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title Quattro - Astro Packaging, Inc.
Contents
1. 6 2 HoseFittines amp Fasteners 22e nA EE REESE eed AR 6 2 Primary Tank Filter Inspection and Cleaning 6 3 Elushwg the Systeni sro la ere och Pe eie Dol tec 6 4 Chapter 7 Troubleshooting General Troubleshooting 7 1 Handling Printed Circuit Boards 7 1 Control Printed Circuit Board 7 2 Overtemp Thermostat EE deren ede 7 3 Tank Overcurrent ipa slip A EOS USER LE AR IR IR 7 3 Relay Contact to Parent 7 3 Temperature Zones Not Heating 7 3 Location of PCB Circuit Breakers Overtemp Thermostat Re set amp RTD Sensor 7 3 R sistance Tables RES M ge ge he 7 4 Troubleshooting 4 7 5 Piston Pump Troubleshooting Guide 7 9 Page iv ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Chapter 8 Disassembly amp Re assembly Procedures Removing Access Panels amp Covers 8 1 To Access Electrical Parts eR ee RELIER EE 8 2 To Access the Control Panel Components
2. Scroll to choose between ON and OFF When programming is or complete wait a few seconds and the controller will return to the 50 actual temperature Note Any time the ASU is switched ON you will briefly see SS1 or SSO displayed ITW Challenger c 2003 Page 5 7 QUATTRO ASU Manual 20 44 Revised 5 04 Service Functions cont To Set Temperature Scale The Temperature Scale may be set to display temperature either in degrees Celsius or Fahrenheit C x4 Press the Service icon four times to set the Temperature FO Scale Scroll to choose between Celsius C or Fahrenheit or F as indicated by the Temperature Scale LED When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature To Set Ready Delay When the system is ready all temperature zones are within tolerance a ready delay may be pro grammed to delay the system s ready output signal x5 Press the Service icon five times to set a Ready Delay You will see d 1 to indicate you are in Ready Delay programming mode Press the Tank icon to display the Ready Delay To change a Ready Delay scroll up or down to the desired length in minutes of delay 0 Default no delay 99 minutes maximum length of delay Wi When programming is complete wait a few seconds and the controller will return to the ASU s actual temperat
3. This temperature zone is now turned OFF To turn ON the temperature zone increase the setpoint When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature ITW Challenger c 2003 QUATTRO ASU Manual 20 44 ITW Challenger c 2003 Page 5 3 QUATTRO ASU Manual 20 44 Revised 5 04 Keypad Locking It is possible to lock or unlock the controller in order to restrict programming changes To change the code which is necessary to over ride or unlock the keypad lock see Service Functions Note the Quattro is shipped with de activated keypad lock Ifthe keypad lock must be used an access code must be programmed prior to locking the keypad Locking or Unlocking the Keypad Important Note the controller must be in the Temperature Display mode in order to allow locking or unlocking of the keypad Locking the Keypad vi amp Press the Down Scroll key then hold and press the Service icon key You will see Loc to indicate that the Keypad Lock is active Unlocking the Keypad Press the Down Scroll key then hold and press the vj Service icon key You will see Cod to indicate that the access code is required or Enter your access code by scrolling up or down Default code Confirm your code input by pressing Tank key Notes 1 Once the keypad lock is ac
4. Page 8 6 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 mum allowable torque on these bolts is 44 Nm 32 4 ft Ib Pump O ring Replacement 1 Remove the pump assembly from the ASU see previous instructions 2 Remove the external pump seals backup ring and o ring from their grooves on the end of the pump delivery tube 3 Clean any debris from the seal groove 4 Install the new seals Re Assembly Procedures Unless noted the ASU s re assembly is simply the reverse sequence of the disassembly proce dures However the following cautions should be followed whenever they apply for proper re assembly CAUTION In general all O RINGS AND SEALS must be replaced whenever hot melt equipment is re assembled All new o rings must be lubricated with o ring lube PN 001U002 CAUTION TAPERED PIPE THREADS are found on air line fittings used with the pump air supply and on the outlet filter manifold Apply thread sealant PN N02892 whenever tapered pipe threaded parts are re assembled CAUTION SOME FITTINGS used for adhesive on the ASU have straight threads and o ring seals Use of thread sealant is not necessary with these parts but the o ring seals should be clean and lubricated Tighten straight threaded parts and fittings until their shoulders are firmly seated Excessive torque may damage straight threaded parts and the use of power wrenches is not recommended CAUTION HOT MELT RESIDUE must be
5. 001V078 Lube TFE Krytox not shown Page 10 11 Revised 2 05 Qty PRR bech Page 10 12 ITW Challenger c 2003 Revised 2 05 QUATTRO ASU Manual 20 44 Bill of Materials for Valve Hose End Panel Assembly 110724 Item No Part Number Description Qty 1 110725 Panel Hose End 1 2 110726 Harness Assembly 4 3 104898 M3 x 0 5 x 10mm Socket Button Head Screw Black 16 4 110727 Cover Wireway 5 107389 x 0 7 x 8mm PH Pan Head Screw with Lockwasher Zinc Plate 3 ITW Challenger c 2003 Page 10 13 QUATTRO ASU Manual 20 44 Revised 6 07 PCB Heat Sink To Base Item No Part Number Description Qty 1 110743 PCB Heat Sink Assembly 1 2 108297 M8 x 20mm Hex Flange Head Screw 3 3 110746 Control Panel Assembly 1 4 110747 Switch DPDT Rocker 1 5 110749 Cable Assembly Power Switch 1 6 110748 Cable Assembly Keypad Display 1 7 102762 Fuse 5 x 20 1 0A Fast 2 8 108566 Fuse 5 x 20 6 3A Very Fast 8 Page 10 14 ITW Challenger c 2003 Revised 2 05 QUATTRO ASU Manual 20 44 iro Challenger Quality Hot Melt Parts APPL HEATER APPL HEATER APPL SENSOR HOSE HEATER HOSE APPL SENSOR GROUND HOSE HEATER HOSE SENSOR SENSOR JUMPER SENSOR JUMPER SENSOR JUMPER ITW Dynatec c 2003 Page 11 1 QUATTRO ASU Manual 20 44 Revised 12 03 Chapter 11 SYSTEM SCHEMATICS amp ENGINEERING DRAWINGS APPLICATOR END FUNCTION ASU END PLUG RECEPTACLE RTD SENSOR SCHEMATIC CHALLENGER HOS
6. 84 4 QV3H 3SOH 64 7 G4 Z 0V3H 3SOH 014 94 L Qv3H 3S0H 1SV3 9 I Q3snd SOVIH S3SOH 0 OVAOEZ OVAO Z N Du MONIA 131014 ama 11 94011 135 SMd NOILVYUNIIANOO 4 INNI INN LX DUO el El Jv 1 M3TIOMINOO M03 SISNI X3 devo ina 994011 Nd 69 01 Nd 1994011 Nd 94011 Nd 2 921011 Nd 18 5 671011 Nd 3I8V9 HOLIMS noes AVISOWH3HL dW3il Y3A0 epu ala y GH aly n 3SOH PH Ce 3 X 3 064011 Nd 318v o tI 3SOH FAKE aly kw 2 VGH LL Nd ree 5 o aly Ts eu 3SOH AOVIY 8X Waviv LX n ON WOO ON ON NOI ON OZZOLI Nd 318VO 894011 Nd 318V9 007011 Nd 89d ESS aly 4 X 1 i aly Uu 3S0H LH O yinvi 924011 Nd 318V9 ON Id YIMOd INNI OVAOOv OCZ OVAOEZ HdE a 1 721 11 N ad OVA0 Z N OVAO0 Z mend mend 3d 3d
7. Page 7 7 Revised 12 03 Tank does not heat and LED is OFF Hose or Head is not heating Hose Head LED on the PCB is ON Head amp Hose are not heating Hose or Head is not heating Hose Head LED on the PCB is OFF Hose or Head actual temperature is much higher than setpoint Inoperative PCB 1 Loose plug connection on PCB 2 Heating element inopera tive 1 Disconnection between ASU and Hose or between Hose and Head 2 Hose or Head fuse on the PCB is inoperative 1 Sequential heat up may be active 2 Inoperative PCB 1 Inoperative Hose or Head triac on PCB corresponding PCB LED is OFF 2 Inoperative Hose or Head temperature sensor corresponding PCB LED is ON Replace PCB 1 Check connectors X10 X11 X12 and X13 and restore connection 2 Check resistance and compare to resistance table on page 7 4 a For head if heater cartridge is inoperative replace heater b For hose if heating element is inoperative replace hose 1 Check plug connections 2 Insert new fuse If fuse blows again check for a short circuit in heater Note there are two fuses for each hose head combination 1 Check controller display at start up Re program if necessary 2 Replace PCB 1 Replace PCB 2 Check resistance and compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoper
8. To Remove the Pump Cover allows ac Pump Cover cess to the pump Hose End Panel 1 Remove one screw in the top of the cover 2 Lift the pump cover straight up and off of the ASU being careful of the Rear Panel ground wire on the inside of the cover not seen in this view To Remove the Front Panel allows ac cess to thermostat heaters RTD sen sor 1 Remove two screws on either side of the cover and two at bottom of panel on either side of the filter manifold 2 Loosen the two top tank cover screws to release the front panel from the ASU being careful of the ground wire on the inside of the cover Front Panel To Remove the Rear Side Panel no ser viceable components are behind this LS Control Panel Control Enclosure panel Assembly face plate Remove in the same manner as the front panel described above being E careful of the ground wire on the inside of the cover To Remove the Control Enclosure allows access to PCB and its connects and the main On Off switch 1 Remove two screws from the bottom of each of the three sides of control enclosure 2 Lift enclosure off being careful of the ground wires on the inside of the cover plus the wires Page 8 2 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 which run from the keypad to the printed circuit board and the ones which run from the main switch To Remove the Control Panel Assembly allows access to PCB and its connects a
