Home

Nordson - NRI Parts

Contents

1. Tag Warning 1 981 800 999 Screw Round Head 0 80 x 0 12 in 1 14 273 742 Thermostat 500 F 260 C w Insulator 1 Insulator Thermostat 1 937 281 Thermostat Close on Rise 500 F 260 C 1 15 843 048 Hose Pneumatic Regulator to Pump Assembly 1 ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved P amp A Division 41 2000 89 Atlanta Georgia TECHNICAL PUBLICATION Figure 11 Base Assembly Part 1 ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A j 41 2000 90 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION BASE ASSEMBLY PARTS LIST PART 2 Item No Part No 933 982 982 275 933 279 275 275 275 239 939 983 939 275 982 275 9 983 10 275 11 982 12 275 13 275 14 273 14 273 15 983 16 982 17 275 17 275 275 939 939 273 275 275 275 275 982 275 275 982 275 983 984 275 275 275 275 18 273 18 273 Inno bw ISSUED 9 85 LITHO U S A 298 119 124 025 297 093 092 069 081 576 573 411 538 054 091 350 408 012 116 040 176 043 044 417 122 322 327 094 574 575 817 130 128 129 146 119 313 099 142 320 400 700 316 319 321 318 038 039 Description Req d Assembly Base Series 2000 Marker Strip 8 Station Terminal Block Screw
2. Solvents may present a toxic or fire hazard even at room temperature Use extreme care in selecting a cleaning solvent other than Type R solvent Some solvents may not be compatible with the hot 2 melt adhesive material Sludge formation can further compound the problem Test the solvents with a small sample of adhesive before using the Solvent in the system ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 U S A All Rights Reserved N Packaging and Assembly Division 41 2000 24 Atlanta Georgia TECHNICAL PUBLICATION 8 Clean the nozzle bore with a pin type probe inserted into the nozzle in a direction opposite to the flow of adhesive NOTE 43 2 for specific information on Nordson nozzle cleaning kits Y Do not use an open torch drill or broach to clean a nozzle Damage may result NOTE Alternate nozzle heating and cleaning methods may include a Heat components with a flameless electric heat gun Wipe nozzles with a clean cloth b Submerge parts in a ultrasonic cleaner C Submerge parts in a chemical cleaner 9 Reassemble nozzle onto guns 10 Restore system to normal operation FILTER ASSEMBLY CLEANING Figure 13 Clean adhesive filter once a week unless operating experience indicates more or less frequent cleaning is required com plete filter assembly is recommended as a spare for faster filter changes Hot melt system must be at operating temperature before filter i
3. D Partially plugged nozzle ISSUED 9 81 SUPERSEDES 6 71 C NORDSON CORPORATION 1981 All Rights Reserved Packaging and Assembly Division Atlanta Georgia 40 0 12 Wor dson Stringing Possible Causes A Adhesive too viscous B Cold adhesive C Lack of an air piloted relief valve between solenoid and gun D Old adhesive beyond recommended pot life Excessive Amount of Cut off Possible Causes A Insufficient air pressure to the pump B Cold adhesive C Insufficient air pressure to the gun Concentric Circles Possible Causes A Material too hot B Material low in viscosity C High speed appli cation fast gun cycling ISSUED 9 81 SUPERSEDES TECHNICAL PUBLICATION eem 7 pm 0 gt oo aa Qmm v9 9 9 6 71 LITHO U S A 941 Packagi bly Division Atlante Georgia ISO TECHNICAL PUBLICATION 40 0 13 HOT MELT TROUBLESHOOTING CHART SYMPTOM PROCEDURE CORRECTIVE ACTION Do not attempt to loosen any part of manifold hose or gun system until air to the unit has been turned off and pres sure has been relieved from hot melt system by triggering the guns Use safety goggles safety gloves P N 902 514 and pro tective clothing to prevent injury from splashed hot material or hot parts ADHESIVE BOUNCES OR SPLASHES FROM SUBSTRATE Al Check adhesive tempera ture settings of appli cator hose and gun NORMAL INDICA
4. 31 and into gear pump housing Secure with two screws 29 and lockwashers 28 Press the air motor mount assembly 6 onto gear reducer housing 31 and secure with six screws 12 and lockwashers 13 Torque the screws to 5 8 ft lb Slide lower coupling onto pinion shaft and secure with set screw Ensure the set screw is against flat on shaft 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 68 11 12 13 14 15 16 17 18 19 20 21 22 Slide rotary air motor and drive coupling through hole in top of mount assembly Align thermoplastic spider in lower half of drive coupling with upper half of coupling Push together firmly Orient the air motor as shown in Figure 17 and tighten set Screws in pump mount NOTE Set screws must mate with groove in air motor Install second set of set screws in pump mount to lock air motor Torque the screws to 1 2 ft lb Slide pump assembly into applicator tank and seat connecting tube in manifold Secure pump assembly to applicator with three screws and lockwashers Remove vent plug 5 and pipe plug 10 from gear reducer housing Fill the gear reducer housing with lubricant P N 275 284 until lubricant flows from the plug hole in side of reducer Reinstall vent plug 5 and pipe plug 10 in gear reducer housing Use te
5. 45 Elbow Applicator to Automatic or 972 618 972 647 Handgun Hose Str Conn FM150 170 to Hose 310 281 For instructions on installation of o ring elbow fittings see page 46 33 1 Note P Ns 972 646 and 972 647 have an extended collar which allows them to be wrenched into the hose ports in the manifold adapter which will allow guns designed for o ring fittings to be attached to a standard 1 4 inch tapered pipe thread fitting is avail able from Specials P N 806 724 Primarily it is used in existing installations It may need to be insulated to prevent excessive heat loss 40 2m Issued 5 87 y hordson Corporation 1987 A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 411 2000 1 SECTION I EQUiPMENT FAMILIARIZATION INTRODUCTION The Nordson Series 2000 Hot Melt Applicators melt and pump hot ielt adhesives and other thermoplastic materials with viscosities within the range of 500 to 50 000 centipoise cs through hoses and extrusion guns to a substrate The applicators melt the adhesive in an aluminum tank with a cast in heater air driven spur gear pump submerged in the tank or an air driven dual acting piston pump transfers molten adhesive into a distribution manifold through a filter and heat exchanger and into heated hoses and extrusion guns Figure 1 shows the Series 2000 hot melt applicator Figure 1 Series 2000 Hot Melt Applicator The tank and hoses are heated ele
6. Continued open gear pump only AIR MOTOR STROKING Pump starved C1 Piston Pump OR ROTATING Gear Hydraulic cylinder malfunction C2 Pump ERRATICALLY piston pump only Input air pressure too high C4 gear pump only Pressure control valve stuck C5 open gear pump only pe ISSUED 1 84 SUPERSEDES 3 83 CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 32 TABLE 2 TROUBLESHOOTING CHART MECHANICAL If the applicator is operable flush the system before disassembly If the pump is not operable but the heating system is functional bring the unit to operating temperature and drain to ease disas sembly Otherwise a heat gun or other flameless heating method must be used to melt solidified adhesive material on internal parts Before removing any panels to start disassembly turn main switch OFF and disconnect and lock out input electrical power to prevent injury from energized electrical components Relieve system pressure before attempting to loosen any part of manifold hose and gun system by securing air to pump triggering all guns and opening manifold drain valve Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot qun surfaces Review the Safety Summary 40 1 before attempting
7. Replace filter and close manifold drain valve Adjust input air pressure to the pump to 20 psi 140 kPa Set pressure control valve in accordance with Section III Pressure Control Valve Adjustment GEAR PUMP Applicators only Replace upper tank enclosure GEAR PUMP applicators only The system is ready for use 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 e mnt Nordson Packaging and Assembly Division r Atlanta Georgia ECHNICAL PUBLICATION 41 2000 19 PRESSURE CONTROL VALVE ADJUSTMENT GEAR PUMP Applicators Only The pressure control valve is adjustable and must be set ac cording to the requirements of the particular application reduce the amount of circulation back to the tank and increase system pressure turn the adjusting screw clockwise Conversely to increase circulation and reduce system pressure turn the ad justing screw counterclockwise Use the following procedure to set the pressure control valve NOTE The visible screw on the side of the pressure control valve indicates the position of the control valve and acts as a stop in the full open and full closed positions 1 With all guns open and the pressure control valve fully closed turned full clockwise increase pneumatic pressure to the air motor until the appropriate bead size is achieved 25 Open the pressure control valve by turning counterclockwise until the valve is fully open 3 With all guns closed and the pneumatic pressu
8. 2 982 091 Screw Pan Head M3 0 5 x 6 mm y 3 982 116 Screw Pan Head Captive 1 4 Lid Assembly See Service Parts List 1 275 023 Hinge Tank Cover Lid 1 275 032 Lid Hinged Tank Cover 1 982 127 Screw Flat Head M4 0 7 x 8 nm 4 5 902 517 Retainer Ball Stud 2 6 981 727 Screw Hi Lo 4 24 x 0 38 in 4 7 275 374 Lid Assembly Inner Tank 2202 2204 1 7 275 373 Lid Assembly Inner Tank 2002 2004 l 275 061 Lid Inner Tank 2202 2204 1 275 060 Lid Inner Tank 2002 2004 1 Stud Ball 2 981 024 Screw Pan Head 6 32 x 0 19 in 2 983 100 Lockwasher Internal Tooth No 6 2 8 275 219 Enclosure Tank 2002 2004 l 8 275 010 Enclosure Tank 2202 2204 1 9 275 379 Cover Tank 2202 2204 1 9 275 378 2002 2004 1 10 275 036 e Gasket Tank Cover 2202 2204 1 10 275 035 Gasket Tank Cover 2002 2004 1 11 937 277 Sensor Tank Temperature RTD 1 12 Nut Wire 22 GA 4 13 Manifold Tank Assembly 1 Tank Machined See Service 1 Parts List MANIFOLD ASSEMBLY See Figure 12 1 940 281 O ring Viton 1 38 x 1 50 in 2 982 109 Screw Hex Head M8 1 25 x 70 mm 6 983 414 washer Flat M8 6 900 236 Paste Teflon 275 224 Valve Assembly Tank Drain l 940 161 909 O ring Viton 0 62 x 0 75 in 1 275 221 Stem Tank Drain Valve 1 275 220 Body Tank Drain Valve 1 273 222
9. 275 338 Lubricant Gear Reducer 1 981 235 Screw Hex Head 1 4 20 x 4 0 in 1 ISSUED 9 85 SUPERSEDES NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A Part No 275 275 275 275 275 901 2 5 240 240 503 503 503 275 275 274 275 275 275 275 073 211 212 371 126 329 515 324 829 635 694 697 708 309 312 463 393 388 384 385 P amp A Division Atlanta Georgia TABLE Description Kit Hose Bracket Tank w Tag Model 2002 2004 Tank w Tag Model 2202 2204 Kit Rebuild Gear Pump Tool Crimp Socket Removal Lid Assembly w Retainer Filter Air 1 4 NPT Kit Door Latch Key Type Crossover Tube Assembly Piston Pump Hydraulic Seat Assembly Siphon Ball TECHNICAL 9 SERVICE PARTS LIST Seat Assembly Large Siphon Ball Seat Assembly Pressure Ball PUBLICATION Manifold Assembly for applicators before and including serial numbers listed below Manifold Assembly for applicators after serial numbers listed below Kit Hose Connector Kit Drive Shaft Replacement Kit Piston to Gear Pump Interchange Kit Gear to Piston Pump Interchange Kit Piston to Gear Pump Interchange Kit Gear to Piston Pump Interchange MANIFOLD IDENTIFICATION CHART All units after this serial number use manifold P N 275 312 Unit Part Number 275 275 275 275 014 144 273 274 275 275 275 275 013 145 275 276 A3K07955 A3K06239 A3K08428 A3L01204 A3K
10. Atlanta Georgia TECHNICAL PUBLICATION 40 0 5 NOMOGRAPH FOR HOT MELT BEADS MATERIAL REQUIRED PER 100 FEET THICKNESS VOLUME WIDTH INCHES GAL IN INCHES 1 00 030 150 30 100 080 20 700 020 060 600 040 10 500 030 6 400 0207 010 009 3 300 008 010 T 007 008 2 2 7 006 006 77 200 005 004 004 2277 008 6 27 002 4 er 100 003 090 001 080 0008 2 070 002 0006 060 0004 1 050 0003 08 06 040 0002 04 001 030 NOMOGRAPH BASED ON FLAT BEADS BEADS WITH A ROUNDED TOP SURFACE REQUIRE APPROXIMATELY 3 THE VOLUME SHOWN POUNDS GALLON 65 70 75 85 90 95 SPECIFIC GRAVITY 085 095 100 105 110 POUNDS cU 1028 0 032 034 036 0038 040 ISSUED 9 1 70 SUPERSEDES NORDSON CORPORATION 1986 LITHO U S A All Rights Reserved 40 0 6 P amp A Division Atlanta Georg a TECHNICAL PUBLICATION NOMOGRAPH FOR HOT MELT BEADS METRIC Thickness Volume Width mm liters mm _ 080 100 30 0 70 50 20 0 60 10 0 50 15 0 40 05 0 30 03 10 02 0 20 01 015 50 0 05 40 0 04 0 10 0 03 30 002 20 0 01 0 06 15 0 05 0 005 i 0 004 0 003 10 0 04 09 0 03 0 002 0 8 07 Material required per 100 meters Rounded Beod Flat Bead BL F 0 66 B F 1 0 t a a Volume in liters Ax Bx Weight in Kilograms 0 Ed Ts x c Specific Gravity EXAMPLE For a flat be
11. Lift the unit from the metal base Route hoses from guns to applicator Hoses must be routed to prevent damage from kinking 2 abrasion and other physical damage Do not allow the hose to be installed with a bend radius less than 6 in 15 cm Do not overtighten hose support clamps Starting with the port nearest the filter bung secure the hoses to the applicator manifold using the fittings provided with the hoses hose should always be connected to the end port nearest the filter bung However if only bottom hose ports are to be used then a hose must be connected to the bottom port nearest the filter bung Failure to connect a hose to the manifold connection Hose No 1 nearest the filter bung could result in serious burns from sprayed hot material when a manifold plug is removed Set air pressure regulator for zero pressure full counter clockwise on applicator front panel Connect an air supply to the applicator on the left hand side of applicator base Use teflon paste P N 900 236 on threads NOTE The air supply should be capable of supplying minimum of 80 psi 550 kPa to the applicator The supply to the piston pump should be filtered The supply to the gear pump should be filtered and lubricated Nordson offers an optional filter and lubricator for use here See Section VI Illustrated Parts List for part num bers Nordson also recommends that a shutoff valve be installed in the supply line to isolate
12. NORMAL INDICATION Heat ABNORMAL INDICATION Heat exchanger passages free of char or adhesive build up Replace heat ex changer and proceed to next step A8 Remove manifold adhesive NORMAL INDICATION Filter screen free of char and particle buildup Rein stall filter and continue to next step exchanger passages clogged with char and ad hesive buildup Clean and reinstall heat ex changer Restore system to normal operation filter and check for blockage ABNORMAL INDICATION Fil ter screen clogged with char and particle build up Clean filter and reinstall Restore sys tem to normal operation A9 Check input air pressure to air cylinder motor at the gauge NORMAL INDICATION 5 to 80 ABNORMAL INDICATION Im psi 35 to 550 kPa proper pressure indica ceed to next step tion Check input air supply A10 Check pressure regulator and solenoid valve to air cylinder motor in the following manner Set regulator for zexo pressure by turning dial full counterclockwise b Shut off air supply to regulator Disconnect regulator and solenoid valve from air cylinder motor at the hose connection on regulator Restore air supply to regulator e Check main circuit breaker ON closed _ _ _ NORDSON CORPORATIO
13. Pan Head M5 0 8 x 10 mm 2004 2002 2202 2204 Screw Pan Head M4 0 7 x 20 mm Insulator Circuit Breaker Marker Strip 5 Station Terminal Block Heat Sink Assembly 2202 2204 Heat Sink Assembly 2002 2004 Panel Rear Electrical Enclosure Gasket Heat Sink Relay Solid State 40 amp Heat Sink Exterior Washer Flat M3 Relay Solid State 25 amp 000 Standoff Circ Board M4 0 7 mm x 0 62 in Screw Pan Head M3 0 5 x 6 mm Bracket Terminal Block 5 Station Washer Flat M5 2002 2202 Enclosure Electrical Fiberglass Screw Pan Head Captive Spacer Tank Spacer Manifold Insulation Tank 2202 2204 Insulation Tank 2002 2004 Washer Flat M8 Oversized OD Screw Hex Head M8 1 25 x 45 mm Temperature Control Assembly 4 Hose Temperature Control Assembly 2 Hose Temperature Control 4 Hose and Tank Board Temperature Control 2004 2204 Board Front Panel 2004 2204 Cable Assembly Ribbon 24 wire Temperature Control 2 Hose and Tank Board Temperature Control 2002 2202 Board Front Panel 2002 2202 Cable Assembly Ribbon 16 wire Screw Pan Head M5 0 7 x 10 mm Door Assembly Control Access 000 Panel Elect Enclosure Front 900 Screw Flat Head M3 x 10 Hinge Control Access Door Lockwasher Split M3 Nut Hex M3 999 Door Control
14. and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Relieve system pressure before breaking any mechanical connections i e gun hose connection filter etc 2 in the following manner a Reduce pump air pressure to zero at the requlator b Trigger all quns to relieve trapped hydraulic pressure Open manifold drain valve Unit must be at operating temperature before valve is opened ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 28 1 ISSUED With unit at operating temperature remove all adhesive from system by pumping adhesive through gun with nozzle removed through hose disconnected from gun or through manifold by opening manifold drain valve If the guns are removed from the hoses the pins on the hose quick disconnects are electrically energized with full voltage Contact with these pins can cause severe electrical shock or equipment damage Reduce pump air pressure to zero at the regulator as draining is completed Place several pounds of fresh uncontaminated adhesive ma terial normallv used in production into the applicator tank Allow material time to melt then pump the molten material through the system 2 R solvent may be used instead of adhesive material to flush the
15. lief valve operates freely with no char or foreign material in valve Reinstall valve and proceed to next step if unit is equipped with an air cylinder Pro ceed to step B5 if the unit is equipped with an air motor ABNORMAL INDICATION Char or foreian material on valve seat Replace re lief valve Reinstall valve and restore system to normal operation B4 Remove piston pump assembly from applicator and disassemble hydraulic cylinder Check for char or foreign material holding pressure ball off its seat Check also for other physical damage NORMAL INDICATION No foreign particles in cylinder No physical damage Disassemble air cylinder and check for damage Repair as necessary Restore SysS tem to normal operation B5 Remove pressure control valve for char and foreign materia position NORMAL INDICATION Valve is free of char and for eign material Disassem ble gear pump assembly and check for physical damage Reassemble and restore system to nor mal operation ABNORMAL INDICATION If char or foreign parti cles are found in hy draulic cylinder disassemble and clean components Reassemble and restore system to normal operation from gear pump assembly Check 1 holding spool in full open ABNORMAL INDICATION Char and foreign material in side valve body Clean valve components and re install in gear pump drive assembly Restore system to normal operation AIR MOTOR STROKING P
16. 10 11 12 13 14 15 16 17 18 19 20 21 22 23 ISSUED LITHO U S A Alt Rights Reserved Remove the upper tank enclosure GEAR PUMP applicators only Set the pressure control valve indicator at the approximate mid point of the scale GEAR PUMP applicator only When the adhesive material in the tank becomes molten in crease air pressure to the pump to 20 psi 140 kPa NOTE The pump will transfer adhesive material from the tank to the manifold hoses and guns The system is full when the pump stalls or slows noticeably Increase air pressure to the guns to 20 psi 140 kPa Trapped air in the hoses and guns may cause spitting of air and molten adhesive when the 2 guns are initially triggered especially if the nozzles are left on the quns Shield the area and operator from splashed material Remove nozzles and trigger the quns to allow adhesive to flow through the entire system to flush any solvent and impurities from the tank hoses and guns NOTE It may be necessary to increase pump air pressure slightly to achieve flow in the system When adhesive flows free of any solvent or contaminants deactivate guns Reduce pump air pressure to zero at the regulator Trigger guns momentarily to relieve trapped hydraulic pressure Open the manifold drain valve Attach nozzles to guns Remove and clean adhesive filter in accordance with Section IV Filter Assembly Cleaning
17. 133 Screw Set Flat Head M4 x 6 nm 2 12 275 153 Valve Assembly Pressure Control 1 See Figure 20 13 987 031 Spring Compression 1 14 985 227 Pin Roll 0 09 in dia x 0 38 in long 1 15 275 197 Ring Floating 1 16 275 208 Seal Face l 17 983 409 Lockwasher M6 2 18 982 129 Screw Hex Head M6 x 10 mm 2 ISSUED 9 85 SUPERSEDES 9 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved P amp A Division 41 2000 111 Atlanta Georgia TECHNICAL PUBLICATION 8 17 A Pd Figure 18 Air Operated Gear Pump Assembly Sheet 2 of 2 ISSUED 9 85 SUPERSEDES 8 84 ONORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 112 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION 9 8 Figure 19 Gear Pump Assembly GEAR PUMP ASSEMBLY PARTS LIST Item No Part No Description Req d 275 190 Pump Gear Ref 1 Plate Pump Upper 1 2 Plate Pump Center l 3 900 013 Ball Steel 0 12 in dia 2 4 275 181 e Shaft Input l 5 Plate Pump Lower 1 6 275 179 Shaft Idler 1 7 275 178 Gear Spur 14 Teeth 2 8 985 226 Pin Dowel 0 19 in dia x 1 50 in long 2 973 403 Plug Pipe 1 16 NPTF 1 9 982 132 Screw Spline Head M6 x 40 mm 4 900 236 Paste Teflon 10 275 173 Tube Inlet 1 11 982 003 Screw Fillister Head M3 x 8 mm 1 12 973 403 Plug Pipe 1 16 NPTF 1 ISSUED 12 86 SUPERSEDES 9 84 NORDSON CORPORATION 1
18. 2002 2202 2 982 125 Screw Pan Head M3 0 5 x 16 mm 4 275 070 Nut Bar 1 933 295 Block Terminal Input 1 275 108 Block Terminal 8 Station 1 273 013 Circuit Breaker 30 amp 1 939 577 Lamp Power On 1 939 631 Circuit Breaker 5 0 amp 2002 2202 only 1 939 532 Circuit Breaker 10 amp 2004 2204 only 1 939 533 Circuit Breaker 10 amp 1 275 140 Panel Socket Cover 2002 2202 Only 2 14 982 169 Screw Pan Head M3 0 5 x 16 mm 4 15 275 065 Nameplate Hose No 4 2004 2204 Only 1 16 275 064 Nameplate Hose No 3 2004 2204 Only 1 17 275 063 Nameplate Hose No 2 Series 2000 1 18 275 062 Nameplate Hose No 1 Series 2000 1 19 275 042 Insulation Base 1 20 275 052 Washer C 8 mm 3 21 843 048 Hose Pneumatic Regulator to Pump Assembly 1 22 843 024 Hose Pneumatic Input to Solenoid Valve 1 23 972 050 Connector Male 9 16 18 x 1 4 NPT 1 ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved P amp A Division 41 2000 93 Atlanta Georgia TECHNICAL PUBLICATION 12 43 18 16 15 17 19 20 Figure 11 Base Assembly Part 3 ISSUED 9 85 SUPERSEDES 8 84 LITHO U S A NORDSON CORPORATION 1985 All Rights Reserved 41 2000 94 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION MANIFOLD ASSEMBLY PARTS LIST Item No Part No Description Req d Manifold Assembly
19. 22 Place slab gasket 5 into cylinder head 4 groove ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 64 23 Secure cylinder head and air cylinder onto pump mount with four screws 2 and four lockwashers 3 Use teflon paste P N 900 236 on threads 24 Torque cylinder head screws 2 to 5 ft lb 7 Nm 25 Place valve gaskets 1 on cylinder head and pump mount 26 Attach four way air control valve 34 to pump with four screws 35 and lockwashers 3 Use teflon paste P N 900 236 on threads 27 Check o ring 27 and backup rina 26 on connecting tube 28 for damage Replace as necessary 28 Slide pump assembly into the applicator and seat connecting tube in manifold 29 Secure pump assembly to applicator with three screws 30 Attach air hose to four way valve 31 Mount upper tank enclosure to applicator and secure with one captive screw AIR OPERATED GEAR PUMP DISASSEMBLY Figure 18 The rotary air motor contains no field serviceable components If service is necessary replace entire air motor with Nordson P N 275 335 The gear pump also contains no field serviceable components However the pump may be disassembled for cleaning and inspection If internal gear pump parts are broken or worn replace entire gear pump with Nordson P N 275 190 NOTE The rotary air motor mechanism
20. 230 VAC units and the other covering installation of 380Y 220 VAC units In addition to describing the steps required for connecting three phase power to the applicator instructions are also included for changing jumpers and wires to accept single phase input power Single phase electrical installation of the Series 2000 applicators is significantly different from any other Nordson hot melt equipment Failure to follow the installation instructions can result in serious equipment damage or electrical shock ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A 7 P amp A Division 41 2000 13 Atlanta Georgia TECHNICAL PUBLICATION 200 230 VAC INSTALLATION Three Phase Installation Check that the applicator main circuit breaker is OFF Set tank and hose temperature controls to minimum setting full counterclockwise Remove top left hand enclosure and back panel to expose electrical subplate by removing three captive screws Route a 200 230 VAC three phase service line through the hole in the control cabinet base and electrical subpanel Make electrical connections at the five station input terminal block TB1 as shown below TB1 L1 L2 L3 200 230 VAC Three Phase Connection Attach the applicator to an earth ground through GND TB1 5 Attach and secure the electrical enclosure cover and continue with Setup and Initial Operation Do not energize input electrical power
