a Alte go a d RR nd tQ RUD a D RR us 7 11 Output amp Output Input Modules 7 12 Heater and Sensor Resistance 7 13 Resistance T abl85 he aga ion kl a alana ada ahs 7 14 Error Indication Alarm Troubleshooting 7 15 Adjustable A dhesive Pressure Relief
7. e elu th e oa eate S 9 3 Controller Options oso Ret E TR GG 9 3 Recommended Service 51150 9 4 Chapter 10 Component Illustrations amp Bills of Material Chapter Format sos rm hag hee Md mes a Rade Be NOS ethan tue 10 1 Pressure Relief amp High Temperature Filter Block Assemblies 10 2 Electrical Panel Box Assembly 4 10 6 Cabinet A ssembly decer UR agate A 10 10 D rive Kssemblies t aede o ant ag tq Rec Ud ce ut et pn anata aaa anes 10 14 Melt amp Grid Assemblies stent eve ee eee he e ees eate a eer die 10 16 eroe ott 10 18 Pump Adapter Assemblies dx eet P ia aie eR a OE Rcs 10 26 Pressure Gauge Kit i ere eer ae EORR NERO XUL NUR BUCO RE D 10 28 In addition to the assemblies listed above this chapter may also contain illustrations for other optional or special assemblies installed on your ASU Chapter 11 System Schematics amp Engineering Drawings Hose Schematic all models eed ex ub NO ume a e ad ER NR 11 2 Head Schematic all 5 11 3 Flow Diagra
8. 18044 131 IO NI 052 p e 00 99 82 3 v90 162 0 r 73 v80 NAOHB A34 J2 a g WOLLdIH DELIVERY TW DYNATEE CC REV PORT iTW Dynatec 1999 DYNAMELT ASU Manual 20 28 20 29 and 20 30 1 168 084 E432 SEE CHART WOODRUFF KEYHAY B 406 NON STO MOUNTING 40 DEPTH 2 HOLES 20 7 REAR VIEW REF 6966 HPB 6074 NO ITEMS 62 xo ITEMS 453 8 9 2 TODLSTEEL AND rae VARIOUS Appendix 27 Revised 10 99 DYNAMELT ASU Manual 20 28 20 29 and 20 30 Tw Dynatec 1999 eee 30 was ONIINDOH UOJ 290 66 0 qe WILT SHAHSVA F ONY co SHILI X ON B t Rova 51798 v1 MUTA O3ddIHS 38 OL 2 9L09 dH 996G QdH 43H MAIA uv3d 1 4 L 02 LNOYS 19 g 90F Desi ABI MLIOVdYJ Appendix 28 iTW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 1999 Appendix 29 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 ZENITH MELF SPINNING PUMPS MANUAL Covers ITW Dynatec part numbers 084 374 084 376 084 387 084E388 084 389 084 438 HEEN E Ig Appendix 30 Revised 10 99 Tbis maintenance manual S
9. 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions TV Dynatec 1999 49 DYNAMELT ASU Manual 20 29 20 30 Revised 4 06 TOOL STEEL HIGH ACCURACY GEAR PUMPS USER S GUIDE Identifier Displacement Type Gears Plates Shaft Seal 108863 0 160 cc rev 807729 108864 0 160 cc rev 807729 108865 0 297 cc rev 807729 108866 0 297 cc rev 807729 108867 0 584 cc rev 807729 108868 0 584 cc rev 807729 108869 1 168 cc rev 807729 108870 1 168 cc rev 807729 108871 1 752 cc rev 807729 108872 2 920 cc rev 807729 108873 4 500 cc rev 807729 108874 2 920 cc rev 807729 108875 8 500 cc rev 807729 110289 20 0 cc rev 808680 110290 30 0 cc rev 808680 110291 45 0 cc rev 808680 F2 F2 amp gt amp amp FN FN Tool Steel High Accuracy Customer should read and thoroughly understand this manual before installation and operation of pump If necessary any Dynatec pump requiring maintenance can be returned to the factory for complete repair and overhaul Please contact our Rebuild Department for further details Appendix 50 iTW Dynatec 1999 Revised 5 04 DYNAMELT ASU Manual 20 29 20 30 Description ITW Dynatec s metering gearpumps are manufactured to precise tolerances To retain their
10. Adhesive flow through filter block to hose Operation of the Adjustable Adhesive Pressure Relief Valve Page 7 24 Troubleshooting iT Dynatec 1999 Revised 7 00 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Operation of the ASU s Gear Pump Manual or Automatic Pump Operation Choose M anual OFF or Auto gear pump operation from the M otor Programming screen on the PanelView keypad When the Dynamelt s pump is to be operated manually that is without a line following signal the manual mode is used to control pump speed and adhesive output For the gear pump to be operated in the automatic mode a tach generator or equivalent attached to the parent conveyor line must be provided and the following set up procedure should be performed 1 The tach generator or the signal isolator must be adjusted so that the voltage from the speed controller is 0 to10 V DC but not more than 10 V DC when the conveyor is at maximum speed This voltage is measured at either the analog input card typically at TB2 on 100100 and 100101 for a tach generator or at terminals 9 and 10 of the signal isolator board 2 The A uto setting then changes pump speed for any given 0 to 10 V DC incoming tachometer signal Voltage will vary given production speed The motor speed can be adjusted trimmed in auto mode by setting maximum and minimum pump speed rpm values on the controller s keypad pump speed will be the true motor speed at
11. ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 1999 Appendix 15 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 DYNATEC ZENITH HIGH ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL PN 084 428 084E 430 084E 432 084E 434 084E 436 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 428 Tool Steel Single High 0 297cc 069X251 084E430 Tool Steel Single High 1 168cc 069X251 084E432 Tool Steel Dual High 1 168cc 069X251 084E 434 Tool Steel Single High 2 920cc 069X251 084E436 Tool Steel Dual High 2 920cc 069X251 Thoroughly read and understand this entire manual before installation and operation of pump Note The instructions given herein cover the description installation operation and maintenance of subject equipment D ynatec and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 16 iTW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw pumps Each had problems with pulsation flow inaccura cies
12. SCREW 838 SIDE PLATE RIGHT GRN YEL 5 ee OPERATOR PANEL GRN YEL 14AWG d SCREW 239 pe SCR AE AAR BEN B MOTOR yoror o 6 GRN YEL 16AWG SCREW HT COVER 1 GRN YEL 14AWG PI HOSE HEAD 1 7012 GRN YEL 16AWG lt tuj A e HOPPER LEFT GRN YEL 12AWG P AUXILARY 1 TO 12 GRN YEL 16AWG KA E m d LEVEL PROBE GRN YEL Z JUNCTION BOX 1 GRN YEL 12ANG G ha SCREW 2 4 HT COVER 2 GRN YEL 14ANG JUNCTION BOX 2 GRN YEL 12AWG S gt gt Eroomnzio M4 Tr Zan HT COVER 3 GRN YEL 14ANG BRITES 2 Imana SCREW 2 9222 me E 4 E 83525775 GRN YEL 12AWG eN e OXO SCREW E SOB OES A M4 B S ozs LEVEL PROBE GRN YEL 250C 2 3 gaz 8504 SCREW 9t 4 46 z 4 8 a 8 GROUNDING DIAGRAM CE MARK PN 804704 REV E nS
13. Sensor open alarm S os e d eere sU etia hal eros a Dy aret yes RS232 and RS485 communications capable yes bevernsday Scheduler rs Ub c a dera M MUS Sac UD e ccu Ul cres Ma s c yes High temperature capable sk tus REIR RARUS AS CES ER Call d o e e SCR ten yes REM Cisplay cedo kac eg eae RACE RP AA ES RM COSA GP b yes Alarm amp system ready outputs 120 yes SLC 5 04 CPU 32K ciis a RPA CAE T DIG RRO eG E Bale TR ed yes Ses oua Ma ue oe yes Standby amp E stop pots D2DV cs Ee RR Yee o eG AU E ER d e gd yes Remote Qn ORE 120 esa sra NOE decet dye ed dE HEP OR yes CE approval granted E VA Ne bae e e a ade Fd NT MR A yes Page 2 4 Description amp Specifications iTWDynatec 1999 Revised 2 04 DYNAMELT M ASU Manual 20 29 67686 D 68 18 iTV Dynatec c 1999 Description amp Specifications P age 2 5 DYNAMELT M ASU Manual 20 29 Revised 2 04 ELSES amp 8 6 86 CIIIS 8 DYNAMELT M140 Installation Dimensions mm 15
14. cont High Flow Filter Manifold Remove the clogged filter s and install a replacement filter Page 6 4 Preventive Maintenance iTWDynatec 1999 Revised 7 99 DYNAMELT M ASU Manual 20 29 and 20 30 Note the filter s may be cleaned or replaced If cleaning a filter use only solvents recommended by your adhesive supplier 7 Inspect the o ring Replace if flat or damaged 8 Apply acoat of silicone lubricant onto the filter plug before re inserting it into the manifold 9 Apply acoat of anti seize compound onto all screws before re inserting 10 Restore application system to normal operation Hose Fittings All hose fittings should be checked for tightness after every three months of operation Fasteners After the first ten hours of operation check all set screws socket head and cap screws for tightness Thereafter re check all fasteners after every three months of operation Filter Shutoff Cleaning or Replacement See the illustrations in Chapter 10 M elt amp Grid Assembly for location of the filter shutoff s DM 70 DM 140 and DM 210 models have two filter shutoffs 1 Pump all the adhesive out of the hopper 2 Lower the temperature of the application system to the adhesive s softening point WARNING HOT SURFACE The ASU will still be hot for this procedure Use insulated gloves and protective clothing when removing the filter shutoff 3 Open the two access doors located at the sides of the ASU Do not pull out th
15. see Chapter 3 Hose Head N o 1 Debris at connection Sensor Short between hose head and ASU 2 Hose Head sensor circuit inoperative 3 Disconnection between RTD module and the rack 4 Hose Head sensor circuit 2 Verify that effected hose is properly connected to heater on the RTD module Replace or repair damaged hose harness as necessary 3 Verify that all modules are properly inserted in their sockets on the module rack 4 Replace head sensor if resistance does not comply with resistance table in this chapter U se hose schematic to check hose sensor at ASU socket Repair or replace hose hose harness or RTD module as appropriate 1 Visually inspect hose plug and ASU Socket for cleanliness and proper contact and seating of pins Using the hose schematic check hose sensor resistance at ASU socket A n ohmmeter can be used to isolate a pinched wire in the hose harness W hen cause is isolated replace hose hose harness or RTD module as appropriate b If head to hose and hose to A SU 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 as appropriate Page 7 22 Troubleshooting Revised 10 99 iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Hose Head No 1 Dis
16. DM210 These ASUs are available as DM M140 or M210 units for applications requiring a pump rate up to 2 625 cc min per pump The high flow models are equipped with high flow grid groups including high flow hoppers filter shutoff assemblies filter manifolds and filter baskets Controller Options On PLC controlled models ITW Dynatec supplies an Allen Bradley SLC 500 system including their DeviceNet communication module and 160 drive s As an option to the SLC system Allen Bradley s Control Logix systems are offered for customers who desire more universal communications Among the communication modules available for Con trol Logix ASUs are DeviceNet EtherNet and ControlNet Drives available are either the 160 or PowerFlex SLC 5 04 CPU 64K SLC 5 05 CPU 32K with Ethernet The above listed Allen Bradley SLC 500 CPU options are available for systems which require addi tonal memory and or networking capability than supplied by the standard SLC Control Logix CPU Models The Control Logix controlled system s communication modules and electronic drives are chosen to meet the specific needs of individual customers Call your Dynatec sales representative to discuss your options Pressure Display The pressure display option enables the controller to read and display adhesive pressure PSI or BAR in the ASU s outlet filter manifold A pressure reading device transducer or gauge is mounted on the outlet filter manifold Line Speed Trackin
17. Dual SSR to Dynacontrol not shown Harness A ux H ead 18 not shown Harness Hose Head 18 not shown Ground Z e o N PRP PPP BBP BPP FP OHNE PP BH a Revised 6 99 Component Illustrations amp BOM s Page 10 9 CODDA iTVW Dynatec 1999 DYNAMELT M ASU Manual 20 29 Page 10 10 Component Illustrations amp BOM s T Dynatec 1999 Revised 10 07 DYNAMELT M ASU Manual All M70 140 Models Bill of Materials for DYNAMELT M70 Series Cabinet Assembly Base Unit 106045 Item No Part Number Description Qty 1 101843 Handle Side Panel 4 2 105880 Panel Top Bracket 1 3 105886 Access Cover 2 4 105978 Rear Cover M70 1 5 107890 Manifold Cover 2 108128 Manifold Cover Hi Flow Only 6 105891 Base Plate M70 140 1 7 105882 Top Panel M70 140 1 8 105975 Heat Barrier Panel Box M70 1 9 802657 Panel Box 1 10 802102 Mounting Bracket 1 11 106110 5 Hex Nut 8 12 009E006 Swivel Caster 2 13 009E009 Rigid Caster 2 14 101074 Receptacle 8 15 103866 Bracket Connector Bank Amphenol 1 16 103516 M8 HHC screw 4 17 MS Star Washer 4 18 078 008 5 16 Flat Washer 4 19 106111 x 12 BHC Screw 16 or 64 20 101304 Blank Plate Dual 0 1 or 7 21 104279 Blank Plate Single 4 22 105111 M3 Hex Nut 0 4 or 16 106048 Lid Assembly 2 23 105117 4 x 8 Pan Head Screw 4 24 106236 MA Star Washer 4 25 106876 Retaining Clip 2 26 106319 M6 Star Washer 4 27 10
18. Figure 1 2 STANDARD ACCURACY PUMP RE ASSEMBLY NOTE During and between each re assembly step manually turn the metering gears to en sure that they are free turning If binding occurs at any time determine the cause and correct itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component Never use force in re assembling or turning a Dynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely R e assemble as follows 1 After all worn parts have been re finished or replaced all parts should be throughly cleaned in a solvent and dried 2 Using the driven gear 5 as an up righting fixture carefully locate the arbor 7 over its press fit hole in the gear rear plate Smoothly drive the arbor into its hole with the help of an appropriate arbor press 3 Place the gear rear plate 1 with the arbor in position in a soft jaw vise or holding fixture 4 Slip together the driving metering gear 6 drive shaft 4 key 8 and retaining rings 21 Position in the front of the gear rear plate 5 Placethe driven metering gear on its arbor and carefully mesh with the drive metering gear 6 NOTE Repeat steps 3 through 5 for four gear pumps 7 Position the front side plate 3 8 Rotate the gears to ensure free rotation 9 Press the roll pins 41 into place 10 Lubricate the binder screws 23 with DAG dispersion 154 or a similar he
19. I NASAO HINZ a SNId 104 304 S7704 O3T1IUO E HOLY T A SSV amp 1 1804 135NI glg ILON y 016 ISNY NON 34 29 1459 cCor3 v80 CR ERES rapes 00 iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Appendix 12 Revised 10 99 XSAN AG DE f CAPACITY PART CO REY m 088 1 Seat CTI MB Ee r WG eZ NDA m i ES D NON ANSI STD LANO RS SECTION A A 813 INLET PORT AFTER ABS Y MATCH 2 DRILL HOLES FOR ROLL PINS HUMBER amp DIGPLACEMENT WITH MINIMUM Ma en d rw ib B ever NOCHE P UG TH gaa PIN CHAT I 3 OUAL STREAM HOO METERING PUMP IRO 440C STAINLESS STE A2 AND TOOLSTEELS Aan atan ano altay steme 2 AMET 33 1556 Appendix 13 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 iTV Dynatec 1999 ee See as 263431596 No 43 geo 10 SNId 71109 303 S3 10H 0371150 g HOLV A SSV 1009 LINI 5770H i708 3LON y NOTLOSS mse CONAN as um ieaoo 7 f men PT 4 e E Ad3 22 Luvd Ali2vqv2 J31YNAQ ALI Appendix 14 iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30
20. Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Tw Dynatec 1999 4 TOHI SGUYN AD HAIN Fr 2023 lt 80 ee ents Yie 011 Ho Y EE 192 dV3H 134005 91 Wis AUNT Sung E NT Bs NATVIG LY WN 1999 Hola g Khu J JETA ov EE XO BEE ERTAN Sravan _ Z Svoo sar rt a X oi oret scivaco 2081 oot mill A38 29 267 5663909 9or3vao ver3rpo szeareo fpi a a Pe I 7905382 _ Qo 5 2r80 5093 007 yj 9 E 31v6 0 6671 bool l eso chy 7404 A337 por 626360 G0r3 BD X 9120 6 asiveco Cedi oot 93 MEETA ee ete EBS GEE EH Bee RC 90r3va 6ZESKEO GOPaeEO X 51 8 6 090 819 002 509 oca 522 39 22 05268 24 s otaran i 2 X 91 96 8 0 0091 0001 523 JTONIS 3 722 5 ESFBO METTRCTEMMNTTETTCNB NETTEN 9 S gvB70 003 0901 027 62 22 8917 ZCESFBO T amp 2 1 8 6 2 x 809 TRIS TAT VEME A GRet EEA EEEE 0 XWNW W MIE OO BIETTTINEBETTTNEBC
21. The DYNAMELT M SERIES ASU stands alone on flat surfaces The main electrical power and the serial communication connections come in from below the unit and connect into the circuit breaker Hopper Lid Controller Keypad Hose Head Electrical Connections Main Disconnect Bm Switch Panel Box Manifold Keylock Cover ll Panel Box VA Keylock 0 Dotted line indicates Access location of Circuit Door gt Breaker within Keylock Panel Box S Panel Box The DYNAMELT M70 M140 ASU model M140 shown Page 3 2 Installation iTVW Dynatec 1999 Revised 7 00 DYNAMELT M ASU Manual 20 29 Re read Chapter 1 Safety Precautions before performing any installation procedures All installa tion procedures must be performed by qualified trained technicians To Open Close Panel Box Door 1 With the key supplied unlock the panel box door 2 Turn the main disconnect switch counterclockwise to Reset while pushing the tab clockwise with your thumb 3 Pull door open 4 To close Turn switch to ON Hold door closed while turning switch to Reset and then back to ON 5 Lock the panel box door with the key Installation After the DY NAM ELT M SERIES ASU has been properly positioned the following general sequence should be followed for installation 1 Make sure that incoming line power to the A SU and the unit s main disconnect switch are turned OFF DANGER HIGH VOLTAGE
22. pump in a luidized bed cleaning bath The bath should he heated to a temperature that is sufficient to carburize the polymer The carburization process usually takes between 3 12 hours depending on the polymer type temperature pump size and furnace toad CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning 2 After gradually cocling to room temperature the pump should be thoroughly Hushed in a clean solvent Again it is Usually necessary to disassemble only the seal arrange ment to remove polymer ash 3 Always replace the carbon seal plate after pump burnout store for future nge simply add rust preventative oil Appendix 31 Revised 10 99 2 Remove all binder screws 3 Remove dowels and arbors with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Most dowels and arbors are press Bit in the front side plate and slip fit in the center and rear side plates When this is the case it is preferable to press from the front side Separate the plates by lightly tapping them with a soft head hammer If pry slots are available in the pump you may use them instead of or in conjunc tion with the above method In either case great care should be taken not to scratch or damage the internal pump suriace when prying the plates apart 4 After disassembly dean all components in a glass bead blast cabinet to remove any debris remaini
23. xooj qj9y 4 H M bojg 10 uonpunb C ssaddoy jong j suaddoy eui ueewjeq LOISIAIP y sejpoipu 0 601 910 ANOZ MOOI8YSL IIS JNOZ LIAW 90d i C LL iL Y 1 02 M201883Ll1lJ 3304 3 5 L dWnd Ge PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 2 of 3 Revised 7 07 Schematics Page 11 9 DYNAMELT M ASU Manual 20 29 and 20 30 TV Dynatec 1999 Zone Configuration for Premelt Grids M3o 1 PREMELI M70 140 2 P ELTS M210 5 PREMELTS PREMELT 1 ZONE 2 PREMELT 1 ZONE 2 PREMELT 2 ZONE 18 PREMELT 1 ZONE 2 PREMELT 2 ZONE 18 PREMELT 3 ZONE 34 M35 2 PREMELTS 70 140 4 PREMELTS M210 6 PREMELTS PREMELT 1 ZONE PREMELT 1 ZONE 1 PREMELT 2 ZONE 17 PREMELT 1 ZONE 1 PREMELT 2 ZONE vi PREMELT 5 ZONE 33 PREMELT 2 ZONE 2 PREMELT 3 ZONE 2 PREMELT 4 ZONE 18 PREMELT 4 ZONE 2 PREMELT 5 ZONE 18 PREMELT 6 ZONE 34 NOTES Indicates the division line between the two hoppers if Dual hoppers are installed PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 3 of 3 Page 11 10 Schematics iTW Dynatec 1999 Revised 10 01 DYNAMELT M ASU Manual 20 29 and 20 30
24. 10 volts input This value cannot exceed 10096 To make this motor speed adjustment follow the programming instructions in Chapter 5 Pump Operation W hen the adhesive in the A SU s hopper has reached a temperature high enough for the pump to op erate safely the controller will place the hopper in Ready condition and power will be supplied to the pump The pump is self priming Pump output is adjusted from the M otor Programming screen on the controller s keypad However if less pressure is needed maximum pressure of the pump can be decreased or increased by adjust ing the pressure relief valve installed on the pump output manifold To change the setting of this valve loosen the locknut and turn the allen screw clockwise to increase pressure or counterclock wise to decrease pressure T he relief valve is factory set at 34 bar 500 psi for Dynamelt M gear pumps iTV Dynatec c 1999 Troubleshooting Page 7 25 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 1 99 Troubleshooting the ASU s Gear Pump No special tools are needed for working on the ASU pump See Chapter 8 of this manual for diaas sembly assembly procedures for the ASU pump and Chapter 10 for locating pump parts on the component illustrations exploded view drawings Gear Pump Priming Start Up The pump is self priming CAUTION DO NOT continue to run the pump if no glue is coming out This could damage the pump since it uses the glue as a lubricant Stop a
25. 105967 Filter Shutoff Assembly L eft N 07588 L ubricant O ring L 15653 Kit Flushing Fluid 1 gallon 001U 002 Hi Temp L ubricant tube 102717 Check Valve pressure relief 108012 Filter Pressure Relief Plug Assembly Tv Dynatec c 1999 Component Illustrations Page 10 1 DYNAMELT M ASU Manual 20 29 Revised 3 05 Chapter 10 COMPONENT ILLUSTRATIONS amp BILLS OF MATERIAL N 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 M SERIES ASU These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Because of the similiarities of the Model M70 and M140 ASUS both are diagrammed on each il lustration When a part number is not identical both models part numbers are given with a note to distinguish between the two models Note most common nuts bolts and fasteners can be obtained locally at your hardware store Spe cialty fasteners are available by contacting Dynatec s Customer Service Page 10 2 Component Illustrations amp BOM s T Dynatec c 1999 Revised 08 06 DYNAMELT M ASU Manual All Models Bill of Materials for Pressure Relief amp High Temp Filter Block Assembly 102710 Items from Heater Control Groups 103571 103572 103573 1
26. 3 See Figure 20 Support the inner race of the new Ball Bearing Item 28 and press the Disc Joumal 8 inte the Ball Bearings Items 28 and 29 and Housing 3 See Figure 20 Side a naw Keyed Washer Item 55 onto the Disc Journal Item 8 and reimstaE the Lock Nut Item 56 Bend down the tabs of the Keyed Washer Item 55 the Lock Nut ikem 56 See Figure 20 VR RR mcm ccs mss sms RUD RR REPLACEMENT PARTS The tem or baBoon number for all Horton products is used for pari identification product parts lists product price lists unit assembly drawings bils of materials and instruction When ordering replacement parts specify mode designation item number part description and quantity Purchase replacement parts through your local Horton Distributor cont Appendix 46 iTVW Dynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont Parts List MODULAR DRIVE UNIT MDU Ball Bearing Hex Head Gap Screw Ring Ext 1 Denotes Repair Kit tem MDU 625 and 875 Repair K amp No 930100 iTV Dynatec c 1999 Appendix 47 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 99 Pneumatic Clutch cont MODULAR OUTPUT UNIT MOU 1 Denotes Repair Kit stem MOU amp 25 and 875 Repair Kit No 830300 Denotes Friction Facing item MBU 625 and 875 Friction Facing Kit No 930276 Appendix 48 iTWDynatec
27. ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 1999 Appendix 1 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 APPENDIX DYNATEC ZENITH STANDARD ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL PN 084E 427 084E 429 084E 431 084E 433 084E 435 084E 437 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 427 Nodular Iron Single Standard 069X251 084E 429 Nodular Iron Single Standard 069X251 084E 431 Nodular Iron Dual Standard 069X251 084E 433 Nodular Iron Single Standard 069X251 084E 435 Nodular Iron Dual Standard 069X251 084E 437 Nodular Iron Single Standard 069X251 Thoroughly read and understand this entire manual before installation and operation of pump N ote The instructions given herein cover the description installation operation and maintenance of subject equipment Dynatec and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 2 iTVW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw
28. Keys PRESSURE DISPLAY PSI PRESSURE 21 0 0 PRESSURE 7 0 0 PRESSURE 2 0 0 PRESSURE 8 0 0 PRESSURE 3 0 0 PRESSURE 9 0 0 PRESSURE 4 0 0 PRESSURE 10 0 0 PRESSURE 5 0 0 PRESSURE 6 0 0 RETURN E m TEBE Arrow Keys iTV Dynatec c 1999 Programming Page 5 13 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the Adhesive Pressure Monitoring Screen Note this screen is functional only if optional pressure transducers are installed on your ASU Press This To Function Key Return Return to the Motor Menu screen This screen is read only Adhesive pressure is displayed as read by the system s pressure transducers installed on the ASU s outlet filter manifold Monitoring Pressure is read as PSI or this selection is registered in the box at the top right of screen To change selection go to Setup Menu screen Page 5 14 Programming Revised 10 02 Setup Menu Screen SETUP MENU TEMPERATURE UNITS DEGREES F SYSTEM STAND BY 1 10 HRS SEVEN DAY SCHEDULER iTWDynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Numeric Entry Keys 1 Arrow Keys iTV Dynatec c 1999 Programming Page 5 15 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 5 03 Use of the Setup Menu Screen Press This To Function Key Temperature Pressure Units Toggle to choose Celsius BAR or Fahrenheit PSI OFF ON Toggle to choose System Standby ON or O
29. RTD SENSO BLUE 20 AWG Lh 9 HOSE SENSOR R BLUE 20 AWG 10 HOSE SENSOR BLACK 18 AWG 11 HOSE HEATER WHITE 18 AWG 120V APPLICATOR END Rew ER WIRE YELLOW 18 AWG 200V ASU END VIOLET 18 AWG 240V i dee Hees GREEN YELLOW 16 AWG L GROUND HOSE CORE NOT GROUND ES 1 ALL WIRING 15 ROUTED THROUGH THE HOSE p 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 HOSE SCHEMATIC PN 101082 REV G ASU to Applicator iTV Dynatec c 1999 Schematics Page 11 3 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 1 01 PLUG HEAD 7 BROWN 22 BROWN 22 GND GRN YEL 18 SOL S ACTIVATES HEAD HEAD SCHEMATIC PN 103117 REV B HEAD SCHEMATIC PN 103117 REV B Page 11 4 Schematics iTW Dynatec c 1999 Revised 5 00 DYNAMELT M ASU Manual 20 29 and 20 30 Function of OutletFilter Manifold s Closeable Cross Channel A Closeable Cross Channel Plug is located inside the Outlet Filter M anifold to prevent adhesive flow between the two outlet filters when a dual pump is in use When a single pump is used ITW D ynatec removes the Cross Channel Plug When changing an ASU from
30. To remedy this we recom mend cormecting the pump driver to the pump shaft with a double universal joint arrangement This type of joint will prevent bending loads from being transmitted to the pump shaft when misaligned This greatly reduces the possibility of premature shaft failure due to fatigne To prevent seizure be sure to apply adequate high temperature lubrication to the universal joints 2 After startup take up gradually and evenly on the pack ing gland screws until slight weepage occurs 35 Be sure to follow up closely throughout the runningin period of the packing unii the seal is thoroughly seated Do not completely seat the packing in one adjustment 5 Cleaning 1 70 dean melt spinning pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer Time at temperature will be related to pump size and degree of polymer contamination and should be determined by trial NOTE Careful control of the furnace temperature and atmosphere is critical Should the temperature exceed the original tempering temperature the steel hardness may draw back and the dimensional stability of the purup may be upset Consult Fable for proper tempering temperature Rockwell c AISI Tempered At Hardness D 2 Ohio Air Die 950 F 510 C 58 60 M2 66 C 61 64 M 4 Neatro 1050 F 566 C 61 64 Another acceptable cleaning method is to immerse the
31. Valve 7 23 Operation of the 50 5 7 24 Troubleshooting the ASU Pump 2 4 7 25 Gear Pump Troubleshooting Guide 7 26 Chapter 8 Disassembly amp Re assembly Procedures Disassembly 8 1 To Remove the Access 00015 8 1 To Open Junction BOXES 8 1 Sensor or Thermostat Replacement 8 2 iTV Dynatec c 1999 Table of Contents Page v DYNAMELT M ASU Manual 20 29 Revised 8 02 To Remove M anifold 8 2 To Remove Lower Manifold 8 2 Heater Replacement 8 2 To Remove R ear Covel Eu o re ie ER AED AG aad ea E 8 3 To Access RTD Sensor in the Optional Drop in Grid 8 3 To Access the Electrical Components Inside the Panel Box 8 3 Fuse Removal se ek ER a eb adel ii ERE D e E
32. a single to a dual pump or vice versa consult ITW Dynatec for complete instructions D Check Valve 2 Adhesive In P ort Adhesive Return When Cross Channel Plug is removed one adhesive outlet must be plugged 2225 7 22 Cross Channel Plug is removed thru port on side of manifold 2 Closeable Cross x Channel Plug 4C Tj Adhesive Outlet To 4 Hose Adhesive Outlet To Hose The second Adhesive In and Adhesive FLOW DIAGRAM OUTLET FILTER MANIFOLD Return ports are not shown i TV Dynatec c 1999 Schematics Page 11 5 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 5 00 Basket TYPICAL HYDRAULIC SCHEMATIC Single Pump Motor Bypass Filter optional Transducer amp optional Pressure Gauge Page 11 6 Schematics iTW Dynatec 1999 Revised 10 01 DYNAMELT M ASU Manual 20 29 and 20 30 CONDUCTOR SIZE BOTTOM PLATE ACCORDING TO