9. 8 3 To Remove ege SE EE RALE A n 8 4 To Remove Tank Pressure Relief Valve 8 4 Piston Pump Removal 8 5 Re assembly Procedures amp Cautions 8 6 Chapter 9 Recommended Spare Parts amp Available Kits Recommended Spare Parts List 9 1 Chapter 10 Component Illustrations amp Bills of Material Cabinet Assembly tec aston se iaia vba ewe pre a e rep 10 2 Tank amp Base Assembly sisi lead aa perio 10 4 Pump Assembly vii gg re Rake rt RR ER EIER A 10 6 Pump Air Manifold Assembly 10 8 Pump Air Manifold i iii RE NEP GRE RARE RR pd i 10 9 Manifold Output Assembly 10 10 Filter Assembly 2 bee ah RIBUS SEEMS E deeg 10 11 Valve Hose End Panel Assembly 10 12 PCB Heat Sink to ciro rale Li aLe 10 13 Chapter 11 System Schematics amp Engineering Drawings Hose Schematic all models 11 1 Head Schematic all models 11 2 Wianng Diagram ssc ced wee epe mee EEUU OUEST EIUS AE MEE ME 11 3 ITW Challenger c 2003 ALL
10. should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is not available frequently touch a bare metal part of the ASU unpainted frame mounting screw etc to safely discharge any electrostatic buildup on your body 2 Handle a PCB by its edges only Don t grip a PCB across its surface 3 When removed from the ASU the PCB must be packaged inside a metallized static drain envelope Do not place the removed PCB on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the PCB to him 5 When unwrapping a PCB from its static drain envelope place the envelope on a grounded nonmetallic surface 6 To cushion a PCB for shipment use only static drain bubble pack Do not use foam peanuts or bubble pack not known to be static draining Page 7 2 ITW Challenger c 2003 Revised 3 06 QUATTRO ASU Manual 20 44 Control Printed Circuit Board Notes 1 The green LEDs cycle on and off as each heater outputs 2 CAUTION Using the incorrect power configuration plug may cause serious damage to the unit The Power Configuration Plug user installed must be correct for your application or serious ASU damage will result See Installation Chapter 3 for details 3 If an overcurrent occurs on tank heater s its circuit breaker s
11. 1 No air pressure 1 Verify system has been provided with at least 0 5 SCFM of air at 20 100 PSIG 014 std cubic meters minute at 6 8 bar 2 3 way solenoid valve is 2 Verify that valve is properly con closed nected electrically inside ASU Verify that valve is properly con nected to Air Control Filter Unit Disconnect valve electrical leads and verify that air is passed through when 240 VAC is applied to the valve terminals Replace valve if defective 3 Fault in compressed air 3 Inspect the system for improper fitting on ASU connections loose tubing or fit tings or kinked tubing Repair or replace tubing or fittings as necessary 4 Adhesive not up to 4 Wait for setpoint to rise or re program temperature setpoint lower 5 Inoperative air cylinder 5 Remove 4 way valve Inspect 4 way valve clean and repair as necessary 6 Start up time delay has not 6 Wait for time delay or re program expired time delay Pump Will Not Stroke Not all the system compo Wait until all system components are adhesive has melted nents including hoses amp ready or adjust the temperature zone heads have attained tolerances ready condition Page 7 10 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 ene Pump Quick Strokes in 1 No adhesive in tank 1 Verify that tank has an adequate Both Directions level of hot melt adhesive 2 Adhesive too cold to flow 2 Check temperature of the i
12. MODELS Page 1 1 Revised 1 07 Chapter 1 SAFETY PRECAUTIONS All operators and service personnel must read and understand this manual before operating or servicing equipment Electrical DANGER HIGH VOLTAGE Dangerous voltages exist at several points in this equipment To avoid personal injury do not touch exposed connections and components while input All maintenance and service on this equip ment must be performed by trained techni cians power is on Disconnect lockout and tag external electrical power before removing protective panels A secure connection to a reliable earth ground is essential for safe operation A disconnect switch with lockout capability must be provided in the line ahead of the unit Wiring used to supply electrical power should be installed by a qualified electrician High Temperatures WARNING HOT SURFACE Severe burns can occur if unprotected skin comes in contact with molten adhesive or hot application system parts Safety glasses gloves and long sleeved clothing must be worn whenever working with or around adhesive application systems High Pressure WARNING HIGH PRESSURE PRESENT To avoid personal injury do not operate the equipment without all covers panels and safety guards properly installed To prevent serious injury from molten adhesive under pressure when servicing the equipment disengage the pumps and relieve the adhesive system s hydra
13. PCB is inoperative cont Page 7 6 Revised 12 03 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Actual tank tempera ture is higher than set point overtemp Display for Tank EOI1 Display for Tank EO2 Tank does not heat but LED is ON 1 Tank sensor not fully inserted 2 Tank sensor inopera tive 3 Inoperative PCB 1 Plug connection X5 1 amp 2 on PCB is loose 2 Temperature sensor in operative 1 Tank sensor short cir cuit 2 Short circuit at plug con nection X5 on Control PCB 3 Inoperative PCB 1 Circuit breaker has tripped on PCB 2 Tank heater element is inoperative 3 Disconnection in tank heater circuit 4 Inoperative PCB 1 Check tank sensor 2 Replace tank sensor if resist ance does not comply with resist ance table 3 Replace PCB 1 Restore connection 2 Replace sensor if resistance does not comply with resistance table 1 Replace sensor if resistance does not comply with resistance table 2 Check and eliminate short circuit 3 Replace PCB 1 Re set circuit breaker and observe ASU If it trips again check for a short circuit in heater 2 Replace tank if element s re sistance does not comply with re sistance table Note remove lead wires from heater element when measuring resistance 3 Check and repair see wiring dia gram 4 Replace PCB ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Problem
14. Specifications IR eh Te 2 1 Specifications e eO Ie Met HO eu RE A a 2 2 DIMENSIONS Sire re le oa 2 4 Chapter 3 Installation amp Start Up Installation iet ete E 3 2 Adding Adhesive iau Ia dad ue er Pee e REP ER RR els P Edd 3 4 Changing the Adhesive Formula 3 4 Typical Start Up and Shut Down Procedures 3 5 Storage and Disposal of the Application System 3 6 Chapter 4 Temperature Controller Set Up Defining Temperature Control Terms 4 1 Error Indication Message ose ae ei e Ere ee ae aca 4 2 Firmware Chip and Checksum 4 2 Settings for a Typical 4 3 System Values 44s tito eil e etes epe es cedes 4 3 Helpful Tips 24 554 eee ME Se EE NE Wed Ee i bd epee weed 4 4 Chapter 5 Programming of the Controller Controller Key pad aa Ree REA aW ER Rs 5 1 Programmi rr ua liane UE wax Y FRE e E 5 1 Service Functions oo ages aod atten ale ee Iaia 5 4 Chapter 6 Preventive Maintenence General Cleaning ire erre PE EE OE EE EA E ER 6 1 Relieving System of Adhesive 6 1 Replacement of Manifold Filter Screen
15. cleaned from parts before they are re assembled particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts must be re tightened at operating temperature ITW Challenger c 2003 Page 9 1 QUATTRO ASU Manual 20 44 Revised 11 06 Chapter 9 RECOMMENDED SPARE PARTS amp OPTIONS Optional Accessories PN 111243 Stand Assembly This static Stand Assembly comes pre drilled with front and back mounting plates for the installa tion of customer selected auxiliary controls Designed with square holes for carriage bolts that al low for one wrench assembly Assembly instructions enclosed Recommended Spare Parts List CCC wem Electrical 110400 Control Printed Circuit Board Assembly 108566 Fuse 6 3 A Super Fst 5x20 on PC Board 102762 Fuse 1 amp on PC Board 110720 Sensor Assembly Tank 104166 Over Temperature Thermostat 110747 Switch DPDT Filters CF1002 Filter Screen 100 mesh 110755 Tank Filter Screen N00186 O ring 019 Viton filter assy N00201 O ring 116 Viton filter assy N00177 O ring 010 Viton drain valve assy 110717 Back up Ring 010 Split TFE drain valve N00360 O ring 906 Viton hose fittings amp plugs N00188 O ring 022 Viton tank manifold 112292 Tank lid seal silicone 110907 Solenoid Valve 3 way CA1008 Pressure Relief Valve 110912 Mini Regulator w Gauge L15653 Kit Flushing Fluid 1 gallon 001U002 Lubric
16. signals to and monitoring signals from the tank hoses and applicators It features lighted LEDs to indicate that heater power is ON The ASU s fuses circuit breakers amp power configuration plug are located on this board Keypad Locking The controller s keypad may be locked or unlocked to restrict or allow further programming Mechanical High Temperature Protection A mechanical redundant thermostat located on the tank that will turn off the system above safe tem peratures RTD Sensors The system uses 120 ohm Nickel resistance temperature detector RTD sensors for all temperature controls Ready Signal The controller provides a ready signal if all temperature zones are within a programmable tolerance and the system is ready for production This signal is available on a dry contact at connector X8 on the Control printed circuit board The ready signal also controls pump operation Page 4 2 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 420 44 Sequential Startup This feature allows the temperature zones to come on in sequence tank followed by hoses and heads W hen activated and the ASU is turned ON from a cold start the tank heats first W hen the tank is within its setpoint tolerances the hoses and heads begin to heat Setpoint A programmable temperature that has been selected for tank hoses and applicators Setpoint Limitation This is a universal maximum temperature for all zones 218 C 425 F The pr