21. 401 Lockwasher Split M5 10 11 245 172 Gear Evoloid 35 Tooth 1 12 275 343 Housing Assembly Gear Reducer 1 Housing Gear Reducer 1 901 374 Bearing Needle 1 955 05 Seal Lip Viton 1 13 275 192 Key Woodruff 0 12 x 0 38 in 1 14 942 352 O ring Viton 1 15 275 201 Bearing Thrust 1 16 973 570 Plug Pipe 1 8 NPT 1 17 275 336 Shaft Assembly Output 1 Shaft Output 9 1 Speed Reducer 1 986 315 Ring Retaining External 1 275 109 Bearing Ball 1 ISSUED 9 85 SUPERSEDES 8 84 ONORDSON CORPORATION 1985 Atl Rights Reserved LITHO U S A P amp A Division 41 2000 109 Atlanta Georgia TECHNICAL PUBLICATION Figure 18 Air Operated Gear Pump Assembly Sheet 1 of 2 ISSUED 9 85 SUPERSEDES 9 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 110 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION AIR OPERATED GEAR PUMP ASSEMBLY PARTS LIST Item No Part No Description Req d 1 982 029 Screw Socket Head M5 x 30 mm 10 2 983 401 Lockwasher Split M5 10 3 275 187 Insert Coupling 1 4 275 195 Hub Coupling 2 5 275 345 Bracket Assembly Pump Mount 1 Bracket 1 Ring Seal Fixed 1 6 982 131 Screw Spline Head M6 x 25 mm 2 7 275 190 GEAR PUMP See Figure 19 1 8 275 198 Tube Crossover 1 940 141 Oering Viton 0 50 x 0 62 in 1 10 275 191 Key Square 0 12 x 0 50 in long 2 11 982
22. 402 Plug Pipe 1 8 NPT Flush 1 12 972 050 Connector Male 9 16 18 x 1 4 NPT 1 13 973 564 Nipple Pipe Hex 1 4 NPT x 1 8 NPT x 1 1 19 in 14 973 953 Adapter Pipe 1 8 NPT x 1 4 NPT 1 15 900 236 Paste Teflon 16 973 151 Elbow Street 90 deg 1 4 NPT 1 Optional filter available as Nordson P N 901 515 SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved ISSUED 9 85 LITHO U S A x P amp A Division 41 2000 107 N ordson Atlanta Georgia TECHNICAL PUBLICATION 11 16 1 WU m uU 10 14 Figure 17 Piston Pump Air Control Assembly ISSUED 9 85 SUPERSEDES 8 84 _ NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 108 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION AIR OPERATED GEAR PUMP ASSEMBLY PARTS LIST Item No Part No Description Req d 275 333 Drive Assembly Gear Pump Air Operated Ref 1 275 335 Air Motor 1 2 982 130 Screw Set Cup M6 x 6 mm 4 3 275 194 Coupling 0 50 in ID x 1 72 in long 1 4 275 347 Mount Assembly Air Motor Pump 1 Mount Gear Pump Motor 1 901 375 Bearing Needle 1 955 051 Lip Seal Viton l 5 275 202 washer Thrust 2 6 275 341 Assembly Pinion Gear 1 Bushing Assembly Pinion 1 986 315 Ring Retaining External 1 275 109 Bearing Ball 1 7 275 334 Spacer 4 8 973 576 Plug O Ring 0 31 in 1 9 982 029 9 Screw Socket Head M5 x 30 mm 10 10 983
23. 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 86 Nordson P amp A Division Atlanta Georgia UNIT ASSEMBLY PARTS LIST PART 2 TECHNICAL PUBLICATION Item No Part No Description Req d Unit Assembly Ref 1 275 089 Assembly Upper Enclosure 1 2 900 236 Paste Teflon 3 972 200 Elbow Male 37 deg 9 16 18 x 1 4 NPT 1 4 275 333 Drive Assembly Gear Pump Air Operated 1 5 BASE ASSEMBLY See Figure 11 l 6 971 501 Elbow Male 3 8 Tube x 1 4 NPT Gear 1 Pump Only 7 275 278 Tubing Copper 3 8 in OD x 15 00 in 1 long Gear Pump Only 8 97 250 Connection Male Tube Gear Pump Only 1 9 Manifold Exhaust Gear Pump Only l 10 982 001 Screw Fillister Head M5 0 8 x 25 mm 2 Gear Pump Only 11 983 401 Lockwasher Split M5 Gear Pump Only 2 275 284 Lubricant Gear Reducer 8 oz Gear 1 Pump only ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved P amp A Division 41 2000 87 Atlanta Georgia TECHNICAL PUBLICATION Figure 10 Unit Assembly Part 2 ISSUED 9 85 SUPERSEDES 8 84 CNORDSON CORPORATION 1985 LITHO U S A Ail Rights Reserved P amp A Division Atlanta Georgia 41 2000 88 BASE ASSEMBLY PARTS LIST PART 1 TECHNICAL PUBLICATION Item No Part No Description Req d Assembly Base Series 2000 Ref 1 983 408 Washer Flat Narrow M5 2002 2202 13
24. A4 Check input air pressure to guns at the filter regulator gauge NORMAL INDICATION 30 to 100 psi 205 to 690 kPa Proceed to next step ABNORMAL INDICATION Re fer to appropriate gun service manual for troubleshootina pro cedure and corrective action The fault may be in the regulator solenoid valve or gun A5 Check guns not firing due to clogged nozzles in the following manner a Reduce air pressure to guns to zero at the regulator Remove a nozzle from each gun Cs Reset gun air pressure to proper pressure d Momentarily trigger guns and check for flow NORMAL INDICATION Material extrudes from guns with noz zles removed Remove and clean nozzles Restore system to normal operation ABNORMAL INDICATION Re fer to appropriate gun service manual for troubleshooting pro cedure and corrective action Continue to next step if blockage is not hose or gun related A6 Secure input air pressure and crack open manifold drain valve to xelieve system pressure ISSUED 1 84 LITHO U S A SUPERSEDES 3 83 9 NORDSON CORPORATION 1984 Rights Reserved Packaging and Assembly Division Atlanta Georgia Nordson TECHNICAL PUBLICATION 41 2000 34 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued Failure to relieve system pressure can result in serious burns when manifold components are removed for mainte nance A7 Remove manifold heat exchanger and check for blockage
25. Controlled Fiberization Easy Screen Fibermelt Flo Tracker PrintGuard and Package of Values are trademarks of Nordson Corporation M M M M M SAL Manual 59 0 0 Issued 9 81 1981 Nordson Corporation All Rights Reserved P amp A Division Atlanta Georgia TECHNICAL PUBLICATION gt 9 1 3 NORDSON TYPE R CLEANING SOLVENT The flash point of Type R solvent is 550 F 288 C Do not heat this material above 475 F 246 C Do not heat Type R solvent with an open flame or in an uncontrolled heating device for example a small pan or unregulated hot plate fire hazard may exist if an open flame or uncontrolled hot plate is used to heat Type R solvent A controlled heating device such as a small deep fat fryer or thermostatically controlled hot plate should be used to heat the solvent above the melting point of the adhesive PHYSICAL PROPERTIES Flash Point 550 F 288 C Freeze Point 32 F 0 C Vapor Odor None Color Clear Viscosity 5 600 CPS 77 F 25 C Pounds Gallon kilograms liter 9 1 Molecular Weight 3 300 Non irritating to skin Non toxic Type R solvent meets the requirements of the following FDA regulations 175 105 175 300 175 380 175 390 176 170 176 180 177 1010 177 1210 USDA approved for use in food processing plants for cleaning hot melt adhesive applicating equipment as long as there is no direct contact with the food Do not take internally Keep
26. GEAR PUMP CONVERSION 41 2000 B1 SERIES 2000 GEAR TO PISTON PUMP CONVERSION 41 2000 C1 ISSUED 9 85 SUPERSEDES 8 84 LITHO U S A NORDSON CORPORATION 1985 All Rights Reserved Figure 1 2 10 11 12 13 14 15 16 17 18 19 20 21 ISSUED 9 85 LITHO U S A P amp A Division Atlanta Georgia LIST OF ILLUSTRATIONS Series 2000 Hot Melt Applicator Series 2000 Dimensions Air Driven Dual Acting Piston Pump Gear Pump Drive Assembly Electrical Schematic 180 256 VAC 3 Phase Electrical Schematic 180 256 VAC Single Phase Electrical Schematic 380 VAC 3 Phase Electrical Wiring 1 2004 2204 Electrical Wiring Model 2002 2202 E s Unit Assembly Base Assembly Manifold Assembly Filter Assembly Piston Pump Assembly Air Control Valve Assembly Pump Valve Shifter Assembly Piston Pump Air Control Assembly Air Operated Gear Pump Assembly Gear Pump Assembly Pressure Control Valve Assembly Gear Pump Air Control Assembly SUPERSEDES 8 84 41 41 41 41 41 41 41 41 41 41 41 41 41 MESS 41 41 41 41 41 41 41 41 2000 03 TECHNICAL PUBLICATION Page 2000 1 2000 3 2000 5 2000 6 2000 77 2000 78 2000 79 2000 80 2000 81 2000 85 2000 89 2000 95 2000 97 2000 99 2000 103 2000 104 2000 107 2000 109 2000 112 2000 113 2
27. Georgia TECHNICAL PUBLICATION 517 200075 Clearance required for removal of heat exchanger element 8 2 210 4 _ 8 9 Dimensions in inches Clearance required 8 2 210 millimeters for removal of filter Clearance required for removal of pump cover 17 3 440 un 549 12 9 328 0 7 18 Z 1 8 1 1 28 13 1 332 21 8 553 13 5 342 1 1 28 24 3 617 4 15 7 398 Figure 2 Series 2000 Dimensions FUNCTIONAL DESCRIPTION The following paragraphs detail the configuration and operation of the Series 2000 hot melt applicators Feature variations and options are also discussed for comparison HOT MELT TANK Each applicator melts adhesive or other thermoplastic Materials ina cast aluminum tank with a cast in resistive heating element The loading lid and condensate pan prevent spillage of excess hot melt adhesive onto the exterior of the applicator The two piece loading The actual power requirement for the Series 2000 hot melt applicators is determined by the additive power requirements of individual components used in the applicator system The total requirement depends on tank size quantity and length of hoses and quantity and type of guns used See Table 5 in Section V Diagrams and Tables for individual component power requirements ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Ail Rights Reserved Packaging and Assembly Division 41 2000 4 Nor
28. In crease temperature slight ly If adhesive still does not penetrate check with adhesive representa tive for compatible ad hesive NOTE Flush and drain system in accordance with pplicator service manual before changing adhesive Check to see that adequate amount of adhesive is being applied to substrate NORMAL INDICATION Adequate Normal Indication Con amount of adhesive being tact adhesive represen applied to substrate tative for a compatible adhesive Abnormal Indication In sufficient adhesive Use one or more of the following steps to in crease adhesive flow l Use higher flow rated nozzle 2 Increase tempera ture slightly 3 Increase appli cator air pressure ISSUED 9 81 SUPERSEDES NORDSON CORPORATION 1981 Rights Reserved Packaging and Assembly Divisi M 40 0 18 Atlanta Georgia TECHNICAL PUBLICATION HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION 4 Change adhesive to another compatible adhesive with lower viscosity ADHESIVE STRINGING Fl Check gun position rela tive to substrate in ac cordance with 43 1 NORMAL INDICATION Pro Normal Indication Pro per height above sub ceed to step F2 strate Adnormal Indication too far from substrate Move closer to substrate F2 Check adhesive temperature and viscosity NORMAL INDICATION Ad Normal Indication Pro hesive temperature
29. Input 180 to 256 VAC between terminals 1 and 2 on TBI 230 VAC Three Phase Input 180 to 256 VAC between terminels 1 and 2 2 and 3 and 1 and 3 on 380 VAC Three Phase Input 4 wire Approximately 220 VAC between terminals 1 and 4 2 and 4 and 3 and 4 on TB1 F2 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage F3 Using an ohmmeter on the lowest resistance scale R x 1 check continuity between the following points ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Ali Rights Reserved 9 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 58 TARLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued TB1 1 and TB2 4 TB1 2 and TB2 1 1 3 and TB2 6 NORMAL INDICATION Con ABNORMAL INDICATION If any tinuity at each point one of the readings is Proceed to next step anything but continuity one portion of the main circuit breaker is open Replace circuit breaker and restore system to normal operation F4 With external power still disconnected remove plug J1 from temperature control board and measure resistance between TB2 5 and J1 6 NO
30. SUPERSEDES ISSUED 8 84 LITHO U S A Packaging and Assembly Division Atlanta Georgia 41 2000 79 TECHNICAL PUBLICATION oseud OVA 08 2052 2005 4 7022 700 9t 4 Or xnv 1984 NORDSON CORPORATION All Rights Reserved SUPERSEDES 1 84 ISSUED 8 84 LITHO U S A TECHNICAL PUBLICATION Packaging and Assembly Division Atlanta Georgia 41 2000 80 702 7002 8 ISOH 3SOH U 4 H31Y3H 3SOH ie 44 1018 ara ll Re 97 LSHL LVLSOWYSHL HL NIVW 21 1 1 CALA Had 19 3SOH fuss ann 26 LINDY vy 10884 i e ty Ene 082 uaxvausg St NNS 2 ov er 09 L 2ndino S1 dNV1 B83MOd t al i Qvo 8e ovo 4 180 2 81 1984 NORDSON CORPORATION AM Rights Reserved SUPERSEDES 1 84 ISSUED 8 84 HTHO SA 41 2000 81 TECHNICAL PUBLICATION Packaging and Assembly Division Atlanta Georgia 1077 2007 BUTITM 9OIJ329 M 6 dit 3SOH YALV3H ISOH Dix O T on MA 1014 GLY ANVIL t 1S
31. and restore system to normal operation disconnect wire Nos 30 and 40 on and check continuity across the two ABNORMAL INDICATION Short circuit Wait 15 minutes for unit to cool down Measure again If still shorted replace thermal relay Restore system to normal operation D7 Attempt to close main circuit breaker NORMAL INDICATION Main cir cuit breaker remains ON Proceed to next step ISSUED 8 84 LITHO U S A SUPERSEDES 1 84 ABNORMAL INDICATION Main circuit breaker continues to trip Replace circuit breaker due to faulty trip mechanism Restore system to normal operation NOROSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 53 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued D8 Restore input electrical power to applicator and note the condition of red and yellow indicating lights on the tempera ture control panel Proceed to the appropriate point in the Electrical Troubleshooting Chart if problem is tank related NORMAL INDICATION Yellow LED ABNORMAL INDICATION If both cn and red LED off indicatina LED s are off power to the the hose should be heating HTC has been lost or the Proceed to step D13 HTC has failed Proceed to the next step If both LED s are on or tbe yellow LED is off and the red LED is on the problem is in the HTC or sensor Proceed to step D15 D9 Check input voltage at term
32. at this time Connect input power at the appropriate step in the Setup and Initial Operation procedure Single Phase Installation 13 Check that the applicator main circuit breaker is OFF 2 Set tank and hose temperature controls to minimum setting full counterclockwise 3 Remove top left hand enclosure and back panel to expose electrical subplate by removing three captive screws 4 Route a 200 230 VAC single phase service line through the hole in the control cabinet base and electrical subpanel Make electrical connections at the five station input terminal block TB1 as shown below TB1 L1 L2 L3 N 200 230 VAC Single Phase mm Connection ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 U S A All Rights Reserved 41 2000 14 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION B Attach the applicator to an earth ground through GND TB1 5 6 On TB2 move the jumper on the terminals 4 and 5 to terminals 3 and 4 and move the jumper wire on terminals 3 and 6 to terminals 2 and 5 TB2 configured for single phase operation is shown below TB2 TB2 12345678 DIOC ERE 123 45 6 78 2004 2204 2002 2202 a Attach and secure the electrical enclosure cover and continue with Setup and Initial Operation Do not energize input electrical power at this time Connect input power at the appropriate step in the Setup and Initial Operation procedure ISSUED 9
33. configu ration utilizes a 350 F 175 C thermostat Optional thermostats are available within a range from 225 to 450 F 105 to 230 C Overtemperature Protection RTD open and short circuits and overtemperature conditions within the hose and on the tank wall are indicated on the temperature control panel by the red and yellow LED s in each channel A time delay resistive type heating device set at approximately two minutes allows time for corrective action before the temperature control circuitry opens the main circuit breaker through its auxi liary trip coil Because the time delay relay is both voltage and temperature sensitive the time delay will range from one to five minutes and once activated may take as long as fifteen minutes before the device cools down enough to allow the relay contacts to open Until the contacts open the main circuit breaker will continue to trip open When temperature rises above 500 F 260 C on the surface of the tank a close on rise thermostat energizes the circuit breaker auxiliary trip coil to open the main circuit breaker Actual tank and hose temperature can be determined by rotating the temperature control knob until the yellow LED begins to flash The setting at this point corresponds to actual tank or hose temperature Extrusion gun circuits are powered directly from the main circuit breaker through the normallv closed gun circuit breaker Turning the hose control knob to the OFF pos
34. end of its stroke in each direction Extremely precise deposition control is possible with this gear pump arrangement Due to the tight tolerances within the gear pump that enable it to dispense adhesive materials extremely high and extremely low in viscosity internal circulation of adhesive material is necessary to prevent the pump from stalling or the pressure relief valve from opening during application The pressure control valve maintains a constant pressure in the svstem regardless of the condition of the extrusion guns i e open or closed bv circulating a small portion of adhesive material from the outlet of the pump back to the tank The floating spool in the pressure control valve also compensates for pressure fluctuations that occur as the extrusion Figure 4 Gear Pump Drive Assembly ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Riahts Reserved Packaging and Assembly Division Nordson Atlanta Georgia TECHNICAL PUBLICATION 41720007 guns are cycled In an air motor driven gear pump applicator where extremely precise weight control or where extremely low output rates are required in both continuous and intermittent applications im proved performance is obtained with the pressure control valve because recirculation back to the tank enables the pump to run at higher more consistent speed than would be possible without the pressure control valve Overpressure protection is provided by a relief
35. end of the screen insert screw 10 through core into filter bung and tighten screw Inspect o ring 2 for damage NOTE Inspect o ring for cuts hardening and other physical damage Replace if necessary with Nordson P N 941 230 Screw filter assembly into the manifold finger tight onlv Increase input air pressure to the pump and purge filter as outlined in step 5 Close manifold drain valve Tighten filter snugly Do not overtighten 2 Ensure manifold is at operating temperature when the filter is reinstalled Cold material on fil ter and or manifold walls can cause filter screen to collapse if filter is tightened in a cold system SPEED REDUCER LUBRICATION GEAR PUMP Assembly Only Initial Oil Change The oil in a new speed reducer should be drained using the drain plug provided at the end of 250 hours of operation Routine Oil Change Under normal conditions after the initial change the speed reducer oil should be changed after every 1000 hours of operation or every six months whichever comes first Under severe conditions rapid temperature fluctuations moist dirty or corrosive environment it may be necessary to change oil at more frequent intervals Use only gearbox lubricant P N 275 338 in this unit ISSUED U S A 2 Nordson lubricant P N 271 416 will not perform satisfac torily in these units The gear reducer will overheat using this lubricant Use only Nordson lubricant P N 275 3
36. gear reducer housing from lower pump mount Inspect insulator and o rings for wear or damage Replace if necessary Remove four spline head screws 17 from pump housing NOTE The gear pump contains no field serviceable parts If replacement is required use Nordson P N 275 190 A 12 point socket is included in the pump assembly rebuild kit for convenience Rotate the pump counterclockwise using a screwdriver on the slotted shaft NOTE If the shaft rotates freely no further disassembly is required If the pump binds or is to be disas sembled for inspection and cleaning continue to the next step Remove four socket head screws from top of gear pump Gently rap on the top of slotted drive shaft and bottom of idler shaft to separate the pump plates Do not pry the pump plates apart Damage to mating surfaces will cause the pump to leak when assembled Solidified hot melt material may prevent the plates from separating If it is necessary to heat the pump use an electric oven with forced air circula tion or a flameless electric heat gun Never heat any component with a torch or other open flame Clean components in a bath of Type R solvent heated to the melting temperature of the hot melt material NOTE Alternate methods of heating and cleaning include a Heat components with a flameless electric heat gun and wipe with a clean cloth b Submerge parts in an ultrasonic cleaner 1 84 SUPERSEDES 4 83 NORD
37. or gun Char can occur when an adhesive is heated above the application temperature recommended by the adhesive manufacturer If this occurs it may be necessary to replace the hose and or gun Do not heat R solvent above 475 F 245 C See 59 1 for further details Do not heat Type R sol vent with an open flame or in an unregulated heating device i e a small pan on an unregulated hot plate A fire hazard exists if an open flame or unregulated hot plate is used to heat Type R solvent controlled heating device i e a small deep fat fryer or thermo statically controlled hot plate must be used to heat the solvent above the melting temperature of the hot melt adhesive material Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Use the following procedure to clean gun nozzles 1 Heat the gun to operating temperature 2 Reduce pump air pressure to zero at the regulator Trigger all guns to relieve any trapped hydraulic pressure in the system 4 Open manifold drain valve 5 Reduce qun air pressure to zero at the regulator Failure to relieve system pressure could result in serious burns when the nozzle is removed 6 Remove the nozzles 7 Place nozzles in a container of R solvent and heat the solvent to the melting temperature of the adhesive material being used
38. out of reach of children USAGE Type R solvent may not be compatible with all adhesives Q Before using Type R solvent with an adhesive for the first time test for compatibility using the procedure described below NOTE For ease of pouring store Type R solvent at room temperature 70 F 21 C Do not store Type R solvent at temperatures over 150 F 65 ISSUED 2 85 SUPERSEDES 3 81 ONORDSON CORPORATION 1985 LITHO U S A All Rights Reserved Publication No 104 708A ca ieee Packaging and Assembly Division 59 1 4 Nordson Atlanta Georgia TECHNICAL PUBLICATION USAGE Continued To clean parts exposed to hot melt nozzles and filters soak the parts in heated Type R solvent at a temperature somewhat above the normal adhesive application temperature but less than 475 F 245 C When cleaning the AD 24 drop in cartridge with Type R 2 solvent do not submerge the entire cartridge in the solvent Be certain the pneumatic section top of the cartridge is not inserted in the molten solvent The mixture of Type R solvent and molten adhesive will cause the pneumatic section to sieze If a question concerning the compatibility of Type R solvent and a specific adhesive arises consult the adhesive supplier or use the following test b Heat the mixture slightly above the application temperature 2 Note changes in the mixture a Discoloration b Increase in viscosity ifa Gelling Separation of any ingr
39. pump applicator See Parts List To accomplish the conversion refer to Figure 1 and follow this procedure 1 Check to be sure the adhesive in the tank is molten 2 Turn the main switch OFF and disconnect and lock out input electrical power The Series 2000 hot melt applicators contain energized electrical components with potentials that could be fatal Disconnect and lock out input electrical power before removing any panels Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot applicator parts and surfaces 3 Remove the cover 1 and disconnect the air line connected to the four way air valve 2 4 Remove the three M8 bolts 3 securing the pump to the unit and remove the pump Remove the strainer from the tank Remove the FRP electrical enclosure 4 and tank enclosure 5 6 Mount the air motor and gear pump assembly P N 275 333 on the unit DO NOT insert the mounting bolts at this time 7 Attach the incoming air line to the port 6 on the air motor NOTE Be sure the incoming air is connected to the port nearest the tank NOTE The air supply to the air motor must be lubricated 8 Mount the exhaust manifold 7 at the tapped holes in the base using the screws 8 and lockwashers 9 provided Attach the muffler 13 to the manifold 9 Using the ell 10 and connector 11 as shown connect the copper tubing 12 to the muffler manifold and air motor 1
40. raise the temperature of the extra insulated section above the PTFE melting point For this reason customers should be cautioned against enclosing the hot melt hoses in any way that will cause overheating of the hose and failure ADDITIONAL CAUTION Hot melt hoses should not be secured so that the hose has a large area of surface contact with a cold floor cold steel angle iron or other cold material This may act as a heat sink reducing the temperature of the hose at that point and restrict the adhesive flow which could cause application problems If a hot melt hose is to be used in an application where the hose is suspended by an overhead tool balancer or similar device it is recommended that a hose support be used to minimize damage to the hose NOTE The hot melt hose should be supported so that the minimum bend radius is no less than 6 inches and so the weight of the hose will not compress the internal teflon tubing The hose support should neither act as a heat sink nor restrict the hose heat dissipation COPYRIGH 4 1978 NOROSON ISSUED 10 78 SUPERSEDES 6 78 Packaging and Assembly Division Wordson Atlanta Georgia TECHNICAL PUBLICATION 35 73 29 AUTOMATIC HOT MELT HOSE QUICK DISCONNECT EXTERNALLY HEATED Figure 1 Quick Disconnect Automatic Hot Melt Hose HOSE CONSTRUCTION The hot melt hose shown in Figure 1 is designed for use with hot melt applicators and automatic extrusion guns equ
41. ring and threads are free of dirt and other foreign particles 40 2e Issued 3 87s Nordson Corporation 1987 40 2 2 b Thread the fitting by hand into the threaded port in the gun or applicator c Tighten the fitting only enough to seat It should seat when the body of the metal fitting contacts the manifold surface Between 7 and 10 ft lbs of torque is required to create an effective seal Any time the fitting is removed the o ring must be replaced Otherwise the o ring will not seat properly Use only Nordson o rings P N 945 032 4 Replacement of O Rinas a Be sure that the o ring Nordson P N 945 032 and its groove are free of foreign particles b Stretch the o ring and carefully roll it over the threads onto the groove in the hose adapter or pipe plug Take care not to stretch the o ring any more than necessary c Install fitting according to instructions in step 3 A complete listing of Nordson fittings and their o ring replacements where replacements are available is provided in the chart below Pipe Th O Ring Description of Fitting and Where Used Fitting Fitting Str Conn Gun to Automatic Hose Applicator 972 051 972 628 to Automatic or Handgun Hose Pipe Plug Extra Ports on Gun or Applicator 973 411 973 574 90 Elbow Gun to Automatic Hose 972 200 274 180 90 Elbow Applicator to Automatic or 972 200 972 646 Handgun Hose 45 Elbow Gun to Automatic Hose 972 618 274 179