33. arrow to store your desired time b Press the first Minute key to program a desired ON minute 1 Use the numeric keypad to enter desired time of day use 24 hour day military time ii Press the Enter arrow to store your desired time c Press On Off to make the Scheduler active or inactive for this day 3 Repeat steps 1 and 2 until all days and times are programmed as desired 4 Press Return to return to the Main Menu Page 5 18 Programming iTV Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 PanelView Configuration Screen CONFIGURATION MODE gt MEMORY CARD LANGUE COMMUNICATION SETUP SPRACHE PRESET OPERATION LINGUA TERMINAL INFO LENGUA SCREEN SETUP LANGUAGE DATE TIME PRINTER SETUP e O COMM FAULT LED LED To Set Seven Day Scheduler s Clock 1 Advance to the Configuration Mode screen seen above by pressing both the left and right ar row keys simultaneously 2 On the menu Scroll down to DATE TIME Press Enter 3 Press F1 and enter the year Press F2 and enter the month Press F3 and enter the day Press F6 and enter the hour Press F7 and enter the minute Press F8 and enter the second Press F10 to Exit Press F2 RUN MODE to return to the hot melt application amp iTV Dynatec c 1999 Programming Page 5 19 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the PanelView Configuration Screen Press This To Function Key F2 Return to Run M
34. at their customer s request Please consult with ITW Dynatec quoting job and pump references if questions arise iTV Dynatec c 1999 Appendix 53 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 5 04 Reconditioning Should reconditioning overhauling become necessary return the pump to ITW D ynatec Pump Shaft Seal Replacement ThelTW Part Number for all Standard Tool Steel High A ccuracy Pump Shaft Seals 8 5cc and smaller is PN 807729 DANGER HOT SURFACE amp HIGH VOLTAGE If the pump is notoperable but the heating system will function raise the temperature of the application system to the operating temperature to aid in the pump disassembly process Otherwise a heat gun or other controlled heating method is recommended to melt hardened hot melt material Never use a torch or an open flame on any of the components of the application system Once the system is up to temperature disconnect all incoming power before proceeding Pump Shaft Seal O ring Replacement In most cases the pump does not have to be removed from the ASU in order to replace the shaft seal 1 Disconnect the drive coupling so that the pump may be accessed 2 Remove the four screws in the pump cap and remove the cap 3 Within the cap is the pump shaft seal move the old seal 4 Clean all pump parts paying particular attention to the pump shaft seal groove 5 Lightly lubricate the shaft seal before inserting it in the shaft se
35. device in scan list table does not A dd the device to the network or delete the exist node number alternately flashes scan list entry for that device Scanner has failed to transmit message Make sure that your module is connected to a valid network Check for disconnected cables Scanner is in IDLE mode None cont iTV Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Troubleshooting Page 7 9 Revised 1 99 Troubleshooting with the Scanner s Error Code Display cont Code 81 82 83 84 85 88 90 91 92 95 97 98 99 Problem Scanner is in FAULT mode Error detected in sequence of fragmented 1 0 messages from device node number alternately flashes Slave device is returning error responses when scanner attempts fo communicate with it node number alternately flashes Scanner is initializing the DeviceN et channel Data size returned is bigger than expected This is notan error At powerup and reset the module dislays all 14 segments of the node address and status display LEDs User has disabled communication port B us off condition detected on comm port Scanner is detecting communication errors No network power detected on comm port A pplication FLASH update in progress Scanner halted by user command U nrecoverable firmware failure U nrecoverable firmware failure Correction None Check scan list table entry for slave devic
36. high performance these pumps must be carefully installed and maintained These pumps are CE Dec laration of Conformity rated Health amp Safety Dismantling Internal components are precisely machined and have sharp edges and corners T hese features are essential to the accurate metering performance Particular care must be exercised when handling these components Cleaning Cleaning fluids and methods are subject to strict Health and Safety regulations Avoid contact with skin do not inhale fumes and protect eyes Operation Pump outlet pressure and speed limits are dependant on fluid viscosity and throughput Pump in let pressure is an important feature for lubrication and fluid homogeneity M aterials for pump construction are important for corrosion and wear resistance Consult ITW D ynatec for detailed applications Normally the pumps are single or dual output Typical speed ranges are 10 90 rev min Flushing To avoid contamination of process fluid the pump should be flushed out to remove test oil Pre caution must also be taken to flush out pumps at plant shutdown since congealed fluid can cause seizure Filtration Unless fluid purity can be guaranteed especially from metal fragments filtration must be installed before pump inlet to avoid damage to pump internals Note The following guide is for general purposes only Due allowance must be made for any spe cial features Installation Ensure pump is free from
37. 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 Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections 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 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 Treatment for Burns From Hot Melt Adhesives Burns caused by hot melt adhesive must be treated at a burn center Care should be used when workin
38. indicates that the controller is booting up b System OFF c System Heating power is ON but zone temperatures have not risen to setpoint d System Ready all zones have reached setpoint temperatures e High Alarm a temperature zone has exceeded its high limit f Standby the system is in a programmed standby state Display flashes when Standby is active ON g Remote E Stop the system has been stopped by a remote emergency stop h Level Low adhesive level in the hopper is low used with optional level control only i Level High adhesive level in the hopper is overfull used with optional level control only j OT T stat Open hopper temperature has exceeded safety limit 232 C 450 k DeviceNet Fault DeviceNet is not connected properly or is faulted refer to pgs 7 7 to 7 9 1 Drive Fault the system is not ready until all of the drives are ready This fault will clear itself out m Pump Low or High Pressure optional transducers indicate that 74 pump has high or low pressure due to a clogged filter adhesive leak excessive adhesive flow etc 2 Low Alarm Zone or High Alarm Zone the controller will list one at a time the identification number of any zone with a low or high alarm the identification numbers are assigned on each zone s Temperature Zone Programming screen The i d numbers on the alarm display disappear as alarms clear 3 Dual Hopper System Ready indicators For ASUS with two adhesive hoppers a d
39. low level is sufficient The two other outputs may be used as safeties such as critical high and critical low for multi ASU systems with bulk feeders iTV Dynatec c 1999 Installation Page 3 11 DYNAMELT M ASU Manual 20 29 Revised 8 99 Typical Start Up and Shut Down of the DYNAMELT M Application System The following simplified sequence assumes that the PanelView 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 contaminants also Switch ON the M ain Disconnect the circuit breaker located on the panel box Atthe controller keypad press the Heater Power ON OFF button The display will read System Heating Allow adequate time approximately 20 30 min for the adhesive to melt and the temperatures of the temperature zones to stabilize M onitor the display until it reads System Ready indicating that all temperature zones are up to ready temperature When temperatures are ready the motor is enabled to pump adhesive a If Motor is in Auto Program For systems with no clutches installed A dhesive will begin to pump when the production line begins to operate ii For systems with clutches installed Press M otor M enu Press desired M otor Setup Toggle Clutc
40. multiple seal areas and slippage which required constant calibration high maintenence and extended downtimes Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering The pump s simple design of only three moving parts two metering gears and a drive shaft provided long life and easy maintenance For years since chemical engineers have relied on Zenith to provide precision fluid han dling solutions for their most difficult pumping applications Zenith gear pumps can be found wherever precise pulseless repeatable metering of fluids is required BENEFITS High Accuracy Stable repeatable flows are assured even under varying conditions of pressure viscosity and temperature High Temperature C apability Operating temperatures to 550 degrees F 288 degrees C Maximum L ife Only three moving parts components are through hardened tool and die steels to 62 HRc or better Replaceable sleeve bearings for low cost rebuilds High Volumetric Efficiency M aximum efficiency is achieved with optimum operating clearances and assured under pressure by built in alignment dowels Minimum Pulsation Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance Precision Construction Ground and la
41. protective packing materials and rotates freely Pump Drive Drive alignment is very important Ensure backlash is 0 1mm 0 004 to avoid shock or radial load In the event of driveshaft connection two flexible components must be incorporated into each driveshaft to allow for misalignment These flexible components must have the capacity to distort over the misalignment range while ensuring that any radial load is minimal Do not allow iTV Dynatec c 1999 Appendix 51 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 5 04 shaft to put end thrust on the pump Rotation Ensure drive rotates in correct direction generally counter clockwise at the pump drive spindle The pump must be checked for smooth operation by hand Fixing and Lubrication The pump must be fixed securely to maintain position and alignment W hen secured by lubricated bolts torque them evenly to the suggested torque see M aintenance Start drive and bring up to speed slowly Flush with process fluid Note motor baseplate assemblies should be pre checked in case the drive alignment has been dis turbed Gland Leakage If oil seal is fitted there should not be any fluid leakage Problem finding Chart Problem Remedy i LEAKAGE Screws not tight Re torque Seal scratched or worn Replace seal FLOW RATE ERROR Gear worn on diameter Return to ITW D ynatec or width Gear teeth damage Return to ITW Dynatec Plates worn scratched or not Return to ITW Dynatec flat
42. pumps Each had problems with pulsation flow inaccura cies multiple seal areas and slippage which required constant calibration high maintenence and extended downtimes Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering The pump s simple design of only three moving parts two metering gears and a drive shaft provided long life and easy maintenance For years since chemical engineers have relied on Zenith to provide precision fluid han dling solutions for their most difficult pumping applications Zenith gear pumps can be found wherever precise pulseless repeatable metering of fluids is required BENEFITS High Accuracy Stable repeatable flows are assured even under varying conditions of pressure viscosity and temperature High Temperature C apability Operating temperatures to 450 degrees F 232 degrees C Maximum L ife Only three moving parts components are through hardened tool and die steels to 56 HRc or better The bodies are cast nodular iron Replaceable sleeve bearings for low cost rebuilds High Volumetric Efficiency M aximum efficiency is achieved with optimum operating clearances and assured under pressure by built in alignment pins Minimum Pulsation Unique design offers virtually pulseless flow without v
43. temperature setpoint which is the setpoint plus its high low alarm setting or when it is below its selected under temperature setpoint which is the setpoint minus its high low alarm setting When a hopper hose or head sensor has an open circuit When a hopper hose or head has a heater with a short circuit Settings for a Typical Operation Note The values given here are approximate settings for a typical packaging operation 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 iTV Dynatec c 1999 Programming Page 5 1 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Chapter 5 PANELVIEW 600 CONTROLLER TOUCHSCREENS PROGRAMMING MANUAL 10 02 Numeric Entry Keys rrwDynatec Main Menu Delete Enter EJEJEJEJES vg re rep ro ro EJ F1 thru F10 used in Configuration Mode Arrow Keys Controller Screens in General 1 To progress through the controller s screens press within the box ke
44. them too clean Please treat them with care and if it s at all possible set aside a separate clean area for pump maintenance To clean High A ccuracy M etering Pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer Time at temper ature will be related to the pump size and the degree of polymer contamination and should be determined by trial Note Careful control of he furnace temperature 700 degrees F max and atmosphere is critical Should the temperature exceed the original tempering temperature the steel hardness will draw back and the dimensional stability of the pump may be upset A nother acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath shold be heated to a temperature that is sufficient to carburize the polymer The car burization process usually takes between 3 and 12 hours depending on the polymer type temperature pump size and furnace load CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning A fter gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent t may be necessary to disassemble the seal arrangement to remove polymer ash If present always replace the carbon seal plate after pump burnout If the pump was perform ing satisfactorily when removed from service and still turns freely after burnout pressure test it and ad
45. up and off 4 Position a heat resistant container below the manifold With a hex key screwdriver allen wrench slowly loosen the manifold s two purge set screws do not attempt to remove them Allow adhesive and pressure to escape out of the manifold A dhesive will drain into the container 5 Wearing insulated gloves push down on the adjustment screw cap with sufficient force to release the slide While holding the cap down pull the slide forward until the groove stops the roll pin Note If the cap moves up before the slide opens fully this is an indication that there is iTV Dynatec c 1999 Preventive Maintenance Page 6 3 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 7 99 still pressure in the system Stop and verify that the motor pump is turned OFF and the applicator s valves are open before proceeding Then repeat step 5 Pull the cap and the filter plug up and out of the filter cavity Dueto adhesive and the o ring seals there will be some resitance before the plug exits the cavity Note the filter basket hangs from the plug by a spring clip If the filter pulls free of the spring clip and remains in the cavity use a hooked tool to extract it Pull the filter basket free from the spring clip The filter should be inspected and replaced as needed Note the char and debris inside the filter basket Before replacing the filter basket inspect the two o rings on the filter plug Replace any cut or damaged o ring A pp
46. 0 To replace the battery Important Note A capacitor provides at least 30 minutes of battery backup while the battery is dis connected Data in RAM is not lost if battery is replaced within 30 minutes Aj DANGER HIGH VOLTAGE Do not remove the processor from the SLC 500 chassis until all power is removed from the SLC 500 power supply 1 Remove all power from the SLC power supply iTV Dynatec c 1999 Troubleshooting P age 7 3 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 1 99 2 Remove the processor from the chassis by pressing the retainer clips at both the top and bottom of the module before sliding it out CAUTION Do not expose the processor to areas that may hold an electrostatic charge See the following section Handling the SLC 500 s Components 3 Unplug the battery connector from the socket and remove the battery 4 Remove the battery from the retaining clips Insert the new battery into the clips 5 Plug the new battery s connector into the socket 6 Re insert the module into the SL C 500 chassis R estore power to the power supply Handling the SLC 500 s Components The Dynamelt ASU and controller utilize several components and modules which are extremely Sensitive to electrostatic charges W hen working near or with these components the following pro cedures must be followed to avoid damage to them DANGER HIGH VOLTAGE Before unplugging connectors from a component ground yourself to the ASU by t
47. 03574 are also Included in this illustration and bill of material Item No Part Number Description Qty 102710 Filter Block Top Assembly 1 1 N00181 O ring 014 6 2 N00185 O ring 018 2 3 N00753 1 8 NPT Level Seal Plug 1 4 N00187 O ring 020 2 5 N00754 1 4 NPT Level Seal Plug 3 6 103626 3 8 BSPP Plug 2 7 102712 Filter Block Insulator Plate 1 8 102717 Check Valve 655 Cart 1 way 2 9 NPN M8 1 25 x 90 SHC Screw 6 10 803173 1 2 BSPP Plug 803984 06 804155 08 803142 12 hose fitting 2 108928 Manifold Sub Assembly 1 11 112667 O ring 124 2 12 78 282 0 1 8 Drive Screw 6 13 N02969 Pin Spring 125 x 1 2 14 105099 MS8 x 25 SHC Screw 2 15 N07429 M8 1 25 x 30mm 6 16 006G112 Cap Adjustment Screw 2 17 012E002 Pressure Relief Spring 2 18 109244 Pressure Relief Adjustment Screw 2 19 109245 Bullet Hi Pressure 2 20 112666 O ring 122 2 21 104733 Plug Pressure Transducer 1 2 20 4 22 078D027 3 4 16 Jam Nut 2 23 101246 Filter Basket 40 Mesh 2 24 102711 Filter Block 1 25 102713 Filter Block Heater Retainer Plate 1 26 102714 Pressure Relief Filter Plug 2 27 102715 Filter Plug Retainer Slide 2 28 N04349 Pin Spring 250 x 875 2 29 102716 Slide Housing Frame 1 30 102718 Filter Pull Clip 2 31 102719 Filter Preload Wave Spring 2 32 103770 O ring 5 005 2 33 103771 O ring 5 254 2 103571 Heater Control Section 240v 1 block 103572 Heater Control Section 240v 2 block 103573 Heater Control Section 240v 3 block 103574 Hea
48. 06 4 850 1301 6 1622 3 177 8 342 9 8382 320 68 1377 7 inches 59 31 33 46 51 24 63 87 7 00 13 5 33 12 625 54 24 Page 2 6 Description amp Specifications iTV Dynatec c 1999 Revised 3 01 DYNAMELT M ASU Manual 20 29 Total System Wattage Capacity Up to 8 Hose Zones 9600 w 9600 w 1200 w each Upto 8 Applicator Zones 9600 w 9600 w 1200 w each Up to 8 AUX Zones 16 000 w 16 000 w 2000 w each Maximum System Wattage mue 57 200 w Main Circuit Breaker Determination M ain circuit breakers vary depending on each unit s system configuration ITW D ynatec typically determines the main circuit breaker by the mains load for a system which by codes should be 12596 to 15096 of the maximum load If a customer later modifies his system by adding heads hoses auxiliary outputs etc the main breaker may need to be upgraded to reflect the increase in load To determine your existing main circuit breaker first determine if the ASU has been modified and the breaker upgraded accordingly If not and the breaker is original to the ASU you will find the main circuit breaker listed in the Panel Box Assembly PBA section of the indented bill of materials inserted at the back of this manual The main circuit breaker is the largest amperage cir cuit breaker listed in that bill of materials TW Dynatec c 1999 Installation Page 3 1 DYNAMELT M ASU Manual 20 29 Revised 3 06 Chapter 3 INSTALLATION Placing the DYNAMELT M ASU
49. 06182 Filter Nut 2 6 807796 Large Filter Basket 20 Mesh Option 2 807797 Large Filter Basket 40 Mesh Option 2 807798 Large Filter Basket 80 Mesh Option 2 807800 Large Filter Basket 120 Mesh Option 2 807799 Large Filter Basket 100 Mesh Option 2 7 806188 Filter Retainer Plate 2 8 006G064 Block Pressure Relief 2 9 006G078 Spring Pressure Relief 2 10 012G001 Relief Piston 2 11 012G010 Pressure Relief Screw 2 12 0480141 Junction Box 1 13 048D142 Cover 1 14 N00220 Snap In Hole Plug 1 15 048J022 3 8 St Conduit Fitting 1 16 806206 O Ring 333 2 17 104733 1 2 NPT Level Seal Plug 4 18 006G112 Cap Adjustment Screw 2 19 078A005 10 24 x 1 2 SHCS 4 20 N04458 1 4 Dowel Pin 4 21 00838 3 8 16 x 1 1 4SHCS 8 22 00839 3 8 16 x 1 3 4 SHCS 4 23 078A164 10 24 x 1 2 HHSMS 1 24 07790 3 8 16 x 4 1 4 SHCS 4 25 078A337 3 8 16 x 5 1 2 SHCS 4 26 078A379 1 4 20 x 4 1 2 SHCS 6 27 078D027 3 4 16 Jam Nut 2 28 078C005 Flat Washer 8 SAE 4 29 0780021 Flat Washer 88 x 1 0 x 13 1 30 101833 10 32 Tamper Proof Screw 2 31 807188 Plug Drain 2 32 N00754 Level Seal Plug 1 4 4 33 00755 3 8 18 Level Seal Plug 2 807179 Heater Control Section 1 34 036A079 Heater 5 8 x 10 240v 1000w 3 35 036B013 T Stat Cartridge N C 1 2 Dia 1 36 106174 Sensor Adapter 1 37 N07958 Temperature Sensor 1 38 807543 Hi Volume Filter Nut Cover Assembly Option 2 39 807542 Cover Plate 1 40 00817 1 4 20 x 1 25 SHC Screw 4 Tv Dynatec c 1999 Componen
50. 099 N02745 N07677 N08236 110504 110503 N00093 N00753 101692 106198 iTW Dynatec c 1999 DYNAMELT M ASU Manual 20 29 Description Coupling Half Pump Side Option not part of this assembly Coupling Center Option not part of this assembly Drive Assembly M70 M140 M210 M6 1 0 x 25mm Coupling Half Motor Side Shaft Gearbox 20 1 Front Drive Assembly 106660 Shaft Gearbox 20 1 Front Drive Assem 106660 4 5cc pump Shaft Rear Drive Assembly 106663 Gear Box 20 1 Key 1 4 Sq x 75 Ring Clip Motor Mounting Bracket Bolt M8 x 40mm Ser Fl Screw Nut Motor AC 3P 240v 1HP K256 Flat Washer M6 External Tooth Lock Washer M6 5 16 18 x 3 4 SHC Screw 5 16 Lock Washer 5 16 Flat Washer Adapter Plate 3 8 16 x 1 HHC Screw 8 1 25 x 40mm SH Set Screw Optional Pneumatic Clutch Assembly Solenoid 120V 3 way Cord Grip 1 8 1 4 1 8 Hex Nipple Clutch Kit 56C In line Fitting Elbow 90deg Brass Muffler Pneumatic Exhaust 1 8 NPT Tubing TFE 25 OD x 125 ID cable 18ga 3C SV Optional Clutch Air Manifold Assembly Air manifold Fitting 1 4 tube x 1 8 NPT 1 8 NPT Level Seal Plug M4 0 7 x 35mm SHC Screw Lockwasher 4mm Qty RP RP rR Re A Ahe FC NN FPN WR e e gt m E 10 RRP NR Ty Dynatec c 1999 Component Illustrations amp BOM s Page 10 15 DYNAMELT ASU M Manual 20 29 Revised 12 03 To Heat Barrier Panel S
51. 1 5 Zone Configuration for Hose Head Aux n sa E M35 Q n DE Hose 5 8 Hose Hose Head 6 9 Head p Head Aux E 10 Aux Aux Hose 5 8 Hose Hose 50 Head 6 9 Head 4 Head 51 Aux 7 10 Aux Aux 32 Hose Hose 11 Head Head 12 Aux Aux 13 Hose 11 14 th 21 24 27 Hose 11 30 Head 12 15 22 25 28 Head 12 31 Aux 15 16 1 23 26 29 Aux 13 22 Hose 11 1 Head 12 Aux 13 NOTES There are no odd hose numbers in the predefined defaults If for example 5 hoses are installed the default has to be loaded for 6 If necessary remove hose 6 manually from the zone table Hose 11 Head Aux ii Indicates the division line between the two hoppers if Dual hoppers 5 are installed These zone numbers are independent from number of pumps and premelt grids TV Dynatec 1999 DYNAMELT M ASU Manual 20 29 and 20 30 PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 1 of 3 Page 11 8 Schematics Revised 7 07 T Dynatec c 1999 DYNAMELT M ASU Manual 20 29 and 20 30 9 3NOZ A004311 3Noz o1883113 v 3NOZ A009414 3NOZ NAN 908d 61 3NOZ NAW 90d 2 3NOZ LIAN 903d 9 MLN S ML v MIN C HL E anale dnd 9 3NOZ 901883Il4 02 3NOZ 5900 1883lT1J 3NOZ 520 18M3L I3 3NOZ LIAW 90 61 3NOZ LIAW 3NOZ 113 90d
52. 1 Module DN 160 Drive 802693 M odule SLC A nalog 8 Input 802694 M odule SLC DC 32 Output 802711 Power Supply 15V DC 40 802109 Drive AB 160 240 VAC 3P 1HP 804914 Drive AB 160 480 VAC 1HP ACG 3 Fuse SLC Power Supply locally available 1747 BA Battery SL C Processor locally available from AB EA EA EA NO PO NJ O rings N00181 O ring 014 outlet filter manifold 16 6 per manifold 69X 133 O ring 124 outlet filter manifold 2 per manifold N00185 O ring 018 outlet filter manifold 2 per manifold N00187 O ring 020 outlet filter manifold 2 per manifold 069X 275 O ring 122 outlet filter manifold 2 per manifold N00199 O ring 114 outlet filter manifold 2 per manifold 103770 O ring 5 005 outlet filter manifold 2 per manifold 103771 O ring 5 254 outlet filter manifold 2 per manifold N00192 O ring 032 4 N00173 O ring 006 2 807729 Pump Shaft Seal Zenith TSHA pump models 2 per pump 069X 061 Pump Shaft Seal optional ITW Dynatec pumps 2 per pump 069X 289 Pump Shaft Seal Hi Flow pump models 2 per pump see Pump A dapter O rings 1 of each per pump Filters 101247 Filter Basket 100 mesh 2 per manifold 101246 Filter Basket 40 mesh optional 2 per manifold 006C 156 High Flow Filter Basket optional 2 per manifold 109482 Filter Basket 200 mesh optional 2 per manifold 105968 Filter Shutoff A ssembly Right
53. 101 M6 x 16mm SHC Screw 4 13 107390 M6 Hex Nut 8 14 009E006 Swivel Caster 2 15 009E009 Rigid Caster 2 16 101074 Receptacle 8 17 103866 Bracket Connector Bank Amphenol 4 18 108296 M8 HHC screw 4 19 8 Star Washer 4 20 106321 5 16 Flat Washer 4 21 106111 M4 x 12 BHC Screw 16 or 64 22 101304 Blank Plate Dual 0 1 or 7 23 104279 Blank Plate Single 4 24 105111 M3 Nut 0 4 or 16 106048 Lid Assembly 2 25 105117 M4 x 8 Pan Head Screw 4 26 106236 4 Star Washer 4 27 106876 Retaining Clip 2 28 106319 M6 Star Washer 4 29 105865 M6 Hex Nut 4 30 106772 Inner Hinge 2 31 106773 Outer Hinge 2 32 105152 M3 x 6mm PHLC Screw 6 33 106892 M3 Flat Washer 6 34 Hinge Hopper Lid 2 35 106770 Heat Deflector 1 36 106771 Collar Hopper 1 37 101842 Handle Hopper Lid 1 38 106769 Lid Hopper 1 39 806399 Lid with level cnt mnt 807141 Lvl Cnt Assm option 1 Revised 11 03 Component Illustrations amp BOM s Page 10 13 DYNAMELT M ASU Manual 20 29 Tv Dynatec 1999 Component Illustration DM M140 Cabinet Assembly Page 10 14 Component Illustrations amp BOM s Revised 12 04 Bill of Materials for DYNAMELT M70 140 AC Drive Assembly 106660 Front 106663 Rear Special Item No 1 2 Part Number 106874 106875 104663 106714 106658 108018 106661 106662 109226 106754 106659 107602 105060 801679 106324 106319 N00732 N00933 N00687 106342 078A183 106341 808916 030A014 048J184 072X004 106877 N00
54. 1800 279 Lbs 279 ibs 655 Lbs 655 Lbs Based on 10 000 hrs average and using 50 psi air TABLE 1 Appendix 42 Revised 12 99 Pneumatic Clutch cont LUBRICATION NOTE iTWDynatec 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumaticaliy actuated devices require clean pressure regulated and lubricated air for maximum performance and long The most effective and economical way to lubricate Horton Clutches and Brakes is with an Alr Line Lubricator which injects oil into the pressurized nir forcing an oil mist into the air chamber Locate the lubricator above and within ten fest of the Clutch or Brake and use a low viscosity such as SAE 10 Synthetic Lubricants are not recomended 1 UBRICATOR DRIP RATE SETTINGS NOTE These settings are for Horton supplied lubricators If you are not using a Horton lubricator calibration must replicate the folowing procedure i Close and disconnect the air fine from the unit 2 Tum the Lubrsicator Adjustment Knob clockwise three complete tums 3 Open the air line 4 Close the air fine to the unit when a drop of forme in the Lubricator Sight Gage Connect the air ine to the unit 6 Tum the Lubricator Adjustment Knob counterclockwise ama closed 7 Tum the LubricetorAdjustment Knob clockwise one third um 8 Open the ai line to the uni U aa A
55. 2000w Zone4 Grid 4 standard 2500w Zone 5 Hopper 1 standard 5000w Zone 6 Hopper 2 standard 5000w Zone7 Primary Filter 1 standard 1000w Zone 8 Primary Filter 2 standard 1000w Dynamelt M70 140 Layout of Pumps amp Hopper Temperature Zones View from Pump Side iTV Dynatec c 1999 Installation Page 3 5 DYNAMELT M ASU Manual 20 29 Revised 8 99 Filter Nut Electrical Connections F1 1 1 Closeable Cross Channel Tamper Proof Screw Bleed Valve Port Heater Channel Retgmer Plate f RTD Sensor Channel Purge Drain Hose Head Electrical and Adhesive Connections Head Hose OO 9 9 OG Connects Return Hose Electrical Al A2 Connects O 511 512 Adhesive supplied Adhesive supplied Adhesive supplied Adhesive supplied by motor pump 1 by motor pump 2 by motor pump 3 by motor pump 4 Up to Four Filter Blocks with up to 16 Adhesive Ports Note Always connect Auxiliary Return Hose 1 A1 to Auxiliary Electrical Connect 1 A1 Feed Hose 1 F1 to Feed Electrical Connect 1 F1 etc as described on page 3 3 Dynamelt M70 amp M140 Electrical Connection and Filter Manifold Arrangement for Maximum Head Hose Configuration Page 3 6 Installation iTWDynatec 1999 Revised 4 00 DYNAMELT M ASU Manual 20 29 Adjusting the Pressure Relief Valve The function of the pressure relief valve is to protect the gear pump s and the pump drive compo nents from overload and to p