17. 00475 Washer Insulating 328 x 750 3 13 110721 Plate Clamp Sensor 1 14 110718 Spacer Tank Stand off 1 15 110858 Washer 52 2 x 9 9 x 1 07 1 16 110719 M8 x 1 25 x 75mm Black Oxide HHC Screw 1 110722 Tank Insulation Assembly Not Shown 17 110733 Tank Cover 1 18 110732 Gasket Tank Top 1 19 111745 Pump Assembly Shown For Ref Only 1 20 110735 Tank Top Insulation 1 21 N00188 O ring 022 Viton 2 22 110755 Screen Tank Filter 1 23 110720 Sensor Assembly Tank 1 24 106235 MS Flat Washer Shown For Ref Only 3 25 107346 MS Split Lock Washer Shown For Ref Only 3 26 107398 M8 x 1 25 x 35mm Hex Head Screw Shown For Ref Only 3 ITW Challenger c 2003 Page 10 5 QUATTRO ASU Manual 20 44 Revised 2 05 Tank and Base assembly 110702 Page 10 6 ITW Challenger c 2003 Revised 2 05 QUATTRO ASU Manual 20 44 Bill of Materials for Piston Pump Assembly 111745 Item No Part Number Description Qty 1 111746 Retainer Pump Cover 1 2 106324 Washer Flat M6 Zn PI 2 3 111738 Piston Pump Lower Assembly 1 4 111341 Retaining Ring Inv Internal 875 1 5 111742 Bush Seal Back Up 1 6 111348 Seal Rod 13 8 x 20 x 4 8 1 7 111740 Pump Shaft Assembly 1 8 111231 Seat Ball Outlet Check Locktite required 1 9 111739 Pump Body 1 10 111233 Seat Ball Inlet Check Locktite Required 1 11 111234 Bearing Cage Inlet Check 1 12 111340 Ball SST 469 Dia 1 13 111432 Pump Transfer Tube Assembly 1 14 111338 Retainer Clip Pump transfer tube include
18. Dyna tec 1 Locate desired fuse by referring to PCB illustration in Chapter 7 2 Grasp fuse from both ends and pull out of the printed circuit board Main On Off Switch Replacement 1 From the back of the switch free it by squeezing it from either side 2 Remove the switch through the back 3 Disconnect four color coded plug in leads from the old switch and connect them to new switch To Remove the Control PC Board Reference the manual section entitled Handling Printed Circuit Boards on page 7 1 before pro ceeding 1 Remove the control enclosure see pg 8 1 2 Disconnect all electrical connections to the board 3 Loosen the three large screws behind the PCB holding its heat sink and slide the PCB assem bly out 1 of 3 large screws holding PCB in place Control Printed Circuit Board PCB Page 8 4 ITW Challenger c 2003 Revised 1 06 QUATTRO ASU Manual 20 44 To Remove the Tank Lid see location on the illustration on page 8 1 1 From one side of the tank lid remove the two phillips flat head screws holding the tank lid hinge to the ASU 2 Slide the tank lid in the direction of the removed screws to remove it To Remove Install the Tank Cover Seal for reference use the illustration on page 10 3 The tank lid seal is located under the sheet metal panels of the ASU 1 Pump out as much of the molten adhesive as possible 0 WARNING HOT SURFACE The ASU will still be hot during this pr
19. E WITH 120 OHM Ni SENSOR HOSE SCHEMATIC ASU to Applicator Page 11 2 ITW Dynatec c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 APPLICATOR PLUG CG II 1 RR UM HEATER 4 HEATER k 4 SCHEMATIC CHALLENGER APPLICATOR WITH 120 OHM Ni SENSOR HEAD APPLICATOR SCHEMATIC Page 11 3 Revised 12 03 QUATTRO ASU Manual 20 44 ITW Dynatec c 2003 68 011 Nd 319V9 12 7 Ze 5255 D QV3H 5 3H 3SOH 924011 Nd 319 D ur A TIT z gt ma n 525 52 OF TIVND d F Sg e 3S0H i 38000 EG TN CAE Set 5 KC QV3H gt 231 sw am gt E 3SOH 921011 Nd 18 9 PI_DI T gt dz ame d5 5 T oan 29 Se G Lamm 2 seta gt 3S0H ES Y 624011 Nd 318vVO 3NWA 10S SIOVINOO AND AQv3M NUVIV OL NOILO3NNOO HINOLSNI 8X LX SH3Q0V3H 33V SIMA 3710H SS399Y YIMOd 1ndNI 01 1 39 0 3SV8 3HL NO Q3lV9O SI ASV 3HL X04 IVNINYIL ANNOYS SISSVHO 3d 3HL H3QMO 3llSOddO JHL NI Q3338WfN 33V 1X 6X SX X ZX SH3Qv3H YO4 SONIA 20 SNOILISOd M3Q0V3H JYV LX 6X SX ZX SM3Q0V3H 04 NMOHS SHIBNNN NOILISOd S310N INIYYNOYIAO MNVL eX 6x T LP SH3 xv3H8 LINDO L3 79 4 i Qv3H 3SOH
20. ITW Challenger OPERATIONS amp SERVICE MANUAL An Illinois Tool Works Company Manual 20 44 31 Volunteer Drive i Hendersonville TN 37075 USA Revised 12 06 Telephone 615 824 3634 FAX 615 264 5222 iro Challenger Quality Hot Melt Parts QUATTRO ADHESIVE SUPPLY UNIT OPERATIONS AND SERVICE MANUAL with Software Version V1 05 IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT It is the customer s responsibility to have all operators and service personnel read and understand this information Contact your ITW Challenger customer service representative for additional copies NOTICE Please be sure to include the serial number of your application system each time you order replacement parts and or supplies This will enable us to send you the correct items that you need ITW Challenger Service Parts Direct Dial 1 800 538 9540 ITW Challenger Technical Service Direct Dial 1 800 654 6711 Page ii Revised 10 03 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 N SAFETY INSTRUCTIONS GENERAL CONSIDERATIONS 1 Read and follow these instructions Failure to do this could result in severe personal injury or death 2 Additional safety instructions and or symbols are located throughout this manual They serve to warn maintenance personnel and operators about potentially hazardous situations 3 Inspect the machine for unsafe conditions daily and replace all worn or defective parts 4 Keep wor
21. OGRAMMING INSTRUCTIONS FOR QUATTRO CONTROLLER Quattro Keypad Temperature EM DEL Hose 1 Temp Zone Icon amp LED Display Hose 2 Temp Zone Icon amp LED Head 1 Temp Zone Icon amp LED Scroll Keys increase value reduce value Head 2 Temp Zone Icon amp LED Head 3 Temp Zone Service Icon amp LED Tank T Pis Head 4 Temp Zone one Icon amp amp LED Hose 3 Temp Zone Icon amp LED de to 4 Hose or Head Hose 4 Temp Zone Icon amp LED Temperature Zones Programming Turn Controller ON I O Turn ON the main power switch System will go through its self diagnostics CAL Controller will display CAL On Off Temperature zone LEDs will flash Controller will display SS 1 On or SS 0 Off to indicate status of the Sequential Statup feature or see info on Sequential Startup later in this chap ter Page 5 2 Revised 12 03 Programming Temperature Setpoints E or o a Choose a temperature zone When flashing the zone s setpoint is displayed and it can be programmed In order to program the temperature setpoint scroll up to increase value or down to reduce value After two seconds the display will read the actual temperature The setpoint is stored Turning Temperature Zones ON OFF Z o Or or gt 14 519 Choose a temperature zone Scroll to reduce value until the temperature setpoint shows
22. W Challenger c 2003 Page 7 5 QUATTRO ASU Manual 20 44 Revised 12 03 Troubleshooting Guide Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 The ASU is supplied with power 3 The ASU is supplied with pneumatic air 4 Pneumatic and electrical connections including the power configuration plug are correct 5 Adhesive is in the tank and it has had time to melt Error Messages see also Chapter 4 EO1 temperature zone has an open sensor EO2 temperature zone has a shorted sensor Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunction does not move with the ap plicator and hose the problem is probably in the ASU Controller setpoints are 1 Main Power switch OFF 1 Switch ON not adjustable 2 Control PCB inoperative 2 Replace Control PCB 3 Keypad is locked 3 Unlock keypad see Ch 5 Pro gramming All channels display Control PCB inoperative Replace Control PCB error message or wrong actual temperatures System is not working 1 Ribbon connector X6 or 1 Check connection display is OFF harness X2 is discon nected 2 Board fuse F1 or F2 on 2 Insert new fuse if it blows the the PCB is inoperative Control
23. al of the Unit 1 Shut OFF all pressure and power sources 2 Release residual air pressure 3 Remove all residual adhesive 4 Remove all air and adhesive supply hoses and all power supply cables 5 Dismantle all components and sort into mechanical and electrical components 6 Arrange for all components to be recycled ITW Challenger c 2003 Page 4 1 QUATTRO ASU Manual 20 44 Revised 12 03 Chapter 4 TEMPERATURE CONTROLLER SET UP Temperature Control Functions in General The Quattro temperature controller provides accurate temperature control for the tank hoses and ap plicators Setpoints are programmed at the user friendly all icon keypad The controller will display an error message any time an open or shorted sensor condition occurs Defining Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained Alarm Signal The controller provides an alarm signal if any zone has a critical situation This signal is available on a dry contact located at connector X7 on the Control printed circuit board CPU Module The central processing unit CPU of the microprocessor temperature control Temperature Controller The built in control system that controls monitors and displays all system temperature values of the Quattro adhesive application system Control PCB The printed circuit board PCB of the ASU It provides control
24. ant N02937 Thread Sealant 1 4 oz PRR RP ki Ech Ech Ech 111353 Output Manifold Seal Kit 111354 Piston Pump Seal Kit TP 111355 Piston Pump Air Valve Assemby Service Kit TP 112128 Piston Pump Seal Kit 112127 Piston Pump Airmotor Service Kit for Piston Pump PN 110756 manufactured before 7 05 for Piston Pump PN 112129 manufactured after 7 05 Page 9 2 ITW Challenger c 2003 Revised 9 03 QUATTRO ASU Manual 20 44 iro Challenger Quality Hot Melt Parts ITW Challenger c 2003 Page 10 1 QUATTRO ASU Manual 20 44 Revised 1 04 Chapter 10 COMPONENT ILLUSTRATIONS amp BILLS OF MATERIAL WARNING All parts must be periodically inspected and replaced if worn or broken Failure to do this can affect equipment s operation and can result in personal injury Page 10 2 ITW Challenger c 2003 Revised 6 07 QUATTRO ASU Manual 20 44 Bill of Materials for Cabinet Enclosure Item No Part Number Description Qty 1 10547 M4x8mm Zinc Plate Pan Head Screw 2 106130 MA Flat Washer Nylon 1 3 110703 Base ASU 1 4 110723 Filter Access Cover 1 5 110725 Hose End Panel 1 6 110727 Hose Socket Wireway Cover 1 7 110730 Rear Wireway Cover 1 8 110731 Front Wireway Cover 1 9 110733 Tank Cover 1 10 110734 x 8mm Zinc Plate Ph Flat Head tank cover to tank lid hinges 13 11 110735 Tank Top Insulation 1 12 110736 Tank Enclosure Cover 1 13 110737 Tank Lid Hinge 2 14 110738 Tank Lid Assembly 1 15 110752 Re