42. secure with special nut 15 and tab lockwasher 16 5 Insert U cup seal 11 into pump mount with groove in seal facing outward 6 Screw pressure ball seat 22 and pressure ball 21 into pump plunger 19 7 Insert air motor end of plunger into pump body up into the bottom hole of pump mount 8 Place trip collar 14 over threaded end of plunger and push plunger out through top hole of pump mount 9 Tighten two set screws 13 on trip collar into groove on plunger shaft Secure second set of set screws 13 in each hole in collar NOTE Make sure inner set screws mate with shaft groove when reassembling collar to plunger shaft 10 Assemble valve shifter 33 to pump mount with two screws 36 11 Lubricate valve shifter and trip collar with lubricant Nordson P N 900 252 12 Pull air motor end of plunger as far out of pump mount as possible 13 Place piston washer 8 onto plunger 14 Place one piston cup 10 over washer with curved edge down ward toward pump mount Place piston seal washer 9 over cup 15 Mount lower slab gasket 5 in pump mount groove 16 Slide air cylinder 6 over partially assembled piston 17 Seat air cylinder onto slab gasket in pump mount 18 Raise air piston to top of air cylinder 19 Place second cup seal on top of seal washer with curved edge toward top of cylinder 20 Place second piston washer 8 onto cup 21 Secure piston assembly with locknut 7
43. 0 Insert the three M8 bolts removed in Step 4 through the mounting plate on the gear pump assembly Tighten the bolts Place the strainer included in the kit in the tank ll Remove the four M5 Screws securing the air control assembly 14 to the front of the unit and pull the assembly out approximately 5 inches ISSUED2 86 SUPERSEDES 8 84 LITHO U S A NORDSON CORPORATION 1986 Rights Reserved Packaging and Assembly Division 41 2000 B2 Atlanta Georgia TECHNICAL PUBLICATION 12 13 14 15 16 Disconnect solenoid leads S1 S2 and 53 from TB2 and the ground stud and remove the solenoid valve Note the locations of all connections See Figure 2 Install the solenoid valve nipple and connector included in the kit 11 connections are identical to those found in Step 12 See Figure 2 Replace the air control assembly tank cover lid electrical enclosure and upper enclosure Remove the plastic plug from the top of the gear reduver housing Caretully remove the pipe plug from the side of the gear reducer housing NOTE Lubricant should be at the level of the plug hole in the side of the unit If the gear reducer is full allow the unit to drain to the level of the plug hole If the level is low refill to the level of the plug hole using the lubricant P N 275 338 included in the kit churning the excess oil can result in overheating If the gear reducer is underfilled the resultant frictio
44. 0 200 280 Web Speed Centimeters Second NOTE One Gun Cycle z One Bead One Gap Minimum Gun Cycle Length 2 Times the Minimum Length shown at left side of chart Curve 152 670 Nordson Automatic Gun with Pneumatic Operation Curve A C D and E Specific information not available ISSUED 9 1 70 SUPERSEDES LITHO U S A NORDSON CORPORATION 1986 All Rights Reserved v Packagi d Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 40 0 11 HOT MELT FAULTS AND TROUBLESHOOTING CHART The photographs below represent samples of bead faults commonly encountered in the application of hot melt adhesives Trouble shooting procedures are outlined on the pages that follow Cold Bead Possible Causes gt ee aw Adhesive colder than mended application tempera ture hood o ot ee B Ambient temperature in the application area below MM III I 6 normal Example Ice cream plant cold draft blow bat ing on nozzle C A stream of air directed at guns and nozzles radiation and convection will cool the nozzle gun and adhesive D Gun thermostat not of the proper temperature rating for the material in use E The nozzle too far from the substrate Excess Amount in Triggering Possible Causes OLS egy A Insufficient air pressure to the gun 2 B Insufficient air pressure to the pump The nozzle too far from the substrate
45. 00 52 Wordson Atlanta Georgia TECHNICAL PUBLICATION TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued D3 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the Main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage D4 Remove the upper electrical enclosure and check for loose connections or exposed wiring on all terminal blocks and temperature control components NORMAL INDICATION All wiring connections tight with no broken or exposed wiring Proceed to next step D5 Disconnect either wire No VISUAL INSPECTION ABNORMAL INDICATION Tighten loose connections and or replace faulty wiring Re store system to normal operation 47 35 or 48 36 tank thermostat at TB2 7 or TB2 2 and measure resistance across tank thermostat Wire numbers in parenthesis are for the 2002 2202 NORMAL INDICATION Open cir cuit when tank wall tempera ture is below 500 F 260 C Proceed to next step D6 Remove 2 pin connector J3 temperature control board pins on board NORMAL INDICATION Open cir cuit after thermal relay is cooled down approximately 15 minutes Proceed to next step ABNORMAL INDICATION Short circuit Replace thermostat
46. 000 115 NORDSON CORPORATION 1985 Ali Rights Reservad 41 2000 04 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION LIST OF TABLES Table Page 1 Troubleshooting Chart Mechanical Summary 41 2000 30 2 Troubleshooting Chart Mechanical 41 2000 32 3 Troubleshooting Chart Electrical Summary 41 2000 42 4 Troubleshooting Chart Electrical 41 2000 45 5 Individual Component Power Requirements 41 2000 82 6 Optional Filter Screens 41 2000 116 7 Recommended Spare Parts List 41 2000 116 8 Shipped With Parts List 41 2000 118 9 Service Parts List 41 2000 119 ISSUED 9 85 SUPERSEDES 1 84 NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A P amp A Division Nordson Atlanta Georgia TECHNICAL PUBLICATION 0 1 1 SAFETY SUMMARY INTRODUCTION Here you will find safety guidelines for the use of Nordson equipment These guidelines apply to anyone working with Nordson equipment including operations and service personnel They are repeated throughout this manual along with specific warnings and cautions not included in this section These safety guidelines cover s Installation Equipment operation Working with hot melt materials Use of hot melt solvents Failure to follow these recommendations may result in personal injury from burns or electrocution and or equipment and propert
47. 08188 A3L06608 A3L02554 A3L02562 2002 2004 2002 2004 2202 2204 2202 2204 Serial Number 41 2000 119 Qty F2 H2 FA dB H EB FH HL ES E BD B ES ji BRR Optional high viscosity ball and seat assembly P N 503 697 may be used in place of standard ball and seat assembly P N 503 694 ISSUED 9 85 LITHO U S A SUPERSEDES NORDSON CORPORATION 1985 Rights Reserved Packaging and Assembly Division _ _ Atlanta Georgia TECHNICAL PUBLICATION 1 2000 0 APPENDIX A RIGHT TO LEFT SIDE CONVERSION SERIES 2000 ISSUED 9 84 SUPERSEDES 8 84 9 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division _ _ Wordsom Atlanta Georgia TECHNICAL PUBLICATION 17 000 1 APPENDIX A RIGHT TO LEFT SIDE CONVERSION SERIES 2000 INTRODUCTION The Nordson Series 2000 hot melt applicators are shipped from the factory with the manifold on the right side of the applicator as the standard configuration Because some applications require that hoses be routed from the left side of the applicator a conversion of temperature electrical and pneumatic controls must be made To facilitate this conversion the heat sink at the back of the unit is interchangeable with the electrical and temperature controls The pneumatic control panel is also interchangeable with the information plate on the back of the unit Additionally the tank lid hinge can be relocated such t
48. 3 14 15 16 17 ISSUED 9 Packaging and Assembly Division Atianta Georgia TECHNICAL PUBLICATION 41 2000 71 b Submerge parts in an ultrasonic cleaner Submerge parts in a chemical cleaner Never clean any component of a pressurized fluid system with halogenated hydrocarbon solvents See Safetv Summary Section 40 1 for further details Using a halogenated hydrocarbon solvent in this system could cause an explosion Inspect valve stem and ball for wear or damage Replace worn or damaged parts NOTE Ball seat should also be checked for scratches and other damage Replace drain valve if seat is damaged Insert ball into valve body Thread valve stem into valve body full clockwise Insert retaining ring into groove in valve body using snap ring pliers Inspect o ring for wear damage or hardening Replace if necessary Attach drain valve to manifold using four screws Attach upper and lower tank enclosure to unit Restore system to normal operation in accordance with Section III Daily Operation EXCHANGER REMOVAL Figure 12 Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Relieve system pressure before breaking any mechanical connections Serious burns may result if heat D exchanger is removed with hydraulic pressure in the system Reduce input pressure
49. 38 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 27 Overfilling or Underfilling If a speed reducer is overfilled the energy used in churning the excess oil can result in overheating If the speed reducer is underfilled the resultant friction can also cause overheating If overheating occurs completely drain the housing and flush thoroughly with a light flushing oil Fill the housing until lubricant begins to drain from the oil level plug hole Rein stall the oil level plug Restart the drive Storage If a speed reducer is to be idle for an extended period of time such as when it is stored as a spare fill the unit completely with oil to protect interior parts from rust and corrosion due to condensation inside the housing Ensure that the speed reducer housing is drained to the proper level before placing the speed reducer in service SYSTEM CLEANING The entire hot melt application system must be flushed per iodically to remove excess dirt and charred material Use the following procedure to clean out and change adhesive material Some solvents may not be compatible with the hot melt Q adhesive material Sludge formation can further com pound the problem Test the solvent with a small sample of the adhesive before using the solvent in the system Wear safety glasses safety gloves P N 902 514
50. 6 5716 Denmark 45 42 648 500 45 42 641 101 France 33 1 64 12 14 00 33 1 64 12 14 01 Germany 49 211 2002 0 49 211 254658 Greece 30 1 941 9058 30 1 942 7623 Hong Kong 852 4287228 852 4804685 India 91 22 6442852 91 22 6427520 Italy 39 2 9078 23 40 39 2 9078 24 85 Japan 81 3 3450 8818 81 3 3472 3301 Korea 82 2 428 1931 82 2 427 9387 Malaysia 60 3 703 7248 60 3 791 5152 Mexico 216 988 9411 4315 216 985 3710 Netherlands 31 3403 77812 31 3403 74189 New Zealand 64 9 634 0179 64 9 579 7797 Norway 47 2 656100 47 2 658858 Pakistan 92 21 568 8609 3869 92 21 568 4585 Philippines 63 2 721 1421 63 2 721 3927 Portugal 351 2 941 3874 351 2 941 3867 Puerto Rico 809 787 2474 809 780 6063 Singapore 65 459 9533 65 459 9514 Spain 34 6 3705013 34 6 3705004 Sweden 46 40 291 585 46 40 932 882 Switzerland 41 61 463 838 41 61 463 818 Taiwan 886 2 581 3172 886 2 581 3074 Thailand 66 2 5141159 66 2 2531571 Turkey 90 1 384 4085 90 1 372 1528 United Kingdom 44 84421 3171 44 84421 5358 USA Continental 770 497 3400 770 497 3500 Alaska amp Hawaii 770 497 3400 770 497 3500 Venezuela 58 2 939 111 58 2 938097 Eastern Europe Africa amp Middle East contact Nordson European Division Erkrath Germany Distributor amp Export Department 49 211 2002 0 49 211 254652 Issued 3 05 NORDSON CORPORATION 1993 _ 306 18 662 US contact numbers updated 3 05 All Rights Reserved P amp A Division Atlanta Georgia TABLE OF CONTENTS Section SAFETY SUMMARY LI
51. 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A P amp A Division 41 2000 15 Nordson Sianta Georgia TECHNICAL PUBLICATION 380Y 220 VAC INSTALLATION Three Phase Installation ls 2 Check that the applicator main circuit breaker is OFF Set tank and hose temperature controls to minimum setting full counterclockwise Remove top left hand enclosure and back panel to expose electrical subplate by removing three captive screws Route a 380Y 220 VAC three phase 4 wire service line through the hole in the control cabinet base and electrical subpanel Make electrical connections at the five station input terminal block TB1 as shown below TB1 L L2 L3 N 380Y 220 Three Phase 4 Wire Connection Attach the applicator to an earth ground through GND TB1 5 Attach and secure the electrical enclosure cover and continue with Setup and Initial Operation Do not energize input electrical power at this time Connect input power at the appropriate step in the Setup and Initial Operation procedure Single Phase Installation Ts Check that the applicator main circuit breaker is OFF 2 Set tank and hose temperature controls to minimum setting full counterclockwise 3 Remove top left hand enclosure and back panel to expose electrical subplate by removing three captive screws 4 Route a 220 VAC single phase 4 wire service line through the hole in the control cabi
52. 941 230 O Ring Viton 1 8 Cap Filter 1 9 983 051 washer Flat 1 10 986 013 Ring Retaining Ext 1 11 982 188 Screw Flathead Soc M5x16 BL 3 12 275 479 Handle Filter 1 13 Driver Handle 1 Shipped with Filter Assembly unless otherwise specified on Purchase Order 41 2000sIssued 11 87a0Nordson Corporation 1987 41 2000 97 itam AS NS lt YUE ESS RSH an 1 lt NL ESS Figure 13 Filter Assembly 41 2000m Issued 11 87s Nordson Corporation 1987 41 2000 98 PUMP ASSEMBLY PARTS LIST PART 1 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION Item No Part No Description Req d 273 141 Pump Assembly Air Operated Piston Ref l 503 656 Gasket Valve 2 2 982 103 Screw Hex Head Cap M6 x 100 mm 4 3 983 409 Lockwasher Split M6 8 4 273 110 Head Air Cylinder Metric 1 5 955 024 Gasket Slab 2 6 504 088 Cylinder 1 7 984 134 Locknut Hex 1 4 20 1 8 503 687 Washer Piston Cup 2 9 503 688 e Washer Piston Seal 1 10 503 686 Cup Piston 2 11 952 100 Seal U Cup 0 38 x 0 88 in 1 12 273 109 Mount Pump 1 13 981 101 Screw Set Socket Head 10 32 x 0 19 in 4 14 240 634 Ring Air Valve Control 1 15 984 534 Nut Body Retaining 1 16 983 183 Tab Lockwasher 1 17 Piston Hydraulic See Service Parts List 1 18 240 354 SHIFTER VALVE See Figure 16 l 19 244 244 VALVE AIR 4 WA
53. 986 LITHO U S A Rights Reserved P amp A Division Atlanta Georgia TECHNICAL PUBLICATION pa d 7 Figure 20 Pressure Control Valve Assembly PRESSURE CONTROL VALVE ASSEMBLY PARTS LIST Item No Part No Description Req d a a 275 153 Valve Assembly Pressure Control Ref 275 151 Adjuster Pressure Control Valve 1 940 111 O ring Viton 0 31 x 0 44 in 1 275 217 Screw Pan Head M5 0 8 x 5 mm 2 275 150 Slide Pressure Adjust 1 941 133 O ring Viton 0 56 x 0 75 in 1 275 159 Tube Assembly Pressure Control Valve 1 Cap Pressure Control Valve 1 Tube Pressure Control Valve 1 Plate Mounting 1 987 025 Spring Compression 1 275 207 Stem Pressure Control Valve 1 940 141 O ring Viton 0 50 x 0 62 in 1 275 158 Nose Pressure Control Valve 1 900 303 Lubricant Silicon High Temperature 986 007 Ring Retaining 1 p m 41 2000 113 MEN aU MM El ISSUED 9 85 LITHO U S A SUPERSEDES 9 84 NORDSON CORPORATION 1985 All Rights Reserved 41 2000 114 GEAR PUMP AIR CONTROL ASSEMBLY PARTS LIST P amp A Division Atlanta Georgia TECHNICAL PUBLICATION Item No Part No Description Req d 275 072 Assembly Air Control Gear Pump Ref 1 275 082 Base Plate Front Ref 2 972 200 Elbow 90 deg 1 4 NPT x 9 16 18 37 deg SAE 1 3 901 444 Regulator Air Pressure 1 4
54. Access Latch Door Control Access 2000 window Control Access Door 000 Retainer Window Insulation Tank Bottom 2202 2204 Insulation Tank Bottom 2002 2004 SUPERSEDES 8 84 ONORDSON CORPORATION 1985 Rights Reserved Ref 18 H iA HERBE aS HI aS IS HI ai HI IE BER HS 3 ES H3 E BPP ED PBB P amp A Division 41 2000 91 Atlanta Georgia TECHNICAL PUBLICATION Figure 11 Base Assembly Part 2 ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved P amp A Division Atlanta Georgia 41 2000 92 Wordsom BASE ASSEMBLY PARTS LIST PART 3 TECHNICAL PUBLICATION Item No Part No Description Req d Assembly Base Series 2000 Ref 1 Base Series 2000 1 2 Nameplate Warning 1 3 985 112 Rivet Pop 2004 2204 8 2002 2202 4 4 275 107 Screw Captive M5 0 8 mm x 1 47 in 2 5 275 083 Subpanel Electrical Enclosure 1 6 983 408 Washer Flat Narrow M5 2002 2202 13 7 Grommet Continuous 0 3 ft 8 982 119 e Screw Pan Head M5 0 8 x 10 mm 2004 18 2002 2202 2204 16 9 275 279 Connector Cable 2 Screw 1 10 275 115 Adapter Pipe 1 4 NPTF 1 11 Marker Wire 12 982 114 Screw Hex Head M8 1 25 x 100 mm 1 13 275 139 Harness Wiring 2 Hose 1 13 275 118 Harness Wiring 4 Hose l 272 848 Dust Cover 2004 2204 4 2002 2202 2 939 541 Base Connector Mounting 2004 2204 4
55. BLY INSTALL THESE PARTS _ PIN 973 037 7 P N 275 021 GEAR PUMP AIR CONTROL ASSEMBLY ISSUED 8 84 SUPERSEDES 3 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Series 2000 Gear to Piston Pump Conversion Appendix C EDB No 41 2000 NORDSON CORPORATION e AMHERST OHIO e USA 7 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 C1 APPENDIX C SERIES 2000 GEAR TO PISTON PUMP CONVERSION The Series 2000 Gear to Piston Pump Kits P N 275 389 2002 2004 and P N 275 385 2202 2204 include the parts required to convert an air operated gear pump Series 2000 applicator to a piston pump applicator See Parts List To accomplish the conversion re er to Figure 1 and follow this procedure l 2 5 Check to be sure the adhesive in the tank is molten Turn the main switch OFF and disconnect and lock out input electrical power The Series 2000 hot melt applicators contain energized electrical components with potentials that could be fatal Disconnect and lock out input electrical power before removing any panels Wear safety glasses safety gloves P N 902 514 protective clothing to prevent injury from hot applicator parts and surfaces Remove the cover 1 the FRP electrical enciosure 2 and the tank enclosure 3 and disconnect the air line 4 connected to the gear pump air motor Disconnect the copper tubing 5 from the muffler manifold 6 by l
56. H1 LVLSOWYSHL ANVIL AN Poc H1 H31 V3H NYL qua I 91 H3TIOHLANOO SHNALVYAdNSL if 99 bd uaxv3us ISOH 989 uav3ug LINDYID NNO ow 16 er v ve LAINE Qnis IND EI S1 989 NO dicus xnv ez 00102 dd 5 cv ca 629 1 1fidNI 2 Qvo Ic l 1820 5 5 4 6 NIVW 1984 NORDSON CORPORATION AM Rights Reserved SUPERSEDES 1 84 ISSUED 8 84 LITHO U S A 41 2000 82 Component Power watts SYSTEM max 2002 2004 2202 2204 TANR 230V 230V 230V 230V 2002 2004 2202 2204 GUNS AD 24 2 4 8 2E 4E 2LP 4LP 8LP H20 AUTOMATIC HOSES Oi Fh et um m m m m m P amp A Division Atlanta Georgia 4680 6280 5600 7200 2310 3000 210 210 330 330 300 150 200 400 180 47 141 188 208V 208V Comp H200 TECHNICAL PUBLICATION Table 5 INDIVIDUAL COMPONENT POWER REQUIREMENTS onent 380V 380V 380V 380V 230V 230V 2 4 8 2E 4E 2 4 8 AD 3 HANDGUN HOSES 8 ft 2 4 m 16 ft 4 9 m LP LP LP 1 Power watts 3930 5280 4700 6050 2580 380V 3360 380V 210 210 330 330 300 150 200 300 60 188 376 235 Unless noted all of the above power consumption figures were ca
57. Hot Melt Applicators Series 2000 Part 104 443A NORDSON CORPORATION e AMHERST OHIO e USA SERVICES PROVIDED TO NORDSON CUSTOMERS Customer Support Before And After The Sale For more than 35 years Nordson has offered unparalleled service to its customers before during and after the sale Nordson representatives will work with you to choose the best system for your application We ll assist you during start up and help train your employees to maintain and operate the equipment Plus parts and service are only a phone call away from one of our strategically located sales and service centers System Engineering Custom designs and modification of standard equipment are available to meet your particular needs From a complete new system for automotive assembly to a special nozzle used in the production of diapers Nordson has the expertise to integrate adhesive and sealant equipment with your manufacturing operation Parts And Accessories In addition to standard replacement parts many accessories are available to help improve productivity and reduce downtime For example heated and non heated in line filters reduce stoppages from clogged nozzles and nozzles in multi orifice offset right angle and other designs are available for special needs Also gloves solvent spare parts kits and other components are in stock for immediate delivery Conversion kits for tapers labelers and box forming equipment are also available To help you el
58. L RELOCATION l 3 4 10 11 12 13 ISSUED Remove the top electrical enclosure by removing three captive Screws Remove the input terminal block support bracket from the elec trical subplate by removing two screws Carefully unplug the ribbon connector from the temperature con trol board Cut and remove the red cable tie from the wire harness NOTE Removal of this cable tie permits the temperature and electrical control panel to be interchanged with the heat sink panel without disturbing the main wiring harness Remove the electrical and temperature control panel from the electrical subplate by removing two screws Remove the main circuit breaker insulator by removing two screws and lockwashers Remove the heat sink assembly panel from the electrical subplate by removing two screws Secure the input terminal block support bracket to the subplate using two screws in the holes provided between termiral block TB2 and the front of the unit Move the heat sink assembly panel to the front of the applica tor and secure with two screws Attach the main circuit breaker insulator to the subplate using two screws and lockwashers Attach the electrical and temperature control panel to the rear of the subplate using two screws Secure the wire harness together using the red cable tie supplied with the applicator Carefully plug in the ribbon connector on the temperature control board 1 84 SUPERSEDE
59. LUMN The Description column presents a written description of the part or assembly Nomenclature dimensional information and material information appear in this column REQUIRED COLUMN The Required column specifies the quantity of the part required per unit or assembly dash in this column indicates that no specific quantity is required The term Ref in this column indicates the part or assembly has been included for reference only ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 41 2000 84 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION UNIT ASSEMBLY PARTS LIST PART 1 Item No Part No Description Req d 275 144 Hot Melt Applicator Model 2002 w Piston Ref Pump 2 Hose 200 230 VAC 275 014 Hot Melt Applicator Model 2004 w Piston Ref Pump 4 Hose 200 230 VAC 275 145 Hot Melt Applicator Model 2202 w Piston Ref Pump 2 Hose 200 230 VAC 275 013 Hot Melt Applicator Model 2204 w Piston Ref Pump 4 Hose 200 230 VAC 275 274 Hot Melt Applicator Model 2002 w Gear Ref Pump 2 Hose 200 230 VAC 215 243 Hot Melt Applicator Model 2004 w Gear Ref Pump 4 Hose 200 230 VAC 275 276 Hot Melt Applicator Model 2202 w Gear Ref Pump 2 Hose 200 230 VAC 275 278 Hot Melt Applicator Model 2204 w Gear Ref Pump 4 Hose 200 230 VAC 275 458 Hot Melt Applicator Model 2004 w Gear Ref Pump 4 Hose 380Y 220 VAC 275 459 Hot Melt Applicator Model 2202 w G
60. Melt Hose 6 ft 1 8 m Quick Disconnect 200 VAC Automatic Hot Melt Hose 8 ft 2 4 m Quick Disconnect 230 VAC Automatic Hot Melt Hose 8 ft 2 4 Quick Disconnect 230 VAC Automatic Hot Melt Hose 10 ft 3 1 m Ouick Disconnect 230 VAC Automatic Hot Melt Hose 10 ft 3 1 m Quick Disconnect 200 VAC Automatic Hot Melt Hose 16 ft 4 9 m Ouick Disconnect 230 VAC Automatic Hot Melt Hose 16 t 4 9 m Quick Disconnect 200 VAC O ring Boss pustcover Connector Receptacle Connector Socket Crimp Contact Order P N 274 126 SUPERSEDES Publication No 104 465A TECHNICAL PUBLICATION Connector Assembly Hose O ring Viton 0 38 in Connector Male 9 16 18 45 3 31 Req d Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref HA gt EA dn NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division 45 3 32 Atlanta Georgia TECHNICAL PUBLICATION SERIES 2000 HOT MELT APPLICATORS IN WATER WASH DOWN APPLICATIONS Nordson Series 2000 hot melt applicators are not designed for water wash down environments and must be protected from hose directed water Water may enter unit Failure to follow these instructions may result in electrical shock and equipment damage Use the following guidelines to protect the applicator in the event Series 2000 hot melt applicators are used in water wash down appli ca
61. N Ad Normal Indication See hesive viscosity within MOISTURE BUBBLES IN AD normal limits HESIVE BEAD ON SUBSTRATE ISSUED 9 81 SUPERSEDES 5 77 C NORDSON CORPCRATION 1981 All Rights Reserved Packagi dA bly Divisi 40 0 20 Wordson Pecteaing and Assembly Division TECHNICAL PUBLICATION Atlanta Georgia HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION Abnormal Indication In crease adhesive tempera ture slightly or use a lower viscosity adhesive material DEPOSIT FROM NOZZLES UNEVEN IN MULTI GUN INSTALLATION Hl Check for clogged nozzles in accordance with gun service manual NORMAL INDICATION Ad Normal Indication Pro hesive flows freely ceed to step H2 through nozzle Abnormal Indication Clogged nozzles Clean nozzles in accordance with gun service manual H2 Check pressure drop across guns and nozzles NORMAL INDICATION Approx Normal Indication None imately equal pressure drop across all guns Abnormal Indication Un equal pressure drop across guns Use one or more of the following steps to correct the problem l Increase applicator air pressure 2 Increase applicator temperature slightly 3 Flush and clean guns and nozzles 4 Use different flow rated nozzle or guns ISSUED 9 81 SUPERSEDES LITHO U S A 9 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 40 0 21 HOT MELT TROUBLESHOOTING CHART CONTIN