56. 5865 M6 Hex Nut 4 28 106772 Inner Hinge 2 29 106773 Outer Hinge 2 30 105152 M3 x 6mm PHLC Screw 6 31 106892 Flat Washer 6 32 105101 M6 x 16mm HHC Screw 2 33 Hinge Hopper lid 2 34 106770 Heat Deflector 1 35 106771 Collar Hopper 1 36 101842 Handle Hopper Lid 1 37 106769 Lid Hopper 1 38 806399 Lid with level cnt mnt 807141 Lvl Cnt Assm option 1 39 808682 Optional ASU Leg Assembly 5 5 1 40 106321 Washer Flat M8 9 x 17 x 1 6 12 41 108297 8 1 25 x 20mm HH Ser Fl 12 42 808778 Leg Machine Support 5 5 4 43 810716 Lid Blank option for one split hopper 44 805026 No Filter Cover Plate option for one split hopper Revised 12 03 Component Illustrations amp BOM s Page 10 11 TV Dynatec 1999 DYNAMELT M ASU Manual All M70 140 Models Component Illustration DM M70 Cabinet Assembly Page 10 12 Component Illustrations amp BOM s ITV Dynatec c 1999 Revised 12 04 DYNAMELT M ASU Manual 20 29 Bill of Materials for DYNAMELT M140 Series Cabinet Assembly 106046 Item No Part Number Description 1 101843 Handle Side Panel 4 2 105880 Panel Top Bracket 1 3 105887 Access Cover M140 2 4 105979 Rear Cover M140 1 5 107890 Manifold Cover 2 108128 Manifold Cover Hi Flow Only 6 105891 Base Plate M70 140 1 7 105882 Top Panel M70 140 1 8 105976 Heat Barrier Panel Box M140 1 9 101853 Lower Manifold Cover 2 10 802657 Panel Box 1 11 802665 Mounting Bracket PV600 1 802755 Mounting Bracket PV550 1 12 105
57. 9 DVA OZT OT aunssai d jeuondo 9T eandu 6ojeuy 9T ET ALY ZL 6 8 lt a u jeuonippy jeuondo O9 I9 DYA OZT p ejnssaJug jeuondo OZ LT 3nduj 6ojeuy 9 E GLY ZE ecandu adu 8c sc andu a u P Layout of Components DM M210 SLC Modules iTV Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 DeviceNet Communications Module Troubleshooting Page 7 7 Revised 1 99 The SLC 500 system utilizes DeviceN et to communicate with the A SU s drives D eviceN et oper ates via two modules the scanner module which is a card on the SLC 500 rack and the D eviceN et module s which is mounted on the drives Theillustrations below provide a brief description of the LEDs and connections For more detail refer to the Allen Bradley DeviceN et manual STATUS MODULE NET Green network is ON Refer to trouble shooting guide on the following pages to interpret display Green Oo LJ scanner module ADDRESS ERROR Scanner Module Layout Red unrecoverable fault Flashing Red 1 0 connection timed out Green DeviceNet is ON and allocated to a master Flashing Green DeviceNet is ON but not allocated to a master Red drive is faulted DeviceNet Green drive is ON READY FAULT UU OU Terminals left to right Black wire Green wire Scanner wire White wire Red wire DeviceNe
58. BOM s Revised 8 99 Tv Dynatec 1999 DYNAMELT M ASU Manual 20 29 Bill of Materials for Typical Electrical Panel Box Assembly 802704 Cont from pg 4 Item No 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Part Number 048F 159 103063 103183 103184 103425 103819 104207 104391 104392 105251 105252 105253 105254 105255 105256 105260 105261 105263 801684 801688 802100 802101 802109 802110 802111 802599 802693 802694 802695 802711 802697 102286 102956 103099 105288 105288 TBD Description Terminal Rail 14 Circuit Breaker 15A 60F 240V 1P Fuse Block Lever Open Fuse GDC4 250VAC Terminal Rail 22 Transformer Circuit Breaker 15A 60F 240V 2P Circuit Breaker 20A DP Circuit Breaker 30A DP Terminal Block Dual 10A End Plate for105251 Terminal Block Single 20A End Plate for105253 Terminal Block Ground End Stop Distribution Block Relay 120v w socket Contactor 3P 600V 120V RTD 1746 NR4 1 0 12 SLC SLC Device Net Drive AB 160 240v 3P 1HP Power Supply AB Module AB DN 160 Dr Filter 160 Drive 240v 3P M odule SLC A nalog 8 Input M odule SLC DC 32 Output Rack 13 Slot Power Supply 15V DC 40w Rack 4 Slot Harness A ux Head not shown Harness Hose H ead 8 not shown Harness
59. CLE IRE 8 3 Relay Removal URS esa sa XC E RR ROO Re 8 3 SEC 500 M odule RemoVal 5 e n RE Rr AR n ER tut aa RT Nc ae Es 8 3 To Access Pump or Motor 2 2 2 8 4 Motor RemoVal 55 scite Saee tot lhe Rd ana 8 4 PUMP Removal ekz Sei al ls Bole PRESSE Rb br els 8 5 Pump Seal O ring Replacement 8 5 Re assembly Procedures amp lt 8 5 Chapter 9 Available Options amp Accessories Pressure Gauge KE rete dete etes cede co pete ede ates 9 1 Pre PSI and Post PSI Transducers 9 1 pia scere SA hats a 9 1 High Temperature Heater GroupS 9 1 Filter Options amp Accessories 9 1 Pump Options amp A CCeESSorieS esis duis eade Ro so e a e e RO e olt E a ocn ols 9 1 Return Re circulating HOSES 2 222 9 2 Pneumatic Gluten zo ee ER ates ee hal EC EE pide vere bane td 9 2 Level Conto MP 9 2 Pressure Transducer Assembly 9 3 D al HOpDer
60. Controller Set Up Requirements siaren a iaa ei eaea Em 4 1 Temperature Control Functions in General 4 1 Defining Temperature Control Terms 4 2 Error Indication Alarms x us tees Palris donet Tarde d ade is 4 4 Settings for a Typical 4 4 Chapter 5 Programming of Controller CFEENS IN UU 5 1 Main Menu Screen cie ease pool pac pacto aaa a e 5 2 Use of M ain M enu System Status Screen 5 3 Temperature Menu Screen 5 4 Page iv Table of Contents iTWDynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 29 Setpoint Entry Programming Screen s 5 6 Adhesive A pplication Unit s A SU s Motor Menu 5 5 8 Motor Programming Screen 5 10 Adhesive Pressure M onitoring Screen 5 12 Setup us P a 5 14 Seven Day Scheduler Programming Screen 5 16 PanelView Configuration Scr
61. Disconnect and lock out input power to the application system using the lockout safety illustrated above before starting any installation procedures Make sure there is no electrical power on the leads you will be connecting Main Disconnect S witch Main Circuit Breaker Ground PA 2 Required Customer Wiring On the insert within the panel box assembly a Connect 3 electrical leads with the appropriate voltage to the main circuit breaker b Connect one electrical lead to the ground PE lug CAUTION Grounding conductors never carry electrical current The use of a neutral conducting wire as earth ground is incorrect and may cause damage to the DYNAMELT controller ITW Dynatec c 1999 Installation Page 3 3 DYNAMELT M ASU Manual 20 29 Revised 5 07 3 Optional Customer Interface Wiring a The I O terminals provide for remote monitoring of an alarm condition A source voltage occurs when any alarm is activated Alarm terminals are binary on off I Os and are located on the Allen Bradley rack in the panel box assembly Refer to the schematics and layout drawings in Chapter 11 for details b The optional LEVEL CONTOL terminals provide for remote monitoring of level control conditions Level Control terminals are binary on off I Os and are located on Allen Bradley module rack in the panel box assembly Refer to the schematics and layout drawings in Chapter 11 for details c The LINE SPEED terminals for Au
62. F the ASU s M ain Disconnect Switch Note If the Seven D Scheduler is employed turn off with eater Power key only Storage and Disposal of the DYNAMELT M Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN L 15653 following the instructions detailed in chapter 6 of this manual 2 Clean or replace both the outlet filter and the primary filter following instructions detailed in chapter 6 3 Shut OFF all pressure and power sources 4 Release residual air pressure if applicable 5 Remove all residual adhesive and wipe components clean 6 Remove all air lines if applicable and all power supply cables 7 Pack the unit in a corrosion proof manner 8 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 Release residual air pressure if applicable 3 Remove all residual adhesive 4 Remove all air and adhesive hoses and all power supply cables 5 Dismantle all components and sort into mechanical and electrical components 6 Arrange for all components to be recycled iTV Dynatec c 1999 Controller Set Up Page 4 1 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 1 99 Chapter 4 CONTROLLER SET UP PLC Logic Requirements IMPORTANT NOTE To Customers who supply PLCs programmable logic computers to operate ITW Dynatec adhesive application systems ITW Dyna
63. FF 38 1 10 HRS Program a Standby delay HHF or C Program a Standby temperature reduction value Seven Day Scheduler Press to procede to Seven Day Scheduler programming M ain Return to the M ain M enu Programming 1 Press Temperature Pressure Units to choose Celsius BAR or Fahrenheit PSI 2 System Standby Programming Standby is a temperature value by which all temperature zones will lower when Standby mode is activated For example if your temperature setpoints are all 300 degrees and you program a 100 degree Standby then the Standby temperature of all zones will be 200 degrees Similarly if your temperature zones setpoints vary and you program a 100 degrees Standby each zone s Standby temperature will be 100 degrees lower than its setpoint Standby must be programmed for the length of time before which these lowered temperatures start To Program a Press 1 10 HRS to enter the number of tenths of a hour the system will delay before going into the standby condition 0 500 Press Enter Examples A Programming the number 10 here results in 1 hour delay 10 10 hour 1 B Programming the number 4 here results in 24 minutes delay 4 10 hour 24 b Press or C to enter the number of degrees below temperature setpoints desired for your standby temperature 0 200 degrees Press Enter c Toggle OFF ON to turn System Standby ON or OFF Press Enter Notes W hen Standby is active i e ON and standing by all th
64. IR CONNECTIONS NOTE For quick response Horton recommends a quick exhaust valve and short air lines between the Control Valves and the Modular Units Allan the air intet ports to a down position to allow condensation to drain out of the the air chambers of the Modular Units Adjust the air pressure to approximately 50 psi 3 45 bar when the Modular Unit is installed between a motor and gear reducer When the Modular Unit is mounted using sheaves or Sprockets the air pressure may be regulated between 10 psi 0 7 bar te 80 ps 5 5 bas to ensure air pressure is adequate for torque requirements CAUTION Low air pressure will cause slippage and overheating Excessive air pressure will cause abrupt starts and stops reducing Modular Unit cont iTV Dynatec c 1999 Appendix 43 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 99 Pneumatic Clutch cont TROUBLESHOOTING contaminated Friction Facings Replace the Friction Facings Appendix 44 iTV Dynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 iTV Dynatec c 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont MODULAR OUTPUT UNIT MOU FIGURE 20 Models 1125 and 1375 1 Bend back the tabs on the old Keyed Washer Item 55 and remove the Lock Nut 56 and Keyed Washer See Figure 20 Fully support the Housing item 3 and press the Disc Journal Item 8 out of the Housing See Figura 20 Using a be
65. ITW Dynatec ITW Dynatec GmbH OPERATIONS amp SERVICE MANUAL An Illinois Tool Works Company Industiestrasse 28 31 Volunteer Drive D 40822 Mettmann Germany 4 se Hendersonville TN 37075 USA Telephone 49 2104 915 0 evise Telephone 615 824 3634 FAX 49 210 2104 915 111 FAX 615 264 5222 ITW Dynatec K K Daiwashinagawa Bldg 7 15 Konan 3 Chome Minata Ku Tokoyo 108 Japan iTwDynatec ORT M Adhesive Application Solutions ISO 9001 Certified DYNAMELT M SERIES ADHESIVE SUPPLY UNIT OPERATIONS AND SERVICE MANUAL JULGE Models DM M70 amp M140 PLC For an online of this manual to www itwdynatec com manuals htm 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 serial number 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 need ITW Dynatec Service Parts Direct Dial 1 800 538 9540 ITW Dynatec Technical Service Direct Dial 1 800 654 6711 Moving Forward Through Technology Page ii iTWDynatec 1999 Revised 12 04 DYNAMELT M70 140 ASU Manual 20 29 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application S ol
66. LN x coraan A e a X CLE TOES TOC UE GORGE THESIS esre 20 45225 WH d 285 WH NAST 826 Act 5 155 Hv3 314 0 45 910091550 314 4 1 321 d Hd 30111 LWN H 9318171 dHnd Ted MH 9270 di N3HIVINS Was 52078 DMIMV3I 11089 STS OF 831832 amp 90 ae 537978 4 3104 23 FOH 062 4 SW EAS UEAK eRe Aut 1 C002 00 637 446390 4 E263 vGD ANd pya Houpg vy LUYHO 2 TwDynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 VOLUMETRIC EFFICIENCY Appendix 34 Revised 10 99 HIGH ACCURANCY PUMP PERFORMANCE ge i aan m S 084E 436 084E376 1 752 cc rev MI 084E 430 084E 432 1 168 cc rev O84E 388 084E 374 084E 387 O84E 428 O84E 389 160 cc rev 297 cc rev 584 cc rev 01 02 05 10 2 5 1 0 VOLUMETRIC EFFICIENCY FACTOR M A P DIFFERENTIAL PRESSURE PSI U APPARENT VISCOSITY CENTIPOISES RPM ITW Dynatec c 1999 Appendix 35 DYNAMELT M ASU Manual 20 28 20 29 20 30 and 20 50 Revised 1 07 PN 804467 805942 Pressure Transducer INSTRUCTION SHEETS for Standard Melt Pressure Transmitter ISI 0130 0131 O132 Oil Filled Melt Pressure Transmitter ISI 3130 3131 3132 4 20 mA Output In
67. Low inlet pressure cavitation Check process High outlet pressure slippage Check process Appendix 52 iTV Dynatec c 1999 Revised 5 04 DYNAMELT M ASU Manual 20 29 and 20 30 Cleaning Before removal from machine the pump should be rotated for a short period with inlet supply shut off to discharge process fluid Care should be taken when removing and stripping the pump to allow for any residual fluid Pump components can be solvent or ultrasonically cleaned by im mersion using a compartmentalized wire baset Dry in air Stubborn residues may be removed with a brass wire brush Avoid burnishing the sharp edges of gear and gear races Fluid immersion in rust inhibitor is advised If components are to be stored for some time they should be lightly smeared with oil Maintenance Tightening Torque for High Tensile ISO 12 9 Lubricated Bolts 300 C max Bolt Size amp Qty Bolt Location Torque Nm Ft lbs M5 4 retainer cap 7 1 5 2 M 10 12 4 mounting bolts 41 30 at ambient temperature M 10 12 4 mounting bolts 24 18 at production temperature Notes If mounting bolts are torqued at production temperature they should be re torqued to 41 Nm 30 Ft Ib when machine is at ambient temperature 1Nm 8 85 in Ibs Torques given above are for M etric and UNF threads M ultiply by 0 8 for UNC and BSF threads M ultiply by 0 8 for BSVV threads multiply by 0 67 for stainless steel ITW Dynatec frequently provides special features
68. ON all system heaters go ON unless they have previously been turned OFF Page 5 22 Programming iTVW Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 1999 Preventive Maintenance Page 6 1 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 7 99 Chapter 6 PREVENTIVE MAINTENANCE Note Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance procedures must be performed by qualified trained technicians General Cleaning The DY NAM ELT9 M SERIES ASU enclosure is finished with an extremely durable polyurethane paint The enclosure may be cleaned with a variety of industrial cleaners following manufacturers directions To prevent discoloration or deterioration of the A SU s finish avoid prolonged contact with strong solvents The molded plastic handles may be cleaned with mineral spirits Preventive Maintenence Schedule The Dynamelt M ASU requires little maintenance T he hopper is fitted with a coarse screen to pre vent large debris from entering the system Normally this screen does not require cleaning The ASU parts that require regular periodic maintenance are as follows Replacing the Outlet Filter Basket The outlet filter should be replaced monthly during the first few months of operation After you gain experience with your system you can determine how of
69. PU s clock which must be synchronized to be reset The clocks are automatically re synchronized whenever all of the scheduler s eight days M onday through Sunday plus Everyday are turned OFF Even when the clocks are in sync their times may read up to a couple of minutes difference iTV Dynatec 1999 Programming Page 5 17 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the Seven Day Scheduler Programming Screen Press This To Function Key Next Select next day Prev Select previous day System ON Hour Program a desired turn ON hour System ON Minute Program a desired turn ON minute System OFF Hour Program a desired turn OFF hour System OFF Minute Program a desired turn OFF minute System ON Hour Program a second desired turn ON hour System ON Minute Program a second desired turn ON minute System OFF Hour Program a second desired turn OFF hour System OFF Minute Program a second desired turn OFF minute ON OFF Toggle the Seven Day Scheduler ON or OFF for this day Return Return to the Main Menu Programming Up to four events may be scheduled for each day An event is a programmed ON or OFF time 1 Press Next or Prev to choose the first day you desire to schedule 2 Hours and minutes are programmed in two steps as follows a Press the first Hour key to program a desired ON hour 1 Use the numeric keypad to enter desired time of day use 24 hour day military time ii Press the Enter
70. Sheld dran wire is bed to cocnector cable camp Wiring Key A Signal Plus Red B Signal Minus Black E R Cal Blue F R Cal Brown Wiring Key Signal Plus Red D Signal Minus Black E R Cal Blue F R Cal Brown 013X 313X4 20ma Transmitter 12 27 00 TWDynatec 1999 Appendix 37 DYNAMELT M ASU Manual 20 28 20 29 20 30 and 20 50 Revised 1 07 PN 804467 805942 Pressure Transducer cont NPT Wiring S Shield See note 2 below Wiring Key S Signal Plus Red a Transmitter ae 52221 Ee m ALCUN UBERON SON RENE OER R Cal Brown Shield drain wire is terminated intemally to the transmitter body Power Supply Instrument or Readout Transducer Connector 1 2 14 NPT R Cal 2 Under normal conditions the transmitter will operate normally with the cable shield not terminated at the instrument end of the cable However in high frequency RF environments it may be necessary to connect this shield to ground 3 The power supply and instrument loading requirements are Transmitter Output 4 20 mA Power Supply Input 18 36 VDC 24 VDC recommended Instrument Load 1200 Ohms max 36 VDC 600 Ohms max Mounting Hole Dimensions 17 MAX 7 MIN FULL THD Appendix 38 iTWDynatec c 1999 Revise
71. a for assembly testing and storing of rebuilt pumps If maintenence is required due to low delivery or seizure the following procedure is recom mended for disassembly NOTE sure to note the location and orientation of all parts to ensure correct re assembl y Refer to assembly drawing located in the back of this manual for your correct pump type 1 Remove the seal arrangement 2 Remove all binder screws 3 Remove pins 10 and arbor 5 with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Dowels and arbors for the standard accuracy pumps are press fit in the gear rear plate 4 Separate the plates by pry slots that are available in the pump Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 5 After disassembly clean all components in a non destructive solvent 6 Wash components in an ultrasonic cleaning tank and air dry Be careful not to bang parts together 7 Inspect all parts for nicks burrs score marks and other signs of wear The plates and faces of the gears may be hand blocked on 600 grit paper and any nicks burrs or sharp edges can be lightly removed with a honing stone Be careful notto round off the edges of the gear teeth while lapping CAUTION Sincethe thickness relationship between the metering gears and the gear rear plate is critical to metering performance and the gear rear plate is non wearing
72. a regular basis we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt pumps If maintenence is required due to low delivery or seizure the following procedure is recom mended for disassembly NOTE note the location and orientation of all parts to ensure correct re assembl y Refer to assembly drawing located in the back of this manual for your correct pump type 1 Remove the seal arrangement 2 Remove all binder screws 3 Remove dowels 10 and arbor 5 with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Dowels and arbors for the high accuracy pumps are press fit in the rear front plate 1 and slip fitin the center 2 and side plates 3 cont iTV Dynatec 1999 Appendix 21 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 4 Separate the plates by pry slots Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 5 After disassembly clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning Alternative non destructive cleaning methods such as Water jet or solvents are also acceptable 6 Wash components in an ultrasonic cleaning tank and air dry Be careful not to bang parts together 7 Inspect all parts for nicks b
73. a universal maximum temperature for all zones The programmer cannot program a tempera ture setpoint higher than the setpoint limitation Seven Day Scheduler A controller feature that provides for the scheduling of OFF and ON times events for the adhe sive application system It therefore allows the operator to program heating cycles which coincide with the work week s production schedule The scheduler also helps conserve electricity and func tions as an additional safety feature Standby The system condition where the ASU hose and head temperatures are maintained at predetermined reduced temperatures Standby temperatures are set lower than setpoint temperatures in order to re duce adhesive degradation and energy consumption when the system is temporarily inactive and to permit rapid system warm up when run condition is selected Page 4 4 Controller Set Up iTVW Dynatec 1999 Revised 1 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Temperature Zone Enable The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not ever appear on the controller s display and heating is switched OFF Trim Percent The desired ratio of the parent machine s pump motor speed to the external reference percent as programmed Used in the controller s Auto mode only Error Indication Alarms The conditions that will trigger an alarm are When a hopper hose or head has exceeded its selected over
74. al groove 6 Before re assembling wrap a small piece of paper around the shaft so that the shaft s woodruff key seat does not damage the new seal 7 Re assemble R emove paper 8 Re tighten four screws 9 Re connect drive coupling 10 Return ASU to operation and check pump for leaks Appendix 54 TW Dynatec 1999 Revised 3 05 DYNAMELT M ASU Manual 20 29 and 20 30 Rebuild Kit for 8 5 TSHA Pump PN 111939 The rebuild kit for the PN 108875 8 5cc TSHA pump consists of the following parts Description Description 111699 Drive Shaft 111707 Retaining Ring 111699 Idler Shaft 111709 Screw 10 24 111701 Bushing Front Plate 807729 Pump Shaft Seal 111702 Bushing Back Plate 111705 Key 111704 Dowel 0781001 Key Woodruff ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions
75. allows remote interface over a much longer distance than the RS232 connection RTD Sensors The standard Dynamelt system uses 100 ohm platinum resistance temperature detector sensors RTDs to read temperatures for all the system s temperature controls As an option the unit can be configured for 120 ohm nickel sensors Ready Temperature The programmable temperature which allows the ASU pump to turn ON The ready temperature range is a deviation x from the setpoint The setpoint minus the deviation 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 with out 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 optional drop in grid heats up Hoses and applicators may be independently programmed If hopper temper ature is above ready temperature when the ASU is turned ON the hose and applicator sequence 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 Setpoint A user selected temperature that has been programmed for each heating zone of the adhesive ap plication system Setpoint Limitation This is
76. alog input card see panel box layout in Chapter 11 3 A To install a tach generator i Verify the tach generator s voltage polarity and connect it to the analog input card s terminals per the schematic in Chapter 11 ii Verify that the gear pump motor is running at full speed when set to 10096 in MANUAL mode this is normally 180 V DC at the pump motor armature The output of the tach generator can be adjusted depending on the application but it must be at least 10 V DC to obtain full adhesive gear pump speed Note under no conditions will the motor ever run faster than this speed 10096 M anual B To install a similar DC tracking device not a tach generator Connect the DC tracking voltage signals to the A llenB radley analog input card per the schematic in Chapter 11 Note the tracking voltage must be at least 0 10 VDC but not more than 0 25 VDC 4 Close the ASU s panel box door 5 Re connect input power and restore the application system to normal operation Page 3 10 Installation iTVW Dynatec 1999 Revised 5 01 DYNAMELT M ASU Manual 20 29 Optional Level Controls The level control device informs the A SU s operator via a Level Low or Level High mes sage on the controller s System Status display that the A SU s hopper needs to be refilled or that itis overfull It may also be wired to stop production Single Point Level Control The single point level control monitors either a low or a high adhesive level Th
77. alves or flexible elements to hinder performance Precision Construction Ground and lapped components for close control of operating clearances iTV Dynatec c 1999 Appendix 3 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating Speed 3 120 rpm depending upon application conditions and fluid viscosity Temperature To 450 degrees F 232 degrees C OPERATION All Dynatec Zenith High Accuracy Pumps are rear ported Fluid enters the pump through a port drilled into the rear side plate the side opposite the drive shaft The fluid fills the ex posed gear tooth volumes and is transported around the outer diameter of the gear pocket As the gears mesh together the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate Since these pumps are not self priming a flooded suction is usually the minimum inlet pres sure required However when high viscosity fluids are used more time is required to fill the tooth volumes As a result the inlet pressure must be increased or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation D ynatec Zenith pumps rely on the metered fluid for lubrication of internal bearing areas The pump should never be allowed to run dry or be allowed to run with non lubricating fluids s
78. andard accuracy gear pump PN 109690 10 cc rev single standard accuracy gear pump PN 108875 8 5 cc rev single high accuracy gear pump PN 084E 374 0 584 cc rev single high accuracy gear pump cont Page 9 2 Options amp Accessories TwDynatec c 1999 Revised 9 07 DYNAMELT M ASU Manual 20 29 and 20 30 PN 084E376 1 752 cc rev single high accuracy gear pump PN 084E428 0 297 cc rev single high accuracy gear pump PN 084E430 1 168 cc rev single high accuracy gear pump PN 084E434 2 920 cc rev single high accuracy gear pump Dual Pumps Note all dual pumps require PN 102049 see below PN 100863 1 54 cc rev dual standard accuracy gear pump PN 100864 3 18 cc rev dual standard accuracy gear pump PN 084E389 0 584 cc rev dual high accuracy gear pump PN 084E432 1 168 cc rev dual high accuracy gear pump PN 108874 2 920 cc rev dual high accuracy gear pump Hi Flow Pumps PN 110289 20cc rev single gear pump TSHA PN 110290 30cc rev single gear pump TSHA PN 110291 45cc rev single gear pump TSHA Feinpruf Pumps Often preferred by the European market where they are readily available Gear Pump Repair Kit PN 103151 Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps Description Description N00198 O ring 069X064 O ring 018X031 Bearing 078F017 Ring Clip 069X061 Seal 0781001 Key Woodruff Return re circulating Hoses Available on all models Use of return hoses allows
79. anual 20 29 Bill of Materials for Assorted Pump Adapter Assemblies Item No A WYN 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 084E 406 0126024 069 058 00179 069 274 00190 078 130 NPN 084E 428 084E 374 084E 430 084E 434 108875 084E 438 084E 389 084E 432 108874 084 419 0126027 069 064 069 230 069 270 078 618 078 141 069 289 084 411 084 412 084 413 103923 103624 103924 00181 069 270 102927 103917 103918 103919 104351 Description TSHA Pump Adapter Assembly Pump A dapter O Ring 28 O Ring 12 Seal Dual Pump to Progmelt not part of this assembly O Ring 24 3 8 Washer 3 4 OD M 10 x 85mm SHC screw Zenith Pump THSA 297 cc Single Outlet THSA 584 cc Single Outlet THSA 1 168 cc Single Outlet THSA 2 292 cc Single Outlet THSA 8 5 cc Single Outlet THSA 30 0 cc Single Outlet THSA 584 cc Dual Outlet THSA 1 168 cc Dual Outlet THSA 2 292 cc Dual Outlet Zenith Pump Adapter Assembly Adapter Z Pump O Ring 041 O Ring 021 O Ring 025 Screw Pump M ounting 7 16 ss Washer 3 4 OD Drive Shaft Seal THSA Pump THSA 20 cc Single Outlet THSA 30 cc Single Outlet THSA 45 cc Single Outlet F einpruef Pump Adapter Assembly Adapter Plate O ring Plate O ring 014 O ring 025 O ring 133 Feinpruef Pump Feinpruef Pump 3 cc Feinpruef Pump 1 2 cc Feinpruef Pump 2 4 cc Coupling Half Not Shown See dri