25. ar Side Panel 1 16 110753 Front Side Panel 1 17 110754 Pump Cover 1 18 110771 M4 x 8mm Black Oxide Ph Pan Head Screw 30 19 107391 x 0 7 nut with ext Lock washer 2 20 107389 Screw Ph Pan Head M4 x 8mm Zinc Plate 5 21 105112 Screw Hex Head M4 x 10mm Black 1 110750 Control Enclosure Assembly 1 22 110751 Control Enclosure 1 23 110746 Control Panel Assembly 1 24 112073 MA x 0 7 x 12mm black Oxide Ph Pan Head Screw 6 25 110747 Switch DPDT Rocker Sealed 1 26 107391 x 0 7 nut with ext lockwasher 1 27 112218 Washer Finish 08 Black Nylon 6 110748 Cable Assembly Keypad Not shown 1 110749 Cable Assembly Power Switch Not Shown 1 110785 Ground Wire Control Enclosure not Shown 1 110774 Ground Wire Control Panel not Shown 1 Page 10 3 Revised 2 05 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Component Illustration Cabinet Enclosure Page 10 4 ITW Challenger c 2003 Revised 2 05 QUATTRO ASU Manual 20 44 Bill of Materials for Tank and Base Assembly 110702 Item No Part Number Description Qty 1 104166 Overtemp Switch Assembly Ir 2 105134 Insulator Spacer 50 3 3 106137 M3 x 0 5 x 8mm Black Oxide SHC Screw 4 4 106235 8 Flat Washer 8 5 107341 M8 x 1 25 x 50mm Black Oxide SHC Screw 5 6 107346 MS Split Lock Washer 3 7 107398 M8 x 1 25 x 35mm Black Oxide Hex Hd Cap Screw 2 8 110382 Tank Assembly 1 9 110703 Base 1 10 110704 Manifold Assembly Output 1 11 110722 Tank Insulation not shown 1 12 L
26. astes it as the setpoint of other temperature zones The paste will apply to only temperature zones that are switched ON Set your Tank setpoint as described earlier in this chapter o o i Push and hold the Tank icon While holding press the 1 Hose icon Release then amp Push and hold the Tank icon again While holding press the 1 Head icon Release The manually programmed setpoint has now been pasted in to all turned on hose and head zones When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Page 5 10 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 iro Challenger Quality Hot Melt Parts ITW Challenger c 2003 Page 6 1 QUATTRO ASU Manual 20 44 Revised 12 03 Chapter 6 PREVENTIVE MAINTENANCE Note Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance procedures must be performed by qualified trained technicians General Cleaning Follow the manufacturer s directions when using industrial cleaners on the enclosure Relieving the System of Adhesive Pressure As a safety precaution relieve pressure in the outlet manifold before changing the filter or before removing any of the hoses or applicators from their manifold port WARNING HIGH PRESSURE During the pressure relief procedure hot adhesive will come out of the manifold Wear safety glasses gloves and protective clothing Stand cl
27. ative replace hose Page 7 8 Revised 12 03 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Display for Hose or 1 No Hose or Head is Head EO1 connected 2 Disconnection between ASU and Hose or be tween Head and Hose 3 Disconnection at X4 or X5 on PCB 4 Hose or Head sensor is inoperative Display for Hose or 1 Hose or Head sensor Head EO2 short circuit 2 Short circuit in plug con nection between ASU and Hose or between Hose and Head 3 Inoperative PCB 1 Connect Hose or Head if need ed If not needed ignore display 2 Check plug connection 3 Make proper connection 4 Check resistance and compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoperative replace hose 1 Check resistance and compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoperative replace hose 2 Make proper connection 3 Replace PCB ITW Challenger c 2003 Page 7 9 QUATTRO ASU Manual 20 44 Revised 12 03 Piston Pump Troubleshooting Guide WARNING HOT SURFACE amp ADHESIVE Some of the procedures in the following Troubleshooting Guide require working near hot adhesive Be sure to wear protective gloves safety glasses and clothing and use proper tools for handling hot melt components For pump disassembly instructions see page 8 5 Pump Will Not Stroke
28. ature Scale ue Change Ready Delay Change Access Code Actual Temperature Display ITW Challenger c 2003 Page 5 5 QUATTRO ASU Manual 20 44 Revised 5 04 Service Functions cont Standby Programming Standby is a temperature value by which all temperature zones will lower when Standby mode is activated For example if your temperature setpoints are all 300 degrees and you program a 100 degree Standby then the Standby temperature of all zones will be 200 degrees Similarly if your temperature zones setpoints vary and you program a 100 degrees Standby each zone s Standby temperature will be 100 degrees lower than its setpoint Press Service icon to enter Service Functions You will see either S 1 standby is On or S 0 standby is Off Press the Tank icon to activate de activate Standby If desired you may set the Standby temperature by scrolling up or down to desired temperature DE When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Note When Standby is active the display will alternate between the ASU s actual temperature and S 1 Page 5 6 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Service Functions cont To Set Tolerance Hi amp Low Temperature Limits The Tolerance high low alarm setpoint is a range and the zone s temperature setpoint be tween which your ASU can safely op
29. ccepts adhesive in all popular forms including pellets slugs and blocks The ASU can accomodate air actuated automatic applicators heads electric applicators hand held applicators and or special applicators Page 2 2 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Specifications Environmental Storape shipping temperature 40 C to 70 C 40 F to 158 F Ambient service temperature 0 C to 50 C 32 F to 122 F INOISE CIBISSIOD ee uve uh ep REA RR yx i Sh x pe da aae a 70 db A at 1 meter Physical Dimensions 7553 9 ed oo cota dai see dimensional layouts on following pages Number or heads loses dux iode Sa ws daa ya uo ata Pan aiti au pad 4 maximum Number of tank temperature zones 1 2 w2vesad es dade ai D TCR Ad RR 1 Number of pumps air motors s oe tU s ve C etn x ab sors ab Mee lU Re dea d 1 Piston PUMP vor Cv a qnit eed opc de do MD eei feed dicun e qd 14 1 tele acus ote hen cda Dass au Ebro da styled durable metal dust and splatter resistant Se EE Electrical 12 pin Mechanical wrench secured fluid fittings 06 37 SAE Tank capacity sea cda a SE Qd e e RUE Lean NOR CARI 8 5 kg 18 7 Ib Tank constr ctlon usce e de cast aluminum cast in heaters TFE coating PaltratiOnz dere aa tank screen manifold filter element Weight empty izle Pea din REESE c i eau CAEDE Gray qu d
30. d with Item 13 1 15 N00179 O ring Pump transfer tube 012 included with Item 13 2 16 111236 Pump Delivery Tube 1 17 N07428 1 25 x 20mm pump delivery tube mouning 1 18 111346 013 Split TFE 1 19 N00180 O ring 013 1 20 111339 Ball SST 312 Dia 1 21 22 11714 Pump Mount Assembly 1 23 111342 Washer Bearing Lock SKFMB6 1 24 111343 Nut Bearing Lock SKF KM6 1 25 N06006 O ring 224 1 26 108700 Lube TFE Krytox GPL206 27 111715 Piston Cap 2 28 111716 Piston Lip Seal 2 29 111717 Piston Spacer 1 30 111743 M6 x 1 x70mm ZN PI 1 31 111345 Washer Split Lock M6 ZN PL 5 32 111718 Cylinder amp Valve Assembly 1 33 N00178 O ring 011 4 34 105104 M6 x 1 x 25mm Hex Head Screw Zn PI 4 35 106324 M6 Flat Washer 4 36 111720 Fitting Connector 6mm Tube Push In x 1 8 NPT Male 1 Page 10 7 Revised 2 05 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 S E dg 07 M ASI Nea Page 10 8 Revised 2 05 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Bill of Materials for Pump Air Manifold Assembly 111830 ltem No a Ut N e Part Number Description 111829 Manifold Pump Air 110907 Valve Solenoid 3 way NC 240VAC 1 4 G 110906 Fitting Hex Nipple 1 4 19 R BSPT Brass 110908 Fitting Breather Vent 1 4 R BSPT 110912 Regulator Mini 1 4 Rc BSPT w Gauge 110910 Fitting Hex Nipple 1 4 19 R X 1 4G x 40mm Brass Gauge 110909 Fitting C
31. dhesive melt rate depends on adhesive used 9 1 kg hr 20 Ib hr AGHESIVO press re a3 ceu M eres ab LE eres Mose ts M sd up to 97 bar 1400 psi maximum Maximum pump speed piston pump 60 pump cycles per minute Adhesive delivery rate openline 0 87 kg min 1 92 Ib min Temperature Controller Controller board e ade 1 board modular construction Display esc NG od hace ila E Ode CUIR Ratte WE ae ewe ts long life bright LED Temperature control zones E to Nee US e ure qe iret ales NEE 9 ar all fuses are size 5mm x 20mm hose applicator head 6 3 amp fast open transformer 1 amp tank 15 amp circuit breaker Other Operator interface digital display with simplified all icon keypad Temperature standby Sauri aaa aa dra ala o CL a sa yes High Tow temperature tolerance a Ou S Sce eben ea a ns s yes REAGY INTETIOCK contact tee ao ER RR Pirati dd oq Br Rd yes EISES oit tus Were LEA as dta usd Met EL EA et pets EA yes CE approval granted 4 4 a sia eek ey SERRA dA ve da acu V a yes Page 2 4 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 20 44 79 38mm 22 75 577 85mm lt 3 125 509mm 13 00 330mm 343 4mm Mounting Hole Dimensions Installation Dimensions ITW Challenger c 2003 Page 3 1 QUATTRO ASU Manual 20 44 Revised 12 03 Cha
32. e to zero 8 Remove the manifold filter and replace it following instructions given in Replacement of the Manifold Filter on page 6 2 Install new o rings and install filter 9 Add new adhesive to the tank and heat to application temperature 10 Slowly turn the air pressure regulator clockwise to increase air pressure 11 Actuate each applicator until all flushing fluid is removed and a steady stream of new adhesive flows 12 Re adjust the pump air pressure for desired flow 13 Re fill the tank and resume production ITW Challenger c 2003 Page 7 1 QUATTRO ASU Manual 20 44 Revised 12 03 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes Note Re read Chapter 1 Safety Precautions before performing any troubleshooting or repair proce dures All troubleshooting or repair must be performed by qualified trained technicians DANGER WARNING HIGH VOLTAGE HOT SURFACE The Quattro ASU uses electrical power that can be life threatening and hot melt adhesives that can cause serious burns Only qualified persons should perform service on the ASU Handling Printed Circuit Boards PCBs DANGER HIGH VOLTAGE Before unplugging connectors from the Control PCB ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the PCB assembly when you are remov ing and replacing connectors CAUTION Printed circuit boards PCB