62. N 1984 All Rights Reserved ISSUED 1 84 LITHO U S A SUPERSEDES 3 83 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 35 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued f Slowly increase air pressure at the regulator by turning dial clockwise NORMAL INDICATION Gradu ABNORMAL INDICATION Con ally increasing audible tinue to next step if noise from regulator air issues from regulator Restore system to normal when regulator is opened Continue to step A11 if Set regulator to zero unit has an air cylinder pressure and secure input Proceed to step A16 if the air to solenoid valve unit has an air motor g Remove regulator from solenoid valve at the male pipe union Slowly restore input air pressure to solenoid valve NORMAL INDICATION Gradu ABNORMAL INDICATION Re ally increasing audible place solenoid valve noise from solenoid valve if no air issues Re Replace faulty regulator store system to normal Restore system to normal operation operation NOTE Air cylinder malfunctions may be caused by seal leakage or mechanical failure Proceed with fault isolation in the following manner All Set pump air pressure to 30 psi 205 kPa and check for air leakage NORMAL INDICATION No air ABNORMAL INDICATION Seal leakage apparent Pro leakage Use the fol ceed to next step lowing table to deter mine failed seal Nordson recommends that all seals be re
63. NPT 1 4 073 126 Elbow Street 90 deg 1 8 NPT 1 5 971 154 Connector 1 8 NPT x 1 4 in Hose Pushon 2 6 275 021 Valve Solenoid 230 VAC 1 4 NPT 1 933 162 Terminal Pushon 3 931 014 Wire 18 GA Black 3 7 ft Wire 18 GA Green w Yellow 1 8 ft 7 901 253 Gauge Pressure 0 t 100 psi 1 4 NPT 1 8 274 423 Hose 0 25 in OD x 7 00 in long 1 9 Not Used 10 973 503 Coupling Pipe 1 8 NPT 1 li 973 402 Plug Pipe 1 8 NPT Flush 1 12 972 050 Connector Male 1 4 NPT x 9 16 18 1 13 973 037 Nipple Pipe 1 4 NPT x 1 45 in 1 15 900 236 Paste Teflon 16 973 151 Elbow Street 90 deg 1 4 NPT 1 Optional filter lubricator available as Nordson P N 273 740 Filter is P N 901 515 ISSUED 9 85 LITHO U S A lubricator is P N 901 514 SUPERSEDES 8 84 QNORDSON CORPORATION 1985 All Rights Reserved P amp A Division 41 2000 115 Atlanta Georgia TECHNICAL PUBLICATION nnn Figure 21 Gear Pump Air Control Assembly ISSUED 9 85 SUPERSEDES 9 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved P amp A Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 116 TABLE 6 OPTIONAL FILTER SCREENS Part Number Description 161 104 Screen Filter 0 004 in mesh 161 106 Screen Filter 0 006 in mesh 161 109 Screen Filter 0 009 in mesh 161 112 Screen Filter 0 012 in mesh 161 115 Screen Filter 0 015 in mesh 161 120 Screen Filte
64. OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage A4 Remove the upper electrical enclosure and check for loose connections or exposed wiring on all terminal blocks and temperature control components VISUAL INSPECTION ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Ail Rights Reserved 2 _ Packaging and Assembly Division 41 2000 46 Nordson Atlanta Georgia TECHNICAL PUBLICATION TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued NORMAL INDICATION 11 wiring connections tight with no broken or exposed wiring Proceed to next step A5 Disconnect either wire No ABNORMAL INDICATION Tighten loose connections and or replace faulty wiring Re store system to normal operation 47 35 or 48 36 tank thermostat at TB2 7 or TB2 2 and measure resistance across tank thermostat between wire Nos 47 35 and 48 36 Wire numbers in par enthesis are for the 2002 2202 NORMAL INDICATION Open circuit when tank wall temperature is below 500 F 260 C Proceed to next step ABNORMAL INDICATION Con tinuity when tank wall temperature is below 500 F 260 C Replace thermo stat and restore system to normal operation A6 Remove 2 pin connector J3 wire Nos 30 and 40 on temperature control board and check continuity across the two pins on board J1 3 and Ji 4 NORMAL INDICATION Open circuit
65. PLUNGER PRESSURE BALL CHECK SIPHON BALL CHECK CROSSOVER TUBE Figure 3 Air Driven Dual Acting Piston Pump Air Driven Spur Gear Pump Assembly The air driven gear pump assembly consists of a regulator solenoid valve rotary air motor speed reducer qear pump and pressure con trol valve The pump is suspended from the speed reducer enabling rapid extraction from the melt tank for servicing similar to the air driven piston pump configuration Fiqure 4 details the air driven spur gear pump and associated drive components The air motor is a rotary vane type motor designed to provide ade quate torque to maintain nominal shaft speed under pump load conditions at 80 psi 550 kPa maximum input air pressure The motor and drive are sealed to prevent damage or corrosion due to exposure to moisture and adhesive materials ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Nordson Packaging and Assembly Division 41 2000 6 Atlanta Georgia TECHNICAL PUBLICATION The speed reducer is an 8 75 1 reduction gear that enables the rotary air motor to run at an optimum maximum speed of 1750 rpm while the gear pump runs at an optimum maximum speed of 200 rpm An insulator between the gear reducer and pump mount protects the reducer from tank heat The spur type gear pump provides a constant pressure output without the pressure fluctuations encountered in a piston pump as the piston reaches the
66. Plug in four three connectors in receptacles on printed circuit board 8 Replace electrical enclosure cover and secure with three captive screws 9 Reset temperature controls to minimum setting 10 Restore input power to the applicator 11 Restore system to normal operation in accordance with Daily Startup Procedure Potentiometer Board Replacement 1 Open the applicator main circuit breaker 2 Disconnect and lock out input electrical power to the applica tor Failure to disconnect and lock input electrical power to the applicator presents a serious shock hazard Input terminal board 1 and input termi nals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is open 3 Remove electrical enclosure top cover by removing three captive Screws ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division 41 2000 74 Nordson Georgia TECHNICAL PUBLICATION 4 a 8 9 10 Remove the ribbon connector from the back of the potentiometer board Open the front glass enclosure and remove the potentiometer board by removing four screws Replace the potentiometer board and secure with four screws Secure the ribbon connector to the back of the potentiometer board Secure electrical enclosure in place with three captive screws Reset temperature controls to
67. RMAL INDICATION Con ABNORMAL INDICATION Open tinuity Proceed to circuit Attempt to reset next step gun circuit breaker using button on front panel Replace CBG if the breaker will not reset Restore system to normal operation F5 Measure the resistance of the cartridge heater and thermostat between pins 2 and 7 on the plug side of the hose electrical connector for the affected gun NORMAL INDICATION Cartridge ABNORMAL INDICATION Open heater resistance in ac Circuit Proceed to next cordance with the appro step priate gun service manual Restore system to normal operation F6 Remove gun service cover and disconnect tbermostat leads at the wire nuts Measure resistance between thermostat leads NORMAL INDICATION Con ABNORMAL INDICATION Open tinuity Replace circuit Replace thermo cartridge heater Re stat Reconnect thermostat connect thermostat leads and restore system to leads and restore system normal operation to normal operation ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Alt Rights Reserved A Packaging and Assembly Division Nordson Atlanta Georgia TECHNICAL PUBLICATION 1 2000 59 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued GUN OVERHEATS Gl Disconnect and lock out input electrical power to the applicator Failure to disconnect input electrical power to the applicator can result in severe electrical shock when the gun cover is removed G2 Remo
68. Resistance Part No ft m VAC watts ohms 272 863 2 0 6 230 47 1040 1149 274 323 2 0 6 200 52 723 799 272 838 4 1 2 230 100 485 536 274 324 4 1 2 200 104 361 399 272 839 6 1 8 230 153 316 350 274 325 6 1 8 200 156 237 262 272 840 8 2 4 230 206 227 250 274 326 8 2 4 200 208 170 188 272 841 10 3 1 230 267 175 194 274 327 10 3 1 200 260 136 150 273 624 16 4 9 230 420 107 118 274 328 l6 4 9 200 416 81 90 Figure 2 Quick Disconnect Automatic Hot Melt Hose Electrical Schematic ISSUED 5 85 SUPERSEDES 1 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved Publication No 104 465A T Packaging and Assembly Division Atlanta Georgia PARTS LIST FOR FIGURE 1 Item No EIE E M C c NEN ee special tool to aid in removal and replacement of crimp sockets Part No 272 863 274 323 272 838 274 324 272 839 274 325 272 840 274 326 272 841 274 327 273 624 274 328 972 628 945 032 272 848 272 856 939 528 is available ISSUED LITHO U S A Description Automatic Hot Melt Hose w Diode 2 ft 0 6 m Quick Disconnect 230 VAC Automatic Hot Melt Hose 2 ft 0 6 m Quick Disconnect 200 VAC Automatic Hot Melt Hose 4 ft 1 2 m Quick Disconnect 230 VAC Automatic Hot Melt Hose 4 ft 1 2 m Quick Disconnect 200 VAC Automatic Hot Melt Hose 6 ft 1 8 m Quick Disconnect 230 VAC Automatic Hot
69. S 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 14 15 16 ISSUED LITHO U S A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION O Pins on the ribbon connector are easily broken and bent Use caution not to push the plug onto the board until all pins are alianed with the plug 41 2000 A3 A4 Carefully check that no wires are pinched under brackets or pulled too tightly Check all terminal connections for tightness Pinched or broken wiring and loose electrical con nections can cause erratic system operation damage to the equipment and severe electrical shock Install the top electrical enclosure on the applicator and secure with three captive screws Install the applicator in accordance with Section II Prepara tion For Use 1 84 SUPERSEDES gt 83 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 B0 APPENDIX B SERIES 2000 PISTON TO GEAR PUMP CONVERSION ISSUED 3 84 SUPERSEDES 3 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved P amp A Division Nordson Atlanta Georgia TECHNICAL PUBLICATION 1 2000 1 APPENDIX B SERIES 2000 PISTON TO GEAR PUMP CONVERSION The Series 2000 Piston to Gear Pump Kits P N 275 388 2002 2004 and 275 384 2202 2204 include the parts required to convert a piston pump Series 2000 applicator to an air operated gear
70. SON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 67 es Submerge parts in a chemical cleaner Never clean any component of a pressurized fluid system with halogenated hydrocarbon solvents Safety Summary Section 40 1 for further details Using a halogenated hydrocarbon solvent in this system can cause an explosion AIR OPERATED GEAR PUMP ASSEMBLY Figure 18 l 10 ISSUED Reassemble pump NOTE Be certain pump plates are aligned properly The stamped letters should appear on the same side of the pump Assemble spacers 9 onto the pump mount 16 Position lower gear reducer housing 31 onto mount and secure with two screws 9 and lockwashers Torque the screws to 5 8 ft lb Assemble the pinion gear assembly and drive gear assembly into the gear reducer housing 2 Tape the end of the drive gear output shaft before chaft is inserted through lower oil seal The keyway edges will cut the oil seal if not taped causing leakage and premature gear reducer failure Assemble lower drive coupling onto the output shaft and secure with two set screws 22 Assemble gear pump onto pump mount 16 and coupling insert 14 Secure with two screws 17 Torque the screws to 8 10 ft lb Check o ring 20 on crossover tube 19 for damage Replace if necessary Push control valve 23 through hole in aear reducer housing
71. ST OF ILLUSTRATIONS LIST OF TABLES I EQUIPMENT FAMILIARIZATION Introduction Specification Summary Functional Description Hot Melt Tank Hot Melt Adhesive Pump Configuration Air Driven Dual Acting Piston Pump Assembly Air Driven Spur Gear Pump Assembly Adhesive Manifold Assembly Tank Hose and Gun Temperature Controls Overtemperature Protection II PREPARATION FOR USE Introduction Unpacking Inspection Installation General Gun Installation H20 or H200 Automatic Gun Applicator Installation Electrical Installation 230 VAC Three Phase Installation 3 380 Three Phase Installation 230 VAC Single Phase Installation 380Y 220 Three Phase Installation 380Y 220 Single Phase Installation III OPERATING INSTRUCTIONS Setup and Initial Operation Pressure Control Valve Adjustment Gear Pump Applicators on Daily Operation Daily Startup Procedure Daily Shutdown Adhesive Loading ISSUED 9 85 SUPERSEDES 1 84 41 2000 01 TECHNICAL PUBLICATION Page 40 1 1 41 2000 03 41 2000 04 41 2000 1 41 2000 1 41 2000 2 41 2000 3 41 2000 3 41 2000 4 41 2000 4 41 2000 5 41 2000 7 41 2000 7 41 2000 8 41 2000 9 41 2000 9 41 2000 9 41 2000 9 41 2000 9 41 2000 9 41 2000 10 41 2000 11 41 2000 12 41 2000 13 41 2000 13 41 2000 13 41 2000 15 41 2000 15 41 2000 17 41 2000 17 41 2000 19 41 2000 19 41 2000 19 41 2000 19 41 2000 20 CORPORA
72. SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Ali Rights Reserved 9 Packaging and Assembly Division z Nordson Atlanta Georgia TECHNICAL PUBLICATION 17 2000745 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL The Series 2000 hot melt applicators and associated hoses and guns contain energized electrical components with potentials that could be fatal Only qualified personnel shall operate and perform maintenance on this equipment Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Review the Safety Summary 40 1 at the front of this service manual before attempting to perform maintenance on this equipment TANK FAILS TO HEAT OR UNDERHEATS Al Check the position of the main circuit breaker 1 NORMAL INDICATION Main cir ABNORMAL INDICATION Main cuit breaker ON Proceed circuit breaker OFF Pro to step AB ceed to next step A2 Attempt to close main circuit breaker NORMAL INDICATION Main cir ABNORMAL INDICATION Main cuit breaker ON Proceed circuit breaker trips to step AB immediately Proceed to next step A3 Disconnect and lock out input electrical power to the appli cator Input terminal block TB and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is
73. See Service Parts List Ref l 275 310 Manifold Tank t od 2 973 574 Plug O ring 9 16 18 Str Thread 16 3 945 032 O ring Viton LG 4 275 008 Plug O ring Boss 1 19 in thread 1 5 945 035 O ring Viton 7 8 in OD Tube 1 6 275 009 Heat Exchanger Manifold 1 7 275 175 Valve Pressure Relief 1600 1 psi 11 0 MPa 275 080 FILTER ASSEMBLY See Figure 13 L 275 288 Drain Valve Filter Assembly 1 8 940 151 O ring Viton 0 56 x 0 69 in 1 9 900 039 Ball 1 10 275 287 Body Drain Valve 1 11 986 601 Ring Retaining Internal 1 12 275 002 Tip Drain Valve 1 13 982 138 Screw Hex Head M8 1 25 x 40 mm 4 14 983 414 Washer Flat 8 mm 4 900 236 e Paste Teflon 15 275 004 Screw Filter Bung 1 Service Kit available See Table 9 ISSUED 9 85 SUPERSEDES 8 84 NOROSON CORPORATION 1985 All Rights Reserved LITHO U S A Packaging and Assembly Division 3 _ Atlanta Georgia TECHNICAL PUBLICATION 17 2000 95 2 D N Figure 12 Manifold Assembly ISSUED 9 85 SUPERSEDES 9 84 NORDSON CORPORATION 1985 LITHO U S A Alt Rights Reserved 41 2000 96 FILTER ASSEMBLY PARTS LIST Item Part No Description Req d 275 486 Filter Assembly Ref 1 900 236 Paste Teflon 2 273 140 Screw Hex Head 1 4 20 x 5 75 SPL l 3 240 459 Support Filter 1 4 273 025 Core Filter 1 5 161 106 Screen 006 1 6 275 477 Bung Filter l 7
74. Shifter Assembly PUMP VALVE SHIFTER ASSEMBLY PARTS LIST Item No Part No Description Req d 240 354 Valve Shifter Air Operated Pump Ref 1 Control Arm Weldment 1 2 503 728 Bracket Control Arm 1 3 Pin Control Arm Bracket 1 4 NOT USED 5 981 738 Screw Hex Head 8 32 x 0 25 in 2 6 Lubricant Moly Disulfide 7 987 002 Spring 1 8 9 Sleeve Control Arm 1 9 Pin Control Arm 1 10 Sleeve Control Arm Bracket l ISSUED 9 85 SUPERSEDES 8 84 ONORDSON CORPORATION 1985 Rights Reserved LITHO U S A P amp A Division 41 2000 105 Atlanta Georgia TECHNICAL PUBLICATION INTENTIONALLY BLANK ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 106 Nordson PISTON PUMP AIR CONTROL ASSEMBLY PARTS LIST P amp A Division Atlanta Georgia TECHNICAL PUBLICATION Item No Part No Description Req d 275 071 Assembly Air Control Piston Pump Ref 1 275 082 Base Plate Front Ref 2 972 200 Elbow 90 deg 1 4 NPT x 9 16 18 1 37 deg SAE 3 901 444 Regulator Air Pressure 1 4 NPT 1 4 973 126 Elbow Street 90 deg 1 8 NPT 1 5 971 154 Connector 1 8 NPT x 1 4 in Hose 2 Pushon 933 162 Terminal Pushon 3 6 275 022 Valve Solenoid 230 VAC 1 8 NPT 1 7 901 253 Gauge Pressure 0 t 100 psi 1 8 NPT 1 8 274 423 Hose 0 25 in OD x 7 00 in long 1 9 Not Used 10 973 503 Coupling Pipe 1 8 NPT 1 11 973
75. TION Ad Normal Indication Pro hesive temperature set ceed to step A2 tings normal Abnormal Indication Ad hesive temperature too high Reduce tempera ture A2 Check air pressure to applicator NORMAL INDICATION Air Normal Indication Pro pressure to applicator ceed to step A3 within normal limits Abnormal Indication Ap plicator air pressure too high Reduce air motor air pressure at the regulator A3 Check adhesive viscosity NORMAL INDICATION Ad Normal Indication None hesive visocity within normal limits ISSUED 9 81 SUPERSEDES 6 71 NORDSON CORPORATION 1981 All Rights Reserved kagi dA mbly Divisi 40 0 14 Wordson and Assembly Divison PUBLICATION HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION Abnormal Indication Ad hesive viscosity too low Adjust one or more of the following parameters as necessary 1 Reduce air motor air pressure 2 Reduce application temperature 3 Use lower flow rated nozzle 4 Use a higher viscos ity adhesive ADHESIVE CHARRING IN TANK Bl Check tank temperature NORMAL INDICATION Tank Normal Indication Pro temperature within nor ceed to step B2 mal limits Abnormal Indication Tank temperature too high Re duce tank temperature B2 Check tank temperature controller in accordance with applicator service manual NORMAL INDICATION Tank Normal Indication Pro temperat
76. TION 1985 All Rights Reserved LITHO U S A 41 2000 02 P amp A Division Atlanta Georgia TABLE OF CONTENTS Continued TECHNICAL PUBLICATION Section Page IV MAINTENANCE 41 2000 21 Introduction 41 2000 21 Preventive Maintenance 41 2000 22 General Maintenance 41 2000 22 Material Change 41 2000 22 Nozzle Cleaning 41 2000 23 Filter Assembly Cleaning 41 2000 24 Speed Reducer Lubrication 41 2000 26 System Cleaning 41 2000 27 Corrective Maintenance 41 2000 29 Troubleshooting Chart Mechanical Summary 41 2000 30 Troubleshooting Chart Mechanical 41 2000 32 Troubleshooting Chart Electrical Summary 41 2000 42 Troubleshooting Chart Electrical e 41 2000 45 Disassembly and Repair 41 2000 59 Air Operated Piston Pump Disassembly 41 2000 60 Air Operated Piston Pump Assembly 41 2000 62 Air Operated Gear Pump Disassembly 41 2000 64 Air Operated Gear Pump Assembly 1 2000 67 Pressure Control Valve Disassembly and Repair 41 2000 68 Manifold Drain Valve Removal and Disassembly 41 2000 70 Heat Exchanger Removal 41 2000 71 Temperature Control Replacement 41 2000 72 Solid State Relay Replacement 41 2000 74 V DIAGRAMS AND TABLES 41 2000 77 VI ILLUSTRATED PARTS LIST 41 2000 83 Introduction 41 2000 83 Column Identification 41 2000 83 Recommended Spare Parts 41 2000 110 APPENDIX RIGHT HAND TO LEFT HAND APPLICATOR CONVERSION SERIES 2000 41 2000 A1 SERIES 2000 PISTON TO
77. UED SYMPTOM PROCEDURE CORRECTIVE ACTION 5 Use flow control valves in the lines GUN DROOLING Il Check gun needle and seat for wear and or char NORMAL INDICATION Gun Normal Indication Pro needle and seat clean ceed to step I2 with no indication of wear Abnormal Indication Clean and or replace worn parts in accordance with gun service manual I2 Check trigger adjustment in accordance with gun service manual NORMAL INDICATION Trigger Normal Indication None adjustment within normal limits Abnormal Indicator Ad just trigger in accor dance with gun service manual MOISTURE BUBBLES IN ADHESIVE BEAD ON SUBSTRATE Jl Apply adhesive to dry sub strate and check for mois ture bubbles NORMAL INDICATION No bub Normal Indication Dry bles on dry substrate substrate prior to appli cation of adhesive heat substrate as neces sary Abnormal Indication See AIR IN ADHESIVE ISSUED 9 81 SUPERSEDES NCRDSON CORPORATICN 1981 Rights Reserved Packaging and Assembly Divisi 40 0 22 Wor dson Atlante Georgia TECHNICAL PUBLICATION HOT MELT TROUBLESHOOTING CHART CONTINUED CORRECTIVE ACTION SYMPTOM PROCEDURE CARTON POP OPEN AFTER LEAVING COMPRESSION SECTION Kl Check adhesive not cooling fast enough too long an open time NORMAL INDICATION Proper Normal Indication Pro open time ceed to step K3 Abnormal Indication Pro ceed to step K2 if open time i
78. UN TEMPERATURE CONTROLS temperature controller in the Series 2000 applicators is a solid state device that monitors and controls the temperatures with in the hot nelt tank and heated hoses The temperature controller utilizes five separate control channels three in the 2002 2202 appiicators Each channel has a dial potentiometer a yellow light emitting diode LED and red LED The yellow LED glows continuously when temperature is below the dial set point flashes when the controller is maintaining the set temperature and remains ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Ali Rights Reserved 9 Packaging and Assembly Division 41 2000 8 Atlanta Georgia TECHNICAL PUBLICATION dark when temperature exceeds the set point by approximately two degrees The red LED indicates overtemperature conditions The red LED glows when temperature reaches the halfway point between the dial set point and 500 F 260 C Both LED s also act to indicate RTD or circuit problems These problem indications are presented in Table 3 Temperature is sensed in the tank and in each of the hoses bv a resistance temperature detector RTD in each component Each RTD has a calibrated operating range of 200 to 430 F 90 to 220 C with limited accuracy down to 150 F 65 C and up to 450 F 230 C Gun temperature is maintained by the use of a cartridge heater in series with an open on rise thermostat The standard qun
79. Y See Figure 15 1 20 982 104 Screw Hex Head Cap M6 x 40 mm 4 ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 All Rights Reserved NORDSON CORPORATION 1985 Division 41 2000 99 Atlanta Georgia TECHNICAL PUBLICATION Figure 14 Piston Pump Assembly Part 1 ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 100 PUMP ASSEMBLY PARTS LIST PART 2 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION Item No Part No Description Req d Pump Assembly Air Operated Piston continued 1 985 307 Pin Roll 0 16 in dia x 0 50 in long 1 2 273 108 Body Hydraulic Pump 1 3 Piston Hydraulic See Service Parts List 1 985 302 Pin Roll 0 12 in dia x 0 50 in long 1 4 900 000 Ball Pressure 0 38 in dia 1 5 Seat Pressure Ball See Service Parts List 1 6 503 696 Cage Ball Siphon 1 7 900 001 Ball Siphon 0 50 in dia l 8 Seat Ball Siphon See Service Parts List 1 954 020 Ring Backup 0 50 x 0 62 in 1 9 940 141 O ring Viton 0 50 x 0 62 in 1 10 Tube Crossover 1 11 973 402 plug Pipe 1 8 NPT 1 12 273 139 Wiper Pump Shaft 1 13 273 138 Washer Flat 0 54 x 0 80 x 0 03 in l 14 986 602 Ring Retaining Internal 0 81 in bore 1 Optional high viscosity ball and seat assembly P N 503 697 may be used in place of standard ball a
80. ad 0 3 mm x 5 0 mm with specific gravity of 0 9 Volume 9 3x 5 0 x 1 0 15 liters 100 3 Weight 0 3 5 01 0 0 9_ 0 135 Grams 100 M ISSUED 9 1 70 SUPERSEDES Q NORDSON CORPORATION 1986 LITHO U S A All Rights Reserved Whichever is Shorter INCHES P amp A Division Atlanta Georgia TECHNICAL PUBLICATION 40 0 7 MINIMUM BEAD LENGTH CHART FOR HOT MELT APPLICATION Minimum Time for One Complete Gun Cycle 20 1 5 12 1 0 WIN ETS TN 0 0 0 100 200 300 Web Speed Feet per Minute 0 20 40 _ 60 80 100 120 Web Speed Inches per Second NOTE One Gun Cycle One Bead One Gap One Cycle RIT RTS ET Minimum Gun Cycle Length 2 Times the Minimum Length shown at Left Side of chart Curve 8 152 670 Nordson Automatic Gun with Pneumatic Operation Curve A C Dand E Specific information not available ISSUED 9 1 70 SUPERSEDES NORDSON CORPORATION 1986 IT S A LITHO U S A All Rights Reserved P amp A Division 40 0 8 Wordson Georgia TECHNICAL PUBLICATION MINIMUM BEAD LENGTH CHART FOR HOT MELT APPLICATION B 5 120 Minimum Time for One a Complete Gun Cycle E 10 0 2 L gt Mm 8 80 5 2 aJo 60 o 2 E 4 0 E E gt 2 0 40 120 16
81. after thermal relay is cooled down approximately 15 min utes Proceed to next step ABNORMAL INDICATION Short circuit Wait 15 minutes for unit to cool down Measure again If still shorted replace thermal relay Restore system to normal operation A7 Attempt to close main circuit breaker NORMAL INDICATION Main Circuit breaker remains ON Proceed to step A8 ABNORMAL INDICATION Main circuit breaker continues to trip Replace circuit breaker due to faulty trip mechanism Restore system to normal operation A8 Restore input electrical power to applicator and note the condition of the red and yellow indicating lights on the temperature control panel Proceed to the appropriate point in the Electrical Troubleshooting Chart if the prob lem is hose related ISSUED 8 64 LITHO U S A SUPERSEDES 1 84 NORDSON CORPORATION 1984 Rights Reserved Packaging and Assembly Division TECH Georgi E Atlanta Georgia NICAL PUBLICATION 41 2000 47 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued NORMAL INDICATION Yellow ABNORMAL INDICATION If both LED on and red LED off LED s are off power to the indicating the tank TTC has been lost or the TTC should be heating Pro has failed Proceed to next ceed to step A13 step If both LED s are on or the yellow LED is off and the red LED is on the prob lem is in the TTC or sensor Proceed to step 16 A9 Check input voltage at term