80. aptive screw 5 Atthe keypad re set the hopper s temperature to its correct run temperature 6 Re program the controller s pump enable temperature to 107 C 225 F refer to Ch 5 Field Installation of Controller Options Customers who choose to modify their adhesive supply unit with ITW Dynatec or Allen Bradley manufactured options should assure that only qualified technicians perform such installations Before controller options are installed always turn the controller s main power switch OFF In most cases turning the controller OFF will assure that the controller will retain its programmed parameters and configuration R e booting is not necessary iTV Dynatec c 1999 Installation Page 3 9 DYNAMELT M ASU Manual 20 29 Revised 10 00 Installation of an Optional Tach Generator or a DC Tracking Signal The installation of a tach generator or a similar DC tracking signal allows speed tracking of the gear pump through voltage following M ultiple motors may be wired in parallel to the tach gener ator On the controller voltage following is referred to as the AUTO M ode of the motor control Installation Procedure DANGER HIGH VOLTAGE Dynamelt systems use electrical power that can be life threatening Disconnect and lock out input power to the application system before starting any installation procedures 1 Disconnect and lockout input power to the application system 2 Open the panel box and locate the Allen Bradley an
81. aspe as but please remember that there are many varieties of Zenith pumps in service If you have any questions about specific parts and their orientation always refer to the drawings and parts lists for your exact pump by type 1f you still have questions refer them to us at the factory 1 Introduction Zenith Melt Spinning Pumps are precision instruments requiring skilled and careful maintenance Constructed of high quality tool and die steels such as AISI types D 2 M2 and M 4 or other high performance alloys they are tempered atter heat treatment ta hardnesses ranging from Rockwell Scale 58 to 64 A Zenith Pump may be constructed from any one or any combination of these steels since their coeffi cients of thermal expansion are almost identical Zenith Metering Pumps consist of two or more gears housed within center and side plates Power is transmitted to the gears by the drive shaft which is either a through shaft as in the packing gland type of pump or a shaft with a tang that engages a universal seal coupling The coupling is both a connection to external power and the rotating member of a mechanical seal In order to develop the high pressures demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow ade quate lubrication Because of these close running clearances fin many cases as law 00257 Zenith Pumps require careful ma
82. at resist ant lubricant and install Torque the screws in even increments to the manufacturer s recom mended limit It is especially important to rotate the gears frequently during this operation 11 Re assemble the seal arrangement making sure the sealing surfaces are perfectly clean and free of scratches nicks or burrs W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 600 grit paper W hen using a carbon seal the coupling housing screws 27 should be torqued to the manufacturer s recommended limit For pumps with a compensation packing seal be sure all old packing is removed cont Appendix 8 iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 from the packing housing 12 Inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn Worn shafts will result in premature seal leakage and should be replaced 13 Inspect lip seals for wear cracks and abrasions Replace if needed 14 Pack lip seals 15 with a silicone based grease and lubricate with Parker Super O L ubricate or an equivalent silicone based oil 15 Install lip seals 15 into seal housing 9 as shown 16 Tighten seal housing screws 22 in a cross pattern to 60 Ibs in Check for free rota tion SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread Torque L ubricated T hreads UNC Alloy Steel L bs in Nxm Lbs ft 10 24 w carbo
83. ated below is the maximum module configuration for a fully loaded M odel 35 ASU AGC3 250v 3a 0 1 2 3 4 5 6 7 8 9 10 11 22 umper SLC POWER SUPPLY DeviceNet Adapter RTD Input 1 4 RTD Input 5 8 RTD Input 9 12 RTD Input 13 16 Terminals 1 Pwr Out 24VDC 2 Pwr Out Com 3 120 240 VAC 4 VAC Neutral 5 Chasis Ground Layout of Components DM M35 SLC Modules iTV Dynatec c 1999 Troubleshooting P age 7 5 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 4 02 Model DM M70 140 AllenBradley SLC Module Configuration Illustrated below is the maximum module configuration for a fully loaded M 70 or 140 ASU For SLC Power Supply s fuse size and terminal definitions see page 7 4 RTD Input 1 8 RTD Input 9 17 Analog Input 1 8 Analog Input 9 17 115 VAC Input Output Relay O 15 8 lt 2 gt 4 RTD Input 18 25 RTD Input 26 32 Solid State Relay DC Output 16 Solid State Relay DC Output 16 Layout of Components DM M70 140 SLC Modules iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Page 7 6 Troubleshooting Revised 9 99 AllenBradley SLC Module Configuration Model DM M210 Illustrated below is the maximum module configuration for a fully loaded odel 210 ASU For SLC Power Supply s fuse size and terminal definitions see page 7 4 ZE INGNO Da RAS pilos JOQUOZD pa Jeuond o O9 I9 DVA OCT O9 I
84. ating puller remove the old Ball Bearing Hem 28 trom the Housing ttem 3 See Figure 20 WARMING attention should be exercised when working Special with retaining rings Always wear safety goggles when working with spring of tension loaded fasteners or devices Remove the Spacer Item 12 and Retaining Ring Item 39 from the Housing ftem 3 Sea Figure 20 Press old Bearing Item 29 out of the Housing Item 3 See Figure 20 Remove the six old Fiat Head Screws Item 25 securing the old Friction Facing 9 to the Disc Joumal Item 8 and remove the oki Friction Facing See Figure 20 Using six new Flat Head Screws Item 25 secure a new Friction Facing ttem to the Disc Journal Item 8 See Figure 20 16 11 12 13 14 15 Appendix 45 Revised 12 99 Tighten the six flat Head Screws to 22 Lbs 2 50 torque Clean the Bearing Bore of the Housing ttem 3 with fresh solvent making sure all oid Loctite residue is removed Bee Figure 20 Apply an adequate amount of PE QUU idi coat ihe outer race of the Ball Bearing item and press the new Ball Bearing into the 3 See Figure 20 Reinstall the Spacer item 12 and the Retaining Ring tem 39 See Figure 20 Apply an adequate amount of Loctite 680 evenly coat the cuter race of the new Ball Bearing Item 28 and press the new Ball Bearing inte the Housing
85. bra sion resistance and it is the most economical of the three steels we most commonly use Type D2 will also provide a higher degree of corrosion resistance than M 2 or M 4 The portion of the side plate subject to the most wear is the shaft bearing hole which has an easily replaceable inexpensive sleeve bearing that can be made of the extremely wear resist ant Type M 4 tool steel Types M 2 and CPM M 4 steels are commonly used for the metering gears drive shaft and universal seal coupling due to their superior torsional strength and abrasion resistance for these items that are the most critical to proper metering performance OPERATION All Dynatec Zenith High A ccuracy Pumps are rear ported Fluid enters the pump through a port drilled into the rear side plate the side opposite the drive shaft The fluid fills the ex posed gear tooth volumes and is transported around the outer diameter of the gear pocket As the gears mesh together the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate cont Appendix 18 iTW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Since these pumps are not self priming a flooded suction is usually the minimum inlet pres sure required However when high viscosity fluids are used more time is required to fill the tooth volumes As a result the inlet pressure must be increased or the gears must ro
86. cHanner E CHANNEL STATUS POWER STATUS STATUS Hin wopuLE status C MODULE STATUS RTD resistance RT D resistance 115 VAC ANALOG ANALOG 8 Input Module 4 Input Module 115 VAC Input RTD Input Module Layouts Module Eu Analog Input Module Layouts Page 7 12 Troubleshooting iTV Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Output Modules On the Output modules each temperature zone has a red LED The LEDs illuminate when the zone s heater comes on ie is outputting On theRelay Output module shown below to the left the top eight outputs are used by ITW Dy natec for 115 VAC The bottom eight outputs may be used by the customer for either AC or DC The DC Source Output modules are used for the ASUs solid state relays Theillustrations below provide a brief description of the LEDs on these modules For more detail refer to the Allen Bradley manual OUTPUT OUTPUT INPUT OUTPUT OUTPUT 0 0 to 15 1 0 to 15 04 81216202428 15 91317212529 2 610 14 18 22 26 30 3 7111519232731 Col Le RELAY 115 VAC DC SOURCE DC SOURCE Output Module Layouts iTV Dynatec c 1999 Troubleshooting Page 7 13 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 5 02 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 Res
87. cate with Parker Super O L ubricate or an equivalent silicone based oil 14 Install lip seals into seal housing 22 as shown 15 Tighten seal housing screws to 60 Ibs in Check for rotation Tw Dynatec 1999 DYNAMELT ASU Manual 20 28 20 29 and 20 30 SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread UNC Alloy Steel 10 24 w carbon seal gasket 10 24 w o carbon seal gasket 12 24 1 4 20 5 16 18 3 8 16 into aluminum 7 16 14 block hopper Appendix 23 Revised 10 99 Torque L ubricated T hreads L bs in 50 64 120 150 305 360 480 Table 1 Nxm Lbs ft 5 7 4 2 7 2 5 3 13 6 10 169 12 5 33 9 25 40 6 30 54 2 40 n critical applications where control of bolt preload is important the torque tension relation should be determined by experimenting on the actual parts involved including thread lubricants At elevated temperatures itis often desirable to reduce screw stress because of deformation creep under sustained loading Screws constructed of type H 11 high temperature alloy steel provide extremely high creep resistance TROUBLESHOOTING GUIDE Trouble Pump will not turn Probable C ause 1 Low pump temperature 2 Drive malfunction 3 Process conditions changed 4 Entrained particle Remedy Check temperature sensor and control loop for proper setting operation Allow sufficient heat up time Verify driv
88. cated to the right in the display 3 Heater output is measured as a percent of the full wattage for that heater Heater output cycles on and off continuously in order to maintain each temperature zone setpoint 4 Temperature setpoint is displayed as programmed 5 High low temperature alarm is designated Alarm BW and is displayed as programmed 6 Zones that are OFF will be bypassed when pressing F1 PREV or F2 NEXT Page 5 8 Programming iTV Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Adhesive Application Unit s ASU Motor Menu Screen Numeric Entry Keys MOTOR 1 MOTOR2 MOTOR3 MOTOR4 SETUP SETUP 0 0 0 0 PUMP PUMP RPM RPM 0 0 0 0 PRES MOTOR 5 MOTOR 6 SURE SETUP SETUP bas TEBE Arrow Keys iTV Dynatec c 1999 Programming Page 5 9 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 5 03 Use of the ASU s Motor Menu Screen Press This To Function Key M otor 1 Setup Program or monitor M otor 1 M otor 2 Setup Program or monitor M otor 2 if applicable M otor 3 Setup Program or monitor M otor 3 if applicable M otor 4 Setup Program or monitor M otor 74 if applicable M otor 5 Setup Program or monitor M otor 5 if applicable M otor 6 Setup Program or monitor M otor if applicable Pressure if applicable onitor pressure values of optional pressure transducers M ain Return to the M ain M enu Programming There is a M otor zz Setup screen for
89. connection between H eater O pen hose head and ASU Sensor Heater 2 Disconnection between cartridge heater and cable assembly inside head Plug Sensor amp 3 Inoperative hose head circuit breaker Heater 4 Open hose head heater element 5 Open wiring inside ASU 1 Visually examine effected hose plug and ASU socket for cleanliness and proper contact and seating R efer to the wiring diagram for pin identifica tion The problem can be isolated by plugging the effected hose head into another A SU socket If the new hose number is then displayed as malfunct ioning the problem is in the hose that was moved Repair or replace hose head or ASU hose harness as appropriate 2 Visually inspect wiring inside head Verify that cartridge heater leads are properly connected in the service block area 3 Refer to schematic in Chapter 11 for location of circuit breaker If itis found to be tripped do not re set it without first finding cause Visually inspect and use an ohmmeter to check for a possible short circut to ground in the hose head heater circuit 4 Use an ohmmeter to measure hose head heater resistance See resistance table in this chapter for resistance values Infinitely high resistance indi cates an open heater element 5 Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate open wires in head heater circuit Repair or replace ASU hose head ha
90. d particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts should always be re tightened at operating temperature Page 8 6 Disassembly amp Re assembly iTV Dynatec c 1999 Revised 8 99 DYNAMELT M ASU Manual 20 29 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 1999 Options amp Accessories Page 9 1 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 6 03 Chapter 9 AVAILABLE OPTIONS amp ACCESSORIES Pressure Gauge Assembly PN 805641 optional analog pressure gauge can be mounted on the outlet filter manifold Reading the adhe Sive pressure at the manifold rather than in line on a hose allows for more precise monitoring of System pressure It is also useful for troubleshooting and maintenance The gauge is installed at one of the adhesive ports on the manifold Fittings and adapter are included in the assembly Pre PS amp Post PSI Transducers 804467 805942 The Pre PSI transducer measures adhesive pressure in the filter manifold before the filter basket The transducer measures the pressure after the filter basket By comparing the two read ings the operator can determine if the filter basket is clogged Pressure transducers are monitored via pressure readouts through the controller See A ppendix for manufacturer s manual Drop in Grids PN 104802 The drop in grid is an extra hea
91. d 1 07 DYNAMELT M ASU Manual 20 28 20 29 20 30 and 20 50 PN 804467 805942 Pressure Transducer cont Transducer tip dimensions 1 08 Transmitter Operation amp Calibration Transmitter Operation amp Calibration M W amp Series The Transmitter will remain in the normal operatng mode until one of the described functions is enabled using either the supplied magnetic pen or the optional remote enable Contents 1 Autozero 2 Fine Autozero 3 Calibration 4 Autospan Partial Reset Total Reset 1 AUTOZERO The Autozero function is activated by The Autozero function results 1 Positioning the magnet pen near the Autozero label 1 The effect of the Autozero function will be visible on the shell of the sensor for a period between 1 and 10 after 2 seconds from the start seconds 2 The zero value precision is defined by the accuracy 2 Short circuiting pins E F for a period between 1 and class of the sensor 10 seconds available only with the optional External 3 See Table 1 for defined limits of the Autozero Autozero feature function It is possible to have a short duration overcurrent up to 7TmA during the Autozero operation iTV Dynatec 1999 Appendix 39 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 99 PN 106877 Pneumatic Clutch Kit HORTON CLUTCH MODEL 625 MODULAR UNITS MDU amp MOU ITW Dynetec ASUs use Model 625 MDU amp MOU The following 9 pages from the Horton clutch manual have b
92. d Terminal 2 26 048F069 End Clamp 2 27 107751 5 16 Conduit Fitting 4 28 N06883 Jam Nut 6 29 107645 107646 5 16 Conduit 12 25 one for each conduit fitting 2 30 048J088 1 2 Sealtite Connector 2 31 108829 108830 1 2 Sealtite Conduit 36 1 2 Sealtite Conduit 40 opposite side lea 104166 Over Temp Switch Assembly Sold as an assembly only 2 32 104165 Insulator Over Temp Thermostat 2 33 104164 Overtemp Reset Thermostat 2 34 103538 M4 X 6mm Pan Head 2 Grid Group 2 35 N00181 O ring 014 8 N007081 O ring 014 Kalrez 8 36 104696 Flange 2 37 003E023 Cover 1 38 N07958 Temperature Sensor 2 39 106174 Sensor Adapter 2 40 104802 Cast Heater 2 41 0487048 1 4 ID Conduit 4 42 NN00192 O ring 032 2 4 069 X285 O ring 032 kalrez 2 4 43 102446 M4 0 70 x 10mm SHC Screw 4 44 N07429 8 1 25 x 35mm SHC Screw 8 45 078A055 10 24 x 3 16 SHS Screw 2 084Q465 Pump Block off Assembly option 46 069X064 O ring 041 1 47 012G009 Block off Plate 1 48 N00834 3 8 16 x 1 25 SHC Screw 4 49 N00754 1 4 Level Seal Plug 2 50 105967 Filter Shutoff Assembly Left 1 105968 Filter Shutoff Assembly Right 1 51 804464 Filter Shutoff Assembly Left HI Temp Option 1 804465 Filter Shutoff Assembly Right HI Temp Option 1 805216 Grid Block Off Assembly 1 2 52 105149 Block off Plate 1 53 N00192 O ring 4 032 1 54 108297 8 x 20mm HHC Flange Screw 4 25 N00181 O ring 014 4 56 105097 M6 x 30mm SH Set Screw 2 57 069 274 Seal Dual Pump to Prog melt n
93. d a high temperature lubricant to prepare it for return to service To store for future use simply add a rust preventative oil It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum By noting the perfor mance of a pump immediately before removing it from service and correlating the perfor mance to measured component wear the user can establish the maximum wear limits for the pump s critical components Further he can predict the service life of the pump and schedule his down time accordingly As with any other Dynatec pump high accuracy pumps may be returned to D ynatec for com plete rehabilitation as necessary This procedure may be desirable if only a few pumps are involved If a large number of pumps are to be maintained at the user s plant it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing gauging and assembly techniques involved in producting the pumps Please contact D ynatec at 1 800 538 9540 for further information on these items Appendix 6 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 STANDARD ACCURACY PUMP DISASSEMBLY If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate clean are
94. d in Auto mode only Max Pump RPM Enter desired maximum pump speed used in Auto mode only Clutch if applicable Toggle optional clutch ON or OFF F1 or F2 Go to the Previous zone the Next zone on active menu Return Return to the Motor Menu screen Programming 1 Press Manual OFF or Auto to choose desired motor mode 2 If in Manual press Enter Pump Speed to program pump speed a Use the numeric keypad to enter desired rpm value b Press the Enter arrow to store your desired value 3 If in Auto a Press Min Pump RPM to program minimum pump speed Enter and store value as above At 0 volts this value will be between 0 and 10 rpm b Press Max Pump RPM to program maximum pump speed Enter and store value as above At 10 volts this value will be between 0 and 90 rpm depending on motor installed on ASU 4 Toggle optional Clutch ON or OFF This key is present only if optional clutch es is installed Adjustments To adjust pump motor speed a In Manual mode use the upper set of adjustment arrows to ramp speed up or down Monitoring 1 Actual Pump RPM is displayed 2 Ext Ref external reference percent the percent of the parent line s full speed Used in Auto mode only 3 PSI or BAR is displayed as chosen on Setup Menu The actual pressure is also displayed Page 5 12 Programming iTV Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Adhesive Pressure Monitoring Screen Numeric Entry
95. de of the panel box use the main disconnect switch to open the panel box door see Chapter 3 for instructions on opening door Fuse Removal Transformer fuses are located on the upper terminal rail item 18 on page 10 7 b Relay Removal 1 The solid state relays item 14 on page 10 5 are located on the right hand side of the inside of the panel box behind the heat sinks s Two screws hold each relay T hey also plug into a connector 2 Drive relays one relay per drive are located on the terminal rail item 31 on page 7 Push the lever located below these relays to release them from the rail C SLC 500 Module Removal Open the door of the selected module to expose the wires and terminals within Disconnect wires from all terminals Press and hold the two module retainer clips simultaneously located at the top back and bottom back of each module then gently pull the module straight out of its slot on the rack To re install module align the module s circuit board to the rack s card guide and slide the module in until both the top and bottom retainer clips engage Page 8 4 Disassembly amp Re assembly iTV Dynatec c 1999 Revised 3 01 DYNAMELT M ASU Manual 20 29 To Access the Pump or Motor DANGER HOT SURFACE amp HIGH VOLTAGE If the pump is notoperable but the heating system will function raise the temperature of the application system to the operating temperature to aid in the pump disassembly process Otherwise a
96. e Monthly or as experience dictates 1 Inspect outlet filter basket Replace as required 2 Check for leaking adhesive under the baseplate caused by a worn pump seal Replace as re quired Every Three Months or as experience dictates 1 Check all hose fittings for tightness 2 Check all fasteners for tightness 3 Inspect filter shutoff Clean or replace as required Flushing the System Contaminated adhesive accumulation of residue in the system and hopper or changing the adhesive formulation may require the system to be flushed To flush the system have at least 6 liters 1 5 gal lons of flushing fluid on hand PN L 15653 per hopper Repeat this procedure for each hopper of a dual hopper ASU WARNING 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 A SU 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 cont Page 6 6 Preventive Maintenance TWDynatec 1999 Revised 7 99 DYNAMELT M ASU Manual 20 29 and 20 30 disconnect the electrical power to the head since that would disable the pump Put the hose in a secured posi
97. e to make sure that input and output data lengths are correct Check slave device configuration Check accuracy of scan list table entry Check slave device configuration None This code clears itself once scanner attempts to initialize all slave devices on the channel Check accuracy of scan list table entry Check slave device configuration None Reconfigure your module Check DeviceN et connections and physical media integrity Check system for failed slave devices or other possible sources of network interference Provide network power M ake sure that scanner drop cable is providing network power to scanner comm port None Do not disconnect the module while application FLASH is in progress You will lose any existing data in the scanner s memory None Service or replace your module Service or replace your module Page 7 10 Troubleshooting iTWDynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 SLC Processor CPU Module TheSL C 500 Processor operates as the system s CPU A keyswitch selects one of the module s three modes Run M ode Remote M ode or Programming M ode To operate the adhesive application system through the PanelView controller select Run M ode To connect to a programming device laptop remote PL C etc select Remote M ode Select Programming M ode to lockout disable all ASU and programming functions Force see illustration is used during Setup or Toublesho
98. e capacitive sensor is mounted in the hopper The sensor cable is plugged into an amplifier DO NOT CUT the sensor cable Adjustment of the Single Point Level Control To adjust the adhesive level control s sensitivity access the control s amplifier located inside the panel box assembly On the amplifier diagrammed below is a sensitivity adjustment screw Turn the screw clockwise to increase sensitivity or counter clockwise to decrease The yellow LED lights to indicate the presence of adhesive W hen the LED goes out the audible and visible alarms will activate Use of Two Level Controls in One Hopper Two single point level controls can work together to maintain a range of adhesive the ASU s hopper In this application one level control s sensor is mounted at the level of high adhesive and the other is mounted at the low level Each amplifier requires its own sensitivity adjustment 123456 Sensor Connect O e Sensitivity Adjustment S crew min max S Yellow LED 101112 OOO OOO O On Oo Ov Amplifier Multi Point Level Control available on DM M140 only Refer to the level control manufacturer s manual for complete instructions on its setup and op eration The multi point level control has the capability for three separately calibrated outputs However for most applications one output calibrated with a high and a
99. e ground wires attached The filter shutoff assemblies are located on either side of the hopper R epeat this procedure for each assembly 4 Wearing gloves use a wrench to unscrew the filter shutoff nut and pull the filter shutoff out 5 a Replace the clogged filter shutoff assembly or b Emerse the assembly in flushing fluid PN 1 15653 to loosen contaminants Remove assembly from fluid and use a hot air gun if necessary and rags to clean all contaminants from it 6 Apply a coat of anti sieze compound onto the threads of the filter shutoff nut before re inserting into the ASU iTV Dynatec c 1999 Preventive Maintenance Page 6 5 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 7 99 7 Replace the filter shutoff o ring Lubricate the new o ring with lube PN N07588 8 When re installing the filter assembly turn the filter s cut out hole toward the pump Align the filter shutoff knob in its open position Note each filter shutoff is stamped 1 open and 0 closed to show position 9 Close the access doors Restore the A SU to normal operation Pump Shaft Leak There is a cutout in the baseplate directly below the pump shaft s which will allow adhesive from a leaking pump to exit the ASU Inspect the area under the baseplate cutout every month for adhe sive A leaking pump shaft indicates a worn pump seal See instructions in Chapter 8 for replace ment of this seal Summary of Preventive Maintenance Schedul
100. e is powered Check to assure all alarm circuits are clear Check drive motor current and speed settings Check all drive couplings Check process conditions for proper melt tempera ture pressures viscosities and materials Disassemble and clean pump replace any damaged parts cont Appendix 24 iTW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 TROUBLESHOOTING GUIDE continued Trouble Probable C ause 5 Possible internal damages Excessive seal 1 Worn seal plate assembly leakage 2 Insufficient inlet pressure 3 Worn lip seal Reduced pump efficiency 1 Worn gear s 2 Worn bearings 3 Process conditions changed Remedy Disassemble and clean pump replace any damaged parts Consult factory Replace seal plate and coupling if necessary Increase inlet pressure Replace lip seal Replace worn gear s Replace worn bearings Consult factory for clearance recommended on new process conditions A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces Appendix 25 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Tw Dynatec 1999 A3H 29 X WW3MLS TONIS eenaa semen amp dH 3d il dL Rm SHILI SH3HSVM ANY x ONN SLE SWALT NO GRCNTONT 5179 SNIINDOM Xpo 3104 310H 09 ONIINnOM 907 2 XZ 310H 1708 ONLLNOON 90p 8
101. e setpoints on the Temperature Zone Programming screens will display the reduced standby temperatures after the duration of the standby delay W hen standby mode is deactivated these temperatures will resume their pre standby values Entering a standby time delay of 0 will result in the unitimmediately going into standby when standby mode is activated 3 Press Seven Day Scheduler to program the Scheduler See the following pages for programming instructions Page 5 16 Programming iTV Dynatec 1999 Revised 3 03 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Seven Day Scheduler Programming Screen The Seven D Scheduler allows the operator to program automatic Turn On or Turn Off events which coincide with his daily production schedule throughout the work week On or Off events may be programmed for any individual day of the week or may be programmed for Everyday of the week at the same time HourKeys Day of E vent Display Minute Keys Numeric Entry Keys system a SYSTEM s system es SYSTEM OFF ee 13 38 35 09 21 00 Arrow Keys PanelView Clock Hours Minutes Seconds Month Day Year CPU Clock Hours Minutes Seconds Clock Synchronization The 7 Day Scheduler screen displays two clocks which must be synchronized periodically in or der for the scheduler to function properly These clocks are the PanelView s clock which can be reset by following instructions on page 17 and the C
102. e torque tension relation should be determined by experimenting structed to type HH alley ae coven high creep resistance 4 Heat the pump thoroughly and evenly including the seal arrangement 5 Tighten the mounting bolts and coupling housing screws to the manufacturer s recommended torque at that operating temperature If your pump has a packing seal take up firmly and evenly on the seal gland screws to compress the packing then back off 4 turn of the screws Be sure to adjust the gland property Do not over tighten Adjustment may be made during operation to control excessive leakage Time Saving Heating Alternative Maintain the clean and ready c ose pump in an oven al operating temperahire This avoids thermal shock and saves valuable beating tire 4 Startup 1 Ensure that the pump is free turning and lubricated Engage the outer drive shalt carefully making sure that it iTV Dynatec c 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 does not hottom in the slot of the coupling and that it is aligned within 1 angular and 005 parallel with the true pump drive axis coupling is the rotating member of the and depends on the internal operating pressure of the pump to force it forward and affect a seal against the carbon or metal seal plate In pumps with a through shaft and compression packing seal the pump to driver axis may shift unevenly dte to pump heating expansion