33. ear of the ASU until all pressure is relieved HOT ADHESIVE Avoid splashing hot adhesive Position a heat resistant container under the manifold drain before proceeding 1 The system should be at operating temperature Turn the pump motor OFF Lock out power 2 Trigger one or more applicators into a heat resistant container until all adhesive flows out 3 Relieve pressure at the manifold drain a Loosen do not try to remove the manifold drain screw with a flat blade screwdriver b Allow surge of pressure and adhesive to escape Filter Bung Manifold Drain Screen Filter Page 6 2 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Replacement of the Manifold Filter Screen During the first weeks of operation the filter screen must be replaced or cleaned weekly to remove foreign and charred material When replacing filter wait until tank is empty or near empty 1 Follow instructions and warnings for Purging the Filter Manifold of Adhesive and Pressure page 6 1 2 Reduce pump air pressure to 0 psi by fully turning air regulator counter clockwise Trigger all applicators 3 Place a heat resistant container beneath the drain valve then turn open valve by turning counter clockwise with a flat blade screwdriver 4 Turn air regulator clockwise slowly until a steady stream of material flows from the valve S Again reduce air pressure to 0 psi by fully turning air regulator counter clockw
34. erate It s lower temperature represents the ASU s ready temperature It s upper value represents the over temperature point Setting the Tolerance range for example if the temperature setpoint is 200 degrees and the Toler ance setpoint is 10 degrees then the high alarm overtemp equals 210 degrees and the low alarm ready temp equals 190 degrees x2 Press the Service icon twice to select the Tolerances of your temperature zones An display of 1 1 indicates the Tolerance function has been selected iz Press the Tank button to display the Tolerance Use the scroll buttons to change the Tolerance range for all zones Note your Tolerance range must be a value between 50 degrees or vi for Fahrenheit 27 degrees for Celsius When Tolerance programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Turning Sequential Startup ON OFF The Sequential Startup feature programs the order in which the temperature zones will come on at startup A Sequential Startup of SS1 On means the tank will begin heating first then when the tank is ready the other zones will begin heating A Sequential Startup of SSO means Sequential Startup is Off and all zones will begin heating immediately x3 Press the Service icon three times to set Sequential Startup The display will flash either SS1 sequential startup is ON or SSO sequential startup is OFF
35. filter may be required to remove moisture and lubrication from the air supply b The air control regulator has a locking cap Lift the cap up then turn clockwise to increase pres sure A counter clockwise turn decreases pressure The recommended pressure is 1 4 to 6 8 bar 20 to 100 psi 5 The adhesive hoses are connected at the hose end panel see illustration on page 3 3 You must make both an electrical and an adhesive flow connection The electrical hose connections are at the four numbered rectangular receptacles on the hose end panel The hose adhesive ports are located below the electrical connections They are numbered 1 4 from right to left There are four ports fittings for the use of up to four hoses When making hose connections follow the number guide label on the ASU above the hose socket ie when using one hose make your hookup to electrical connection 1 and adhesive port 1 When using two heads hoses connect hose head 1 to electrical connection 1 and adhesive port 1 then hookup hose head 2 to electrical connection 2 and adhesive port 2 In a similar manner connect a third and a fourth hose head if desired Route hoses so that there is at least an eight inch radius at any bend Do not hang hoses without prop er support Do not crimp clamp squeeze or tie hoses Refer to the hose and applicator manuals for further details on these items Adding Adhesive WARNING HOT ADHESIVE Do not overfill the mel
36. ftware Revision Q Checksum example gt CS 9FA6 ITW Challenger c 2003 Page 4 3 QUATTRO ASU Manual 20 44 Revised 12 03 System Values That Are Permanently Programmed Minimum setpoint value 40 C 100 F Maximum setpoint value 218 C 425 F System Values as Programmed by the Factory ITW Dynatec can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the temperture con troller at the factory They may be changed by reprogramming through the keypad Temperature scale displayed in degrees Farenheit Applicator head and hose setpoints OFF Tank setpoint 177 C 350 F All zones are switched off except for the tank Access Code not active All programmable time delays set to zero 0 Tolerance range for high amp low temperature limits 27 C 50 F Page 4 4 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Helpful Tips for the User When the ASU is turned on all temperature setpoints and other operating parameters will be exactly where they were when the ASU was turned off When the ASU is turned on all system heaters go on unless they have previously been set below 40 C 100 F When the ASU is turned on the controller checks all RTDs If a zone does not have a valid RID this zone will be switched off ITW Challenger c 2003 Page 5 1 QUATTRO ASU Manual 20 44 Revised 5 04 Chapter 5 PR
37. he application system HIGH VOLTAGE Once the system is up to temperature disconnect and lockout all incoming power before proceeding HIGH PRESSURE BEFORE PERFORMING ANY PUMP REPAIR YOU MUST PURGE ALL ADHESIVE PRESSURE FROM THE ASU Position a heat resistant container under the filter manifold s drain valve Carefully loosen the drain valve s screw and allow adhesive to escape See page 6 1 for detailed instructions Disconnect power valve air line Piston Pump Removal To Access the Pump Remove the pump cover see pg 8 1 Removal from ASU The ASU should be at operating temperature and the adhesive in its molten state see warn ings above 1 Turn OFF air pressure then disconnect the power valve s air line from the solenoid valve Note do not attempt to disconnect the power valve from the pump Locking nut 2 Remove the three mounting bolts that se n id cure the pump assembly to the ASU 3 Lift the pump up and out of the ASU Re assembly notes a If installing a new pump do not tighten the locknut that secures the pump body to the pump mount until after the pump is installed and the three 8mm hex head cap screws are installed and tightened Tighten the locknut with a hammer and punch then bend one tab of the lockwasher into a groove on the lock nut s outer diameter b Torque the 3 pump mounting bolts to 22 6 Nm 200 in Ib at room temperature With pump and tank at 177 C 350 F the maxi cont
38. ilter 3 Use a hook or a pair of pliers to pull the tank filter out 4 Emerse the clogged filter in flushing fluid PN L15653 then use a hot air gun and rags to clean 5 Remove any accumulation of debris from the floor of the tank before re installing tank filter 6 Re insert the filter into the tank 7 Refill the tank and resume production Page 6 4 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 20 44 Flushing the System Contaminated adhesive accumulation of residue and debris or changing the adhesive formulation may require the system to be flushed At least 6 liters 1 5 gallons of flushing fluid is required PN L15653 WARNING HOT ADHESIVE The flushing fluid will splash easily Wear protective clothing gloves and goggles to prevent severe burns 1 Pump out as much of the molten adhesive as possible 2 Purge the manifold following the instructions given in Purging the System of Adhesive and Pressure on page 6 1 3 Disconnect one of the supply hoses from its applicator head Put the hose in a secured position within a container to catch the used flushing fluid 4 Add flushing fluid to the tank and allow approximately fifteen minutes for it to reach tank tem perature Carefully stir the flushing fluid to mix with any remaining adhesive 5 Slowly turn the air pressure regulator clockwise 6 Pump the fluid into the container 7 Turn the regulator counter clockwise to reduce air pressur
39. ise 6 Using a large flat blade screwdriver loosen the filter bung Pull filter assembly out of ASU see illustration on previous page 7 Remove screw from filter assembly and separate filter screen from assembly 8 Clean the filter plug of any char or debris 9 Examine the o rings the filter bung and replace if necessary Apply o ring lubricant to new o ring 10 Install new filter screen reassemble and apply anti seize to the threads of the filter bung 11 Slide assembly back into the ASU Tighten assembly into ASU 12 Turn the drain valve clockwise to close Tighten the assembly Do not over tighten 13 Restore the ASU to operating pump pressure Note if not damaged the filter may be cleaned instead of replaced Disassemble as above and use Flushing Fluid and a non abrasive brush on the filter screen Hose Fittings amp Fasteners Periodically check all hose fittings and screws for tightness ITW Challenger c 2003 Page 6 3 QUATTRO ASU Manual 20 44 Revised 12 03 Primary Tank Filter Inspection amp Cleaning The primary filter is a coarse L shaped screen located in the bottom of the tank It fits around the tank s drain hole and prevents any large debris from entering the pump 1 Pump all adhesive out of the ASU 2 Open the tank lid and inspect the tank filter WARNING HOT SURFACE The ASU will still be hot during this procedure Use insulated gloves and protective clothing when handling the tank f