82. age Replace as necessary Remove two set screws 13 from trip collar 14 NOTE These screws do not secure the collar to the shaft but instead lock the set screws beneath them Loosen third and fourth set screws 13 until collar slides freely along piston shaft Loosen special retaining nut 15 that anchors hydraulic pump body 18 to the pump mount 12 Slide nut and tab lockwasher 16 away from body NOTE The entire hydraulic section may now be removed by pulling pump body away from pump mount Air valve 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 61 trip collar 14 retaining nut and tab lockwasher may be removed from piston shaft as the shaft is withdrawn from pump mount 16 Inspect U cup seal 11 in the upper face of pump mount Replace if damaged 17 Remove siphon ball seat 25 from bcttom of pump body Avoid scratching pump plunger 19 and inside of pump body during disassembly and repair of pump Surface scratches on these parts may cause ex cessive leakage during operation 18 Hold pump body 18 and push threaded air cylinder end of pump plunger 19 toward siphon ball seat 25 until pres sure ball and seat 22 appear 19 Pull pressure ball seat from pump body 20 Unscrew pressure ball seat from pump plunger 21 Inspect ball seats and balls for wear and damage Replace if nece
83. aker Hose 10 amp thermal 1 939 532 Circuit Breaker Gun 10 amp magnetic 1 2004 2204 939 631 Circuit Breaker 5 Amp 2002 2202 1 939 577 Lamp Indicator White 230 VAC 1 See Table 6 for optional filter screens ISSUED 9 85 LITHO U S A SUPERSEDES NORDSON CORPORATION 1985 Atl Rights Reserved 41 2000 118 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION TABLE 7 RECOMMENDED SPARE PARTS LIST Continued Part No Description Qty 939 574 Temperature Control Board 2004 2204 1 939 575 Potentiometer Board 2004 2204 1 275 128 Temperature Control Board 2002 2202 l 275 129 Potentiometer Board 2002 2202 l 939 538 Solid State Relay 25 amp 2002 2004 1 939 576 Solid State Relay 40 amp 2202 2204 1 939 541 Base Connector Mounting 1 AIR CONTROL ASSEMBLY 901 253 Pressure Gauge 0 to 100 psi 1 8 NPT 1 275 022 Solenoid Valve 230 VAC 1 8 NPT Piston 1 Pump Only 275 021 Solenoid Valve 230 VAC 1 8 NPT Gear 1 Pump Only MISCELLANEOUS 275 338 Lubricant Gear Reducer Gear Pump Only 1 900 236 Paste Teflon l 900 252 Lubricant Piston Pump Valve Shifter 1 902 514 Gloves 1 EF LEEREN AMET ENTM NER TABLE 8 SHIP WITH PARTS LIST Part No Description Qty SECRETO SER ARM IDEO TT TREDECIM Kit Ship With Piston Pump 939 579 Cable Tie Red 1 981 235 Screw Hex Head 1 4 20 x 4 0 in 1 Kit Ship With Gear Pump 939 579 Cable Tie Red l
84. al base INSPECTION After unpacking the following inspection should be performed lis Inspect surfaces for evidence of cracks in the fiberglass cover scratches corrosion and other physical damage to Remove the electrical enclosure and inspect for loose electrical connections and loose contaminants 3 Inspect hose for broken connectors rips in the outer cover and evidence of kinks or other damage 4 Inspect guns for loose mechanical and electrical connections 5 Inspect all fasteners and mechanical connections for tightness INSTALLATION GENERAL La Instali the hot melt applicator so panels can be removed and the unit is otherwise accessible for operation ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Ail Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 10 25 3 Avoid unusual ambient temperature conditions i e below 30 0 or above 120 F 50 The applicator should also be protected from unusual dust con ditions and severe vibration If the applicator is installed outdoors or in a drafty area the guns must be shielded from the wind Rapid heat dissipa tion due to air movement across the guns can prevent the guns from operating properly Hoses and guns are shipped separately and must be attached when the applicator is installed Hose and gun installation and air connection must precede connection of electri
85. and gt ceed to step F3 viscosity within normal limits Abnormal Indication Cold adhesive too viscous Increase adhesive temperature slightly Use lower viscosity adhesive F3 Check adhesive shelf life NORMAL INDICATION Ad Normal Indication Pro hesive shelf life recom ceed to step F4 mended by adhesive manu facturer Abnormal Indication Drain and flush old adhesive Add new adhesive to tank OO eee ISSUED 9 81 SUPERSEDES LITHO U S A Packagi d Assembly Division Atlanta Georgia _ TECHNICAL PUBLICATION 40 0 19 HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION F4 Check for cold air blowing on gun and or low ambient temperature NORMAL INDICATION Normal Normal Indication Check ambient temperature with with adhesive manufacturer little air movement around gun Abnormal Indication Cold air blowing on gun and or low ambient temperature Use one or more of the following steps to cor rect the problem 1 Protect gun from air movement 2 Increase adhesive temperature slightly 3 Preheat substrate 4 Heat ambient air AIR IN ADHESIVE Gl Check adhesive tank full of molten adhesive NORMAL INDICATION Ad Normal Indication Pro hesive tank full of ceed to step G2 molten adhesive Abnormal Indication Ad hesive melt tank empty Refill tank and operate guns until bubble dis appears G2 Check viscosity of ad hesive NORMAL INDICATIO
86. anta Georgia TECHNICAL PUBLICATION 5172000749 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued NORMAL INDICATION 16 9 to ABNORMAL INDICATION Open 19 8 ohms for the 2002 2004 Circuit or high resistance and 13 1 to 15 2 ohms for the Replace tank Reconnect 2200 2202 Replace solid wire No 51 39 and restore state relay Reconnect wire system to normal operation No 51 39 and restore System to normal operation A16 Disconnect and lock out input electrical power to the applicator Input terminal board 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage 17 Unplug J2 from the temperature control board and measure the resistance across the tank RTD between pins 2 and 5 on the plug NORMAL INDICATION The RTD is ABNORMAL INDICATION If RTD calibrated in the range from resistance is outside the 120 to 320 ohms If resis range from 120 to 320 ohms tance is within acceptable open or shorted replace tolerance replace tempera the RTD Restore system ture control board Restore to normal operation system to normal operation TANK OVERHEATS ABOVE 500 F 260 C On an overtemperature condition where tank temperature rises above 500 F 260 C the close on rise thermostat THS sho
87. ated by a red LED on the tank temperature controller when temperature on the tank wall reaches halfway between the temperature setting on the controller and 500 F 260 C Approximately two minutes later the temperature controller will open the main circuit breaker through the circuit breaker auxiliary trip coil Cl With the main circuit breaker closed check the condition of the temperature controller indicators Refer to Table 3 for indications NOTE It may be necessary to wait as long as 15 minutes for the thermal relay contacts to open before the main circuit breaker can be reclosed NORMAL INDICATION With ABNORMAL INDICATION If temperature above the set both the red and yellow point but below the haif LED s are lit proceed way point between the set to the next step point and 500 F both LED s should be dark Above the halfway point the red LED should be lit for approxi mately two minutes until the main circuit breaker trips Proceed to step C4 ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division T Nordson Atlanta Georgia TECHNICAL PUBLICATION 5172000751 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued C2 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main cir cuit breaker are still electrically energized if external power is not disconnected eve
88. cal power to the applicator GUN INSTALLATION H20 or H200 Automatic Gun l ISSUED Install the gun on the parent machine in proper alignment with the substrate NOTE The gun mount should be protected from vibration and secured so that the gun will not change po sition during application NOTE Nordson recommends the installation of a heated or non heated inline filter between the gun and hose Connect the hose mechanically to the gun Connect the hose electrically to the gun Ensure the pins are properly aligned and the con nectors are locked together Connect a filter regulator and solenoid valve to the gun NOTE The solenoid valve should be placed as close as practical to the gun to prevent introduction of lag time between solenoid valve actuation and gun operation Set the regulator to zero pressure full counterclockwise and connect external air supply NOTE The air supply should deliver a minimum of 50 psi 345 kPa to the filter regulator to ensure proper gun operation Connect solenoid leads to the appropriate timing device 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 the A Alt Rights Reserved P amp A Division 41 2000 11 Atlanta Georgia TECHNICAL PUBLICATION APPLICATOR INSTALLATION 1 Mount the hot melt applicator securely to the parent machine so that controls and panels are accessible Do not attempt to lift the applicator by any of the fiberglass panels or hose connectors
89. chloroethylene Brominated Solvents Ethylene Dibromide Methyl Bromide Methylene Chlorobromide Iodinated Solvents Ethyl Iodide Methyl Iodide N butyl Iodide Propyl Iodide IF MOLTEN MATERIAL COMES IN CONTACT WITH THE SKIN Do NOT try to remove molten material from the skin Imnediately immerse the affected area in cold clean water Keep the affected area immersed until the material has cooled Do NOT try to remove the cooled material from the skin Cover the affected area with a clean wet compress In cases of severe burns look for signs of shock If shock 15 suspected have patient lie down use blankets to preserve body heat and elevate the feet several inches Call a physician immediately ISSUED 7 86 SUPERSEDES 2 85 NORDSON CORPORATION 1986 LITHO U S A All Rights Reserved P amp A Division m 40 1 6 Atlanta Georgia TECHNICAL PUBLICATION This page intentionally left blank ISSUED 7 86 SUPERSEDES 2 85 NORDSON CORPORATION 1986 U S A All Rights Reserved 40 2 1 IDENTIFICATION AND USE OF NORDSON FITTINGS There are two different types of hose adapters and pipe plugs used on Nordson equipment one with an o ring seal and one with a pipe thread seal Some Nordson H20 noncirculating automatic guns H200 automatic guns and Series 2000 applicators use hose fittings and pipe plugs with o ring seals for the fluid ports These o ring fittings which have straight pipe threads are not intercha
90. ckagi dA bly Division 40 0 24 Atlante Georgia S TECHNICAL PUBLICATION HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE z E CORRECTIVE ACTION 9 Use longer open time adhesive See ad hesive manufacturer Check for sheared ad hesive deposit NORMAL INDICATION Ad Normal Indication None hesive deposit not sheared Abnormal Indication Sheared adhesive de posit Ensure sub strate is not twisted jogged or otherwise subjected to adverse movement in the com pression section See adhesive manufacturer if compression section is smooth ISSUED 9 81 SUPERSEDES LITHO U S A Hot Melt Hose 45 0 0 NORDSON CORPORATION e AMHERST OHIO e USA Nordson CORPORATION Amherst Ohio 44001 TECHNICAL PUBLICATION 45 0 1 10 78 Revised Information USA MELT HOSES 7 Our instruction manuals clearly state that hot melt hoses are not to be placed inside of conduit but do not state a reason why Hot melt hoses should not be placed inside of any closed cover where heat cannot be dissipated from them This includes electrical conduit insulation of any type or tight metal covers Com plete failure of the hose can result if the hose is insulated beyond the insulation that is included with the hose If the thermocouple section is exposed to a lower temperature it will call for heat even though the extra insulated section is at or above correct operating temperature This will
91. ctrically and controlled independ ently by means of resistance temperature detectors in the tank and hoses and solid state circuitry in the applicator Extrusion guns are heated by cartridge heaters and controlled by open on rise ther mostats in the guns Depending on the material being melted the Model 2002 2004 has a melt rate of 14 lb hr 6 4 kg hr and the Model 2202 2204 has a melt rate of 22 lb hr 10 0 kg hr Maximum delivery rate instantaneous with the gear pump or piston pump is noted in the Specification Summary The Series 2000 hot melt applicators are shipped from the factory with the pump and air control assembly completely installed and with the manifold on the right side of the applicator Because some applications require that hoses be routed from the left side of the applicator the temperature control panel and electrical panel are interchangeable with the heat sink at the back of the unit The air control panel can also be moved to the back of the unit ISSUED 8 84 SUPERSEDES 1 84 CORPORATION 1984 LITHO U S A Ail Rights Reserved 41 2000 2 amp Division Atlanta Georgia TECHNICAL PUBLICATION Additionally the tank 114 hinge can be moved such that the lid will open to the left or to the right as required by the installation SPECIFICATION SUMMARY Tank Volume 2002 2004 2202 2204 Tank Capacity 2002 2004 2202 2204 Melt Rate nominal 2002 2004 2202 2204 Pump Rates max Pis
92. d heating device i e a small deep fat fryer or thermo statically controlled hot plate must be used to heat the solvent above the melting temperature of the hot melt adhesive material There are several methods for cleaning a hot melt filter screen depending on the type of hot melt adhesive material used as noted below Place the filter components in a container of Nordson Type R solvent and heat above the melt temperature of the adhesive Scrub screen with a fine bristle brush Do not use a metal brush Damage may result to the screen mesh preventing proper tion of the filter Screens may be heated with a flameless electric heat gun Wipe screen with a clean dry cloth Use an ultrasonic cleaner filled with solvent to clean screen Inspect the screen 7 for damage NOTE 8 84 LITHO U S A Any dents or breaks in the mesh indicate damage be yond repair Replace with a new screen The Series 2000 applicators are shipped with a 0 006 inch mesh filter screen This screen should always be smaller than the smallest nozzle orifice Optional filter screens are available See Section VI Illus trated Parts List for optional filter screens SUPERSEDES 1 84 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 26 11 12 13 14 15 16 17 Slide screen over core 8 Place support 9 on the
93. d in a clockwise direction If the air motor turns freely continue with the disassembly procedure The rotary air motor is designed to be turned only in the CLOCKWISE direction Damage to the motor internal parts may result if the motor is turned in the counterclockwise direction Remove socket head screws and lockwashers from the top of the gear reducer Remove set screw on lower half of drive coupling 3 and slide coupling off shaft Push down on the pinion gear shaft and remove the air motor assembly mount 6 Remove two set screws 22 from the lower drive coupling to free the drive gear assembly Invert the gear reducer housing over an open container to drain the gear reducer lubricant Carefully work the pinion gear shaft and drive gear shaft out of the gear reducer housing Inspect pinion gear and drive gear assemblies bearings and shaft surfaces for wear or damage Replace as necessary 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 4 Nordson Packaging and Assembly Division TECHN T 41 2000 66 Atlanta Georgia ICA UBLICATION 17 18 19 20 21 22 23 24 ISSUED Q If replacement is required the gears should be replaced as a set Failure to replace the mating gears as a set will result in continued wear or damage Remove two screws and lockwashers from gear reducer housing Remove pressure control valve 23 by removing two screws 29 and lockwashers 28 Remove
94. d is clean and free of contaminants Do not allow contaminants or foreign material to enter the hot melt tank Foreign parti cles may lodge in the pump and cause it to stall or be damaged Foreign particles passing through the pump can clog the filter screen Check the tank strainer occasionally for large particle contaminants Do not operate the applicator without the tank strainer in place ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 Riahts Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 19A DAILY START UP 1 Turn the applicator Allow the adhesive in the tank to melt 2 Adjust tank and hose temperature controls to the desired settings 3 Adjust input air pressures to the pump and guns to the desired settings 4 Check tank level and add adhesive material as necessary DAILY SHUTDOWN 1 Shut the applicator main circuit breaker OFF Da Reduce pump and gun air pressures to zero at the regulator SAFETY PRECAUTIONS l Do not touch the hot melt guns when in use They are hot 24 Reduce pump air pressure to zero and relieve hydraulic pressure by triggering the gun before removing the adhe sive filter or opening the manifold drain valve Shut OFF the applicator main circuit breaker before opening the electrical enclosure OPERATION Set the tank and hose temperature controllers and air pressure to the settings recommended by Nordson personnel and o
95. dson Atlanta Georgia TECHNICAL PUBLICATION lid further functions to prevent the introduction of dust and other contaminants into the tank Once the unit has cooled down the inner lid cannot be removed The outer lid may be opened to facilitate removal of the fiberglass enclosure for maintenance The tank mounts directly onto the adhesive distribution manifold A drain valve on the back of the tank allows the tank to be drained directly without going through the pump and manifold Temperature control is accomplished by means of a resistance tempera ture detector RTD mounted on the tank and solid state circuitry located in the electrical enclosure The temperature control range is from 200 to 430 F 90 to 220 C although this range may be extended down to 150 F 65 and up to 450 F 230 C with some re duced accuracy at the extremes Over temperature protection is provided by a close on rise thermostat set at approximately 500 to 550 F 260 to 290 C to trip the applicator main circuit breaker through its auxiliary coil HOT MELT ADHESIVE PUMP CONFIGURATION The Series 2000 applicators incorporate either an air driven spur gear pump or an air driven dual acting piston pump to transfer molten adhesive material from the tank to the distribution manifold A piston pump is normally used with low to medium viscosity materi als in applications not requiring high cycle speeds and in applica tions insensitive to pressure pulsa
96. ear Ref Pump 2 Hose 380Y 220 VAC 275 460 Hot Melt Applicator Model 2204 w Gear Ref Pump 4 Hose 380Y 220 VAC 275 461 Hot Melt Applicator Model 2202 w Gear Ref Pump 2 Hose 380Y 220 VAC 275 462 Hot Melt Applicator Model 2204 w Piston Ref Pump 4 Hose 380Y 220 VAC 275 463 Hot Melt Applicator Model 2004 w Piston Ref Pump 4 Hose 380Y 220 VAC 275 464 Hot Melt Applicator Model 2002 w Piston Ref Pump 2 Hose 380Y 220 VAC 275 465 Hot Meit Applicator Model 2202 w Piston Ref Pump 2 Hose 380Y 220 VAC 1 275 089 Assembly Upper Enclosure 1 2 900 236 Paste Teflon 3 973 953 Adapter Pipe 1 4 NPT x 1 8 NPT l 4 972 200 Elbow Male 37 deg 9 16 18 x 1 4 NPT 1 982 050 Screw Hex Head M8 1 25 x 35 mm 3 6 983 414 washer Flat M8 3 7 273 141 Drive Assembly Piston Pump Air Operated 1 8 985 112 Rivet Pop 6 9 982 119 Screw Pan Head 8 10 275 071 Air Control Assembly Piston Pump 1 10 275 072 Air Control Assembly Gear Pump 1 11 BASE ASSEMBLY See Figure 11 1 12 275 045 Baseplate Rear 1 273 143 Strainer 2002 2004 Piston Pump 1 273 042 Strainer 2202 2204 Piston Pump l 273 041 Strainer 2002 2004 Gear Pump 1 273 142 Strainer 2202 2204 Gear Pump 1 ISSUED 9 85 SUPERSEDES 8 84 ONORDSON CORPORATION 1985 All Rights Reserved LITHO U S A P amp A Division 41 2000 85 Atlanta Georgia TECHNICAL PUBLICATION Figure 10 Unit Assembly Part 1 ISSUED 9
97. edients in the mixture e Sharp drop in viscosity Do not use Type R solvent when flushing equipment using 2 Polyamide Surlyn Polyester or certain other high performance hot melt materials A gelled contaminant may form which will cause nozzle plugging and charring in the various heated components Before using a cleanout material other than Nordson Tvpe R Solvent check to be sure the material meets these Specifications d Non toxic and non sensitizing 2 Does not produce toxic vapors when heated 34 Flash point at least 50 F 28 C above intended use temperature 4 Non corrosive Refer to the specific Nordson applicator service manual for additional information regarding the use of Type R solvent Description 270 755 Solvent 1 Gallon 3 8 Liters 270 756 Solvent Type R 5 Gallon 18 9 Liters 270 757 Solvent Type R 55 Gallon 208 2 Liters ISSUED 3 81 SUPERSEDES 12 76 LITHO U S A Publication No 104 708A
98. er Cylinder head slab gasket d Between air valve Upper valve gasket and cylinder head A12 Visually inspect four way air control valve actuating rod for binding or physical damage NORMAL INDICATION Actuating ABNORMAL INDICATION Actu rod straight with no evi ating rod damaged or dence of binding Proceed there is evidence of to next step binding Replace actu ating rod Restore system to normal opera tion A13 Visually inspect valve shifter and trip collar for proper lubrication and evidence of binding or physical damage mo ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO USA All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 37 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued NORMAL INDICATION Valve ABNORMAL INDICATION Valve shifter and trip collar shifter and or trip collar properly installed and damaged or binding Re lubricated No evi place damaged parts Re dence of binding or store system to normal physical damage Pro operation ceed to next step A14 Remove and disassemble four way air control valve Check for binding and physical damage NORMAL INDICATION No ABNORMAL INDICATION Evi binding or physical dence of binding and physi damage Reinstall cal damage to internal valve on air cylinder valve parts Replace dam Proceed to next step aged parts Restore sys tem to normal operat
99. fective temperature control A13 board Defective solid state relay 14 SSR Defective tank heaters A14 Defective tank RTD 16 TANK OVERHEATS Faulty main circuit breaker B1 ABOVE 500 F auxiliary trip coil 260 C Failed tank thermostat THS m B1 TANK OVERHEATS TO Defective tank RTD C2 POINT WHERE MAIN CIRCUIT BREAKER Defective temperature controller C2 OPENS Defective solid state relay C4 HOSE FAILS TO HEAT Loose connection or exposed D3 OR UNDERHEATS wiring Defective tank thermostat THS4 D5 il ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division 41 2000 44 Nordson Atlanta Georgia TECHNICAL PUBLICATION TABLE 3 TROUBLESHOOTING CHART ELECTRICAL SUMMARY Continued FAULT CONDITION PROBABLE CAUSE REF HOSE FAILS TO HEAT Defective thermal relay D6 OR UNDERHEATS Continued Defective 1 trip mechanism D7 Improper input voltage D9 Defective main circuit breaker D10 Defective tank hose circuit D12 breaker Defective temperature control D12 board Defective hose heater D13 Defective hose RTD D15 HOSE OVERHEATS Defective hose RTD E2 Defective hose temperature E2 controller GUN FAILS TO HEAT Improper input voltage F1 OR UNDERHEATS Defective main circuit breaker F2 Defective gun circuit breaker FA Defective cartridge heater F5 Defective gun thermostat F5 GUN OVERHEATS Defective gun thermostat G1 ISSUED 1 84
100. flon paste P N 900 236 on threads Attach air hose to air motor inlet port Attach copper tubing to air motor outlet port Mount upper tank enclosure to applicator and secure with one captive screw PRESSURE CONTROL VALVE DISASSEMBLY AND REPAIR Figure 20 1 Remove upper tank enclosure from applicator with one captive screw The captive screw is at tank temperature Wear safety gloves P N 902 514 safety glasses protective clothing to prevent burns 2 Relieve system pressure in the following manner a Set pump air regulator to zero b Trigger all quns to relieve trapped hydraulic pressure C Open manifold drain valve ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 69 Failure to relieve system pressure may result in serious burns when pressure control valve is removed 3 Remove two screws and lockwashers that secure pressure control valve to pump housing 4 Remove pressure control valve from gear pump bv lifting straight up through the hole in pump mounting bracket 5 Remove set screw 3 from the gear pump end of control valve body 6 6 Remove pressure control valve nose 10 from valve body Solidified hot melt material mav prevent parts from separating If it is necessary to heat the valve use an electric oven with forced air circulation or a flameless electric hea
101. ging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 30 TABLE 1 TROUBLESHOOTING CHART MECHANICAL SUMMARY FAULT CONDITION PROBABLE CAUSE REF ATP MOTOR NOT Cold adhesive in tank A1 STROKING Piston Pump OR ROTATING Cold joints in hydraulic system A3 Gear Pump No air pressure to gun solenoid A4 valve Faulty gun solenoid valve A5 Guns not firing due to clogged A5 nozzles Adhesive filter blocked A6 Adhesive heat exchanger A6 blocked No air pressure to air piston A9 motor Faulty pump solenoid valve A10 Air cylinder leakage piston A11 pump only 4 way air valve damage piston A14 pump only Air cylinder mechanical fail A15 ure piston pump only Hydraulic cylinder malfunction A15 piston pump only Air motor malfunction gear A16 pump only Speed reducer malfunction A21 gear pump only Gear pump malfunction gear 21 pump only AIR MOTOR STROKING Pump starved Bl Piston Pump OR ROTATING Gear Pressure relief valve stuck B2 Pump TOO FAST open ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 31 TARLE 1 TROUBLESHOOTING CHART MECHANICAL SUMMARY FAULT CONDITION PROBABLE CAUSE REF AIR MOTOR STROKING Hydraulic cylinder malfunction n4 Piston Pump OR piston pump only ROTATING Gear Pump TOO FAST Pressure control valve stuck B5