103. each motor installed on your system 1 Press M otor 1 Setup to program the first ASU motor See the following two pages for pro gramming instructions 2 If more than one motor is installed on your ASU press each M otor Setup to program each one in the same manner Monitoring 1 Actual Pump RPM is displayed for each motor 2 f pressure transducers are installed on your A SU press Pressure to advance to the A dhesive Pressure M onitoring screen see pages 12 amp 13 of this chapter Motor Limits 1 Model DM 35 asu s may utilize one motor only 2 Model DM 70 and DM 140 asu s may utilize up to four motors 3 Model DM 210 asu s may utilize up to six motors Page 5 10 Programming Revised 10 02 iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Motor Programming Screen MOTOR 1 PUMP RPM HE CLUTCH OFF EXT REF HHH MIN PUMP RPM AUTO MODE HHH H F1 PREV F2 NEXT MAX PUMP RPM AUTO MODE RETURN Numeric Entry Keys E TEBE Arrow Keys iTV Dynatec 1999 Programming Page 5 11 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the Motor Programming Screen Press This To Function Key Manual Choose Manual Mode OFF Choose Motor OFF Auto Choose Auto Mode Enter Pump Speed Program Pump Speed used in Manual mode only Up amp Down Arrows Adjust Pump Speed up or down used in Manual mode only Min Pump RPM Enter desired minimum pump speed use
104. easure resistance as follows M odel M 35 across H3A and H3B M odels 70 140 across H5A and H5B M odel 210 across H7A and H7B See the resistance table in this chapter for normal resistance values Infinitely high reisistance values indicate an open heating element which must be replaced Hopper Circuit Breaker Optional Drop in 1 Setpoints have been Re program setpoints allowing a Grid Overtemp programmed without larger deviation between the high etc Terminals enough deviation and low limits 2 Disconnection between 2 Verify that all modules are properly the RTD module and the inserted in their sockets on the rack module rack 3 Grid sensor inoperative 3 Examine grid sensor assembly for intermittent break in sensor lead Remove sensor bulb from grid Replace grid sensor if resistance does not comply with the resistance table in this chapter 4 Grid control solid state 4 a Verify that the relay is not shorted by relay inoperative removing all of its output wires and verifying that resistance is greater than zero b Verify condition of relay by discon necting then re connecting properly cont Page 7 18 Troubleshooting IT Dynatec 1999 Revised 7 00 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Then when Temperature Zone is OFF use a VOM AC voltmeter to verify that 240 volts are not present at the heater terminal Optional Drop In 1 Sensor cable has bec
105. ection Component Illustration DYNAMELT AC Drive Assembly 106660 amp 106663 Page 10 16 Component Illustrations amp BOM s TV Dynatec c 1999 Revised 8 07 DYNAMELT M ASU Manual All M70 140 Models Single 106040 M140 Single High Flow 106694 and M140 Dual 106039 Melt amp Grid Assemblies AD No Part Number Description Qty 1 036B015 Pump Enable Thermostat 2 2 N07958 Temperature Sensor 4 3 105999 Hopper Support 4 4 105883 Hopper Weldment Dual M70 106037 2 5 105884 Hopper Weldment Dual M140 106039 2 6 105889 Hopper Weldment M70 Single 106038 1 7 105890 Hopper Weldment M140 Single 106040 1 106620 Hopper Weldment M140 Single High Flow 106694 1 8 105881 Heater Plate M70 140 2 9 105135 Spacer 12 10 108297 M8 x 1 25 x 20mm HHC Screw 12 11 107602 8 x 40 HHC Screw 24 12 N00686 Flat Washers 1 4 48 13 N00697 Lock Washer 1 4 48 14 072X093 Filter Shut off plug fits in place of or opposite Filter shut off 2 4 15 N00210 O ring 912 fits in place of or opposite Filter shut off 2 4 16 Filter Block Assembly See Your order for part Number and Oty 17 106103 Ball Valve Assembly Option 2 Junction Box Assembly 2 18 105885 Junction Box Prog Melt M70 140 1 19 106001 Cover Junction Box 1 20 078C021 Flat Washer 88X1 0X 13 2 21 048J018 Bushing Plastic Cap 1 2 2 22 048F125 Terminal Rail 11 5 one of each 2 23 048F136 Block Terminal 35 Amp 44 24 048F137 Cover End 6 25 048F021 Groun
106. een 5 18 Configuration M ode M ain M enu Parameter 5 5 20 Helpful Tips for the Juice eee eben Gre bonc Gobbi nep eet ded 5 21 Chapter 6 Preventive Maintenence General Cleaning bare Es dob iui Diae taba piede qa e bec s pu ce aah a 6 1 Preventive M aintenance Schedule 6 1 Replacing the Outlet Filter 6 1 Standard Outlet Filter Manifold illustration 6 2 Replacing the Optional High Flow Outlet Filter Basket 6 3 High Flow Outlet Filter Manifold illustration 6 3 Hose Fittings RO aed wae eC keke ace e de 6 4 5 Pr 6 4 Filter Shutoff Cleaning or 6 4 PUMP ShattLCak aie ca YN d 6 5 Summary of Preventive anintenance 5 6 5 Flushing the System 6 5 Chapter 7 Troubleshooting General Troubleshooting Notes 7 1 High Temperature Redundant Overtemp Thermostat
107. een edited to include only information on the 625 clutch Read this manual carefully making full use of its explanations and Instructions The Know How of safe continuous trouble iree operation depends on the degree of your understanding of the system and your willingness to keep components in proper operating condition Pay particular attention to all NOTES CAUTIONS and WARNINGS to avoid the risk of personal injury or property damage it is important to understand that these NOTES CAUTIONS and WARNINGS are not exhaustive Horton cannot possibly know or evaluate all conceivable methods in which Service may be performed or the possible hazardous consequences of each method Accordingly anyone who uses a procedure that is not recommended by Horton must first satisfy themselves that neither thelr safety or the safety of the product will be jeopardized by the service method selected Appendix 40 iTW Dynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont CONNECTING UNITS TO FORM COMBINATIONS MODULAR CLUTCH MDO NOTE The Modutar Drive Unit MDU Ball Bearing Kem 27 Itam 14 unti the iaces of both units are flush See Figure 1 is loose fitting by design Do not allow this Ball ak Bearing to fall off the MDU WARNING 1 Place the Modular Drive Unit MDU on a table with the Head Cap Screws item 31 Ball Bearing Item 27 facing up and
108. eens TERMINAL INFO Boot V01 06 Firmware V04 00 Hardware Memory Card Screen HWCFG KP TS PO 232SS6 0 Filename M50 Fontfile No Card Inserted APPLICATIONS ON CARD F1 Memory Card Listing 95993 Bytes Used 149702 Byes Free SCREEN SETUP Screen Normal Saver Intensity Reset F1 F2 F9 Communication Setup Screen SCREEN SAVER F2 Restore from Card F3 Save to Card F4 Erase Fomat Card F5 Disconnect Card Timeout Intensity DH 485 10 min n 19200 F3 DATE TIME Year Month Day 98 11 5 F1 F2 F3 Hour Minute Second 15 17 40 F6 F7 F8 EXIT PRESET OPERATIONS 11 5 1998 03 17 40 Key Repeat Rate Presets F4 gt Last States PRINTER SETUP Key Del Communication Handshaking Parameters Baud Rate No Parity F9 None 8 Data Bits 9600 Power up With F1 Restart Unit 1 Stop Bit Load Values Fl F2 F3 Port Mode Port Not EXIT Installed F10 iTV Dynatec 1999 Programming Page 5 21 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Helpful Tips for the User When the ASU is turned ON the controller will detect any unused hose circuits which are turned ON for example a hose not plugged in and will go into alarm For this reason all unused temperature zones must be programmed OFF 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
109. els into place moving in the direction of the shortest press distance Usually from the rear side of the pump 10 Lubricate the binder screws with DAG Dispersion 154 or Similar beat resistant lubricant and install Torque the screws in even increments to the manufacturer s recom mended limit It is especially important to rotate the gears frequently during this operation 11 Reassemble the seal arrangement making sure the seal ing surfaces are perfectly clean and free of scratches nicks or burrs When a carbon seal plate is used always use a new carbon seal that has been fightly polished on 400 600 grit paper When using a carbon seal the coupl ing housing screws should be torqued to the turer s recommended torque limit For pumps equipped with a compression packing seal be sure all old packing is removed from the packing housing 22 inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn 13 Dip the packing rings into high temperature cil and graphite This aids in assembly and nunning in of the packing Nichols Copyright 1887 Parker Hannifin Cozporation Zanith Division iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 M Place the first packing over the shaft and force it firmly and evenly to the bottom of the packing housing Tap it firmly into place Rotate the drive shaft by hand affer each ring 6 istalled 10 aid in seat
110. enu Go to the M otor M enu Screen Setup M enu Go to the Setup M enu Screen iTV Dynatec c 1999 Programming P age 5 3 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the Main Menu System Status Screen cont Programming Sequence 1 Press Heater Power to turn the Heater Main Power ON or OFF 2 Press Setup Menu to setup the system in Celsius BAR or Fahrenheit PSI screen is diagrammed on page 14 of this chapter Note after temperature zone and motor programming is complete if desired you may return to this screen to program the Standby and Seven Day Scheduler 3 Press Temperature Menu to choose a temperature zone Then program or monitor the following temperature functions see details beginning on page 4 of this chapter a Temperature setpoints c Heater output b High low alarms d Actual temperature 4 Press Motor Menu to a Choose a motor Then setup or monitor the following functions for each motor 1 Motor ON OFF Manualor Auto iv External reference percent Auto mode only ii Pump speed v Minimum pump rpm Auto mode only iii Motor rpm vi Maximum pump rpm Auto mode only b Monitor adhesive pressure PSI BAR or c Turn clutches ON or OFF 5 Press Setup Menu to program System Standby and or Seven Day Scheduler Monitoring 1 System Status Display describes system status as one of the following a System Initializing seen immediately after a power on this screen is of short duration It
111. es and it in cludes self diagnostic malfunction alerts and failure alarms Note Some controller functions are di rect temperature conversions between degrees Celsius and F ahrenheit Other parameters are inde pendently selected values Page 4 2 Controller Set Up iTVW Dynatec 1999 Revised 1 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Defining Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained Error Indication Alarms Alarms which indicate that the programmed over temperature values have been exceeded for one or more hopper hose or head zones Alarms may also indicate an open or short circuited sensor External Reference Percent The numeric percentage of the parent line s full speed Used in the controller s Auto mode only Heater Output Percent Heater output fluctuates in order to maintain each temperature zone s setpoint Heater output is mea sured as a percentage of the full wattage of each individual heater Heating Sequence Priority A program which allows certain temperature zones those assigned priority 1 to begin heating first before other zones those assigned priority 2 or 3 in the system See also the definition of Sequential Heating High Low Alarms BW The high low alarm setpoints This is a range bandwidth and a zone s temperature setpoint For example if
112. essary to disassemble the seal arrangement to remove polymer ash If present always replace the carbon seal plate after pump burnout If the pump was perform ing satisfactorily when removed from service and still turns freely after burnout pressure test it and add a high temperature lubricant to prepare it for return to service To store for future use simply add a rust preventative oil It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum By noting the perfor mance of a pump immediately before removing it from service and correlating the perfor mance to measured component wear the user can establish the maximum wear limits for the pump s critical components Further he can predict the service life of the pump and schedule his down time accordingly As with any other Dynatec pump high accuracy pumps may be returned to D ynatec for com plete rehabilitation as necessary This procedure may be desirable if only a few pumps are involved If a large number of pumps are to be maintained at the user s plant it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing gauging and assembly techniques involved in producting the pumps Please contact D ynatec at 1 800 538 9540 for further information on these items HIGH ACCURACY PUMP DISASSEMBLY If pumps are to be disassembled on
113. etpoint value 0 450 F b Press the Enter arrow to store your desired value 3 Press Alarm BW to program the zone s high and low alarm value Note The high low alarm setpoint is a range and the zone s temperature setpoint For example if the temperature setpoint is 200 degrees and the high low alarm setpoint is 10 degrees then the high alarm equals 210 degrees and the low alarm equals 190 degrees a Use the numeric keypad to enter desired high low alarm range 10 50 b Press the Enter arrow to store your desired value 4 If a heating sequence priority is desired press Priority Note Priorities of 1 2 or 3 are allowed A priority 1 programs a zone to begin heating first before other zones in the system If no priorities are programmed the controller will default to 41 for each zone causing all zones to begin heating simultaneously a Use the numeric keypad to enter desired priority 1 thru 3 b Press the Enter arrow to store your desired value 5 Press Temp Screen 1 or 2 and repeat programming steps for another temperature zone Monitoring 1 Zone in upper right corner the number which appears here is the controller s identifica tion number for this zone This i d number will appear on the Main Menu screen any time the zone has a high or a low alarm 2 Actual temperature may be viewed as a a line item of the display for example Actual 117 5 or b a graph lo
114. f component parts T he slightest burr nick or particle of foreign matter can cause scoring or even seizure These pumps are precision in struments you can t keep them too clean Please treat them with care and if it s at all pos sible set aside a separate clean area for pump maintenance To clean High A ccuracy M etering Pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer Time at temper ature will be related to the pump size and the degree of polymer contamination and should be determined by trial Note Careful control of he furnace temperature 950 degrees F max and atmosphere is critical Should the temperature exceed the original tempering temperature the steel hardness will draw back and the dimensional stability of the pump may be upset A nother acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath shold be heated to a temperature that is sufficient to carburize the polymer T he car burization process usually takes between 3 and 12 hours depending on the polymer type temperature pump size and furnace load cont Appendix 20 iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning A fter gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent t may be nec
115. f the fuses there are no user replaceable parts on the printed circuit boards If there is a non fuse failure on a PCB the PCB must be replaced DANGER HIGH VOLTAGE Some of the procedures in the following Troubleshooting Guide require poten tially dangerous electricity to be present Only qualified service personnel should perform these procedures H opper tank 1 Setpoints have been 1 Re program setpoints allowing a Overtemp programmed without larger deviation between the high enough deviation and low limits 2 Disconnection between 2 Verify that all modules are properly an RTD module and the inserted in their sockets on the rack module rack 3 Hopper sensor 3 Replace hopper sensor if resistance inoperati ve does not comply with the resistance table in this chapter 4 Hopper control solid state 4 a Verify that the relay is not shorted by relay inoperative removing all of its output wires and verifying that resistance is greater than Zero b Verify condition of relay by discon necting then re connecting properly Then when Temperature Zone is OFF use a VOM AC voltmeter to verify that 240 volts are not present at the heater terminal Solid Sta Relay E S olid State Relay Page 7 16 Troubleshooting iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Hopper Sensor O pen 1 Sensor cable has become 1 Verify that hopper sensor cable is unplugged from RTD mod p
116. factory set pump enable temperature 7 Drive circuit breaker 7 Refer to schematic Ch 11 to locate tripped circuit breaker With an ommeter verify that the drive input is not shorted If itis shorted replace the drive Reset the breaker if it trips again replace the breaker iTV Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Troubleshooting Page 7 27 Revised 1 99 Pump doesn t operate in Auto mode hopper is at ready conditon Pump runs but there is no adhesive output 1 Parent machine is not running 2 A uto motor is set at zero at controller keypad 3 No incoming line following signal 4 Low temp alarm 1 ASU is out of adhesive 2 f pump has been serviced and leads reversed pump will run with no output 1 Check parent machine 2 Re program motor 3 Check for presence of 0 to 10 VDC control signal at analog input card If signal is not present check A SU wiring connections and tachometer drive connections If control signal is present there the problem is within the ASU 4 Verify that ASU is warmed up and that hopper temperature is above the factory set pump enable temperature 1 A dd adhesive to hopper 2 Check pump wiring to schematic Page 7 28 Troubleshooting Revised 1 99 iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Low or inconsistent 1 Pump filter clogged adhesive output eee 99 2 Adhesive used is
117. g This option allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage input One of the following devices must be installed PN 015D050 Tach Generator a mechanically operated device which produces a reference voltage that allows the ASU s gear pump to track a parent machine s production line speed PN N06642 Signal Isolator a device which conditions a parent machine s production line s DC speed reference voltage to allow the ASU s gear pump to track line speed Remote HMI Interface An option that allows controller monitoring and adjustments from a customer provided program mable logic controller PLC or a remote location Page 9 4 Options amp Accessories iTV Dynatec c 1999 Revised 10 04 DYNAMELT M ASU Manual 20 29 Recommended Service Parts List E lectrical 103184 Fuse GDC4 terminal rail 036B 103 RTD Sensor PT N07958 RTD Sensor PT 104166 Over Temp Thermostat amp Insulator A ssy 036B015 Pump Enable Thermostat 102411 B oot Insulator 105261 Relay 120v 048H 384 Solid State Relay Dual 036A 077 Heater 2000w 036A 170 Heater 500w for 1 filter block 036A 079 Heater 1000w for 2 filter blocks 102149 Heater 1500w for 3 filter blocks 036A 077 Heater 2000w for 4 filter blocks 801680 Printed Circuit Board SLC 5 04 802101 Printed Circuit Board SLC DeviceN et 802110 Power Supply AB 801684 Module RTD 801688 M odule 1 0 80211
118. g or wear marks here will allow increased slippage from the high pressure discharge port section across the throat to the lower inlet port reducing efficiency Therefore carefully gauge this area for flatness after each resurfacing 10 After all components are hospital clean the pump is ready for assembly P 2 Appendix 22 iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 HIGH ACCURACY PUMP RE ASSEMBLY NOTE During and between each re assembly step manually turn the metering gears to en sure that they are free turning If binding occurs at any time determine the cause and correct itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component Never use force in re assembling or turning a Dynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely R e assemble as follows 1 After all worn parts have been re finished or replaced all parts should be throughly cleaned in a solvent and dried 2 Using the driven gear 7 as an up righting fixture carefully locate the arbor 5 over its press fit hole with the help of an appropriate arbor press 3 Place the rear side plate 3 with the arbor in position in a soft jaw vise or holding fix ture 4 Slip together the driving metering gear 6 drive shaft 4 key 8 and retaining ring Position in the front of the side plate by installing the drive shaft through t
119. g 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 cause severe burns When working near a hot melt application system always wear safety gloves safety glasses and long sleeved protective clothing ITW Dynatec 1997 ALL MODELS Always have first aid information and supplies available Page 1 3 Revised 1 07 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 compounds 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 precautions 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 partic ularly in the capacitors within the panel box To ensure that all stored energy is relieved wait at least one min ute before servicing electrical capacitors Use of PUR Polyurethane Adhesives PUR adhesives emit fume
120. gement to remove all traces of the oil but disassemble only if necessary After flushing the pump should be lubricated internally for start up purposes Pour a suitable high temperature lubricant silicone oil into the inlet port Rotate the metering gears until lubricant appears at the discharge port M ount the pump to a block with a flatness of true flat to 0001 convex and a surface finish of 4 to 8 rms to prevent leakage between the pump and block M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to D ynatec s recommended limit for the bolt size used See Table 1 on page 8 for torque values The following is a brief standard installation procedure For any special applications con siderations or simply to ask our advice please contact D ynatec TO PREPARE THE PUMP FOR USE 1 Always flush out the plumbing system before connecting the pump 2 Filters should be installed prior to the pump inlet that filter ideally to half the pump run ning clearances 3 Turn pumps by hand before running Pumps should turn freely 4 Engage the outer drive shaft carefully making sure that it does not bottom in the slot of the coupling and that it is aligned within one degree angular and 005 parallel with the true pump drive axis Note the coupling is the rotating me
121. h ON If other motors desired to run repeat by pressing Return press a desired M otor Setup toggle Clutch ON etc Adhesive will begin to pump when the production line begins to operate b If Motor isin Manual Program i Press Motor M enu ii Press desired M otor Setup iii Press M anual button iV Enter desired pump speed v If motor is installed with a clutch toggle Clutch ON vi If other motors are desired to run press Return then repeat steps ii thru v v Adhesive will begin to pump after ready condition is attained Return the PanelView controller to its M ain M enu System Status Screen while ASU is operating to monitor potential alarms Shut Down Procedures If Motor is in Auto Program 1 2 a When the production line stops the motor s will automatically stop or b Turn OFF the motor s manually by pressing the M otor M enu press desired M otor Setup then press OFF Repeat for each motor in the system a Toggle Heater Power OFF on M ain M enu or cont Page 3 12 Installation Tv Dynatec 1999 Revised 4 00 DYNAMELT M ASU Manual 20 29 b If all power is to be removed turn OFF the ASU s Main Disconnect Switch If Motor isin Manual Program 1 Turn OFF the motor s by pressing the M otor M enu press desired M otor Setup then press OFF Repeat for each motor in the system 2 a Toggle H eater Power OFF on M ain M enu or b If all power is to be removed turn OF
122. hat could damage a new o ring 1 Verify that all four pump screws are tightly assembled to the hopper 2 Remove pump and inspect bottom of hopper Repair or replace hopper as necessary TW Dynatec c 1999 Disassembly amp Re assembly Page 8 1 DYNAMELT M ASU Manual 20 29 Revised 6 01 Chapter 8 DISASSEMBLY amp RE ASSEMBLY PROCEDURES Note Re read Chapter 1 Safety Precautions before performing any disassembly procedures All disassembly and repair procedures must be performed by qualified trained technicians Disassembly Procedures Note Use the exploded view drawings referenced with each procedure in conjunction with the in structions outlined in this chapter Read the cautions on page 8 5 before re assembling the ASU To Remove the Access Doors There are two access doors one on either side of the ASU Use the key to unlock the door then lift it off being careful not to pull off the ground wire attached Remove the ground wire and re attach when the door is re installed These doors allow access to the motor pump junction boxes op tional drop in grids filter shutoffs and optional ball valves To Open J unction Boxes There are two junction boxes one on either side of the hopper s A junction box cover is removed by two screws at the bottom of the box Within the juction boxes are thermostats heater terminals and the hopper sensor See also the detailed illustration on the following page Acces
123. he bearing 49 5 Placethe driven metering gear on its arbor and carefully mesh with the drive metering gear 6 Carefully lower the center plate 2 over the gears NOTE Repeat steps 5 and 6 for four gear pumps placing the middle plate between gear plates 7 Position the front side plate 1 8 Rotate the gears to ensure free rotation 9 Press the dowels 10 into place moving in the direction of the shortest press distance Usually from the rear side of the pump 10 Lubricate the binder screws 47 48 with DAG dispersion 154 or a similar heat re sistant lubricant and install Torque the screws in even increments to the manufacturer s rec ommended limit It is especially important to rotate the gears frequently during this operation 11 Re assemble the seal arrangement making sure the sealing surfaces are perfectly clean and free of scratches nicks or burrs W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 400 600 grit paper W hen using a carbon seal the coupling housing screws 27 should be torqued to the manufacturer s recommended lim it For pumps with a compensation packing seal be sure all old packing is removed from the packing housing 12 Inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn Worn shafts will result in premature seal leakage and should be replaced 13 Pack lip seals 15 with a silicone based grease and lubri
124. heat gun or other controlled heating method is recommended to melt hardened hot melt material Never use a torch or an open flame on any of the components of the application system Once the system is up to temperature disconnect all incoming power before proceeding Remove access door s using the key being careful not to pull off the ground wire attached Turn OFF the filter shutoff valve by turning it to its closed 0 position Motor Removal Open the motor junction box cover 2 screws Inside the junction box dis connect the wires leading to the motor On the outside of the junction box unscrew the hex nut conduit fitting Slide the wires through the conduit fitting Remove the four bolts which attach the motor to the gear box Lift the motor up and out of the ASU For re assembly torque should be approximately 1 8 Nm 16 foot Ibs at room temperature With hopper at 177 C 3509 the maximum allowable torque on screws is 4 1 Nm 36 foot Ibs TW Dynatec c 1999 Disassembly amp Re assembly Page 8 5 DYNAMELT M ASU Manual 20 29 Revised 5 02 b Pump Removal Verify that the filter shutoff is in its closed 0 position Loosen motor adapter plate screws and slide adapter plate with motor away from pump and coupling Slide the coupling off the pump shaft Remove the four pump mounting bolts Shaft Key C Pump Seal O ring Replacement R emove the pump from the A SU see instructions above b Remove the external