40. ive setpoints see instructions in Chapter 5 or use the factory settings listed below Allow adequate time approximately 20 30 min for the adhesive to melt and the temperatures of the temperature zones to stabilize Note When the ASU leaves the factory it is programmed with the following factory settings unless special factory settings were requested Tank 177 C 350 F Hose 177 C 350 F Applicator 177 C 350 F Sequential Startup OFF 4 Once the ASU has reached temperature the ASU will automatically begin to pump adhesive 5 Use the air pressure regulator located at the rear of the ASU to regulate pump speed and adhesive output Shut Down Procedures 1 Turn OFF the Main Power Switch Page 3 6 ITW Challenger c 2003 Revised 10 03 QUATTRO ASU Manual 20 44 Storage and Disposal of the Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN L15653 following the instruc tions detailed in chapter 6 of this manual 2 Clean or replace both the applictor filter and the ASU manifold filter screen following instruc tions detailed in chapter 6 3 Shut OFF all pressure and power sources 4 Release residual air pressure 5 Remove all residual adhesive and wipe components clean 6 Remove all air lines and all power supply cables 7 Pack the unit in a corrosion proof manner 8 Store the unit in such a way that it is protected from damage Dispos
41. k area uncluttered and well lit 5 All covers and guards must be in place before operating this equipment For precautions and definitions of safety symbols refer to the Safety Chapter of the service manual iro Challenger Quality Hot Melt Parts SERVICING EQUIPMENT 1 Only trained personnel are to operate and service this equipment Never service or clean equipment while it is in motion Shut off the equipment and lock out all input power and air supply at their sources before attempting any maintenance Follow the maintenance and service instructions in the manual SIGNS 1 Read and obey all of the warning labels signs and caution statements on the equipment Do not remove or deface any of the warning labels signs and caution statements on the equipment Replace any warning labels signs and caution statements which have been removed or defaced Replacements are available ADDITIONAL CONSIDERATIONS 1 To ensure proper operation of the equipment use specified electrical and or air supply sources Do not attempt to alter the design of the equipment unless written approval is received from our factory Keep all manuals readily accessible at all times and refer to it often for the best performance from your equipment ITW Challenger c 2003 Page iii QUATTRO ASU Manual 20 44 Revised 12 03 TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Chapter 2 Description amp
42. must be reset by depressing one or both of the round breakers illustrated below 4 Fuses 1 amp 2 1 amp Fuses 3 6 6 3AF amp fast Connect to RTDs Software 1 amp 2 Tank Firmware Dip switches 384 Hose 1 Chip Future Use 5 amp 6 Head 1 788 Hose 2 Not Connectto Alarm Ready Connect to 9 amp 10 Head 2 Used Keypad Pump Solenoid a eo e N o Connect to Connect to RTDs Z Head Hose 1 1 amp 2 Head 3 384 5 amp 6 Head 4 2 7 amp 8 Hose 4 M Connect to Head Hose 2 Connect to Connect to Head Hose 3 Overtemp Controller Fuses 2 doi Connect to Switch Head Hose 4 Connect to Tank Heater 5 Connect to Main Power Configuration Plug Circuit Breakers 2 Ground Lug to the left Power Supply user installed for Tank Heater of PCB Connect to Overcurrent Main Power Supply we me n supply ITW Challenger c 2003 Page 7 3 QUATTRO ASU Manual 20 44 Revised 12 03 Overtemp Thermostat The overtemp thermostat cuts off power to all temperature zones if the tank temperature exceeds 224 C 435 F The overtemp thermostat must be re set manually by opening the ASUS front panel and pressing the reset button in the center of the overtemp switch note the reset button is protected by a plastic insulator Tank Overcurrent If only the power to the tank zone cuts off the circuit breaker s on the printed circuit board must be reset Eithe
43. n 39 kg 86 Ib Adhesive ty DE ec PEU ei thermoplastic hot melt adhesive Electrical PONWOL vet navi iae sata ad e ado qued eta Va 230 VAC 1 PH 230 VAC 1 PH with neutral 230 VAC 3 PH Delta 230 400 VAC 3 PH Wye astra Spec da d WU alii 1800 watt 240 VAC Power consumption system maximum 30 amp 7200 watts 0240 VAC Maximum current available for each hose amp head combined 6 amp standard 1400 watts 0240 VAC Temp rature Control cora xa or E eu OP QE Rege d CC Y E RC CONT microcontroller Teniperature SeHSOIS ns rex ate DURO ar e od e N1120 Ohm RTD standard Electrical Connectors 42s edu Rai ES ERAN CO oun bad e Rs durable latching connectors ITW Challenger c 2003 Page 2 3 QUATTRO ASU Manual 20 44 Revised 12 07 Pressurized Air Alt pressure supply TNS aa A AGE RR 1 4 to 6 8 bar 20 to 100 psig Air consumption at 60 pump cycles per minute 90 normal liters minute 3 2 SCFM at 100 psig Performance Adhesive temperature control range 40 C to 218 C 100 F to 425 F Adhesive temperature control 1 C x 1 F Overstemperature cutoff for tank sein s ies RO ere ec AGE ER ees 232 C 450 F Adhesive VISCOSIEY Hah eC AC ce ee bia 500 to 30 000 centipoise Warm up time full tank EE da BYR V SS approximately 0 5 hour A
44. nd the main On Off switch 1 Remove the six screws around the face panel s outside edge 2 Pull face plate straight out being careful of the wires which run from the keypad to the printed circuit board wires which run from the main switch to the PCB and the ground wire To Access Electrical Parts Remove the front panel see pg 8 1 to access the following Thermostat Replacement 1 Pull out the two thermostat wires 2 Remove the old thermostat 3 Insert the two wires into the new thermostat RTD Sensor Replacement 1 Remove two screws to remove the plate 2 Pull the sensor out of its groove 3 Unplug the sensor wires from X4 or X5 on the control PCB see PCB illustration in Chapter 7 4 Connect new sensor wires to PCB insert new sensor in groove in ASU 5 Re install plate with two screws Note on the Cast in Heaters The cast in heaters installed in the base of the tank are not replaceable and will last the life of the ASU Overtemp Thermostat Thermostat Insulator y N NI ji i N N N SR e i d SP Control PCB RTD Sensor Sensor Cover ITW Challenger c 2003 Page 8 3 QUATTRO ASU Manual 20 44 Revised 11 03 To Access the Control Panel Components See illustrations on pg 8 1 To remove the following components remove the face plate of the control panel enclosure only Printed Circuit Board Fuse Replacement Note Use replacement fuses of the same type If in doubt obtain the correct fuses from ITW
45. nto pump thermostat to make sure there has been enough time for the adhesive to rise to the hopper setpoint temperature 3 Verify that adhesive selection and 3 Adhesive used is too tank setpoint temperature are viscous compatible and that both are appropriate for your application 4 Prime the pump by first lowering the 4 Pump needs priming air pressure then letting the pump cycle very slowly until primed 5 Inspect system for open filter drain 5 Large opening in system disconnected or ruptured hose or downstream of pump disconnected head Repair as necessary Pump Quick Strokes Inlet check valve blocked Clean inlet check valve on the Forward Stroke open Only shaft moving into pump body Pump Motion on the Outlet check valve is Clean outlet check valve Forward Stroke shaft blocked closed moving into pump is very slow or stopped Pump Quick Strokes on Outlet check valve is Clean outlet check valve the Reverse Stroke blocked open shaft moving out of pump ITW Challenger c 2003 Page 7 11 QUATTRO ASU Manual 20 44 Revised 12 03 Low or Inconsistent 1 Output filter clogged 1 Remove and inspect filter screen Adhesive Output Clean or replace as necessary See Chapter 6 Preventive Maintenance for procedure 2 Adhesive used is too 2 Verify that system components are VISCOUS at proper temperature and that selected adhesive is correct for your application 3 Blocked hose 3 Inspect hose f
46. ocedure Use insulated gloves and protective clothing when handling components As described on page 8 5 unwire the pump solenoid and remove the manifold and pump Remove the machine s front and rear panels Remove the tank enclosure cover Remove the white insulation Do not remove the blue insulation Gently pry off the old tank seal from around the tank opening Clean away any debris that may have accumulated under the old lid seal Fit the new lid seal around the tank opening In reverse order as described above replace insulation panels and top pump and manifold Re wire the pump solenoid tA RU D To Remove the Tank Pressure Relief see location on the illustration on page 10 10 The pressure relief is pre set at the factory and is not adjustable 1 Pump out as much of the molten adhesive as possible See hot surface warning above 2 Open the tank lid Use a socket wrench to loosen and remove the pressure relief valve by turn ing it counter clockwise ITW Challenger c 2003 Page 8 5 QUATTRO ASU Manual 20 44 Revised 1 05 PUMP DISASSEMBLY WARNINGS HOT SURFACE If the pump is not operable but the heating system will function raise the temperature of the application system to the operating temperature to aid in the pump disassembly process Otherwise a controlled heating method is recommended to melt hardened hot melt adhesive Never use a torch or an open flame on any of the components of t