102. hat the lid will open to the left or to the right as required by the applica tion The following paragraphs detail the conversion procedure to convert the applicator to a left side unit PNEUMATIC CONTROL PANEL RELOCATION 1 Remove four screws and slide the pneumatic control panel out of the applicator until the solenoid valve is exposed 2 Disconnect the pneumatic hoses from the regulator and solenoid valve connections 3 Unplug the electrical connector on the solenoid coil or dis connect wiring at TB2 4 Remove the information plate from the back of the applicator by removing four screws 5 Slice the air control assembly into the back of the applicator until the solenoid valve electrical connection can be plugged into the coil or the wires can be connected at TB2 6 Attach the pneumatic hoses to the regulator and solenoid valve Attach the input hose to the solenoid valve and the output Q hose to the regulator If the input hose is inadvert ently connected to the regulator no air will flow to the air motor ISSUED 9 84 SUPERSEDES 8 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 A2 7 8 Slide the assembly all the way into the applicator base and secure with four screws Attach the information plate to the front of the applicator base and secure with four screws ELECTRICAL AND TEMPERATURE CONTROL PANE
103. hazard by using only a controlled heating device to heat solvents for example small deep fat fryer or thermostatically controlled hot plate DO NOT USE PAINT TYPE SOLVENTS UNDER ANY CIRCUMSTANCES These solvents are volatile and may create a fire and or toxic vapor hazard even at room temperature Always be sure the work area is adequately ventilated Avoid prolonged or repeated breathing of solvent vapors ISSUED 7 86 SUPERSEDES 2 85 NORDSON CORPORATION 1986 LITHO U S A Rights Reserved P amp A Division s 40 1 5 Atlanta Georgia TECHNICAL PUBLICATION HALOGENATED HYDROCARBON SOLVENTS Halogenated hydrocarbon solvents are dangerous when used to clean aluminum components in a pressurized fluid system No available stabilizers prevent halogenated hydrocarbon solvents from reacting under all conditions with aluminum components in a pressurized fluid pumping system NEVER clean any aluminum component or flush any system using halogenated hydrocarbon solvents Use Type R solvents or contact your solvent or hot melt supplier for a non halogenated hydrocarbon solvent for cleaning and flushing Halogenated fluids include the following solvents Fluorocarbon Solvents Dichlorofluoromethane Trichlorofluoromethane Chlorinated Solvents Carbon Tetrachloride Chloroform Dichloromethane Ethylene Dichloride Methylene Chloride Monochlorobenzene Monochlorotoluene Orthodichlorobenzene Perchloroethylene Tri
104. ifter link 6 and unscrew detent pin 7 NOTE Removing detent pin frees the upper poppet 8 Pull the shifter link out of air valve body d Inspect poppets 8 and poppet seats 4 for wear or damage Replace worn or damaged parts NOTE Replace entire poppet seat if poppet seat washer is damaged Disassemble valve shifter in the following manner Use Figure 16 as a guide a Remove two screws to disconnect valve shifter from pump mount b Remove two screws and lockwashers to disconnect control arm bracket from control arm Push control arm away from bracket to relieve spring pressure d Slide pin out of bracket inside wall to remove spring AIR OPERATED PISTON PUMP ASSEMBLY Figure 14 Ts ISSUED Insert pump shaft wiper 30 into pump body with groove in seal facing inward Q All hot melt adhesive material must be removed from wiper cavity and retaining ring groove in pump body to properly install and seat pump shaft wiper Insert flat washer 31 into pump body over pump shaft wiper Install pump shaft wiper retaining ring 32 in pump body using snap ring pliers or other pointed tool NOTE audible snap will indicate when the ring enters the groove 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Ail Rights Reserved Packaging and Assembly Division Nordson scissa TECHNICAL PUBLICATION 45 63 4 Place threaded end of pump body 18 into pump mount 12 and
105. iminate downtime and costly inplant repairs Nordson has developed a Rebuilt Exchange RBX Program which can save you up to 50 percent of the cost of new equipment You may trade in your old worn units hoses and guns for rebuilt Nordson equipment which has the same warranty as new equipment The Nordson Package of Values From specifications assistance to post installation troubleshooting the Nordson Package of Values is designed to keep our customers productive and profitable by providing Carefully engineered durable products Strong service support The back up of a well established international company with financial and technical strength corporate commitment to deliver what was specified This service not available in all countries 306 18 662 NORDSON CORPORATION 1993 Issued 2 93 All Rights Reserved How To Order Nordson Parts Replacement parts may be ordered through your local Nordson representative or by contacting our Customer Service Centers When ordering parts please use the description shown in the parts list the part or service kit number when listed and the quantity desired Country Telephone Facsimile Argentina 54 1 921 3058 54 1 924 3206 Australia 61 2 838 7144 61 2 838 7394 Austria 43 222 707 5521 43 222 707 5517 Belgium 32 2 720 9973 32 2 720 7371 Brazil 55 11 274 6011 55 11 632300 Canada 416 475 6730 416 475 8821 Chile 56 2 555 7190 56 2 551 7549 Colombia 57 4 266 6965 57 4 26
106. inal block 1 NORMAL INDICATION Voltage ABNORMAL INDICATION Unequal as indicated in the below or no voltage measured table Proceed to the next Check input voltage source step 230 VAC Single Phase Input 180 to 256 VAC between terminals 1 and 2 on TBI 230 VAC Three Phase Input 180 to 256 VAC between terminals 1 and 2 2 and 3 and 1 and 3 on TBI 380 VAC Three Phase Input 4 wire Approximately 220 VAC between terminals 1 and 4 2 and 4 and 3 and 4 on 1 A10 Disconnect and lock out input electrical power to the appli cator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage All Using an ohmmeter on the lowest resistance scale R x 1 check continuity between the following points TBl1 1 and TB2 4 TB1 2 and TB2 1 TB1 3 and TB2 6 ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division 41 2000 48 Atlanta Georgia TECHNICAL PUBLICATION TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued NORMAL INDICATION Con ABNORMAL INDICATION If tinuity at each point any one of the readings Proceed to next step is anything but continu ity one portion of the main circuit brea
107. inal block 1 NORMAL INDICATION Voltage ABNORMAL INDICATION Unequal as indicated in the below or no voltage Check input table Proceed to next voltage source step 230 VAC Single Phase Input 180 to 240 VAC between terninals 1 and 2 on TB 230 VAC Three Phase Input 180 to 240 VAC between terminals 1 and 2 2 and 3 and 1 and 3 on TBI 380 VAC Three Phase Input 4 wire Approximately 220 VAC between terminals 1 and 4 2 and 4 and 3 and 4 on TBI D10 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia 41 2000 54 TECHNICAL PUBLICATION TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued 11 Using an ohmmeter on the lowest resistance scale 1 check continuity between the following points 1 1 and TB2 4 TB1 2 and TB2 1 TB1 3 and TR2 6 NORMAL INDICATION Con tinuitv at each point Proceed to next step ABNORMAL INDICATION If any one of the readings is anything but continuity one portion of the main circuit breaker is open Re
108. ion A15 Air piston failure is usually indicated by the pump stalling in an extreme position at one end of the stroke or the other Check this condition by manually shifting the four way air control valve with air pressure applied from the regulator NORMAL INDICATION Air ABNORMAL INDICATION Air piston makes one stroke piston does not stroke and stops Disassemble Disassemble hydraulic air cylinder and replace cylinder and replace damaged or binding parts damaged or binding parts Restore system to nor Restore system to nor mal operation mal operation A16 Reduce system pressure to zero by securing air pressure to the pump triggering all guns to relieve trapped hydraulic pressure and opening manifold drain valve A17 Disconnect air line from control valve Remove gear pump assembly from applicator tank Reconnect air line to control valve A18 Remove gear pump from pump assembly at the drive coupling A19 Check air motor and speed reducer for free rotation by applying air pressure to air motor eee ER ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Nordson Packaging and Assembly Division 41 2000 38 Atlanta Georgia TECHNICAL PUBLICATION TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued NORMAL INDICATION Air ABNORMAL INDICATION Air motor and speed reducer motor and speed reducer turn smoothly Rebuild do not turn smoothly or replace gear pump with air app
109. ipped with quick disconnect electrical fittings It is an aircraft type hydraulic hose constructed with a PTFE innertube and reinforced with stainless steel wire braid Heat is generated in the hose by a serpentine heating element spirally wrapped around the wire braid Insulation is provided by wrapped lavers of fiberglass polyester felt and vinyl tape The hose is covered with polvester braid for abrasion resistance An electrical cordset with connectors runs the length of the hose to provide electrical power to the The 2 ft 0 6 m hose cordset contains a diode in the heater wiring to compensate for resistance in the hose heaters Electrical power to the hose and gun is 230 VAC from the hot melt applicator control console Temperature in the hose is monitored and controlled by a resistance temperature detector RTD in the hose wall and solid state circuitry in the hot melt applicator cabinet Hoses sold for use in Japan and other low voltage areas are specially designed to operate on 200 VAC They are identical in appearance to 230 VAC hoses except for a red tracer stripe in the hose sheathing Figure 2 shows the electrical schematic for the hot melt hose and cordset ISSUED 1 84 SUPERSEDES 12 82 9 NOROSON CORPORATION 1984 LITHO U S A Aii Rights Reserved Publication No 104 465A P amp A Division Atlanta Georgia TECHNICAL PUBLICATION 45 3 30 TABLE 1 HOSE ELECTRICAL DATA Length Voltage Power Cold
110. isi 40 0 16 Atlante Georgia SOP TECHNICAL PUBLICATION HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION ADHESIVE JELLING 21 Check temperature settings of applicator and hose NORMAL INDICATION Normal Indication Pro Temperature settings ceed to step D2 in proper positions Abnormal Indication Over heating Drain and flush system in accordance with applicator service manual Reduce temperature D2 Check compatibility by mixing adhesives in separate container NORMAL INDICATION Com Normal Indication Pro patible mixture ceed to step 03 Abnormal Indication In compatible mixing Drain and flush system in accor dance with applicator ser vice manual D3 Adhesive may be unstable Use a more stable adhesive ADHESIVE NOT PENETRATING SUBSTRATE El Check adhesive tempera ture NORMAL INDICATION Ad Normal Indication Pro hesive temperature within ceed to step E2 normal limits Abnormal Indication Low adhesive temperature Increase temperature slightly ISSUED 9 81 SUPERSEDES LITHO U S A 7 Packagi dA bly Divisi Atlanta Georgie TECHNICAL PUBLICATION 40 0 17 HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION E2 Check substrate surface NORMAL INDICATION No Normal Indication Check coating on substrate with adhesive represen tative for a compatible adhesive Abnormal Indication Coated substrate
111. iston Pump OR ROTATING Gear Pump ERRATICALLY NOTE Erratic stroking of the piston pump is indicated by two exhaust sounds close together followed by a pause double stroking This results because the piston is moving faster in one direction than the other Erratic operation of the gear pump is indicated by a change in pitch noise level of the air exiting the air motor ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 Al Rights Reserved Packaging and Assembly Division Atlanta Georgia 41 2000 40 TECHNICAL PUBLICATION TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued Cl Check adhesive tank for sufficient melting Inner tank lid cannot be removed until adhesive around tank lid is molten NORMAL INDICATION Ad hesive in molten state and tank at least one half full of adhesive Proceed to next step if the unit is equipped with an air cylinder Proceed to step C4 if the unit is equipped with a rotary air motor ABNORMAL INDICATON In crease tank temperature setting and or add fresh adhesive to tank If tank is not heating re fer to Electrical Trouble shooting Chart for pro cedure and corrective action C2 A foreign particle that prevents material from flowing past the siphon ball seat may cause erratic pump stroking Attempt to dislodge the particle by increasing and decreasing pump air pressure while holding guns open NORMAL INDICATION Parti cle is freed and pu
112. ition de energizes only the hose heating circuit Additionally if the gun is disengaged at the quick disconnect coupling the sockets on the hose end of the coupling are electri cally energized Disconnect and lock out input electrical power to the applicator if any part of the system is to be worked on to prevent severe electrical shock or equip ment damage ISSUED 1 84 SUPERSEDES 3 83 CORPORATION 1984 US A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41720007 SECTION II PREPARATION FOR USE INTRODUCTION The Series 2000 hot melt applicators are shipped in an assembled condition with the manifold on the right side in the configuration specified on the purchase order The applicators are factory wired for 230 VAC three phase input electrical power Hoses and guns are shipped separately The following paragraphs detail infor mation necessary for proper installation of the applicator hoses and guns The Appendix at the end of this service manual describes the proper electrical and pneumatic conversion that will permit hoses to be connected to the left side of the applicator UNPACKING No special instructions are necessary to unpack the Series 2000 applicators Normal care should be exercised not to damage the equipment during unpacking Do not attempt to lift the applicator by any of the fiber glass panels or hose connectors Lift the unit from the met
113. ker is open Replace circuit breaker and restore system to normal operation A12 With external power still disconnected remove plug J1 from temperature control board and measure resistance between TB2 5 and 11 6 NORMAL INDICATION Con ABNORMAL INDICATION Open tinuity Replace tempera circuit Attempt to reset ture control board TTC hose tank circuit breaker Restore system to normal using button on front operation panel Replace CBH if the breaker will not reset Restore system to normal operation A13 Measure the dc voltage across wire 44 32 and wire No 43 31 on the solid state relay SSR NORMAL INDICATION 12 Vdc ABNORMAL INDICATION 0 Vdc Proceed to next step Replace temperature con trol board Restore system to normal operation 14 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage A15 Disconnect wire No 51 39 from TB2 2 and measure the tank heater resistance between wire No 51 39 and wire No 50 38 on the solid state relay ISSUED 1 84 SUPERSEDES 3 83 NOROSON CORPORATION 1984 LITHO U S A All Rights Reserved A Packaging and Assembly Division _ Atl
114. lculated at 230 VAC power arrangements optional input voltage For applications using other input recalculate power consumption using the The actual power requirement for the Series 2000 hot melt applicators is determined by the additive power requirements of individual components used in the applicator system The total requirement depends on tank size quantity and length of hoses and quantity and type of guns used ment of the system is shown here ISSUED 9 85 LITHO U S A The maximum power require SUPERSEDES 8 84 NORDSON CORPORATION 1885 All Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 17 2000 85 SECTION VI ILLUSTRATED PARTS LIST INTRODUCTION The Illustrated Parts List details and illustrates the assemblies and components of the Series 2000 hot melt applicators with an air driven dual acting piston pump or spur gear pump Those configurations defined in Section I are detailed in the following lists COLUMN IDENTIFICATION FIGURE ITEM COLUMN The Figure Item column indicates the callout number in the as sociated figure dash in this column denotes that no callout has been made for that part PART NUMBER COLUMN The Part Number column indicates the Nordson part number for the physical part or assembly A dash in this column indicates a nonsaleable part or a nonsaleable subassembly of a saleable as sembly DESCRIPTION CO
115. lidified hot melt adhesive material on components ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georg a TECHNICAL PUBLICATION 41 2000 60 Never heat any component with a torch or other open flame Use an electric oven with forced air circulation or a flameless electric heat gun AIR OPERATED PISTON PUMP DISASSEMBLY Figure 14 l 10 11 12 13 14 15 ISSUED LITHO U S A Remove upper tank enclosure housing by removing one captive screw The captive screw is at tank temperature Wear safetv gloves P N 902 514 to prevent serious burns Set regulator air pressure to zero Open main circuit breaker Remove air hose from air motor control valve 34 Remove three screws and lockwashers anchoring pump to appli cator unit Pull pump straight up to disengage connecting tube from mani fold Remove four way air valve 34 from air motor by removing four screws 35 and lockwashers 3 on side of control valve Remove four screws 2 and lockwashers 3 from cylinder head 4 Remove cylinder head 4 and cylinder 6 from air pump Check slab gaskets 5 at top and bottom of cylinder Replace gaskets if damaged Hold piston shaft with a wrench and remove piston locknut 7 Remove piston cup washers 8 piston seal washer 9 and piston cups 10 from piston shaft Inspect cups and seals for dam
116. lied Pro Restore system to nor ceed to next step mal operation A20 Remove air motor from speed reducer at the coupling A21 Check air motor for proper operation by applying air pressure to the air motor NORMAL INDICATION Air ABNORMAL INDICATION Air motor turns freely motor does not turn with air applied Re freelv Replace air place speed reducer motor Restore system Restore system to to normal operation normal operation AIR MOTOR STROKING Piston Pump OR ROTATING Gear Pump TOO FAST Bl Check adhesive tank for sufficient melting Inner tank lid cannot be removed until adhesive in tank is molten NORMAL INDICATION Ad ABNORMAL INDICATION In hesive in molten state crease tank temperature and tank at least one setting and or add fresh half full of adhesive adhesive to tank If Proceed to next step tank is not heating re fer to Electrical Trouble shooting Chart for pro cedure and corrective action B2 Relieve system pressure by reducing pump air pressure to zero at the regulator momentarily triggering all guns and opening manifold drain valve B3 Remove pressure relief valve and check for char or foreign material on seat ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 2609 39 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued NORMAL INDICATION Re
117. minimum setting Restore system to normal operation in accordance with Daily Startup procedure SOLID STATE RELAY SSR REPLACEMENT 1 2 4 ISSUED The Series 2000 hot melt applicators contain energized electrical components with potentials that could be fatal Disconnect and lock out input elec trical power to the applicator before attempting to perform maintenance on this equipment Wear safety gloves P N 902 514 to prevent injury from hot heat sink and solid state relay Open applicator main circuit breaker Disconnect and lock out input power to the applicator Failure to disconnect external power to the appli cator presents a serious shock hazard Input termi nal board 1 and input terminals on main circuit breaker are still electrically energized if ex ternal power is not disconnected even though the main circuit breaker is open Remove electrical enclosure top cover by removing three captive screws Disconnect four wires from solid state relay NOTE Carefully note the position of the wires The two large wires Nos 49 37 and 50 38 carry 230 VAC and the two smaller black wires Nos 43 31 and 44 32 carry 12 Vdc 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Ail Rights Reserved A Packaging and Assembly Division Wordson Atlanta Georgia TECHNICAL PUBLICATION 4172000 75 76 5 Remove the solid state relay from the heat sink by removing two SCrews 6 Secu
118. mp strokes normally Re adjust air pressure to normal level ABNORMAL INDICATION Piston pump continues to stroke erratically Proceed to next step C3 Remove pump assembly from applicator and inspect for foreian particle holding siphon ball off its seat Attempt to clear seat area NORMAL INDICATION Seat area is cleared of for eign material Reassem ble pump drive unit into applicator Restore sys tem to normal operation ABNORMAL INDICATION Seat area cannot be cleared or shows no indication of clogging Disassemble hy draulic cylinder and inspect for foreign material holding pressure ball off its seat Reassemble pump drive unit into appli cator and restore system to normal operation C4 Check input air pressure to rotary air motor NORMAL INDICATION Input air pressure should be low enough so that air motor runs slowly when guns are not firing Proceed to next step ABNORMAL INDICATION Re duce input air pressure at the regulator PP ISSUED 1 84 LITHO U S A SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Rights Reserved 3 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 41 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued C5 Relieve system pressure by reducing pump air pressure to zero at the regulator momentarily triggering all guns and opening manifold drain valve C6 Remove pressure control valve from gear pump drive as
119. n can also cause overheating If the gear reducer is overfilled the energy used in 17 Replace the pipe plug in the side of the housing Use PTFE paste P N 900 236 on the threads 18 Install the vent plug in the plastic bag in the place of the plastic plug Use teflon paste on the threads 19 Replace the cover and restore the applicator to normal operation Part No Description Req d 275 388 Kit Pump Piston to Gear 2002 2004 Ref 275 384 Kit Pump Piston to Gear 2202 2204 Ref 275 333 Gear Pump Drive Assembly 1 275 021 Solenoid Valve 1 973 037 Nipple 1 273 041 Strainer with P N 275 388 only 1 273 142 Strainer with P N 275 384 only 1 971 501 e Ell 1 275 278 Copper Tubing 1 971 250 Connector 1 275 277 Exhaust Manifold 1 982 001 Screw 2 983 401 Lockwasher 2 275 338 Lubricant 1 ISSUED 8 84 SUPERSEDES 3 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 B3 FIGURE 1 Series 2000 Hot Melt Applicator with Piston Pump 10 Series 2000 Hot Melt Applicator with Gear Pump 12 13 ISSUED 8 84 SUPERSEDES 3 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 41 F Packaging and Assembly Division 2000 54 Atlanta Georgia TECHNICAL PUBLICATION FIGURE 2 DE REMOVE THESE PARTS PISTON PUMP AIR CONTROL ASSEM
120. n though the main circuit breaker is OFF open C3 Unplug J2 from the temperature control board and measure the resistance across the tank RTD between pins 2 and 5 on the plug NORMAL INDICATION Re ABNORMAL INDICATION Short sistance value within circuit or resistance the range specified in well below the range step 17 Replace tem specified in step 17 perature control board Replace RTD and restore and restore system to system to normal operation normal operation C4 Measure the dc voltage across wire Nos 44 32 and 43 31 on the solid state relay SSR Wire numbers in paren thesis are tor the 2002 2202 NOTE Set tank temperature control to minimum setting NORMAL INDICATION 0 Vdc ABNORMAL INDICATION 12 Vdc Replace solid state Replace temperature control relay Restore system ler Restore system to to normal operation normal operation HOSE FAILS TO HEAT OR UNDERHEATS 21 Check the position of the main circuit breaker CB1 NORMAL INDICATION Main ABNORMAL INDICATION Main circuit breaker ON circuit breaker OFF Proceed to step D8 Proceed to next step D2 Attempt to close main circuit breaker NORMAL INDICATION Main ABNORMAL INDICATION Main circuit breaker ON circuit breaker trips Proceed to step D8 immediately Proceed to next step a ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division 41 20
121. nd seat assembly P N 503 691 ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved P amp A Division 41 2000 101 Atlanta Georg a TECHNICAL PUBLICATION Figure 14 Piston Pump Assembly Part 2 ISSUED 9 85 SUPERSEDES 8 84 CNORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 102 X Division Atlanta Georgia TECHNICAL PUBLICATION AIR CONTROL VALVE ASSEMBLY PARTS LIST Item No Part No 244 981 503 243 243 981 243 243 270 270 211 973 503 600 I ISSUED 9 85 U S A 244 052 737 512 511 053 515 519 042 044 360 402 656 138 Description Req d zu eh N HN N D Valve Air Control 4 Way Screw 8 32 x 0 62 in w Lock Patch Spacer Detent seat Poppet Screw 8 32 x 0 50 in w Lock Patch Link Shifter Pin Detent Poppet Valve Spool Valve Body Air Control Valve Plug Pipe 1 8 NPTF Gasket Valve Tag Directions 0000000000000 SUPERSEDES 8 84 NORDSON CORPORATION 1985 Rights Reserved Atlanta Georgia TECHNICAL PUBLICATION Figure 15 Air Control Valve Assembly ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved LITHO U S A 41 2000 104 Division Atlanta Georgia TECHNICAL PUBLICATION NET L CL Len n 10 Ji 7 T7 PA 153 8 Figure 16 Pump Valve
122. net base and electrical subpanel Make electrical connections at the five station input terminal block 1 as shown below TB1 220 VAC Single Phase 4 Wire Connection Esc ISSUED 9 85 SUPERSEDES 8 84 NORDSON CORPORATION 1985 Rights Reserved LITHO U S A 41 2000 16 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION 5 Attach the applicator to an earth ground through GND TB1 5 6 Using the two jumper wires shipped with the applicator attach one jumper wire to terminals 1 and 5 TB2 attach the other jumper wire to terminals 4 and 6 on TB2 TB2 configured for single phase operation is shown below 2004 2204 2002 2202 7 Attach and secure the electrical enclosure cover and continue with Setup and Initial Operation Do not energize input electrical power at this time Connect input power at the appropriate step in the Setup and Initial Operation procedure ISSUED 9 85 SUPERSEDES NORDSON CORPORATION 1985 Ali Rights Reserved LITHO U S A A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 17 SECTION III OPERATING INSTRUCTIONS SETUP AND INITIAL OPERATION ISSUED Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces The Series 2000 hot melt applicators hoses and guns contain energized electrical components with po ten