125. higher adhesive pressures from the head to the sub strate because the head is overfed adhesive The overflow adhesive is re circulated to the hopper Pneumatic Clutch PN 106877 A clutch is available to relieve adhesive pressure quickly in applications where there are periods of time when adhesive is not being applied Level Control Options Single Point Level Control Kit PN 810237 DMM140 amp DMM210 only Multi Point Level Control Assembly PN 084Q210 DMM140 amp DMM210 only Level control devices inform the operator via a message on the controller that the hopper s adhesive level is low They may also be wired to stop production turn on an alarm light or signal or signal a PLC T Dynatec c 1999 Options amp Accessories Page 9 3 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 5 07 Pressure Transducer Assembly PN 801122 A pressure transducer is an electronic probe that allows the melted adhesive s pressure to be pro cessed by the ASU s control system They are used to monitor system operating pressures and their limits They troubleshoot clogged nozzles and filters Dual Hopper Available on DM M70 M140 and M210 The adhesive hopper on the dual hopper models is divided into two separate chambers to allow the application of two different adhesives simultaneously Each chamber is an independent temperature zone allowing them to operate at different adhesive temper atures High Flow ASUs PN 106696 DM140 PN 106697
126. ill of Materials for 3 2 cc Rev Dual Gear Pump Assembly 100864 Item No Part Number Description Qty 1 012D088 Drive Shaft 1 2 0781001 K ey Woodruff 1 3 101626 M5x12SHCS 4 4 069X 160 Seal retainer amp Bearing Housing 1 5 069X 061 Lip Seal 1 6 018X 041 Bearing Sleeve 2 7 100867 Front Plate A ssembly 1 8 0120087 Driven Gear Shaft 1 9 018X 031 Ball 1 8 Dia 5 10 012C019 Drive Gear 4 5 cc Rev 4 11 069X 064 O ring 041 3 12 078F017 Shaft Retaining Ring 4 13 018X 041 Bearing Sleeve rear Plate 2 14 100865 Rear Plate Assembly 1 15 101691 M4x40SHCS 2 16 NPN M 10 1 5 x 85mm 4 17 100870 M iddle Plate 1 18 N 00198 O ring 113 2 19 NPN M 10 Flat Washer 4 iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 25 DYNAMELT M ASU Manual 20 37 8 02 Bill of Materials for 10cc Single Gear Pump Assembly 109690 Item No Part Number Description Qty 1 018X031 Ball bearing 1 8 Dia 6 078F 017 Snap ring 1 2 4 3 0781001 Key Woodruf 404 1 4 069X061 S haft Seal 1 5 069X064 O ring 041 2 6 100908 M4 0 7 x 25mm SHC Screw 2 7 101626 M5 0 8 x 12mm SHC Screw 4 8 109685 Pump 10 Rev 1 9 109686 Rear Bearing Plate 10cc Rev 1 10 109689 Gear 10cc Rev 2 11 109687 Drive Shaft 10cc 20cc 1 12 109688 Driven shaft 10cc 20cc 1 13 069X160 S haft seal retainer 1 14 0010002 Dow Corning 112 Lubricant Not Shown Page 10 26 Component Illustrations amp BOM s Revised 7 03 TW Dynatec 1999 DYNAMELT M ASU M
127. ing the packing Continue to install the rings in this manner until the proper mimber of packings have Firmly compress the parking by alternating and evenly tightening up the gland screws then back off turn Be sure 10 adjust the gland evenly 8 Some Causes of Pump Failure Problem Cause Seimre a foreign partide b mounting block not flat C uneven heating of fabrication ejinterference fit of moving parts Excessive a wom gears thickness and out reduced pump side reduced diameter corners efficiency of teeth not square h worn center C side plates scored at throat d side plates not itat Leakage worn or scratched coupling or seal plate b drive shaft bottoming in slot of drive shalt misaligned 9 Rehabilitation Pumps may be returned to an authorized repair facility for rehabifitation All repaired pumps must pass the same strict standards as new ones 10 Factory Visit E pumps are to be maintained at your plant it can be very worthwhile to have key maintenance people spend a day at the Zenith factory to view manufacturing gauging and assembly techniques Please contact us concerning plans for such a visit or with any questions you may have regard ing the application or maintenance of your Zenith Melt inning Puraps Parker Hannifin Corporation Zenith Divisi 48 Woerd Avenue Box 9115 Waltham MA 02254 617 894 0650 Telex 283905 Appendix 33
128. ingle Gear Pump Assembly 100862 Page 10 22 Component Illustrations amp BOM s Revised 9 01 TwDynatec 1999 DYNAMELT M ASU Manual 20 29 Bill of Materials for 1 54 cc Rev Dual Gear Pump Assembly 100863 Item No oo t NO e e e e e e e a 1 OQ an A WO C Part Number 012D083 0781001 101626 069X160 069X061 018X041 100866 012D082 018X031 012C020 069X064 078F017 018X041 100865 101692 NPN 100869 N00198 NPN Description Drive Shaft Key Woodruff M5 x 12 SHCS Seal retainer amp Bearing Housing Lip Seal Bearing Sleeve Front Plate Assembly Driven Gear Shaft Ball 1 8 Dia Pump Gear 1 5 cc Rev O ring 041 Shaft Retaining Ring Bearing Sleeve rear Plate Rear Plate Assembly x 35 SHCS M10 1 5 x 85mm SHC Screw Middle Plate O ring 113 M10 Flat Washer Qty FN e A Ne WO WO RP e AA me eR iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 23 DYNAMELT M ASU Manual 20 29 9 01 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread Component Illustration 1 54 cc Rev Dual Gear Pump Assembly 100863 Page 10 24 Component Illustrations amp BOM s T Dynatec c 1999 Revised 8 02 DYNAMELT M ASU Manual 20 29 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread B
129. intenance and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure 2 General Operating Requirements Since Zenith Pumps depend upon metered fluids for hibrica tion of their internal bearing surfaces their recommended optimum operating speed range is between 10 and 75 rpm depending upon viscosity and operating pressures Increasing their operating speed improves their efficiency but also pro vides less time to fill the gear tooth spaces Cavitation may occur if sufficient inlet pressure is not pro vided Cavitation or the failure to fill the tooth spaces com pletely causes jow delivery and excessive wear It also encourages the introduction of air through seals Under ideal conditions speeds up to 200 r have been maintained over long periods of time You can however expect accelerated wear in such instances depending on the tubricity of the solution and the differential pressure in the application Another cause of jow through put is slippage across the sides of the gears from the high pressure discharge section to the lower pressure inlet section when thin fluids are metered against a substantial differential pressure This slippage is dependent on three factors viscosity of the material speed of the pump and the differential pressure Therefore even though the clearance between the gears and their housing may be as litte as 00025 high slippage
130. isplay appears when each hopper is at ready temperature 4 Error Screen an error will cause this screen to appear Touch within the error screen and it will disappear 5 Seven Day Scheduler s Time of Day Clock clock must be set for scheduler to function See Panel View Configuration Screen in this chapter for clock setting instructions Page 5 4 Programming iTVW Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Temperature Menu Screen Example of Temperature Menu Screen 1 Selected Zone Numeric Entry Keys SP 350 PV 305 100 Arrow Keys Example of Temperature Menu Screen 2 additional temperature zones if applicable HOSE 3 ZONE 33 SP 35 347 CV 15 F1 PREV F2 NEXT lt screen MAIN 3 1 Temperature Menu Screen 3 shown additional termerature zones if applicable iTV Dynatec c 1999 Programming Page 5 5 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 5 03 Use of the Temperature Menu Screen Press This To Function Key 2 Program or monitor this numbered temperature zone Main Return to the M ain M enu Setpoint Entry Go to the Setpoint Entry screen 1 2 Go to the Previous or N ext numbered zone Temp Screen 2 or Go to the second or third Temperature M enu screen for more zones Temp Screen 3 if applicable Programming 1 Press Z1 to go to the first temperature zone screen See the followi
131. istance 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 unplug ging the affected head or hose connection and measuring resistance across the affected pins see wiring diagram in Chapter 11 for pin numbers DANGER HIGH VOLTAGE Disconnect input power to the application system before disconnecting re connecting electrical connections Make sure there is no electrical power on the leads you will be connecting The Nominal Hose Heater R esistance 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 H ead H eater Resistance table gives values for several different head wattages A suspected head heater problem can be isolated by measuring head heater resistance and comparing itto 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 M Series model and for the optional drop in grids The Nominal Filter M anifold Heater Resistance table gives heater resistance for the heater located in the optional filter manifold pressure relief block The heater inside the manifold varies depend ing o
132. ive damage to the pump motor and seals Be aware that the higher the adjusted pressure the more sensitive the adjustment is i e at higher pressures smaller adjustments to the screw will make larger changes to actual pressure 10 After desired pressure is achieved tighten the jam nut down onto the adjustment screw and lock itin place 11 Replace and tighten the adjustment screw cap 12 While the motor is operating at maximum speed observe the adhesive flow from the applica tor s 13 Reduce the motor speed in increments of about 1096 until the adhesive flow begins to de crease Note Though the speed of the motor is reduced there will be no change in the amount of adhesive flow coming out of the applicator This is because the pressure relief is designed to allow only a maximum adhesive pressure regardless of the motor speed past a certain point Then increase motor speed in smaller increments 1 to 596 until adhesive flow returns to the de sired amount Note This is the optimum point of operation for the motor pump and pressure relief It will also facilitate the best system performance and reduce wear on these components The application system is now adjusted for normal operation 14 Re tighten the two purge screws and re install the access cover Page 3 8 Installation iTV Dynatec 1999 Revised 11 00 DYNAMELT M ASU Manual 20 29 Pump Enable Ready Thermostat Calibration The Pump Enable R eady Ther
133. l Dimensions ccs ee iterate sas e EE EE Tas see dimensional layouts on following pages Number of heads 5 1 to 8 Number of return hoses or auxillary ZONES 108 Number of hopper temperature ZONES 102 NUMDEr of PUMP INOS DUXI RS bU RE DU TRE 1104 Number of optional drop in gridS Gat enh tebe exe 2 N mber sbandar tacks uoa E a ye 2 Gear PUMPS i 1 ene usc ico n Rod ere d Roe Es p OUR xit Zenith 2 92 cc rev standard cssc UOTIS eked ieu es styled durable metal dust and splatter resistant Hose connections universal 15 pin Amphenol connectors at asu wrench secured fluid fittings 6 JIC Hopper tank Capacity 2 136 oe a reto EE A GA EEE eu 210 kg 420 Ib Hopper 5 machined welded aluminum Teflon impregnated Filtration ee rsen E ER hopper bottom screen large pleated pump outlet filter tat 3 E O oe Pt Wace TBD Adhesive tormi eoe estado E payer med ge abe a ee Ee ee EE quer Yos accepts most forms Electrical S pply voltage os sea eM e ER he lui 200 240 VAC 3p 50 60 Hz 380 VAC 3p Wye Y or 5 wire connec
134. le on and off then the relay has failed and must be replaced Verify that all modules are properly inserted in their sockets on the module rack a Visually examine socket connect ion where hose head attaches to ASU Verify that pins are properly seated If pins or plug housing are damaged repair or replace hose If socket is damaged repair or replace harness b If hose to A SU plug and socket are okay hose may have intermittent short or open circuit Repair or replace hose hose harness or DC output module as appropriate Alternately problem can be isolated by connecting the effected hose to a different ASU hose socket to tell whether the problem is in the hose or in the DC output module C If head to hose and hose to A SU 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 as appropriate Visually examine connection where hose plugs into ASU socket for proper contact and seating If pins or housings are damaged repair or replace hose or hose harness in ASU Tw Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Troubleshooting Page 7 21 Revised 1 99 2 Hose sensor harness unplugged from RTD module inoperati ve Note DMM 70 140 210 arrange ment shown above For DMM 35
135. len Bradley SLC small logic controller 500 systems and they interface with Allen B radley s PanelView touchscreen control panel The Dynamelt M Series 505 are available in three cabinet sizes and offer four hopper sizes Their microprocessor temperature control closely controls the temperature of hot melt adhesive for up to 8 hoses and 8 heads Temperature setpoints are operator selected for up to 32 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions The Dynamelt system provides accurate proportionate temperature control for the hopper hoses and applicators Sequential heating delays may be programmed for turn on of the hoses and heads A standby temperature may be programmed so that the temperature zones can be maintained at a lower temperature when the A SU is not in active use enabling rapid return to normal operation The seven day scheduler allows programmable automatic startup and shutdown of the A SU throughout the workweek With these flexible temperature programming features the D ynamelt System increases adhesive life by eliminating prolonged high adhesive temperatures It reduces en ergy consumption and brings the system up to normal operating temperatures in the shortest pos sible time The SLC 500 maintains all temperature zone setpoints alarms and motor parameters as well as the scheduling parameters The SL C s processor CPU monitors the electronic circuitry and p
136. ly hi temp lubricant PN 001U 002 to a new o ring before installing maintaining system pressure A cut or scuffed scratched o ring can allow 1 CAUTION The condition of the lower o ring PN 069X275 is especially critical to system pressure to escape 9 Replace or re install the filter basket onto the spring clip Push the filter onto the clip The clip should straddle the wire bar located inside the hole at the top of the filter 10 Lower the filter basket and the filter plug back into the filter cavity 11 Position the two flat surfaces at the top of the filter plug parallel to the movement of the 12 Re tighten the two purge screws slide The slide will not return to its operating locked position unless these flat surfaces are aligned properly If necessary twist the plug to align o 2 Retainer gt Plate Screws SW lt Filter Plug Replacing the Optional High Flow Outlet Filter Basket 1 The system should be at operating temperature before starting lt Oring this procedure lt lt Filter Before proceeding verify that the motor s is turned OFF and TE ut the applicators have been triggered to relieve pressure Remove the M anifold A ccess Cover Note it is not necessary to remove the Lower M anifold Cover Using insulated gloves and an allen wrench remove the retainer plate screws Lift out the retainer plate filter plug assembly Outlet Filter Manifold
137. m Outlet Filter M anifold Cross Channel 11 4 Typical Hydraulic Schematic 2 22 2 2 2 2 11 5 Grounding acris o se c n ee dese a ua be cana aes xs n d 11 6 Page vi Table of Contents iTW Dynatec 1999 Revised 5 04 DYNAMELT M ASU Manual 20 29 Pump amp Zone Configuration 2 2 2 2 2 2 11 7 DynameltM ASU 5 2 22 2 end of chapter Appendix Optional Dynatec Zenith Standard Accuracy Gear PUMPS A ppendix 1 Optional Dynatec Zenith High Accuracy Gear PUMPS A ppendix 15 Optional Zenith M elt Spinning A ppendix 29 High Accuracy Pump Performance Chart A ppendix 34 Optional Pressure Transducer A ppendix 35 Optional Pneumatic CIUECh tte eb Lea p eoe leote reae A ppendix 39 Optional TSHA PUMPS eee eH y Ae d ola ORO nd eave nog ane A ppendix 49 ITW Dynatec 1997 ALL MODELS Page 1 1 Revised 1 07 Chapter 1 SAFETY PRECAUTIONS All operators and service personnel must read and understand this ma
138. may still occur from high to low pressure ports if viscosity is low and pressure high i iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 3 Preparing Your Zenith Pump for Use Assembled with mineral oil Assembly with Acetone or MEK Since Zenith Pumps are precise instruments their assembly requires detalled attention to every step 1 Zenith Pumps are shipped filled with a rust preventative oil Flush the oil out thoroughly with a cleaning solvent it may be necessary to disassemble the seal arrangement to remove ali traces of the oil but disassemble only if 2 Alter flushing the pump should be lubricated internally Pour a suitable hich temperature lubricant into the inlet port Rotate the metering gears until the lubricant ap pears at the discharge port 3 Mount the pump to a block with a flatness of true flat to 0007 convex and a surface Finish of 4 to 8 rms to pre vent leakage between the pump and the block Make sure mounting bolts are lubricated with DAG Dispersion 4154 for example and alternately torqued in even in cements up to the manufacturer s recommended limit for the bolt size used see Table Screw Torque Values Standard Alloy Steel Torque Lubricated threads w Carbon Seal Gasket w o Carbon Seal Gasket ee ee 5 55 critical applications where control of bolt preload is important th
139. mber of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate 5 Tighten the mounting bolts and coupling housing screws to D ynatec recommended torque at room temperature 6 Make sure fluid is in the pump before starting 7 Start pump slowly and if possible run it with a lubricating fluid 8 W hen satisfactory operation is achieved the pump and system may be gradually brought up to normal process speeds and pressures 9 f at any time during operation the pump does not appear to be running smoothly stop the pump immediately to avoid any serious internal damage CLEANING INSPECTION AND REPAIR REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op the high pressure demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow adequate lubrication All parts are ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances cont iTV Dynatec 1999 Appendix 5 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 these pumps require careful maintenence and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure These pumps are precision instruments you can t keep
140. mostat is preset to 132 C 270 F unless the customer has specified a different preset temperature on his original ASU order Generally the pump enable thermostat is set approximately 30 C 50 F lower than the application setpoint If a different temperature is desired use the following procedure to re calibrate the thermostat Note The thermostat must be re calibrated and the controller s pump enable temperature must be re programmed CAUTION DO NOT set the pump enable thermostat lower than the softening point of your adhesive or pump damage may result As an example the operator desires to lower the preset Pump Ready temperature to 107 C 225 F 1 Atthe controller keypad set the hopper temperature to the temperature at which you want the pump to start i e 107 C 225 F 2 Open the heater access door after loosening its captive screw 3 Wait for the hopper temperature to stabilize at 107 C 225 F then a For thermostats with purple amp black wire leads or solid tan wire leads turn the thermostat s adjustment screw counter clockwise to increase the temperature or clockwise to decrease it until the pump s motor begins turning A djust no further b For thermostats with tan with tracer wire leads turn the thermostat s adjustment screw clockwise to increase the temperature or counter clockwise to decrease it until the pump s mtor begins turning A djust no further 4 Closethe heater access cover and tighten its c
141. n seal gasket 50 57 4 2 10 24 w o carbon seal gasket 64 7 2 5 3 312 24 120 13 6 10 1 4 20 150 16 9 12 5 5 16 18 305 33 9 25 3 8 16 into aluminum 360 40 6 30 7 16 14 block hopper 480 54 2 40 Table 1 n critical applications where control of bolt preload is important the torque tension relation should be determined by experimenting on the actual parts involved including thread lubricants At elevated temperatures itis often desirable to reduce screw stress because of deformation creep under sustained loading Screws constructed of type H 11 high temperature alloy steel provide extremely high creep resistance iTV Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 TROUBLESHOOTING GUIDE Trouble Pump will not turn Excessive seal assembly leakage Reduced pump efficiency Probable C ause 1 Low pump temperature 2 Drive malfunction 3 Process conditions changed 4 Entrained particle 5 Possible internal damages 1 Worn seal plate 2 Insufficient inlet pressure 3 Worn lip seal 1 Worn gear s 2 Worn bearings 3 Process conditions changed Appendix 9 Revised 10 99 Remedy Check temperature sensor and control loop for proper setting operation Allow sufficient heat up time Verify drive is powered Check to assure all alarm circuits are clear Check drive motor current and speed settings Check all drive couplings Check pr
142. n the number of filter manifolds mounted on the A SU therefore resistance varies also Page 7 14 Troubleshooting iTV Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Resistance Hose Length Resistance in Ohms Meters Feet in Ohms 323 358 201 223 155 172 120 133 102 114 15 84 51 57 Nominal Hose Heater Resistance for DynaFlex Hoses Watts Resistance in Ohms Nominal Head Heater Resistance N ote Resistance is measured at ambient temperature 20 C 68 F m mem Qty Hopper Heaters 1 2 3 Max of Drop in Grids 2 4 6 Resistance Ohms for each Hopper Heater 11 5 11 5 11 5 Resistance Ohms for each Drop in Grid Heater 23 23 23 Nominal Hopper Heater Resistance in Ohms of Filter Manifolds M70 140 on ASU 115 2 115 2 51 6 51 6 Temperature Sensor Resistance 0 00385 PT 100 RTD not available 38 4 not available 28 8 not available not available not available not available Nominal Filter Manifold Heater optional Resistance in Ohms Troubleshooting Page 7 15 iTV Dynatec 1999 Revised 1 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Error Indication Alarm Troubleshooting Guide The operation of error indication alarms is described in Chapter 4 W hen checking 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 o
143. natec Zenith pumps are shipped filled with a rust preventive oil Flush the oil throughly with a cleaning solvent It may be necessary to disassemble the seal arrangement to remove all traces of the oil but disassemble only if necessary After flushing the pump should be lubricated internally for start up purposes Pour a suitable high temperature lubricant silicone oil into the inlet port Rotate the metering gears until lubricant appears at the discharge port M ount the pump to a block with a flatness of true flat to 0001 convex and a surface finish of 4 to 8 rms to prevent leakage between the pump and block M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to D ynatec s recommended limit for the bolt size used See Table 1 on page 23 for torque values The following is a brief standard installation procedure For any special applications con siderations or simply to ask our advice please contact D ynatec cont iTV Dynatec 1999 Appendix 19 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 TO PREPARE THE PUMP FOR USE 1 Always flush out the plumbing system before connecting the pump 2 Filters should be installed prior to the pump inlet that filter ideally to half the pump run ning clearances 3 Turn pumps by hand before running Pumps sho
144. nd troubleshoot Page 7 26 Troubleshooting iTV Dynatec 1999 Revised 10 00 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Gear Pump Troubleshooting Guide 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 Note Each motor in the system can run independently or dependently and may have its own operating parameters Therefore each motor should be troubleshot independently Pump doesn t operate 1 M otor on off is off atthe 1 Check k d setti in M anual mode controller keypad a 2 Hopper temperature is Pump cannot operate until hopper has below ready setpoint reached ready condition Verify that hopper has reached ready Re program hopper operating setpoint and ready setpoint if necessary 3 No incoming electrical 3 Check to see if ASU temperature power control is operating If not check for presence of incoming supply voltage 4 If pump on off is being 4 Check condition of the remote switch controlled by a remote iteh i e a hand held the hand held applicator applicator the switch or switch circuit may be open 5 Inoperative SLC 160 5 If the drive is inoperative it must be drive replaced 6 Low temp alarm 6 Verify that ASU is warmed up and that hopper temperature is above the
145. ng after heat cleamng 5 Wash companents in ultrasonic cleaning tank and gt gt Inspert all paris for nicks burrs score marks and other signs of wear plates and sides of the gears may be hand blocked on 400 600 grit paper and any nicks burrs or sharp edges can be lightty removed with an Arkansas stone CAUTION Since the thickness relationship between the metering gears and center plate is critical to metering performance es Japping 0 and should not be done under any circumstances 7 To keep maintenance costs to a minzoum the following procedure is recommended A Measure used parts and compare their dimensions with new pert standards This wil provide you with precise mformation on the wear of the pump parts and aid in maximizing the nseful life of each component B Replace worn gears shalts bearings and center plates d gra and or lapping them to remove wear markings and return them to flatness within convex and a surface nish of 4 to 8 rms Replace the sleeve bearings as necessary and hone in the plate to the original new part specifications 9 After each resurfacing carefully gauge the area between the intel and discharge ports at the mesh of the gears This area commonly referred to as the throat is the mosi critical part of the plate Scoring or wear rarks here will allow increased slippage from the high pressure discharge par
146. ng two pages for program ming instructions 2 Press each of the zone keys to program each temperature zone in the same manner 3 Press Temp Screen 2 or press Temp Screen 3 to program the zones on the other Tempera ture M enu screens if applicable N otes 1 Hoses are numbered according to the hose outlet each is connected to For example Hose 3 is the hose connected to the 3 hose outlet 2 Your PanelView controller may have up to three Temperature M enu screens depending on the number of temperature zones in your adhesive application system Monitoring 1 W hen selected each temperature zone is displayed in the upper right corner of this screen with its identification number ie Zone 1 Zone 2 etc or Z1 Z2 etc in addition to its name ie Prog M elt 2 Hose 3 etc 2 W hen selected each temperature zone is displayed in the middle right area of this screen with its Setpoint SP Process Variable which represents the actual temperature and its Control Variable which represents the percentage of heater output 3 A bar indicator to the right of each zone s key signifies if the zone is currently ON heating The indicator appears green on the PanelView For example Temperature M enu Screen 1 on the previous page indicates the following zones are ON Z1 Z4 Z5 Z8 Z11 212 Z15 216 Z18 219 222 and 223 Temperature Zone Limits 1 DM 35 asu s have up to 16 zones of tempe
147. nual before operating or servicing equipment All maintenance and service on this equip ment must be performed by trained techni cians Electrical DANGER HIGH VOLTAGE Dangerous voltages exist at several points in this equipment To avoid personal injury do not touch exposed connections and components while input 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 A 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 Safety glasses gloves and long sleeved clothing must be worn whenever working with or around adhesive application systems 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 fitting
148. o reset turn OFF the ASU s main power switch push the center of the thermostat s insulator then restart the ASU Pump Enable Thermostat The pump enable thermostat is a low temperature safety feature of the Dynamelt ASU designed to prevent the pump from powering on before the adhesive is molten It is a cartridge thermostat and it is factory set at 132 C 270 F The thermostat is adjustable so that operators using adhesives with extraordinarily high or low melting points can tailor the low temp setting to their production needs To access the pump enable thermostat follow the instructions given in Chapter 8 To calibrate the thermostat refer to instructions in Chapter 3 SLC 500 Power Supply Fuse An AGC 3 fuse located inside the SL C s power supply is intended to guard against fire hazard due to a short circuit See illustration on page 7 4 for location If all of the LEDs on the power supply and SLC 500 modules inside the panel box are unlit this indicates an inoperative fuse Before attempting fuse replacement all power must be removed from the SLC 500 power supply Note the exposed pin on the 3 pin jumper located directly below the fuse is electrically live Contact with the pin may cause injury DANGER HIGH VOLTAGE SLC Processor Battery Inside the SLC processor module is a replaceable lithium battery W hen the battery gets low a red LED will illuminate on the module for LED location see illustration on page 7 1