47. oes Safe Installation and Operation To avoid possible failure of hoses make sure all hoses are routed to avoid kinking tight radius turns 8 or less and abrasive contact Hot melt hoses should not have prolonged contact with heat absorbing surfaces such as cold floors or metal troughs These heat absorbing surfaces can alter adhesive flow and cause incorrect calibration Hoses should never be covered with materials that prevent heat dissipation such as insulation or sheathing Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections Do not use adhesive that is dirty or that may be chemically contaminated Doing so can cause system clogging and pump damage When adhesive hand held applicators or other movable applicators are used never point them at yourself or at any other person Never leave a hand held applicator s trigger unlocked when not actually in use Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until the adhesive s temperature is within the operating range Severe damage could result to internal parts and seals Treatment for Burns From Hot Melt Adhesives Burns caused by hot melt adhesi
48. ogrammer cannot program a temperature setpoint higher than the setpoint limitation Standby Setback D uring breaks or delays in production itis possible to reduce the temperature of all zones by a specified amount through programming of a standby T he programmed standby also referred to as setback is the difference in temperature by which all zones will reduce below their setpoints when standby is activated Standby is always OFF when the A SU is turned ON In standby mode the ready signal is OFF and the pump will stop Error Indication Messages A controller display of EO 1 indiates that the selected zone ie a hose applicator or the tank has an open sensor A display of EO 2 indicates a shorted sensor If either alarm occurs first verify that the following three connections are made correctly 1 The A SU to hose connection s located at the back of the A SU 2 The hose to applicator connection s 3 The RTD Input connections X 4 amp X 5 located on the Control Printed Circuit B oard If the problem is not with a connection check the sensor and replace if necessary Firmware Chip and Checksum The firmware chip is on the Control Printed Circuit Board see Ch 7 Inscribed on the controller s chip is information that is required if your controller needs service including the controller s check sum and software revision Chip example lt Firmware chip mW Challenger uattro ASU VX XX a So
49. onnector 1 4 R x 8mm Push In 109472 Fitting Cable Clamp PG09 x 24 DIA 111135 Cable Assembly Solenoid Valve 106421 M4 x 30mm SHC Screw air manifold mounting screws Qty Lm e e e e e e Lm e ITW Challenger c 2003 Page 10 9 QUATTRO ASU Manual 20 44 Revised 2 05 Page 10 10 ITW Challenger c 2003 Revised 2 05 QUATTRO ASU Manual 20 44 Assembled View Bill of Materials for Manifold Output Assembly 110704 Item No Part Number Description Qty 108350 M4x07x8mmSHCScew 1 2 110705 Manifold Output 1 3 110706 Filter Assembly 1 4 CA1007 Valve Assembly Manifold Drain 1 5 110717 Ring Backup 010 Split TFE 1 6 N00177 O ring 010 75 Duro Viton 1 7 CA1008 Pressure Relief Valve Assembly 1 8 N00360 O ring 906 Duro Viton 7 9 N01831 Fitting Adapter 06 37 x 06 St Thd ORS 4 10 N02040 Fitting Plug Hex Socket 06 St Thd ORS 3 11 N08024 Fitting Cap 06 37 SAE 4 12 001V078 Lube TFE Krytox GPL206 not shown 13 N02937 Sealant Thread W TFE not shown ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Bill of Materials for Filter Assembly 110706 ltem No ta P AHA ra Part Number Description 110707 Bung Filter N00201 O ring 116 75 Duro Viton N00186 O ring 019 75 Duro Viton CF1001 Support Filter 5 718 Lg CF1002 Screen Filter 006 Mesh 5 39 LG CF1003 5 x 160mm Slotted Pan Head Screw Zinc Plated 107324 Anti Seize Compound not shown
50. or kinks internal plugs of debris or char degraded adhesive Clean or replace hoses as required 4 Blocked applicator heads 4 Inspect heads for plugged nozzles proper air valve operation or plugged filters Clean or repair heads as needed 5 Pressure relief valve in 5 Verify that air supplied to pump is output block is opening less than 6 8 bar 100 PSIG If relief valve is opening with air pres sure less than 6 8 bar 100 PSIG remove pump and replace pressure relief valve Adhesive Leak at 1 Manifold drain valve not 1 Close and tighten manifold drain valve Manifold Drain tightly closed 2 Manifold drain valve 2 Remove drain valve assembly from blocked open output manifold clean and re install Page 7 12 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 iro Challenger Quality Hot Melt Parts ITW Challenger c 2003 Page 8 1 QUATTRO ASU Manual 20 44 Revised 11 03 Chapter 8 DISASSEMBLY amp RE ASSEMBLY PROCEDURES Disassembly Procedures Note Re read Chapter 1 Safety Precautions before performing any disassembly procedures All dissassembly procedures must be performed by qualified trained technicians When needed cross reference the exploded view component drawings in Chapter 10 with each pro cedure in addition to the instructions and illustrations given in this chapter Read the Cautions on page 8 6 before re assembling the ASU Removing Access Panels and Covers
51. pter 3 INSTALLATION amp START UP Mounting the QUATTRO ASU The Quattro adhesive supply unit ASU can be mounted on most flat surfaces on either an open or a solid frame as shown below An open frame is preferred for easy service The main electrical power comes in at the front left corner of the base of the unit and connects behind the keypad Ac cess to the underside of the ASU is not a necessary consideration in mounting the unit For installation dimensions see illustration on page 2 4 Lifting the ASU WARNING bg The unit must be lifted by two persons using proper lifting technique one person at either end Securely hold it under its base plate No belts or hooks should be used Never allow anyone to stand on the ASU Pump Cover Hose Connections not seen in this view E Input Power Base Plate W Zali TON ug Drain Valve amp Filter Screen Main ON OFF Power Switch Controller Keypad Components of the Quattro ASU Page 3 2 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 20 44 Installation NOTE Re read Chapter 1 Safety Precautions before performing any installation procedures All installation procedures must be performed by qualified trained technicians After the Quattro ASU has been properly mounted the following general sequence should be fol lowed for installation 1 Make sure that incoming line power to the ASU and the unit s main power
52. r remove the control enclosure or the control panel face plate locate the circuit breakers see illustration on previous page identify the one which has popped up and push it down back into place Ready Contact to Parent Machine A ready contact from the controller to the parent machine can enable the parent machine if it is con nected on the control printed circuit board Temperature Zones Not Heating If two temperature zones simultaneously cool down the problem could be a bad fuse on the main PCB as these fuses relate to hose head combintions If only one temperature zone cools the prob lem could be a bad heater or a PCB problem such as a PCB connection Overtemp Thermostat Thermostat LS Insulator N N N N Sm 57 LZ RTD Sensor Sensor Cover Circuit breakers on Printed Circuit Board Location of Printed Circuit Board and Circuit Breakers Overtemp Thermostat and RTD Sensor Page 7 4 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 20 44 Resistance Tables Temperature Resistance in Ohms Hose Length Resistance in Ohms Meters Feet Nominal 240V Nominal Hose Heater Resistance for Challenger Hoses with Ni120 Sensor Resistance in Ohms Nominal 240V Temperature Sensor Resistance Nominal Head Heater Resistance for Ni120 RTD Nominal Resistance in Voltage Ohms 33 4 28 9 Tank Heater Resistance Note Resistance is measured at ambient temperature 20 C 68 F IT
53. rnationally operator friendly The Quattro ASU uses a microprocessor temperature control to closely control the temperature of hot melt adhesive for a tank and up to four hoses and four heads Temperature setpoints are opera tor selected for up to nine zones and the system automatically provides warnings for operator errors and system malfunctions The system provides accurate proportionate temperature control for the tank hoses and applicators Sequential heating delays may be programmed for turn on of the hoses and heads A standby tem perature may be programmed so that the temperature zones can be maintained at a lower tempera ture when the ASU is not in active use enabling rapid return to normal operation With these flexible temperature programming features the Quattro system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time The temperature control can interlock the parent machine with preselected adhesive temperatures so that production automatically begins when adhesive temperatures are correct for the application All system temperature values can easily and quickly be programmed The ASU uses an extremely dependable constant pressure piston pump The air operated pump in sures a high pressure adhesive output from a low pressure compressed air input Quattro s teflon coated tank a
54. s Use of PUR Polyurethane Adhesives PUR adhesives emit fumes MDI and TDI that can be dangerous to anyone exposed to them These fumes cannot be detected by the sense of smell ITW Dynatec strongly recommends that an exhaust hood or system be installed over any PUR system Consult with your adhesive manufacturer for specifics about required ventilation CAUTION Because of the nature of PUR A N adhesives to strongly bond in the presence of moisture care must be taken to prevent them from curing inside Dynatec equipment If PUR adhesive solidifies in a unit the unit must be replaced Always purge old PUR adhesive from the system per your adhesive manufacturer s instructions and time table ALLOWING PUR ADHESIVE TO CURE IN A UNIT VOIDS ITW DYNATEC S WARRANTY In This Manual WARNINGS and CAUTIONS are found throughout this manual WARNINGS mean that failure to observe the specific instructions may cause injury to personnel CAUTIONS mean that failure to observe the specific instructions may damage the equipment Page 1 4 ITW Challenger 2003 Revised 1 07 ALL MODELS iro Challenger Quality Hot Melt Parts ITW Challenger c 2003 Page 2 1 QUATTRO ASU Manual 20 44 Revised 12 03 Chapter 2 DESCRIPTION AND SPECIFICATIONS Description The ITW Challenger Quattro adhesive supply unit ASU is a computer controlled hot melt supply unit designed on metric standards Its all icon control panel is inte