123. ngeable with the fittings which rely on tapered pipe thread NPT for a seal The use of the incorrect fitting may result in excessive leakage and possibly in serious burns especially with low viscosity fluids 1 Identification of Fittings Required To determine which type of fittings should be used with any given gun or applicator first look at the fluid ports in the manifold The ports designed for the o ring fittings will have a smooth machined cavity on the face of the manifold around the female threads whereas the ports designed for the pipe thread fittings will have only female pipe threads See Figure 1 for an illustra tion of the difference 2 Selection of Correct Parts Use Figure 1 to select the Correct part 972 825 O RING ADAPTER APPLICATOR OR GUN C MANIFOLO DESIGNED O RING FITTINGS QUL M res RH ve 1 CD 972 051 mos PIPE ADAPTER ARAE ia 973 411 PIPE PLUG APPLICATOR OR GUN SMOOTH CAVITY 973 574 FOR O RING SEAL O RING PLUG 945 032 O RING REPLACEMENT Pipe Thread Fittings O Ring Fittings And Manifold of Gun And Manifold of Gun or Applicator or Applicator Figure 1 Diagram of O Ring and Pipe Thread Fittings for H20 Noncirculating Guns H200 Automatic Guns and Series 2000 Applicators 3 Installation of O Ring Fittings a Lubricate the fitting threads and o ring with Never Seez P N 900 344 making sure first that the O
124. onto applicator and secure with one captive screw 22 Close manifold drain valve 23 Start up system in accordance with Section III Daily Startup Adjust pressure control valve in accordance with Section Pressure Control Valve Adjustment MANIFOLD DPAIN VALVE REMOVAL AND DISASSEMBLY Figure 12 Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Relieve system pressure before breaking any mechanical connections Serious burns may result if drain valve is opened or removed with hydraulic pressure in the system lix Reduce input pressure to the air motor to zero at the regulator 2 Trigger all guns to relieve trapped hydraulic pressure 3s Open manifold drain valve 4 Remove upper and lower tank enclosure from unit 5 Remove drain valve from side of manifold by removing four hex head screws 6 Remove retaining ring using snap ring pliers re Unscrew drain valve internal stem with screwdriver 8 Remove valve stem 9 Clean components in a bath of solvent heated to the melting temperature of the adhesive material NOTE Alternate methods of heating and cleaning include a Heat components with a flameless electric heat gun Wipe parts with a clean cloth ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 10 11 12 1
125. oosening the connector 7 Remove the three M8 bolts securing the pump to the unit and remove the pump These bolts 8 are in the same locations that will be used to mount the piston pump Remove the strainer from the tank Mount the piston pump assembly P N 273 141 on the unit Insert and tighten the three mounting bolts 8 Attach the incoming air line 9 to the four way air valve 16 using the reducer adapter P N 973 953 shipped with the kit Place the new strainer in the tank Replace the cover electrical enclosure and tank enclosure and restore the applicator to normal operation Part No Description Req d 275 275 273 273 973 389 385 143 042 953 Kit Pump Gear to Piston 2002 2004 Ref Kit Pump Gear to Piston 2202 2204 Ref Strainer Tank with P N 275 389 only 1 Strainer Tank with P N 275 385 onlv 1 Adapter Reducer 1 ISSUED 9 84 SUPERSEDES NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division 41 2000 C2 Atlanta Georgia TECHNICAL PUBLICATION Series 2000 Hot Melt Applicator with Gear Pump Series 2000 Hot Melt Applicator with Piston Pump ISSUED 9 84 SUPERSEDES NORDSON CORPORATION 1984 LITHO LS A All Rights Reserved _ CORPORATION Amherst Ohio 44001 TECHNICAL PUBLICATION 40 0 0 GENERAL INFORMATION ISSUED 6 81 SUPERSEDES 4 79 NCRDSON CORPORATICN 1981 Rights Reserved P amp A Division m a
126. place circuit breaker and restore system to normal operation D12 With external power still disconnected remove plug Jl from temperature control board and measure resistance between TB2 5 and 11 6 NORMAL INDICATION Con tinuity Replace tem perature control board Restore system to normal operation ABNORMAL INDICATION Open circuit Attempt to reset hose tank circuit breaker using button on front panel Replace CBH if the breaker will not reset Restore sys tem to normal operation D13 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF Failure to disconnect and lock out input electrical power could result in electrical shock or equipment damage D14 Disconnect the hose electrical connector from the applicator and measure hose heater resistance at pins 1 and 2 on the plug ISSUED 1 84 LITHO U S A SUPERSEDES 3 83 NORDSON CORPORATION 1984 Ali Rights Reserved T Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 55 TABLE 4 TROURLESHOOTING CHART ELECTRICAL Continued NORMAL INDICATION Hose heater resistance within the range specified in the below chart Attach the connector and restore system to normal operation ABNORMAL INDICATION Re sis
127. placed when the cylinder is disassembled NOTE Improper adjustment of the trip collar and valve shifter may cause air leakage and improper pump operation because the spool in the air control valve does not shift completely when the air piston reaches the end of its stroke Check this by pushing the valve shifter in the direction it is supposed to be traveling If the shifter moves and leakage stops the shifter must be adjusted If the shifter does not move and leakage continues air leakage is due to a failed seal or gasket Also check for worn bearings in control arm bracket et ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 36 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued With Piston on Up Stroke Air Leakage Location Probable Failed Seal a Around shaft in U cup pump mount side pump mount b Top exhaust port Lower piston cup or poppet open upper poppet c Bottom exhaust Lower poppet seal washer port poppet closed d Bottom of cylinder Pump mount slab gasket e Between air valve Lower valve gasket and pump mount With Piston on Down Stroke Air Leakage Location Probable Failed Seal a Bottom exhaust port Upper piston cup or poppet open lower poppet b exhaust port Upper poppet seal washer poppet closed c Top of cylind
128. pplicator guns unshielded from the wind Rapid heat dissipation due to air movement across the guns may cause operational problems With handgun trigger left unlocked while the gun is unattended In addition SAFETY ISSUED U S A Use only the metal base when attempting to lift or move this equipment Do not use equipment covers doors panels or hose connectors as braces or grips Never use this equipment as a ladder or stepping stool Route all hoses so as to prevent damage from kinking abrasion and other physical damage Do not allow a hose to be installed with a bend radius of less than 6 inches 150 mm Never point an applicator handgun at yourself or anyone else DURING SERVICING Do not perform internal service or adjustment on any equip ment unless another person capable of rendering first aid and resuscitation is present Only qualified personnel should service Nordson equipment To avoid personal injury never touch exposed connections and components while power is ON Dangerous voltages exist at several points in the equipment Disconnect lock out and tag external electrical power before removing protective panels or replacing electrical components Remove all jewelry rings watches etc before servicing equipment If possible stand on a rubber mat when servicing Nordson equipment Do not work on equipment if Standing water is present Avoid working in a high humidity atmosphere Cove
129. pressure before breaking any mechanical a Reduce pump air pressure to zero at the regulator bs Trigger all guns to relieve trapped hydraulic pressure Open the manifold drain valve d Reduce gun air pressure to zero at the regulator Never heat any component with a torch or other open flame If it becomes necessary to heat components for maintenance or repair use an electric oven with forced air circulation or a flameless electric heat gun Halogenated hydrocarbon solvents are dangerous when used to clean components in a pressurized fluid system See the Safety Summary Section 40 1 for further details Use of halogenated hydrocarbon solvents in this system could result in an explosion ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 22 PREVENTIVE MAINTENANCE GENERAL MAINTENANCE 1 J 2 Keep applicator clean at all times Hot melt adhesive material supply must be be kept clean and free of contaminants Foreign particles in the hot melt ad hesive can block the filter or ruin the pump plugged filter can shut down the svstem Flush the adhesive filter daily Periodically clean regulator air filter Periodically clean manifold heat exchanger Periodically clean the inside of the electrical enclosure Check electrical connections and terminal blocks periodically for secu
130. r 0 020 in mesh Shipped with applicator unless specified otherwise on Purchase Order TABLE 7 RECOMMENDED SPARE PARTS LIST Part No Description Oty MANIFOLD AND TANK 275 035 Gasket Tank 2002 2004 1 275 036 Gasket Tank 2202 2204 1 275 080 Filter Assembly 1 941 230 O ring Viton 1 19 x 1 38 in 1 Screen Filter 2 945 035 O ring Viton 7 8 in OD Tube Heat Exchanger 1 275 175 Valve Pressure Relief 1600 psi 11 0 MPa 1 940 141 O ring Viton Crossover Tube 1 NORDSON CORPORATION 1985 All Rights Reserved ISSUED 9 85 SUPERSEDES LITHO U S A P amp A Division Atlanta Georgia 41 2000 117 TECHNICAL PUBLICATION TABLE 7 RECOMMENDED SPARE PARTS LIST Continued Part No Description Qty PISTON PUMP ASSEMBLY 244 376 Seal Kit Pump 1 503 656 Gasket Valve 4 503 686 Cup Piston 2 952 100 Cup U Viton 1 955 024 Gasket Slab 2 244 244 Valve 4 Way Air Control 1 273 139 Wiper Pump Shaft 1 240 354 Shifter Valve 1 273 141 Piston Pump Assembly 1 986 602 Ring Retainer 1 243 511 Seat Poppet 2 273 138 Washer Special T 940 141 O ring 1 954 020 Backup Ring 1 GEAR PUMP ASSEMBLY 275 188 Rotary Air Motor 1 275 190 Gear Pump l 275 371 Rebuild Kit Gear Pump 1 275 153 Pressure Control Valve 1 955 051 Lip Seal Viton 1 ELECTRICAL 937 277 Sensor Tank Temperature RTD 1 937 281 Thermostat Close on Rise 500 F 260 C 1 273 013 Circuit Breaker Main 3 pole 30 amp l 939 533 Circuit Bre
131. r exposed terminals and work area with rubber sheeting to avoid accidental contact while the power is ON 7 86 SUPERSEDES 2 85 NORDSON CORPORATION 1986 All Rights Reserved P amp A Division 40 1 4 Atlanta Georgia TECHNICAL PUBLICATION Always wear safety glasses protective gloves Nordson P N 902 514 or equivalent and long sleeved protective clothing to prevent injury from hot applicator parts splashed hot melt adhesive and hot gun surfaces To prevent serious injury from molten adhesive under pressure always relieve system hydraulic pressure by triggering the handgun for example before opening any hydraulic fitting or connection Never use an open torch drill or broach when cleaning a nozzle a Never continue to operate equipment with a known leak in the System SAFETY WHEN USING HOT MELT ADHESIVES AND SOLVENTS HOT MELT ADHESIVES Use extreme care when working with molten materials They solidify rapidly at high temperature and present a hazard Severe burns can occur if the molten materials come in contact with the skin Even when first solidified they are still hot Always wear protective clothing and eye protection when handling molten m terial or working near equipment contain ing hot melt adhesives under pressure HEATING SOLVENTS Do NOT use an open flame or uncontrolled heating device to heat solvents for example a small pan on an unregulated hot plate Avoid fire
132. r adhesive representative Tank Temperature F Hose Temperature F Gun Temperature Thermostat oF Pump Air Pressure psig Gun Air Pressure psig REMOVE THIS PAGE FROM THE SERVICE MANUAL HANG IT NEAR YOUR APPLICATOR FOR REFERENCE ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division E Nordsor Atlanta Georgia TECHNICAL PUBLICATION 5172000721 SECTION IV MAINTENANCE INTRODUCTION Both preventive maintenance and corrective maintenance procedures are presented in the following paragraphs Preventive maintenance procedures describe measures such as periodic inspections nozzle cleaning and material changeover Corrective maintenance pro cedures describe equipment troubleshooting removal and replace ment of assemblies and disassembly and repair of particular com ponents in the system The Series 2000 hot melt applicators hoses and guns contain energized electrical components with po tentials that could be fatal Disconnect and lock out input electrical power before performing maintenance on this equipment Only qualified personnel shall operate this equipment Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces connections i e gun hose connection filter etc in the following manner 2 Relieve system
133. re a new solid state relay to the heat sink using two Screws 7 Connect the four wires to the solid state relay in accordance with the below illustration 49 37 50 38 Wire numbers in parenthesis Iu are for the 2002 2202 applicators 43 31 44 32 8 Replace enclosure and secure with three captive screws 9 Set temperature controls to minimum setting 10 Restore input power to applicator 11 Restore system to normal operation in accordance with Daily Startup Procedure ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Rights Reserved 41 2000 77 TECHNICAL PUBLICATION Packaging and Assembly Division Atlanta Georgia SECTION V DIAGRAMS AND TABLES eseud OWA 3S C U8I AAA az 1 IL 2 re 1814 eds 81 ee 9 BE 15 SE 42 ez xnv e ss G eanoty vO0cc V0OOZ NORDSON CORPORATION 1984 1 84 SUPERSEDES 8 84 ISSUED All Rights Reserved LITHO U S A TECHNICAL PUBLICATION Packaging and Assembly Division Atlanta Georgia 41 2000 78 eseug eTHuts 96 081 9 2022 2002 ib CNT 4 91 vz 52 ce ve 1914 Op 18 HL 65 855 7077 7002 NORDSON CORPORATION 1964 All Rights Reserved 1 84
134. re set de termined in Step 1 turn the adjusting screw on the pressure control valve clockwise until the air motor slows noticeably but is still running continuouslv 4 With the guns cycling normally adjust pneumatic pressure to the air motor and the position of the pressure control valve until the desired bead size is achieved DAILY OPERATION DAILY STARTUP PROCEDURE L4 Turn ON applicator main circuit breaker 25 Adjust tank and hose temperature controls to desired settings 35 When all yellow LED indications are flashing or off adjust input air pressures to the pump and guns to the desired settings 4 Check tank level and add adhesive material as necessary DAILY SHUTDOWN 1 Shut OFF main circuit breaker 2 Reduce pump and gun air pressures to zero at the regulators ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division 41 2000 20 Atlanta Georgia TECHNICAL PUBLICATION ADHESIVE LOADING Refill adhesive tank with fresh clean adhesive to a point 1 in 2 5 cm below the top of tank when the material level in the tank drops below one half full NOTE Keeping adhesive level in the tank above the half full point eliminates the problem of starving the pump because the tank runs out of molten adhesive To prevent the adhesive supply from becoming contaminated store the fresh adhesive in a closed container 2 Be certain the adhesive adde
135. reaker can be reclosed because the resistor must cool down enough to allow the thermal contacts to open If possible a starting condition should be established to enable determination of a fault condition The applicator should be at normal operating temperature The main circuit breaker should be ON closed Air pressure to the air motor and extrusion guns should be at normal settings The following chart indicates the condition of the LED s during normal and fault situations SITUATION YELLOW LED RED LED Tank or hose heating NORMAL ON OFF Tank or hose at temperature NORMAL FLASHING OFF Tank or hose slightly above appli cation temperature NORMAL OFF OFF Tank or hose overheating Half way between set point and 500 F FAULT OFF ON RTD sensor shorted FAULT ON ON RTD sensor open FAULT OFF ON ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Nordson Packaging and Assembly Division TECHNICAL PU Atlanta Georgi L PUBLICATION and LICATION 11 5000 43 TABLE 3 TROUBLESHOOTING CHART ELECTRICAL SUMMARY Continued FAULT CONDITION PROBABLE CAUSE REF TANK FAILS TO HEAT Loose connections or OR UNDERHEATS exposed wiring A3 Defective tank close on A5 rise thermostat Defective thermal relav A6 Defective 1 trip mechanism A7 Improper input voltage A9 Defective main circuit A10 breaker Defective tank hose circuit A12 breaker De
136. rity Q Vibration and heating cooling cycles may loosen terminals resulting in possible damage to elec trical components or improper system operation Lubricate piston pump shaft and trip collar semiannually with lubricant P N 900 252 PISTON PUMP applicators onlv Change speed reducer lubricant semiannually or after every 1000 hours of operation whichever comes first Use only gearbox lubricant P N 275 338 in this unit GEAR PUMP applicators only Q Nordson lubricant P N 271 416 will not perform satis factorily in these units The gear reducer will overheat using this lubricant Use only Nordson lubricant P N 275 338 MATERIAL CHANGE If the old and new adhesives are compatible add the new adhesive to the tank If the old and new adhesives are not compatible flush the system using the procedures detailed in Section IV Svs tem Cleaning Contact vour adhesive supplier for compatibilities and acceptable flushing solvents ISSUED Do not flush the system with halogenated hydrocarbon solvents See the Safety Summary Section 40 1 for further details Using halogenated hydrocarbon sol vents in this system could cause an explosion 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Nordson ree TECHNICAL PUBLICATION _ gt 000 2 NOZZLE CLEANING Nozzle clogging occurs when a filter screen is damaged or when there is charred material in the hose
137. s removed for cleaning Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot appli cator parts splashed hot melt adhesive material and hot gun surfaces Use the following procedure to clean the adhesive filter Heat the system to operating temperature 2 Reduce pump air pressure to zero at regulator 3 Momentarily trigger all guns to relieve trapped hydraulic pressure 4 Open manifold drain valve over an open container 5s Increase pump air pressure until adhesive material flows steadily from the drain Allow material to flow until it is clean and free from all contaminants ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 6 Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION _ 5172000725 Shut Unscrew filter assembly and remove from manifold 7 8 off input air pressure to the pump at the regulator Failure to relieve system pressure can result in serious burns when the filter is removed Remove screw 10 from filter bung 1 and disassemble filter 10 ISSUED Do not heat Type R solvent above 475 F 245 C See 59 1 for further details Do not heat Type R sol vent with an open flame or in an unregulated heating device i e a small pan on an unregulated hot plate A fire hazard exists if an open flame or unregulated hot plate is used to heat Type R solvent A controlle
138. s too short Use one or more of the fol lowing steps if open time is too long l ISSUED 9 81 SUPERSEDES Decrease air pres sure to air motor to decrease bead size Reduce adhesive temperature slightly Reduce line speed through compression Move guns further from substrate Increase distance from deposition to compression Increase compression length Cool substrate Use lower flow rated nozzle Change bead pattern from constant to intermittent LITHO U S A P d Assembly Division Alenia G o TECHNICAL PUBLICATION 40 0 23 HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION 10 Use adhesive with shorter open time See adhesive manu facturer K2 Check adhesive cooling too fast too short an open time NORMAL INDICATION Pro Normal Indication Pro per open time ceed to step K3 Abnormal Indication Use one or more of the fol lowing steps to correct the problem l Increase air pres sure to air motor to increase bead size 2 Increase adhesive temperature slight ly 3 Move guns closer to substrate 4 Shorter distance from deposition to compression 5 Heat substrate 6 Use higher flow rated nozzle 7 Change bead pattern from intermittent to constant or in crease bead length 8 Protect deposit and or gun from cold or moving air ISSUED 9 81 SUPERSEDES 11 73 NORDSON CORPORATION 1981 Pa
139. sembly and check for char or foreign material holding spool in full open position NORMAL INDICATION Valve ABNORMAL INDICATION Char is free of char and and foreign material in foreign material Dis side valve body Clean assemble pump drive valve components and re assembly and check for install in gear pump physical damage Re drive assembly Restore assemble and restore system to normal operation system to normal operation ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Rights Reserved Packaging and Assembly Division 41 2000 42 Nordson Atlanta Georgia TECHNICAL PUBLICATION TABLE 3 TROUBLESHOOTING CHART ELECTRICAL SUMMARY Electrical troubleshooting the Series 2000 hot melt applicators may be simplified by noting temperature control panel indicators and the position of the main circuit breaker Light emitting diodes LED s indicate whether heaters are energized and if a fault has developed in the solid state circuitry or the resistance temper ature detectors RTD s If the main circuit breaker has tripped an overtemperature condition or circuit failure is indicated Time delay circuitry in the temperature controller allows sufficient time to make observations and checks before the main circuit breaker trips open This delay occurs because of the time required to heat the resistor enough to close the thermal contacts Likewise a delay of up to 15 minutes exists before the circuit b
140. should be lubricated However very little daily lubrication is required Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot applicator parts hot melt adhesive material and hot gun surfaces Ds Remove upper tank enclosure by removing one captive screw This captive screw is at tank temperature Failure to wear safety gloves could result in serious burns 2 Set pressure regulator to zero 3 Remove copper tubing and hose assembly from rotary air motor 1 NORDSON CORPORATION 1984 1 84 d LL 3 83 P Rights Reserved 10 11 12 13 14 15 16 ISSUED LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 65 Remove three screws and lockwashers that anchor pump assembly to applicator tank Pull pump straight up disengaging connecting tube from mani fold Remove two set screws 2 from pump mount assembly 6 NOTE These set screws do not secure the air motor to the pump mount but instead lock the set screws beneath them Loosen third and fourth set screws 2 until air motor moves freely in the pump mount Lift air motor 1 and top half of drive coupling 3 out of pump housing NOTE The elastomer spider in the drive coupling may or may not separate from the bottom of the coupling when the air motor is removed Attempt to turn the rotary air motor by han
141. ssary 22 Remove pump shaft wiper retaining ring 32 from pump body using snap ring pliers or other pointed tool Retaining ring may be damaged when removed Replace with new ring during reassembly 23 Remove pump shaft wiper 30 and flat washer 31 from pump body NOTE It may be necessary to heat the top of pump body with a flameless electric heat gun to soften hot melt ad hesive around the seal 24 Clean all components of hydraulic section by heating in a container of Type R solvent to the melting point of the adhesive NOTE Alternate heating and cleaning methods include a Heat components with a flameless electric heat gun Wipe parts with a clean cloth b Submerge parts in an ultrasonic cleaner Submerge parts in a chemical cleaner Do not clean any component of a pressurized fluid svstem in halogenated hydrocarbon solvents See Safety Summary Section 40 1 for further details Using halogenated hydrocarbon solvent could cause an explosion ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A Alt Rights Reserved A Packaging and Assembly Division 41 2000 62 Atlanta Georgia TECHNICAL PUBLICATION 25 26 Use the following procedure to disassemble the four way air control valve Use Figure 15 to aid in disassembly a Remove four screws 1 5 holding each poppet seal 4 to air valve body 10 NOTE Removing poppet seats frees the detent pin 7 and spacers 2 p Hold the sh
142. ssible to relieve air pressure and lock out the pneumatic system before undertaking maintenance or repairs GAS SYSTEM Pertains to FoamMelt Applicators and Nitrogen Blanket Kits Only Cylinders of compressed gas are under high pressure and can present significant safety hazards if handled improperly Refer to OSHA General Industry Standards paragraphs 1910 101 1910 166 and 1910 167 for safety precautions that apply to the use handling and storage of compressed air SAFETY DURING OPERATION Do NOT operate Nordson equipment under the following conditions At a pressure higher than the rated maximum working pressure of any component in the system Near volatile or otherwise explosive gases or materials Without the covers panels and safety guards properly installed At temperatures below 20 F 6 C or above 120 F 50 C ISSUED 7 86 SUPERSEDES 2 85 un NORDSON CORPORATION 1986 LITHO U S A Rights Reserved PA Division 40 1 3 Atlanta Georgia TECHNICAL PUBLICATION With hoses enclosed in any material that interferes with heat dissipation This includes electrical conduit insula tion of any type or tight metal covers With large areas of hoses in contact with a cold floor cold supports or other such surfaces Cold points along the hose restrict the flow of adhesive inside the hose and can create potential problems during operation If outdoors or in drafty areas with the a