149. ocess conditions for proper melt tempera ture pressures viscosities and materials Disassemble and clean pump replace any damaged parts Disassemble and clean pump replace any damaged parts Consult factory Replace seal plate and coupling if necessary Increase inlet pressure Replace lip seal Replace worn gear s Replace worn bearings Consult factory for clearance recommended on new process conditions A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Appendix 10 Revised 10 99 OUTLET PORT 2502 OUTLET PORT 4069 MOUNTING SCREW HOLE 2 HOLES 2X 406 MOUNT ING BOLT HOLES 813 INLET PORT Y tend CAP SCREW 62 CHADS amp L SLACK axtioro 5 20 LONG FOUR WASHERG ITENS 63 FOR HOUNTING NNNM S GGUS 2 NE eT SIF tT do a es TI gt LUN D TUR STD ZO D SECTION A A 3404 WOODRUFF KEYHAY NON ANSI STD 40 2 19 z NOTE gt AFTER ASS Y MATCH 2 DRILLED HOLES FOR ROLL PINS a DUAL STREAM HOB METERING PUMP BREY IRON 440C STAINLESS STEEL AIST AZ AND D2 TOOLSTEELS euam 1 E 35 16662 AND AIST 4 40 ALLOY STEEL Appendix 11 Revised 10 99 DYNAMELT ASU Manual 20 28 20 29 and 20 30 Tw Dynatec 1999 Guy Ta
150. ode Main Menu F8 Select the displayed language F9 Reset Video The Configuration Mode screen allows the operator to adjust parameters that pertain to the Pan elView controller only These parameters do not pertain to the hot melt application The Seven Day Scheduler s clock is set via the Configuration screen Among the many adjustable parameters are screen brightness and backlight display language date and time printer parameters communications and fault LED etc Use the up and down arrows and the function keys F1 thru F10 to move through the configura tion screens To select items on the main Configuration Mode menu the menu beginning with Memory Card and ending with Printer Setup use the up and down arrows to select an item then press Enter to bring up its parameter screen Follow instructions on each screen to make adjustments or return to the configuration screen For examples of each of the Configuration Mode Main Menu parameter screens see the following page COMM LED and FAULT LED are read only status monitors Press F9 to reset the video No further adjustment is necessary Use F8 to choose a display language for the Configuration screen only French German Ital ian Spanish or English Press F2 to return to the Main Menu and the hot melt application Page 5 20 Programming iTVW Dynatec 1999 Revised 10 02 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Configuration Mode Main Menu Parameter Scr
151. ome 1 Verify that grid sensor cable is Grid Sensor Open unplugged from RTD properly connected to its RTD module module 2 Disconnection between 2 Verify that all modules are properly RTD module and the inserted in their sockets on the rack module rack 3 Drop in grid sensor 3 Replace sensor if resistance does inoperative not comply with the resistance table in this chapter Optional Drop in 1 Pinched sensor lead wire 1 Visually inspect sensor lead wire Grid Sensor Short break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the sensor lead to the plug at the RTD module R epair or replace any damaged wire 2 Drop in grid sensor 2 Replace sensor if resistance does inoperative not comply with the resistance table in this chapter 3 RTD moduleisinopera 3 ReplaceRTD module tive IT Dynatec c 1999 Troubleshooting Page 7 19 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 7 00 mem _ Sh Optional Drop in 1 Disconnection in grid s 1 Inspect grid s heater wiring for Grid H eater Open heater circuit proper connections comme e D M eme on ds chc ea tt itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit to ground in the grid s heater circuit This will be limited to between the grid s control relay and the grid s heater 3 Open drop in grid heater 3 Attheterminal rail use an ohmme
152. on its sides lapping these components is not necessary and should not be done under any circum stances Place a layer of 600 Grit Emery Cloth on a lapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 1 approximately five times until a smooth finish appears Turning in a circular fashion or other non uniform motion may cause the ground holes to lose their perpendicularity to the faces Always use clean lint free rags and compressed air to clean components Paper towels are not acceptable they may leave small pieces of paper and dust on the components U se chemical brushes to clean between gear teeth bores and reliefs 8 Replace sleeve bearings as necessary and hone in the plate to the original new part specifications 9 After each resurfacing carefully gauge the area between the inlet and discharge ports at the mesh of the gears T his area commonly referred to as the throat is the most critical part of the plate Scoring or wear marks here will allow increased slippage from the cont iTV Dynatec 1999 Appendix 7 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 high pressure discharge port section across the throat to the lower inlet port reducing effi ciency Therefore carefully gauge this area for flatness after each resurfacing 10 After all components are hospital clean the pump is ready for assembly o
153. one bearing in this Shaft Pump 100861 has two bearing in this shaft Pump 100861 has two bearing in this Shaft Pump 100860 has one bearing in this shaft In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104042 M10 1 5 x 100 All Thread Component Illustration 1 54 cc Rev Single Gear Pump Assembly 100860 Page 10 20 Component Illustrations amp BOM s Revised 9 01 TwDynatec 1999 DYNAMELT M ASU Manual 20 29 Bill of Materials for 4 50 cc Rev Single Gear Pump Assembly 100862 Item No 00 FF W NY e e me Be a NA nA FB t NY Part Number 012D072 0781001 101626 069X160 069X061 018X041 100868 012D073 018X031 012C018 069X064 078F017 018X041 100865 100908 104776 NPN Description Drive Shaft Key Woodruff M5 x 12 SHC Screw Seal Retainer amp Bearing Housing Lip Seal Bearing Sleeve Front Plate Assembly Driven Gear Shaft Ball 1 8 Diameter Drive Gear 4 5 cc rev Pump Seal Shaft Retaining Ring Bearing Sleeve Rear Plate Rear Plate Assembly 4 x 25 SHC Screw M10 1 5 x 80mm M10 Flat washer Qty A A N e N A N N A e e N e e iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 21 DYNAMELT M ASU Manual 20 29 Revised 9 01 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104042 M10 1 5 x 100 All Thread Component Illustration 4 50 cc Rev S
154. or repair procedures All troubleshooting and repair procedures must be per formed by qualified trained technicians CAUTION The SLC 500 modules are prone to damage from static electrical charges during handling Read Handling Printed Clrcuit Boards on page 7 3 before handling or attempting service on the ASU s modules Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 TheASU is supplied with power 3 The ASU is supplied with pneumatic air 4 Pneumatic and electrical connections are correct 5 Adhesive is in the hopper High amp Low Alarm Zone Messages PanelView s M ain M enu lists the identification numbers of zones with either high or low tempera ture alarms as they occur Low Alarms At startup all zones will show alow alarm until adhesive temperatures have reached their Ready setpoints W hen Ready temperatures have been met the alarms will automati cally clear from the controller s display High Alarms The controller will automatically turn OFF any temperature zone which registers a high alarm High alarms indicate either 1 a zone which is over its high temperature limit 2 a short circuit or 3 an open circuit To correct a high alarm refer to the troubleshooting guide in this chapter A fter correction the operator must return to the M ain M enu and toggle Heater Power ON The controller will then clear the alarm and scan the system for other alarms Drive 1 2 etc Fa
155. ot Shown 4 58 811278 Grid Support As needed Revised 8 06 Component Illustrations amp BOM s Page 10 17 DYNAMELT M ASU Manual All M70 140 Models TWDynatec 1999 Note the dual progmelt for the M70 is identical to the dual M140 with a shorter hopper Note the Single progmelt for the M70 M140 is identical to the dual with only one melting compartment to base plate Page 10 18 Component Illustrations amp BOM s TwDynatec 1999 Revised 9 01 DYNAMELT M ASU Manual 20 29 Bill of Materials for 1 54 cc Rev Single Gear Pump Assembly 100860 Bill of Materials for 3 2 cc Rev Single Gear Pump Assembly 100861 No Part Number Description Qty 100860 100861 1 012D079 012D077 Drive Shaft 1 2 0781001 Key Woodruff 1 3 101626 M5 x 12 SHC Screw 4 4 069X160 Seal Retainer amp Bearing Housing 1 5 069X061 Lip Seal 1 6 018X041 Bearing Sleeve 2 7 100866 100867 Front Plate Assembly 1 8 012D080 012D078 Driven Gear Shaft 1 9 018X031 Ball 1 8 Diameter See illustration for quantity 2 4 10 012C020 012C019 Drive Gear 1 54 cc rev 2 11 069X064 Pump Seal 2 12 078F017 Shaft Retaining Ring 4 13 018X041 Bearing Sleeve Rear Plate 2 14 100865 Rear Plate Assembly 1 15 100908 M4 x 25 SHC Screw 2 16 104775 104776 M10 1 5 x 75mm 80mm 4 17 NPN M10 Flat Washer 4 iTW Dynatec c 1999 Component Illustrations amp BOM s Page 10 19 DYNAMELT M ASU Manual 20 29 Revised 9 01 Pump 100860 has
156. oting It is a warning that a device has been turned on when the ASU is not ready Theillustration below provides a brief description of the LEDs on this module For more detail re fer to the Allen Bradley manual Green a device has been forced ON Green Run Mode is ON EM SLC 5 xx CPU P when not ready Force Red CPU is faulted 3 rir Green za PLC is in use 5232 Green P anelView is in use RUN REM PROG e T RUN Run Mode REM Remote Mode PROG Programming Mode Red CPU s battery backup is low SLC Processor CPU Module Layout iTV Dynatec c 1999 Troubleshooting Page 7 11 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Input Modules The SLC 500 utilizes RTD Analog and 115 VAC Input modules Pressure transducers and or line speed inputs are wired into the A nalog Input module s The system s RTDs are wired into the RTD Input module s Each temperature zone in the A SU System utilizes an RTD to measure temperature Each RTD is wired into a terminal of a RTD Input module One RTD Input module can accomodate up to four RTDs channels The 115 VAC Input modules accomodates items such as the overtemp and pump enable thermostats and temperature zones A green light on the module means that itis ON inputting Theillustrations below provide a brief description of the LEDs on these modules For more detail refer to the Allen Bradley manual
157. ouching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the components when you are removing and replacing connectors CAUTION The Allen Bradley modules should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is notavailable 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 the component by its edges only Don t grip a component across its surface 3 When removed from the ASU each component must be individually packaged inside a metallized static drain envelope Do not place the removed component on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a component to another person touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the component to him 5 When unwrapping a component from its static drain envelope place the envelope on a grounded nonmetallic surface 6 To cushion components for shipment use only static drain bags or packaging Do not use foam peanuts or bubble pack not known to be static draining The following pages detail the SLC 500 modules Page 7 4 Troubleshooting iTVW Dynatec 1999 Revised 9 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Model DM M35 AllenBradley SLC Module Configuration Illustr
158. oved from the extruder barrel cont GEFRAN 1 Revised 1 07 DYNAMELT M ASU Manual 20 28 20 29 20 30 and 20 50 PN 805942 804467 Pressure Transducer cont Removal of the transducer from a cold extruder may cause diaphragm damage due to polymer adhesion Cleaning of Transmitter 1 The transmitter sensing diaphragm can be cleaned with a clean dry cloth while the tip is still hot If there is solid polymer present a fluidized bed cleaning system may be used 2 Tools such as wire wheels or abrasive cloths should not be used to clean the transmitter tip 3 The transmitter must be removed before using an abrasive material or wire brush to clean the extruder barrel Wiring Diagrams 1 The power supply instrument end of the cable should be wired as shown below 6 Pin Wiring PTO6A 10 6S SR Shield See note 2 below Mating Connector Power Supply 1 4 Transmitter pans Instrument Transducer Shield drain wire is ted to S or Readout Connector connector via cable clamp a 02 10 6 R Cal oe 8 Pin Wiring 12 85 58 Shield See note 2 below Mating Connector eroe m A Power Supply sua B T Transmitter e 3 2 E D E J F Instrument G g 0 Readout Transducer H y gt Connector PCO2E 10 8P iS 4
159. overhung load data Exceeding the data in Table 1 will result in premature failure to the Modutar Unit 1 Placethe Key Hem 19 output shaft of the Modular Uni and side the output shaft of the Moduiar Unit and motor into the reducer 2 Rotate the Modular Unit and motor until the hotes in the Moduler Unit are aligned with the holes m the veducer flange and the air inlet ports of the Modular Unit are facing down 3 Using four Hex Head Screws secure the Modular Uni and motor w the reducer 4 Altemately and evenly tighten the tour Head Cap Screws making sure the Modular Unit and reducer faces are flush with each other HOUSING GUARD INSTALLATION WARNING Always have the Housing Guard in place when operating Modular Units See Figure 9 Each Modular Unit is provided with Housing Guard After combining the Modular Units install the Housing Guard 50 one of the ribs of the Modular Unit housing is directly beneath the clamp on the Housing Guard Waterproof guards are also available Purchase waterproof guards your focal Horton Distributor Appendix 41 Revised 12 99 OVERHUNG LOAD DATA Load 1 25 4 from Pilot Face ex ws nz 455 1200 281 Lbs 281 Lbs 1544 Lbs 610 Lbs 1800 321 Lbs 321 Lbs 636 Lis 700 Lbs 1200 1281 Lbs 281 Lbs 544 Lbs 610 Lbs 1800 1321 Lbs 321 Lbs 636 Lbs 700 Lbs 1200 244 Lbs 244 t bs 570 Lbs 570 Lbs
160. pped components for close control of operating clearances iTV Dynatec c 1999 Appendix 17 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 99 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating Speed 3 120 rpm depending upon application conditions and fluid viscosity Temperature To 550 degrees F 288 degrees C DESIGN D ynatec Zenith High A ccuracy M etering Pumps consist of two gears rotating in mesh with in a closely fitted housing that is comprised of three plates The center gear plate fits closely around the outside diameter of the metering gears The front and rear plates sandwich the center plate and restrict axial movement of the gears Power is transmitted to the gears by the drive shaft which is a through shaft Shaft sealing is accomplished with a high tempera ture cup seal High accuracy pumps are precision instruments requiring skilled and careful maintenence Constructed of high quality tool and die steels such as AISI D2 M2 M 4 and CPM M 4 or other high performance alloys they are tempered after heat treatment to hardnesses ranging from HRc 58 to HRc 64 Sincethe thermal expansion rates for all three steels are almost identical and are otherwise entirely compatible itis possible to combine them so as to take advantage of their best qualities in the most economical way TheType D2 tool steel is often selected for the side and center plates as it offers good a
161. pplicator manuals for further details 5 Connect optional PSI transducers at the PSI ports labeled on the filter manifold Position them from left to right across the manifolds as shown in the lower illustration on page 3 5 Transducers measuring adhesive pressure before it enters the filter use the ports stamped Pre PSI and transducers measuring pressure after the filter use the ports stamped Post PST Transducers are ITW Dynatec factory calibrated Units not using transducers may use either a PSI port or a feed hose port to mount an optional pressure gauge If all ports are in use the pressure gauge may be installed in line with a hose Page 3 4 Installation iTVW Dynatec 1999 Revised 4 00 DYNAMELT M ASU Manual 20 29 Adding Adhesive Theadhesivelevel in the melt tank should be maintained at 13mm to 100mm 1 2 to 4 from the top of the hopper W here applications demand a high output volume of adhesive add small amounts of adhe sive frequently A dding large amounts of adhesive to an almost empty hopper will lower the tempera ture 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 haveto beflushed if thetwo formulations areincompatible See Chapter 6 of this manual forthe proper flushing procedure W hen in doubt about adhesive compatibility flush your system
162. property seated against the Retaining Ring on Models 625 75 and 1375 NOTE or the Hub on Model 1125 See Figure 1 Make sure the air inet ports are property aligned for your mounting requirements 2 Setthe Modular Output Unit MOU onto the MDU making sure the Ball Bearing Item 27 is fully seated into the 5 Using the four Socket Head Cap Screws Item 31 secure bore of the MOU See Figure 1 the MOU to the MDU See Figure 1 3 Rotate the MOU until the four clearance holes are aligned 6 Altemately and eventy tighten the four Socket Head Cap with the four MDU tapped hotes See Figure 1 Screws Item 31 to 50 Ft Lbs E9 Nem torque See Figure 1 4 Press the MOU down against the Compression Spring MOUNTING MODULAR UNITS MODELS 625 AND 875 TO A MOTOR 1 Place the Kay ttem 19 into the motor shaft then slide the motor shaft into the Modular Unit See Figure 7 2 Rotate the Modular Unit until the clearance holes in the Modular Unit are aligned with the tapped holes in 1he Moior then using the four Hex Head Cap Screws Item 33 and Lock Washers item 24 secure the motor to the Modutar Uni See Figure 7 3 Altemately and evenly tighten the four Hex Head Cap Screws to 20 Ft Lbs 27 Nem torque cont iTV Dynatec 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont ALL MODELS AND MOTOR TO A REDUCER CAUTION When mounting sheaves or sprockets refer to Table 1 for
163. pump seal from its groove on the back of the pump adapter plate this is the seal located between the adapter plate and the hopper Install the new seal Screws Re Assembly Procedures Unless noted the M Series ASU s re assembly is simply the reverse sequence of the disassembly procedures H owever the following cautions should be followed whenever they apply for proper re assembly WARNING HOT SURFACE It order to protect personnel and equipment it is important to replace all insulation whenever it is removed from the ASU 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 07588 CAUTION TAPERED PIPE THREADS are found on air line fittings used with the pump air supply if applicable and on the outlet filter manifold Apply thread sealant PN N02892 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 assemble
164. rature zone capability 2 Model DM 70 and DM 140 asu s have up to 32 zones of temperature zone capability 3 Model DM 210 asu s have up to 46 zones of temperature zone capability 5 6 TwDynatec c 1999 Revised 1 05 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Setpoint Entry Programming Screen s Numeric Entry Keys ZONE NAME HEATER OUTPUT E 9 ZONE SETPOINT E ACTUAL E E E ALARM BW F1 PREV F2 NEXT 100 SCREEN PRIORITY 0 Delete Enter Arrow Keys For a list of the names numbers of the Temperature Zones for your system see the electrical schematic in Chapter 11 and or the last page of this chapter iTV Dynatec 1999 Programming Page 5 7 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 10 02 Use of the Setpoint Entry Programming Screen s Each of the temperature zones is programmed individually by using the function keys as follows Press This To Function Key ON OFF Toggle zone ON or OFF Setpoint Program the zone s temperature setpoint Alarm BW Program the zone s high and low alarm range Priority Program a heating sequence priority for this zone F1or F2 Go to the Previous zone the Next zone on active menu Temp Screen 1 or 2 Return to a Temperature Menu Programming 1 Toggle to turn the zone ON or OFF 2 Press Setpoint to program the zone s temperature setpoint a Use the numeric keypad to enter desired s
165. rness or other ASU wiring as necessary Troubleshooting Page 7 23 Tw Dynatec 1999 Revised 1 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Adjustable Adhesive Pressure Relief Valve Dynamelt pumps are outfitted with a high pressure relief valve located on the outlet filter manifold The valve is adjustable and it does not affect adhesive pressure under normal operating conditions The adjustable pressure relief valve is factory set at 34 bar 500 psi for Dynamelt M gear pumps W hen adhesive pressure exceeds the set limit the pressure forces the valve to move away from its seat compressing the spring and allowing adhesive to flow back to the hopper This adhesive flow reduces pressure When the pressure falls below the set limit the spring forces the valve against its seat cutting off adhesive flow The check valve seen below is not instrumental in pressure relief t serves as an overflow valve preventing adhesive from flowing out of the hopper when the filter plug is removed Normally Closed Unrelieved In the drawing below the pressure relief valve is closed Check Valve Spring return Pressure to Relief hopper Valve mmm from pump to hose Adhesive flow through filter block to hose Open Relieved In this drawing pressure has exceeded the setting of the valve causing it to open and discharge adhesive to the hopper Check Valve Pressure Relief Valve Filter Basket
166. roperly connected on the RTD mod ule ule 2 Disconnection between 2 Verify that all RTD modules are RTD module and the rack properly inserted in their sockets on the module rack 3 Inoperative hopper sensor 3 Replace hopper sensor if resistance does not comply with resistance table in this chapter ees Hopper Sensor Hopper Sensor Short 1 Pinched sensor lead wire 1 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 RTD module R epair or replace any damaged wire 2 noperative hopper sensor 2 Replace hopper sensor if resistance does not comply with resistance table in this chapter iTV Dynatec c 1999 Troubleshooting P age 7 17 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 1 99 Hopper Heater Open 1 Disconnection in hopper 1 Inspect hopper heater wiring for heater circuit proper connections Hopper E 2 Hopper circuit breaker 2 Refer to the schematic in Chapter 11 tripped to locate the hopper circuit breaker If itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit to ground in the hopper heater circuit This will be limited to between Az the hopper control relay and the hopper TA Hopper N Heater Wire 3 Open hopper heater 3 Atthe terminal rail use an ohmmeter Thermostat element to m
167. rotect other components from potentially damaging pressure levels The system will allow pressures up to 1000 PSI however typical factory settings are 500 PSI WARNING HIGH PRESSURE NOTE The following sleeved protective clothing must be worn procedure will require the to prevent the possibility of serious injury hot melt adhesive to be at from the molten adhesive Refer to a high temperature and the application Chapter 1 and the section entitled system to have substantial pressure SAFETY PRECAUTIONS for further Safety glasses insulated gloves and long details and First Aid information To Adjust Pressure Relief Note This adjustment should be done with a melt pressure gauge or a pressure transducer installed ailure to use proper equipment can result in excessive pressure levels 1 Turn the application system ON and raise the temperatures of all components to normal operat ing temperatures Note Position a bucket or other waste receptacle under the applicator s so that adhesive will be collected during the adjustment procedure 2 Atthe controller set the motor speed to 0 so that the gearmotor is not turning 3 Locate the pressure relief assembly on the filter manifold where the hoses attach to the A SU and remove the access cover Note itis not necessary to remove the Lower M anifold Cover 4 Position a heat resistant container below the manifold With a hex key screwdriver allen wrench slowly loosen
168. rovides alarms for error conditions A DeviceN et module provides communication to the A SU s drives The PanelView 600 touchscreen color controller is the operator s interface to the SLC 500 system The temperature control can interlock the parent machine with preselected adhesive temperatures so that production automatically begins when adhesive temperatures are correct for the application A II System temperature values can easily and quickly be programmed The Dynamelt M ASU uses an extremely dependable gear pump s to assure a smoother and higher precision flow The single or dual pumps are driven by individual drives The Dynamelt s teflon coated hopper accepts adhesive in all popular forms including pellets slugs and blocks The ASU can accomodate air actuated automatic applicators heads electric applica tors hand held applicators and or special applicators Options available include pressure gauge two drop in grids dual hopper pneumatic clutches digital pressure readout and adhesive level control The DM 140 is also available in a high flow model Page 2 2 Description amp Specifications iTV Dynatec 2001 Revised 2 01 DYNAMELT M ASU Manual 20 37 Specifications Environmental Storage shipping temperature 40 C to 70 40 F to 158 F Ambient service temperature 7 C to 50 20 F to 122 F Noise emissio NEN lt 60 dbA at 1 meter 39 inches Physica
169. s 7 By Filter Shutoff Keylock Assembly 2 Panel Box x Assembly Over Temp Reset Thermostat for dual hopper Pump Enable Thermostat SS for dual hopper M Manifold SP Nu Filter Shutoff Assembly gt MZ 2 Cover y Ker 2 J n 707 Ball Valve Assembly ab ae n OT y zi J unction Box 4 Pump Enable 27 Thermostat Over Temp Reset Thermostat Page 8 2 Disassembly amp Re assembly iTV Dynatec c 1999 Revised 3 01 DYNAMELT M ASU Manual 20 29 J unction Hopper Box cover J unction Cutouts for conduit connectors for filter manifold heater and sensor Over Temp Reset Thermostat Cutouts for drop in grid assembly Filter S hutoff Pump Enable i i ge Thermostat P ort erminals J unction Box Side View Sensor or Thermostat Replacement Remove the junction box cover a Over Temperature Thermostat Replacement Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper b Pump Enable Thermostat Replacement Disconnect two wires from the terminal strip and slide the thermostat out C RTD Sensor Replacement Disconnect two wires from the terminal strip and slide the sensor out To Remove the Manifold Cover Unscrew its captive scre
170. s MDI and TDI that can be dangerous to anyone exposed to them These fumes cannot be detected by the sense of smell ITW Dynatec strongly recommends that an exhaust hood or system be installed over any PUR system Consult with your adhesive manufacturer for specifics about required ventilation CAUTION Because of the nature of PUR A N 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 table ALLOWING PUR ADHESIVE TO CURE IN A UNIT VOIDS ITW DYNATEC S WARRANTY 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 1 4 ITW Dynatec 1997 Revised 3 97 ALL MODELS ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 1999 Description amp Specifications P age 2 1 DYNAMELT M ASU Manual 20 29 Revised 6 99 Chapter 2 DESCRIPTION AND SPECIFICATIONS Description The DY NAM ELT M 70 and M 140 adhesive supply units A SU are computer controlled hot melt supply units designed on metric standards They utilize Al
171. s or connections IMPORTANT NOTE Even when a system s pressure gauge reads O psig residual pressure and trapped air can remain 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 equipment 1 2 Revised 3 97 Protective Covers WARNING DO NOT OPERATE WITHOUT GUARDS IN PLACE ITW Dynatec c 1997 ALL MODELS Keep all guards in place To avoid personal injury do not operate the application system without all covers panels and safety guards properly installed Eye Protection amp Protective Clothing WARNING EYE PROTECTION REQUIRED q PROTECTIVE CLOTHING REQUIRED It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment Wear safety glasses with side shields which conform to ANSI 787 1 or EN166 Failure to wear 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 Safe Installation and Operation To avoid possible failure of
172. stallation Procedure 1 Remove protective cap from sensing diaphragm 2 Lubricate threads with Neverseez by Bostik or C5A by Felpro 3 Clean hole before installing transmitter to ensure that any residue that may damage the sensor tip is removed 4 Thread transmitter into the mounting hole hand tight then turn with a wrench The recommended torque is 150 500 inch pounds maximum 5 Bring the extruder to operating temperature To correct for the temperature induced zero offset With the extruder at operating temperature and with no pressure applied to the transmitter adjust the zero trim pot on the transmitter until the readout indicates 4mA This equals zero pressure The span is factory set for 20 at full scale and does not require adjustment This zero shift is normal and expected and does not affect span or linearity 6 The calibration pressure of the readout instrument is factory set at 80 of full scale pressure This can be done by pushing the calibra tion button on the readout instrument if so equipped or by shorting the blue Pin E and brown Pin F wires This will create an output of approx 16 8mA 80 of 4 20mA 7 Perform calibration procedure according to last page of this document Note Transducers installed on ITW Dynatec ASUs have been factory calibrated Transmitter Removal It is good operating practice to ensure that the extruder is at operating temperature when the transmitter is rem