55. switch are turned OFF DANGER HIGH VOLTAGE A lockable power disconnect switch with overload protection must be provided by the customer as part of the ASU installation The disconnect must isolate the ASU from its power source DANGER HIGH VOLTAGE Disconnect and lockout input power to the application system before start ing any installation procedures Make sure there is no electrical power on the leads you will be connecting 2 Your power supply should be rated for 30 Amp service and should include an earth ground con ductor CAUTION Grounding conductors never carry electrical current The use of a neutral conducting wire as earth ground is incorrect and may cause damage to the controller 3 Make two connections to the printed circuit board Remove control panel enclosure by loosening the six screws in notched positions on the enclosure then lifting up the enclosure a Select proper power configuration plug for your system four plugs are shipped with the unit CAUTION Using the incorrect power configuration plug d SL 7j rj may cause serious damage to the unit ch 4 for 230 VAC 1PN system use PN 110763 white plug with light blue wire for 230 VAC 1PH with neutral use PN 110764 white plug with black wire for 230 VAC 3PH Delta use PN 110765 white plug with violet wire for 230 400 VAC 3PH Wye use PN 110766 white plug with yellow wire b Insert proper power configuration plug into socket J1 at bo
56. t tank since adhesive generally expands as it melts and a full tank may overflow CAUTION Using adhesive with viscosity over 50 000 centipoise may cause the pump to stall The adhesive level should be maintained at 13mm to 50mm 1 2 to 2 from the top of the tank Where applications demand a high output volume of adhesive add small amounts of adhesive fre quently Adding large amounts of adhesive to an almost empty tank will lower the temperature of the adhesive in the tank and may cause the ASU to fall below its READY setpoint Changing the Adhesive Formula If a different adhesive formulation from the one being currently used is needed the system will have to be flushed if the two formulations are incompatible See page 6 4 of this manual for the proper flushing procedure When in doubt about adhesive compatibility flush your system ITW Challenger c 2003 Page 3 5 QUATTRO ASU Manual 20 44 Revised 12 03 Typical Start Up and Shut Down of the Application System Start Up Procedures 1 Fill the ASU s tank with clean hot melt adhesive as described on page 3 4 Close the tank lid immediately to prevent contaminants from falling in Cover your bulk supply of adhesive to pre vent contaminants also 2 At the control panel turn ON the Main Power Switch The controller will perform its initial calibration cycle The display will read CAL All of the nine temperature zones LEDs will flash as a lamp test 3 Program your adhes
57. tive unauthorized programming is not possible even after turning the ASU OFF then back ON again 2 Once the keypad lock is unlocked programming is possible until the ASU is turned OFF then back ON or the keypad is locked again 3 If the keypad must be unlocked permanently the access code must must be de activated in the Ser vice Functions Page 5 4 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Service Functions After the basic programming of Temperature Setpoints is complete the programmer proceeds to programming of the Service Functions if desired The Service Functions are a continuous loop of programming steps functions which the pro grammer moves through by pressing the Service key These steps are described in this section of the chapter The Service Functions loop and basic programming is diagrammed below There are three ways to exit the Service Functions loop 1 Just wait approx 10 seconds and the controller will automatically return to the actual temper atures display 2 Press the Service key until you are back to the actual temperatures display or 3 Press any Hose or Head key and you will return to the actual temperatures screen Diagram of the Service Functions Loop Actual Temperature Display Activate De activate Temperature Setback Change Setback Temperature Value _ Change Hu Lo Tolerance Value Activate De activate Sequential Startup Select Temper
58. ttom center of control printed circuit board located within the control enclosure see illustration of PCB in Chapter 7 for location c Wire main power into Line Input Power Plug and the ground lug 1PH 230VAC shown here to the left of board Main power connections amp the ground lug are at the bottom left of the PCB X1 Conduit fitting or cable grip not supplied cont LINE INPUT POWER PLUG WIRING FOR EACH TYPE POWER SUPPLY PE Ome PE 1PH 230VAC 1PH N 230VAC 230VAC DELTA 3PH 230 400VAC WYE Page 3 3 Revised 12 03 ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Pump Cover Air Line To Pump s Power Valve Air Control Assembly regulator and gauge Adapter fitting for 1 4 NPT Customer Connection Air Line from Air Manifold Customer Supplied Factory Air In 100 PSI 7 Bar max Adhesive Adhesive Hose 4 Hose Head Adhesive Hose at Electrical Connector Port Fittings Adhesive numbered right to left Connect SR 1 Filter 4 Hose Head Electrical Manifold Connections amp Drain numbered right to left Hose End Panel Hose Head amp Air Connections Page 3 4 ITW Challenger c 2003 Revised 1 05 QUATTRO ASU Manual 20 44 4 a Connect a compressed air supply 100 psi 7 bar max to the air regulator using a 1 4 BSPT male connector filling CAUTION The compressed air supply must be clean and dry NEVER use lubricated oil Use of an air line
59. ulic pressure e g trigger the heads hand held applicators and or other application devices into a waste container before opening any hydraulic fittings or connections IMPORTANT NOTE Even when a system s pressure gauge reads 0 psig residual pressure and trapped air can remain within it causing hot adhesive and pressure to escape without warning when a filter cap or a hose or hydraulic connection is loosened or removed For this reason always wear eye protection and protective clothing Protective Covers WARNING DO NOT OPERATE WITHOUT GUARDS IN PLACE Keep all guards in place To avoid personal injury do not operate the application system without all covers panels and safety guards properly installed Page 1 2 Revised 1 07 Eye Protection amp Protective Clothing WARNING EYE PROTECTION REQUIRED q PROTECTIVE CLOTHING REQUIRED It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment ITW Challenger 2003 ALL MODELS Wear safety glasses with side shields which conform to ANSI Z87 1 or EN166 Failure to wear safety glasses could result in severe eye injury It is important to protect yourself from potential burns when working around hot melt adhesive equipment Wear protective gloves and long sleeved protective clothing to prevent burns that could result from contact with hot material or hot components Always wear steel reinforced safety sh
60. ure Page 5 8 ITW Challenger c 2003 Revised 12 03 QUATTRO ASU Manual 20 44 Service Functions cont To Change Access Code De activate Keypad Locking x 6 To change the Access Code press the Service icon six times You will see C 1 to indicate you are in Access Code programming mode Press the Tank icon to see the programmed Access Code For example 999 numeric value D To change the Access Code scroll down to the desired no Access Code Access code is de activated no Keypad Locking 1 999 possible Access Code values When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature ITW Challenger c 2003 QUATTRO ASU Manual 20 44 Controller Features System Ready Indicator Light When not in programming mode a flashing temperature scale light LED indicates that the ASU is not Ready for production This LED will cease to flash when all temperature zones are within the pro grammed temperature tolerance window Error Indication Messages EO1 the temperature sensor is open no sensor attached or has high resistance EO2 the temperature sensor is shorted or has low resistance To Copy and Paste Setpoints Page 5 9 Revised 5 04 FO The Copy Paste feature of the controller copies the tank setpoint and p
61. ve must be treated at a burn center Care should be used when working with hot melt adhesives in the molten state Because they rapidly solidify they present a unique hazard Even when first solidified they are still hot and can cause severe burns When working near a hot melt application system always wear safety gloves safety glasses and long sleeved protective clothing Always have first aid information and supplies available Call a physician and or an emergency medical technician immediately ITW Challenger c 2003 ALL MODELS Service Refer all servicing to qualified personnel only Page 1 3 Revised 1 07 Explosion Fire Hazard Never operate this unit in an explosive environment Use cleaning compounds recommended by ITW Challenger or your adhesive supplier only Flash points of cleaning compounds vary according to their com position so consult with your supplier to determine the maximum heating temperatures and safety precautions Lockout Tagout Follow OSHA 1910 147 Lockout Tagout Regulation for equipment s lockout procedures and other impor tant lockout tagout guidelines Be familiar with all lockout sources on the equipment Even after the equipment has been locked out there may be stored energy in the application system partic ularly in the capacitors within the panel box To ensure that all stored energy is relieved wait at least one min ute before servicing electrical capacitor
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