143. store system to normal operation in accordance with Section III Daily Operation TEMPERATURE CONTROL REPLACEMENT The Series 2000 hot melt applicators contain energized electrical components with potentials that could be fatal Disconnect and lock out input elec trical power to the applicator before attempting to perform maintenance on this equipment The temperature control board and potentiometer board contain no field serviceable components The boards are shipped as complete calibrated units The boards need not be replaced as a set ISSUED LITHO U S A 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division Nordson Atlanta Georgia TECHNICAL PUBLICATION 417 2000 73 Temperature Control Board Replacement 1 Open the applicator main circuit breaker 2 Disconnect and lock out input power to the applicator Failure to disconnect external power to the appli cator presents a serious shock hazard Input terminal board 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is open 3 Remove electrical enclosure top cover by removing three captive screws 4 Disconnect three two plugs and ribbon connector from temper ature control printed circuit board 5 Remove temperature control board from applicator 6 Mount new temperature control board on applicator 7
144. t gun Never heat any component with a torch or other open flame 7 Remove pressure control valve spool 8 and inspect for char and foreign material in tapered grooves and drilled holes Also check spool surfaces for burrs that would prevent free movement in the valve nose 10 Replace if damaged 8 Turn control valve adjusting screw 1 full clockwise Remove upper set screw 3 9 Remove spring 7 and adjusting slide 4 from valve body 10 Inspect o rings 2 5 for damage Replace if worn damaged or hardened 11 Push adjusting slide 4 into valve body until it mates with adjusting screw 1 12 Turn adjusting screw counterclockwise to engage threads on slide 13 Rotate slide until hole in slide shows through slot in valve body 14 Install set screw 3 into adjusting slide 4 and tighten 15 Insert compression spring 7 into valve body 16 Insert valve spool 8 into valve nose 10 17 Insert nose into valve bodv and secure with set screw 3 18 Inspect o rina 9 for damage Replace if worn cut or hardened ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved 9 Packaging and Assembly Division 41 2000 70 Atlanta Georgia TECHNICAL PUBLICATION 19 Insert pressure control valve downward through hole in pump mount and into gear pump housing 20 Secure pressure control valve to pump mount with tvo screws and lockwashers 21 Install upper tank enclosure
145. tance outside the range specified in the below chart the hose and restore system to normal opera tion Replace Part No Hose Type Hose Length Cold Ohms Resistance 272 863 Automatic 2 ft 0 6 m 245 270 272 838 Automatic 4 ft 1 2 m 489 541 272 839 Automatic 6 ft 1 8 m 326 360 272 840 Automatic 8 ft 2 4 m 245 270 272 841 Automatic 10 ft 3 1 m 196 216 273 624 Automatic 16 ft 4 9 m 122 L35 273 204 Handgun 8 ft 2 4 m 245 270 273 205 Handaun 16 ft 4 9 m 102 135 215 Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF and lock out input electrical power could result in electrical shock or equipment damage Failure to disconnect D16 Disconnect the 9 pin connector J2 on the temperature control board and measure the resistance of the hose RTD on the plug pins noted below Hose No 1 pin Hose No 3 pin 1 Hose No 2 pin 1 1 1 Hose No 4 pin NORMAL INDICATION The hose RTD is calibrated in the range from 120 to 320 ohms If resistance is within acceptable tolerance re place the temperature con trol board to normal operations ISSUED 1 84 LITHO U S A Restore system to to to to pin pin pin pin gt eJ ABNORMAL INDICATTON If the RTD resistance is ou
146. tank pump and manifold components Do not pump Type R solvent through the hoses Solvent absorbed by char in the hoses may leach out during later operations re sulting in reduced adhesive bond strength or odor contamination of packaged food products The solvent can also cause large pieces of char to break off during later operations resulting in clogged nozzles Do not use halogenated hydrocarbon solvents Refer to Safety Summary 40 1 for further details Using halogenated hydrocarbon solvent in this system could result in an explosion NOTE System can be flushed best if molten adhesive is cir culated through pump and hoses with hoses positioned over the tank Flush the system for 15 minutes If necessary remove the tank from the applicator Use stiff bristle brush to scrub the inside of the tank When finished replace the tank and applicator cover 2 The tank is teflon coated Using metal brush or scraper will remove the teflon coating When all of the cleaning agent has been pumped through the system decrease pump air pressure to zero Remove and clean adhesive filter 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Nordsor Atlanta Georgia TECHNICAL PUBLICATION 41 2000 29 8 Disconnect and lock out input electrical power 9 Reconnect guns to hoses 10 Restore system to normal CORRECTIVE MAINTENANCE Obvious causes of malf
147. the applicator supply air for maintenance The valve must be customer furnished On units equipped with gear pump assemblies check gear reducer lubrication in the following manner a Remove the tank upper enclosure by removing one captive screw b Remove the plastic plug from the top of the gear reducer housing ISSUED 9 85 SUPERSEDES 1 84 NORDSON CORPORATION 1985 LITHO U S A All Rights Reserved 41 2000 12 P amp A Division Atlanta Georgia TECHNICAL PUBLICATION C Carefully remove the pipe plug from the side of the gear reducer housing NOTE Lubricant should be at the level of the plug hole in the side of the unit If the gear reducer is full allow the unit to drain to the level of the plug hole If the level is low refill to the level of the plug hole using Nordson lubricant P N 275 338 If the gear reducer is overfilled the energy used Q in churning the excess oil can result in over heating If the gear reducer is underfilled the resultant friction can also cause overheating d Replace the pipe plug in the side of the housing Use teflon paste P N 900 236 on threads e Install the vent plug in the plastic bag in the place of the plastic plug Use teflon paste on threads ELECTRICAL INSTALLATION The Series 2000 hot melt applicators are factory wired for use on a three phase service line The following instructions are divided into two section one covering electrical installation for 200
148. tials that could be fatal Only qualified personnel shall operate this equipment Do not trigger guns with cold material in the guns Damage may result to the ball and piston seat or module seals Check air pressure to pump at zero pressure on gauge Fill the adhesive tank with clean hot melt adhesive material Close applicator tank lid immediately to prevent introduction of contaminants Set tank temperature control to the recommended temperature for the adhesive being applied NOTE Hose temperature controls should remain at minimum setting OFF position on dial When the main circuit breaker is closed the guns will also start to heat regardless of the position of the hose temperature control knob Energize input electrical power Close main circuit breaker NOTE Yellow LED indicator above tank temperature control knob should glow steadily After 15 minutes increase hose temperature controls to ap plication temperature of adhesive Never allow an empty hose to remain at application Q temperature for more than 15 minutes Damage may result to the hose when it is pressurized NOTE As the components of the applicator system i e tank and hoses reach application temperature the yellow LED indicators will start to flash 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 18 8 9
149. tions l Mount the applicator so that it is above any draining or drip ping areas 2 Route hoses and electrical conduit so water will not run down the hose hose cordset or input electrical cable into the applicator 3 Provide a metal or plastic shield between the applicator and any source of water spray or mist The shield should not impair heat dissipation from the applicator or hoses ISSUED 1 84 SUPERSEDES NORDSON CORPORATION 1984 LITHO U S A he All Rights Reserved Publication No 104 465A Miscellaneous Technical Data Hot Melt NORDSON CORPORATION e AMHERST OHIO e USA Nordson Corporation welcomes requests for information comments and inquiries about its products Address all correspondence to Nordson Corporation 11475 Lakefield Drive Duluth GA 30136 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 1981 No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Nordson Corporation The information contained in this publication is subject to change without notice Trademarks AquaGuard Blue Box Control Coat Equi Bead FloMelt FoamMelt FoamMix Helix Hot Shot Hot Stitch Meitex MicroSet MultiScan Nordson the Nordson logo OmniScan Porous Coat Posi Stop RBX Sure Bond UniScan UpTime and Versa Spray are registered trademarks of Nordson Corporation BetterBookSM CF
150. tions The gear pump is normally used with medium to high viscosity materials in applications re quiring high cycle rates and constant pressures Air Driven Dual Acting Piston Pump Assembly The air driven dual acting piston pump assembly consists of a regu lator solenoid valve air piston with 4 way control valve and a dual acting hydraulic pump The air cylinder and hydraulic cylinder are tied together through a common shaft crossover tube connects the output of the hydraulic pump to the distribution manifold Figure 3 shows a schematic of the dual acting air driven piston pump The spring loaded ball and seat arrangement at the bottom of the hydraulic cylinder and the relative volumes of the areas above and below the hydraulic piston cause adhesive to be forced under pressure through the crossover tube into the manifold on both the up and down strokes of the air piston An optional high viscosity ball and seat assembly is available to increase the working viscosity range of the piston pump Overpressure protection is provided by a relief valve in the adhesive manifold that opens at 1600 psi 11 0 MPa to relieve system pressure back to the adhesive tank ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 Rights Reserved Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 5 AIR CONTROL VALVE AIR CYLINDER AIR PISTON VALVE SHIFTER PUMP MOUNT
151. to perform maintenance on this equipment gt gt gt gt AIR MOTOR NOT STROKING Piston Pump OR ROTATING Gear Pump Al Check tank temperature for indication corresponding to setting on controller NORMAL INDICATION Tem ABNORMAL INDICATION Elec perature in tank cor trical Troubleshooting Chart responds to setting for corrective action Proceed to next step A2 Reduce pump air pressure to zero crack open manifold drain valve and then increase air pressure to the pump Check for adhesive flow NORMAL INDICATION Air ABNORMAL INDICATION If motor starts to stroke the air motor does not or rotate when valve stroke or rotate is opened Blockage is blockage is upstream of downstream of the drain the drain valve Pro valve Proceed to next ceed to step A8 step ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 00033 TABLE 2 TROUBLESHOOTING CHART MECHANICAL Continued A3 Check for cold joints in hydraulic system NORMAL INDICATION 11 joints in hydraulic sys tem are hot Proceed to next step ABNORMAL INDICATION If a cold joint is identi fied install insulation around joint If insula tion is not enough in stall a heated inline filter at the joint NOTE Refer to Electrical Troubleshooting Chart if component hose or gun is not heating
152. to the air motor to zero at the regula tor Trigger all guns to relieve trapped hydraulic pressure Open manifold drain valve 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 U S A Rights Reserved Packaging and Assembly Division 41 2000 72 Nordson Atlanta Georgia TECHNICAL PUBLICATION 4 Remove o ring boss plug 4 and heat exchanger 5 from rear of manifold Use a 1 4 20 screw to pull heat exchanger from manifold If it is necessary to heat the manifold to soften solidified hot melt adhesive material use a flame less electric heat gun Never heat components with a torch or other open flame Clean the heat exchanger in a bath of Type R solvent heated to the melting temperature of the adhesive material NOTE Alternate heating and cleaning methods include a Heat components with a flameless electric heat gun Wipe parts with a clean cloth b Submerge parts in an ultrasonic cleaner Submerge parts in a chemical cleaner Never clean any component of a pressurized fluid system with halogenated hydrocarbon solvents See Safety Summary Section 40 1 for further details Using halogenated hydrocarbon solvents in this system could cause an explosion Inspect external surfaces for damage and burrs that could in terfere with smooth fluid flow causing blockage in passages Replace heat exchanger if damaged Insert heat exchanger and tighten plug into manifold Close manifold drain valve Re
153. ton Pump Gear Pump Tank Heating Method Tank Heater Power Requirement 2002 2004 2202 2204 Ambient Temperature Range Operating Temperature Range Operating Air Pressure Piston Pump Gear Pump Hose Capacity 2002 2202 2004 2204 Electrical Requirements Dimensions 288 cu in 4717 cu cm 540 cu in 8847 cu cm 10 4 lb 4 7 kg 19 5 lb 8 9 kg 14 lb hr 6 4 kg hr 22 lb hr 10 0 kg hr 54 lb hr 24 5 kg hr 68 lb hr 31 0 kg hr Cast in resistive heating element 2310 watts at 208 VAC 3000 watts at 208 VAC 35 to 120 F 0 to 50 C Linear calibration from 200 to 425 F 93 to 218 C plus open ended scale from 150 to 200 F and 425 to 450 F 10 to 60 psi 69 to 412 kPa 5 to 80 psi 138 to 447 kPa 2 48 ft max 4 64 ft max for 230 VAC hoses 58 ft max for 200 VAC hoses 180 to 256 VAC 50 60 Hz 3 1 phase 380 VAC 50 60 Hz 3 phase only See Figure 2 Tank capacity shown is an approximation based on the specified tank volume and the use of an adhesive with a specific gravity of 1 0 Tank capacity will be greater for adhesives with high specific gravities less for adhesives with lower specific gravities Under actual operating conditions tank capacities may be somewhat lower than calculated since tanks are not always filled completely ISSUED 9 85 LITHO U S A SUPERSEDES 8 84 NORDSON CORPORATION 1985 All Rights Reserved Packaging and Assembly Division Atlanta
154. tside the range from 120 to 320 ohms open or shorted proceed to next step SUPERSEDES 3 83 NORDSON CORPORATION 1984 All Rights Reserved Packaging and Assembly Division 41 2000 56 Atlanta Georgia TECHNICAL PUBLICATION TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued D17 Disconnect the hose electrical connector from the applicator and measure hose RTD resistance at pins 3 and 4 on the plug NORMAL INDICATION 120 to 320 ABNORMAL INDICATION Resis ohms Locate and replace tance outside the range faulty wiring Restore from 120 to 320 ohms open system to normal operation or shorted Replace hose and restore system to normal operation HOSE OVERHEATS An overheating condition in the hose will be indicated by a red LED on the hose temperature control panel when temperature in the hose reaches a point halfway between the temperature setting on the controller and 500 F 260 C Approximately two minutes later the temperature controller will open the main circuit breaker through the circuit breaker auxiliary trip coil EJ With the main circuit breaker closed check the condition of the temperature control indicators for that hose Refer to Table 3 for indications NOTE It may be necessary to wait as long as 15 minutes for the thermal relay contacts to open up before the main circuit breaker can be reclosed NORMAL INDICATION With ABNORMAL INDICATION If temperature above the set both the red and vello
155. uld open the main circuit breaker through the circuit breaker auxiliary trip coil If the main circuit breaker does not open proceed in the following manner Bl Disconnect and lock out input electrical power to the applicator Input terminal block 1 and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the Main circuit breaker is OFF open ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A All Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 50 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued B2 Disconnect wire Nos 47 35 and 48 36 from TB2 7 and TB2 2 Measure the resistance across the tank thermostat with tank in hot condition NORMAL INDICATION Short ABNORMAL INDICATION Open circuit when tank is circuit when tank is above 500 F Replace above 500 F Replace Main circuit breaker thermostat THS Pro Proceed to next step ceed to next st p NOTE Even though the main circuit breaker auxiliary trip coil or thermostat indicated defective a fault still remains in the tank temperature control circuitry that allowed temperature to increase above normal control band Continue the troubleshooting sequence to isolate and correct the fault TANK OVERHEATS TO THE POINT WHERE THERMOSTAT OPENS MAIN CIRCUIT BREAKER An overheating condition in the tank will be indic
156. unction such as broken wires and missing fasteners are generally not considered as part of corrective maintenance These types of failures should be noted and eliminated during periodic cleaning and inspection unless the failure presents an immediate hazard to the equipment or to personnel Tables 1 and 3 present a summary of the mechanical and electrical troubleshooting charts respectively Only typical faults and probable causes are listed If the cause of failure is reaaily apparent refer to the appropriate Troubleshooting Chart for cor rective action The alphanumeric designation listed in the Ref erence column specifies the step in the Troubleshooting Chart Tables 2 4 present the mechanical electrical trouble shooting charts respectively for the Series 2000 hot melt applicators The tables introduce typical fault situations and the procedural steps necessary to isolate and confirm the fault Alphanumeric designations in these tables serve to organize the tables into related groups of procedural steps The tables then specify the corrective action to be taken based on the results of the associated procedural statement A normal indication usually requires continuation of the fault isolation procedures or a re evaluation of the fault The charts designate specific steps for gear pump and piston pump configurations ISSUED 8 84 SUPERSEDES 1 84 NORDSON CORPORATION 1984 LITHO U S A Rights Reserved Packa
157. ure controller ceed to step B3 functioning properly Abnormal Indication Faulty temperature con troller Repair or replace controller B3 Check adhesive level in tank NORMAL INDICATION Tank Normal Indication Pro full of adhesive ceed to step B4 ISSUED 9 81 SUPERSEDES 6 71 LITHO U S A 9 Packagin d Assembly Divisi Atlanta Georgia TECHNICAL PUBLICATION 40 0 15 HOT MELT TROUBLESHOOTING CHART CONTINUED SYMPTOM PROCEDURE CORRECTIVE ACTION Abnormal Indication Ad hesive level low Keep tank full B4 Hot melt adhesive may be oxidizing in tank NORMAL INDICATION Normal Indication None oxidation in tank adhesive Abnormal Indication Hot melt adhesive oxidizing in tank Keep tank lid closed In extreme cases change adhesive or use nitrogen gas blanket applicator ADHESIVE FUMING OR SMOKING Cl Check tank temperature setting NORMAL INDICATION Proper Normal Indication Pro tank temperature setting ceed to step C2 Abnormal Indication Tank temperature too high Reduce temperature C2 Adhesive may be unstable chars easily NORMAL INDICATION Normal Indication None char Abnormal Indication Un Stable adhesive Use one or more of the following steps to reduce charring l Keep tank lid closed 2 Use a more stable adhesive 3 Use nitrogen gas blanket applicator ISSUED 9 81 SUPERSEDES Ne RDSON CORPORATION 1981 4 Packagi bly Div
158. valve in the distri bution manifold set to open at 1600 psi 11 0 MPa to relieve system pressure at the outlet of the pump back to the tank ADHESIVE DISTRIBUTION MANIFOLD ASSEMBLY An aluminum adhesive distribution manifold assembly mounted on the bottom of the hot melt tank in the Series 2000 applicators receives hot melt adhesive from the air driven pump filters and reheats the adhesive and distributes the hot melt adhesive to the heated hoses and extrusion guns The filter assembly consists of a core and fine mesh screen to filter out particulate contaminants and char The filter is threaded onto a threaded sleeve to prevent overtorquing and allow easy removal for inspection and cleaning A finned core heat exchanger in the adhesive path reheats adhesive irom the tank to application temperature Because the tank is mounted directly to the manifold the heat exchanger and manifold are also heated by the tank heaters The heat exchanger comes into effect when fresh adhesive added to the tank drops the temperature of the adhesive being pumped into the manifold and when pumping high flowrates A drain valve in the manifold allows material to be pumped through the filter assembly without using hoses and extrusion guns The valve also provides a convenient method to prevent pressure buildup in the system during maintenance operations Hoses may be connected to the side bottom or back of the distribu tion manifold TANK HOSE AND G
159. ve gun service block cover and disconnect thermostat leads at the wire nuts Measure the resistance across thermostat leads NORMAL INDICATION Open ABNORMAL INDICATION Con circuit Reconnect tinuity Replace thermo thermostat leads and stat and restore system restore system to nor to normal operation mal operation NOTE If the thermostat operates properly the rating of the thermostat may be too hot for the adhesive being used Consult adhesive manufacturer for proper appli cation temperature Replace thermostat with a lower temperature unit if necessary DISASSEMBLY AND REPAIR The Series 2000 hot melt applicators contain energized electrical components with potentials that could be fatal Disconnect and lock out input elec trical power to the applicator before removing any panels or performing maintenance procedures Do not attempt to loosen any part of manifold hoses or guns until air to the applicator has been turned off and pressure in the system has been relieved Wear safety glasses safety gloves P N 902 514 and protective clothing to prevent injury from hot applica tor parts splashed hot melt adhesive material and hot gun surfaces If applicator is operable flush system before disassembly If pump is not operable but the heating system is functional heat the applicator to operating temperature to ease disassem bly Otherwise a heat gun or other flameless heating method must be used to melt so
160. w point but below the half LED s are lit proceed way point both LED s to the next step should be dark Above the halfway point the red LED should be lit for approximatelv two minutes until the main circuit breaker trips E2 Disconnect and lock out input electrical power to the applicator Input terminal block and input terminals on main circuit breaker are still electrically energized if external power is not disconnected even though the main circuit breaker is OFF open ISSUED 1 84 SUPERSEDES 3 83 NORDSON CORPORATION 1984 THA All Rights Reserved A Packaging and Assembly Division Atlanta Georgia TECHNICAL PUBLICATION 41 2000 57 TABLE 4 TROUBLESHOOTING CHART ELECTRICAL Continued E3 Remove the hose electrical connector for the affected hose and measure the RTD resistance on pins 3 and 4 of the hose end connector NORMAL INDICATION Re ABNORMAL INDICATION Short sistance value within circuit or resistance the range specified in well below range speci step D16 Replace tem fied in step 016 Re perature control board place hose Reconnect Restore system to normal hose connector and re operation store system to normal operation GUN FAILS TO HEAT OR UNDERHEATS FI Check input voltage at NORMAL INDICATION Voltage ABNORMAL INDICATION Unequal as indicated in the below or no voltage Check input table Proceed to next voltage source step 230 VAC Single Phase
161. y damage EXPLANATION OF TERMS AND SYMBOLS The following symbols are used in Nordson publications to alert the reader to potential physical harm or equipment damage WARNING CAUTION Failure to observe may cause Failure to observe can cause DEATH or PERSONAL INJURY DAMAGE TO EQUIPMENT General Electrical Pressure Figure 1 Nordson Corporation Safety Symbols ISSUED 7 86 SUPERSEDES 2 85 NORDSON CORPORATION 1986 LITHO USA All Rights Reserved P amp A Division 40 1 2 Atlanta Georgia TECHNICAL PUBLICATION SAFETY DURING INSTALLATION m ELECTRICAL protective electrical ground connection to a reliable earth ground is essential for safe operation Without one all accessible conductive components including knobs and controls that appear insulated can render an electric shock disconnect switch with lockout capability must be provided between the power source and the equipment The power supply wire gauge and insulation must be sufficient to meet the temperature and power requirements Only fuses of the correct type voltage rating and current rating should be used Refer to the Nordson equipment parts list for fuse recommendations Using incorrect or nonrecom mended fuses can present a fire hazard PNEUMATIC Nordson recommends installing a lockout three way manual valve in the air supply line to the filter regulator This valve makes it po

Download Pdf Manuals

Related Search

Related Contents

living connect®, Z-Wave Certified Electronic Ra- diator  Fiche Séquence  Vector VEC022APC Automobile Parts User Manual  LG N224WHA  Benutzerhandbuch  取扱説明書 (933.33 KB/PDF)  service manual, rear brake caliper replacement  OMRON - Documentation: Terminaux opérateur - NS  SPIRIT / SPIRIT XL MANUAL DE USUARIO    

Copyright © All rights reserved. Failed to retrieve file