173. t Illustrations amp BOM s Page 10 5 DYNAMELT M ASU Manual All Models Revised 8 05 Optional x 2 Pd a 03 Nz MO 5x 2 Swe a N Note The junction box can be mounted either side ofthe filter block depending on the application set up Component Illustration Hi Vol Filter amp Pressure Relief Assembly 809534 Page 10 6 Component Illustrations amp BOM s Revised 8 99 T Dynatec 1999 DYNAMELT M ASU Manual 420 29 Bill of Materials for Typical Electrical Panel Box Assembly 802704 Item No gt rn PP H F O Part Number 802710 802626 102329 103377 103378 103438 103438 104382 104383 104384 104767 802657 802658 048H 384 Description Allen Bradley Panel View Kit Color Heat Sink Panel Box Lock Kit Wire duct 1 5 W x 3 H Wire duct 2 W x 3 H Wire Duct Cover 2 25 Wire Duct Cover 1 5 Rotary Handle Shaft 8 M echanical Operator Circuit B reaker Circuit Breaker 175A 240V ED Series Panel Box Insert Panel SSR Dual 40 240VA C Continued on pages 6 thru 7 PrP amp mn a Revised 11 00 Component Illustrations amp BOM s Page 10 7 iTVW Dynatec 1999 DYNAMELT M ASU Manual 20 29 Page 10 8 Component Illustrations amp
174. t Module Layout Page 7 8 Troubleshooting iTV Dynatec 1999 Revised 9 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 DeviceNet cont Troubleshooting with the Scanner s Error Code Display The Scanner M odule displays an A ddress Error code that is interpreted as follows Code 0 63 70 71 72 73 74 75 76 77 78 79 80 Problem Correction Normal operation The numeric display Do nothing matches the scanner s node address on the DeviceN et network Scanner failed Duplicate N ode A ddress Change the scanner channel address to check another available one The node address you selected is already in use on that channel data in scan list table node number Reconfigure the scan list table and alternately flashes remove any illegal data Slave device stopped copmmunicating Inspect the field devices and verify node number alternately flashes connections Device ID does not match scan list table Enter a matching scan list device ID entry node number alternately flashes D ata overrun on port detected M odify your configuration and check for invalid data No network traffic at all has been detected Verify connections No direct network traffic for scanner None The scanner hears other network detected communication Data size returned does not match scan Reconfigure your module and change the lists entry node number alternately flashes addressing Slave
175. t section across the throat to the lower inlet port reducing effiGency Therefore carefully gauge this Appendix 32 Revised 10 99 7 Reassembly NOTE During and between each reassembly step manually turn the metering gears to ensure that they are free turning If binding occurs at any time determine the cause and correct it immediately A tiny nick burr or foreign particle can extensively damage avaluable pump component Never use force in reassembling or turning a Zenith Pump If properly aligned the pieces will fit easily into place and the pump will tura freely Reassemble the pump as follows 1 After all wom parts have been refinished or replaced all parts should be thoroughly cleaned in solvent and dried 2 Using the driven gear as an uprighting fixture carefully locate the arbor over its press fit hole in either the front or rear plate Smoothly drive the arbor into its hole with the help of an appropriate arbor press 3 Place the front side plate with the arbor in position in a soft jaw vise or holding fixture 4 Slip together the driving metering gear drive shaft and key Position in the front of the side plate by installing the drive shaft through the bearing 9 Place the driven metering gear on its arbor and careful ly mesh with the driving metering gear Carefully lower the center plate over the gears 7 Position the rear side plate 8 Rotate the gears to ensure free rotation S Press the dow
176. tate at a slower speed to ensure complete volume filling and to prevent cavitation D ynatec Zenith pumps rely on the metered fluid for lubrication of internal bearing areas pump should never be allowed to run dry or be allowed to run with non lubricating fluids Such as water B ecause of the close clearances in the bearing areas lack of sufficient lubrica tion can cause pump seizure or some other catastrophic failure Slippage will occur across the faces of the gears from the high pressure side to the low pres sure side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate High Accuracy Pumps are designed for high temperature and high pressure operation As such operating temperatures to 550 degrees F can be achieved INSTALLATION Pumps should be carefully unpacked to make sure that the shipment is complete If any items are missing or damaged the freight carrier and D ynatec should be notified immediately While the pump is composed of steel itis a precision instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat them as you would any other precision gauging instrument D y
177. tec s product warranty is in effect only if the following safeguards are written into the logic of customer provided PLCs WARNING Any software deviations from the following may cause unsafe conditions including fire in the hopper hoses and applicators Shorted and open sensors must open the main heater contactors Shorted and open sensors must stop all pump motors The under temperature switch must stop all pump motors The under temperature alarms must stop all pump motors The over temperature switch must stop all pump motors The over temperature switch must open the main heater contactors The over temperature alarms must open the main heater contactors 0 1 A U N The E stop and the auxiliary disconnect must stop all pump motors DANGER HIGH VOLTAGE Never open the control panel without switching off the main disconnect switch to ensure that it is disconnected from its power source Temperature Control Functions in General The microprocessor based proportional temperature controller in the ASU performs a number of functions that help to maintain adhesive setpoints in all temperature zones of the DYNAMELT SyS tem It maintains permanent system values fixed proportional and integration values that have been programmed at the factory It enables the user to program temperature settings and heater on off se quencing that are appropriate to a specific application It displays programmed valu
178. ted grid s which is installed near the bottom of the A SU s hopper The additional grid s allows faster melting of adhesive for applications requiring higher melt rates and higher volumes of adhesive W hen installed the drop in grid becomes an auxiliary temperature zone on the controller High Temperature Heater Groups M ore accurate temperature control may be gained by using a High Temp Heater Group in the filter manifold pressure relief block A heater and sensor are contained inside the block and become their own temperature zone on the controller Six groups are available depending on the number of filter manifolds on the ASU Filter Options and Accessories 40 Mesh Outlet Filter PN 101246 Some situations do not call for a fine mesh outlet filter A clean adhesive or one with a long pot life are examples Systems utilizing lower temperatures or systems running in a clean environment can also utilize a 40 mesh filter Standard equipment on D ynamelt is a 100 mesh filter PN 101247 Pump Options and Accessories Gear Pumps For higher tolerances and precision several gear pumps are available for the Dynamelt Gear pumps give better service for continuous applications or applications which require more control over the volume of adhesive pumped Gear pumps available are Single Pumps PN 100860 1 54 cc rev single standard accuracy gear pump PN 100861 3 2 cc rev single standard accuracy gear pump PN 100862 4 5 cc rev single st
179. ten you need to replace it The outlet filter is located on the outlet filter manifold on the hose connection panel of the ASU See illustra tion of theoutlet filter on page 6 2 Use the following procedure to replace the standard outlet filter cont WARNING HIGH PRESSURE Turn the motor OFF and trigger the applicators to relieve adhesive pressure before performing any outlet filter maintenance WARNING Avoid splashing hot adhesive The filter screen will be covered with hot adhesive and must be handled with proper tools Position a heat resistant container under the manifold before proceeding Page 6 2 Preventive Maintenance TWDynatec 1999 Revised 3 01 DYNAMELT M ASU Manual 20 29 and 20 30 Adjustment Screw O ring PN A69X133 N Filter Plug pcm Spring Clip gt Filter Basket gt PN 101246 40 mesh H NE PN 101247 100 mesh Roll Pin in Groove Slide in Open Position Outlet Filter Manifold Purge Set Screw Purge Drain 3 Purge Set Screw Purge Drain Standard Outlet Filter Manifold located at the Hose Connection Panel 1 The system should be at operating temperature before starting this procedure 2 Before proceeding verify that the motor s is turned OFF and the applicators have been triggered to relieve pressure 3 Remove the M anifold Access Cover by unscrewing one screw Then lift
180. ter element to measure resistance as follows Thermostat Forlgrid amp N 380v 07 H1A amp H1B 240v 1750w For 2nd grid H2A amp N 380v H2A amp H2B 240v For 3rd grid H3A amp N 380v H3A amp H3B 240v For 4th grid H4A amp N 380v H4A amp H4B 240v For 5th grid H5A amp N 380v H5A amp H5B 240v For 6th grid H6A amp N 380v H6A amp H6B 240v See the resistance table in this chapter for normal resistance values Infinitely high reisistance values indicate an open heating element which must be replaced 4 RTD moduleisinopera 4 ReplaceRTD module tive Page 7 20 Troubleshooting Revised 10 99 Problem iTW Dynatec 1999 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 H ose H ead No Overtemp Note DMM 70 140 210 arrange ment shown above For DMM 35 see Chapter 3 Sensor Plug Sensor amp Heater ose Head No Sensor Open 1 Hose Head setpoints incorrectly programmed 2 head hose dual solid state relay 3 Disconnection between RTD module and the rack 4 Hose Head sensor circuit inoperative 1 Disconnection between hose and ASU 1 2 3 4 Im Re program setpoints to allow a larger deviation Refer to the schematic in Chapter 11 to locate the correct head hose relay U se a clamp on ammeter to monitor head hose current If current does not cyc
181. ter Control Section 240v 4 block 34 036A170 Heater 5 8 x 5 240v 500w used with 1 Filter Block Assembly 1 036A079 Heater 5 8 x 10 240v 1000w used with 2 Filter Block Assemblies 1 102149 Heater 5 8 x 15 240v 1500w used with 3 Filter Block Assemblies 1 036A077 Heater 5 8 x 20 240v 2000w Used with 4 Filter Block Assemblies 1 35 036E032 Sensor Adapter 1 36 036B103 Temperature Sensor 1 37 107754 Cover Hi Temp Sensor amp Heater Section 1 38 107645 Conduit 10 1 39 106156 M4 x 6mm SHSS 1 40 104163 M6 x 25mm SHC Screw 2 41 101833 10 32 x 1 2 Tamper Proof screw 2 42 104852 M10 x 12 cone Relief Set Screw 2 43 N00199 O ring 114 2 44 107751 Conduit Fitting located in junction box 1 45 N06883 Jam Nut located in junction box 1 46 103570 MS x 8 x 6 CUD SH Set Screw 1 Note These items are included in 108012 Plug Assembly Revised 6 03 Component Illustrations amp BOM s Page 10 3 DYNAMELT M ASU Manual All Models T Dynatec c 1999 N o o o lt a Component Illustration Filter amp Pressure Relief Assembly 102710 Page 10 4 Component Illustrations amp BOM s il Tv Dynatec c 1999 Revised 8 06 DYNAMELT ASU Manual Hi Vol Filter amp Pressure Relief Assembly 809534 Item No Part Number Description Qty 1 N00185 O ring 018 6 2 003D105 Heater Plate 1 3 006B043 Heat Isolator 1 4 809533 Block Filter 2 5 8
182. the manifold s two purge set screws do not attempt to remove them Al low adhesive and pressure to escape out of the manifold A dhesive will drain into the container 5 Remove the adjustment screw see diagrams below and loosen the jam nut Turn the ad justment screw counter clockwise until it is two turns from being completely out of the filter plug Note if the adjustment screw comes out of the filter plug be prepared for some adhesive to flow out of the screw hole cont P Turning adjustment screw Screw cap A counterclockwise opens the outlet and decreases the e pressure to the hose am nut 3 A Turning the adjustment screw clockwise closes the outlet Adjustment screw ang ine teases the pressure to the hose iTV Dynatec 1999 Installation Page 3 7 DYNAMELT M ASU Manual 20 29 Revised 8 99 6 Atthe controller turn the motor ON to its maximum operating speed 7 Actuate open the valves on the applicator s in order to fill them with adhesive and purge air from the system 8 Closethe valves those openend in the last step to stop the flow of adhesive 9 Using a wrench turn the adjustment screw clockwise to increase the pressure to the applica tor s 1 CAUTION Approach desired pressure with caution DO NOT TURN THE ADJ USTMENT SCREW COMPLETELY CLOCKWISE BOTTOMING IT INTO THE PLUG since this would shut off the pressure relief channel and could cause extens
183. the temperature setpoint is 200 degrees and the high low alarm setpoint is 10 de grees then the high alarm equals 210 degrees and the low alarm equals 190 degrees Mechanical High Temperature Protection A mechanical redundant thermostat located on the ASU hopper that will turn OFF the system at 232 C 450 F Microprocessor based Proportional Temperature Control The built in control system that controls monitors and displays all system temperature values Over Temperature Setpoint The programmable temperatures that will cause display alarms to occur when those temperatures are exceeded Power is disconnected the READY contact opens and the alarm contact closes If an ex ternal alarm has been connected for example to a PLC it will activate 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 board from damage by not allowing the pump to activate until a low limit the programmed pump enable tem perature is achieved The pump enable thermostat is manually calibrated iTV Dynatec c 1999 Controller Set Up Page 4 3 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 1 99 RS232 RS485 Serial Communication A bi directional data transfer connection to a remote computer which enables system parameters to be monitored and or controlled from the remote station The RS485 serial port connection
184. tion 50 60 Hz M inimum supply amperes see circuit breaker size Power consumption 10 000 watts Power consumption 2 drop in 01105 5 000 watts Hopper heater type coss et er puc EEDE E ira whet eeu cast in Temperature microprocessor based proportional integral derivitive PID Temperature 5 5 100 Ohm Platinum RTD standard She AGING HME RA E A 120 Ohm Nickel RTD optional Electrical CONNCCIONS shiv chara teen eee as TA durable latching connectors cats oda wit 1 2 hp alternating current motor TEFC direct drive vertical orientation right angle gearbox M aximum current available for each hose head 10 ampere totally enclosed fan cooled 1999 Description amp Specifications Page 2 3 DYNAMELT M ASU Manual 20 29 Revised 2 04 Performance Adhesive temperature control range 40 C to 232 C 100 F to 450 F Standby adhesive temperature range up to 80 C 150 F lower than setpoint Hopper ready adhesive temperature deviation factory set field adjustable 20 C 36 F from setpoint Over temperature cutoff for
185. tion within a container which will catch the used flushing fluid 4 Addflushing fluid to the hopper and allow approximately 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 Avoid splashing the flushing fluid from the end of the hose 6 Reduce the pump speed to zero 7 Remove the outlet filter and replace the basket following the procedures outlined in the Outlet Filter section of this chapter 8 Add new adhesive to the hopper and allow it to reach application temperature 9 Slowly increase motor speed to the pump 10 A ctuate each of the heads until all the flushing fluid is removed and a steady stream of new adhesive flows T Re adjust the pump speed for the desired flow 1 Re fill the hopper with adhesive The system is now ready for production iTV Dynatec c 1999 Troubleshooting P age 7 1 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Revised 8 01 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes DANGER WARNING HIGH VOLTAGE e 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 trou bleshooting
186. to operation of the motor s are analog There are two wires for each terminal INO and INO on the Allen Bradley analog input Polarity must match from wire to terminal to and to Line speed varies between 0 and 10VDC Refer to the schematics and layout drawings in Chapter 11 for details 4 The adhesive hoses are connected at the rear of the ASU see illustration on page 3 5 Remove the manifold cover and the lower manifold cover for access Each hose is connected at both an adhesive port and an electrical connect Make your electrical hose connections at the numbered connects above the filter manifolds Route hoses so that there is at least an eight inch radius at any bend Do not hang hoses without proper support Do not crimp clamp squeeze or tie hoses Two feed hose adhesive ports are located at the bottom of each filter manifold When making hose connections use the numbered guides shown on the illustration to coordinate ie when using one hose make your hookup to electrical connection 1 and adhesive port 1 When using two head hoses hookup head hose 1 to electrical connection 1 and adhesive port 1 then hookup hose head 2 to electrical connection 2 and adhesive port 2 etc Two return hose adhesive ports are located at the top of each filter manifold Use the illustration to coordinate adhesive port and electrical connections as above Return hoses are designated as auxiliary ports Refer to the hose and a
187. too VISCOUS 3 Clogged hose 4 Clogged applicators 5 The fixed pressure relief valve is Opening 6 Inoperative lower o ring in filter plug is allowing pressure to escape Adhesive leak at pump shaft seal Seal Assembly Rear Plate O ring 4 Adhesive leak at pump to hopper interface 1 Pump seal is incorrectly positioned inside the seal and bearing assembly 2 Pump seal inoperative 1 Pump assembly screws are missing or loose 2 Helicoil insert pulled out of hopper 1 Remove and inspect filter basket and filter shutoff 2 Verify that system components are at appropriate temperatures and that the selected adhesive is correct for the application 3 Inspect hose for kinks or internal plugs of debris or char Clean or replace hoses as necessary 4 Inspect applicators for plugged nozzles or filters Clean or repair applicators as necessary 5 W hen fully closed clockwise and all applicators are off adhesive pressure should be around 34 bar 500 psi If itis significantly less the pressure relief valve should be replaced 6 Replace o ring Follow diagram and instructions in Chapter 6 for Outlet Filter to locate the o ring 1 Remove seal and bearing from pump Verify that all components are correctly positioned 2 Remove seal from pump inspect it and replace it if worn or damaged Be sure there are no burrs or other sharp edges on the rear plate o ring groove t
188. uch as water B ecause of the close clearances in the bearing areas lack of sufficient lubrication can cause pump seizure or some other catastrophic failure Slippage will occur across the faces of the gears from the high pressure side to the low pres sure side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate The Standard A ccuracy Pumps are designed for high temperature and high pressure opera tion As such operating temperatures to 450 degrees F can be achieved INSTALLATION Pumps should be carefully unpacked to make sure that the shipment is complete If any items are missing or damaged the freight carrier and D ynatec should be notified immediate ly W hile the pump is composed of steel it is a precision instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat cont Appendix 4 iTVW Dynatec 1999 Revised 10 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 them as you would any other precision gauging instrument D ynatec Zenith pumps are shipped filled with a rust preventive oil Flush the oil throughly with a cleaning solvent It may be necessary to disassemble the seal arran
189. uld turn freely 4 Engage the outer drive shaft carefully making sure that it does not bottom in the slot of the coupling and that it is aligned within one degree angular and 005 parallel with the true pump drive axis Note the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate 5 Tighten the mounting bolts and coupling housing screws to D ynatec recommended torque at room temperature 6 Make sure fluid is in the pump before starting 7 Start pump slowly and if possible run it with a lubricating fluid 8 W hen satisfactory operation is achieved the pump and system may be gradually brought up to normal process speeds and pressures 9 f at any time during operation the pump does not appear to be running smoothly stop the pump immediately to avoid any serious internal damage CLEANING INSPECTION AND REPAIR REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op the high pressure demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow adequate lubrication All parts are ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances these pumps require careful maintenence and handling especially o
190. ult or DeviceNet Fault Messages PanelView s M ain M enu System Status indicator may specify a faulted drive or a faulted Device Net In most instances these faults will automatically clear in up to 30 seconds If they do not au tomatically clear turn the SUs power Off then ON again at the circuit breaker Observe the D evi ceN et module it may indicate a numbered fault If so refer to the AB DeviceNet manual to clear Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the A SU 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 ap plicator and hose the problem is probably in the ASU Page 7 2 Troubleshooting iTV Dynatec 1999 Revised 9 99 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 High Temperature Redundant Overtemp Thermostat The Dynamelt M Series ASU includes a mechanical redundant overtemp thermostat that acts as a Safety back up If the ASU s hopper temperature should exceed 232 C 450 F the thermostat will cause the A SU s circuit breaker to open and power to the hopper and all hoses and heads will be cut off The mechanical thermostat must be manually re set after the hopper temperature falls below 204 C 400 F The overtemp thermostat is located behind the heater access door see Chapter 8 T
191. urrs score marks and other signs of wear The plates and faces of the gears may be hand blocked on 400 600 grit paper and any nicks burrs or sharp edges can be lightly removed with a honing stone Be careful not to round off the edges of the gear teeth while lapping CAUTION Sincethe thickness relationship between the metering gears and the center plate is critical to metering performance and the center plate is non wearing on its sides lap ping these components is not necessary and should not be done under any circumstances Place a layer of 400 Grit Emery Cloth on a lapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 1 approximately ten times until a smooth finish appears Turning in a circular fashion or other non uniform motion may cause the ground holes to lose their perpendicularity to the faces Always use clean lint free rags and compressed air to clean components Paper towels are not acceptable they may leave small pieces of paper and dust on the components U se chemical brushes to clean between gear teeth bores and reliefs 8 Replace sleeve bearings as necessary and hone in the plate to the original new part specifications 9 After each resurfacing carefully gauge the area between the inlet and discharge ports at the mesh of the gears This area commonly referred to as the throat is the most critical part of the plate Scorin
192. utions iTV Dynatec c 1999 Table of Contents Page iii DYNAMELT M ASU Manual 20 29 Revised 3 01 TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Electrical T ieee hated 1 1 High Temperatures nude Oda ceed heh ed GAME Vased edat Qed 62 1 1 MIG PLESSUFE poa Raha RAMS bale pata patto pate opo led 1 1 Protective COVGrS seus occae edebat balneo base honda Wate Gs desea pA 1 1 Eye Protection amp Protective Clothing 1 2 Safe Installation and Operation 1 2 Treatment for Burns From Hot elt 1 2 SII cM 1 3 Explosion Fire Hazard 1 3 LOCKOUT TAQOUE erp icy Sead aig a Dene e don p wi dd 1 3 Chapter 2 Description amp Specifications Description xen ober PERO CORR ea EUR xb Rc Fl i e gor Ed 2 1 Specifications x eR por kd xe eo x ber pow ober prc n 2 2 Dimensions dk doc Su RA NGA Rc 2 4 Total System Wattage Capacity 2 6 Main Circuit Breaker Determination
193. ve Section O 2 AeA oq MN HH Ep TwDynatec 1999 Component Illustrations amp BOM s Page 10 27 DYNAMELT M ASU Manual 20 29 Revised 7 03 THSA Pump Adapter Assembly 084E 406 Page 10 28 Component Illustrations amp BOM s Revised 9 01 Item No 1 2 3 4 5 6 Pressure Gauge Assembly 805641 Part Number Description 806883 Fitting 1 4 NPTM x 6 JIC x 90 101174 Pressure Guage 1000 PSI 104325 Fitting Adapter Swivel 6J x 1 4 MPT 805632 Fitting 1 4 NPT 1 2 20 Tranducer 102987 Insulator N00104 Fitting 1 4 NPTM x 6 ST TWDynatec 1999 DYNAMELT M ASU Manual 20 29 iTV Dynatec 1999 Schematics Page 11 1 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 02 Chapter 11 SCHEMATICS amp ENGINEERING DRAWINGS Drawing Found on Hose Schematic ASU to A pplicator page 11 2 A pplicator H ead Schematic page 11 3 Flow Diagram Outlet Filter M anifold page 11 4 Typical Hydraulic Schematic page 11 5 Grounding Diagram CE M ark Page 11 6 Pump amp Zone Configuration Page 11 7 ASU Schematics end of chapter Page 11 2 Schematics TwDynatec 1999 Revised 7 07 DYNAMELT M ASU Manual 20 29 and 20 30 WHT AW 1 1 TRIGGER WHT BLK 20 AWG 2 2 TRIGGER WHT BLU 20 AWG 5 5 HEAD SENSOR WHT YEL 20 AWG 6 6 HEAD SENSOR RED 18 AWG F 7 HEAD HEATER ORANGE 18 AWG 8 8 HEAD HEATER PT100
194. w and slide cover off Cover allows access to the hose connections on the filter manifold outlet filters heaters and the pressure relief Heater Replacement The heaters are located underneath the hopper Remove the access door Use a hex head socket wrench to remove the six heater plate bolts Disconnect the heater wires Slide the old heater plate out Connect heater wires to new plate Slide new plate in place and fasten with the six bolts TW Dynatec c 1999 Disassembly amp Re assembly P age 8 3 DYNAMELT M ASU Manual 20 29 Revised 2 00 To Remove Rear Cover No customer replaceable components are behind the rear cover To remove remove the two ac cess doors in order to access and remove the five screws which hold the rear cover in place Two screws are located in the upper corners of the rear cover Three screws are located across the bot tom of the cover To Access the RTD Sensor in the Optional Drop in Grid Remove the access door Remove the screws on the drop in grid s junction box cover in order to remove the cover Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter To Access Electrical Components inside the Panel Box DANGER HIGH VOLTAGE Dynamelt systems use electrical power that can be life threatening Disconnect and lock out input power to the application system before starting any disassembly procedure Verify again that the main power is OFF On the outsi
195. y of a desired descrip tion function on the touchscreen For example as seen above to go to the Temperature Menu press within the Temperature Menu box located at the upper right corner of the touchscreen 2 Once a function is selected active use the numeric entry keys to program a desired value Press the Enter arrow on the numeric entry keypad to enter your value 3 The Delete arrow located below the numeric keypad see above also serves as an es cape key 4 This chapter describes a typical system Your ASU may have more or less temperature zones motor pumps clutches or pressure transducers installed 5 go to Panel View Configuration press the left and right arrow keys lower right of dia gram simultaneously See pages 18 thru 20 of this chapter for details on Configuration Mode 6 To close an error screen touch it Page 5 2 Programming iTVW Dynatec c 1999 Revised 1 05 DYNAMELT M ASU Manual 20 28 20 29 and 20 30 Main Menu Screen Optional Display for dual hopper ASUs System Status Display not available on DM35 Numeric Entry Keys iTWDynatec 1 Temp SY STEM HEATING LOW ALARM ZONE HIGH ALARM ZONE HEATER POWER 10 05 28 2 8 2000 ALII Arrow Keys Use of the Main Menu System Status Screen Press This To Function Key H eater Power Toggle Heater Power ON or OFF Temperature M enu Go to the Temperature M enu Screen M otor M

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