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dynamelt m series adhesive supply unit operations and service

1. BACKBONE SIZE TABLE WIRE MUST o RUN CONTINUOUS 8 pe EC 281A 4 SND o e 1T SIDE PLATE LEFT CRN YEL 14AWG zs GND BOTTOM PLATE GRN YEL N zd V 2 6 SCREW STUD amp ig SCREW z STUD D 5 A 24 E 4122 4 M8 zziz SIDE PLATE RIGHT GRN YEL 14AWG MOUNTING PLATE ORN YEL 6AWG c 92 CREW SCREW 2 glo olo z 2A a SCREW gt w iw Z 4 _ E Z TOP PLATE GRN YEL M35 14AWG M8 CABINET GRN YEL __ 6AWG 3 M70 140 amp 210 12AWG AM Sea SCREW SCREW 6 DOOR LEFT GRN YEL 12AWG N SCREW G vo DOOR RIGHT GRN YEL 12AWG E SCREW o 8 VI E MS DYNACONTROL POWER BOARDGRN YEL 14AWG ES E E gt 4 HOPPER COLLAR GRN YEL 14AWG lt gt 5 S v DYNACONTROL MTR IF BD _GRN YEL 14AWG 2 VAL e SCREW S 4 HOPPER COLLAR GRN YEL 14AWG 5 DYNACONIROL MIR IF BD GRN YEL 14AWG f I 2 0 m bs SCREW g ee 4 8 JUNCTION BOX COVER GRN YEL S 5 Tw HEATSINK 1 GRN YEL 14AWG S5 e S AM m S SCREW 9 2x JUNCTION BOX COVER
2. 8 1 To 00015 8 1 To Openttie Junction BOX a pet t d acte e CA 8 1 Sensor or Thermostat Replacement 8 2 To Remove the Manifold 8 2 Heater Replacement oso acne teas Raed bea edu aod hehe heals Med ol tna Re dots 8 2 To Remove the Rear Cover 8 3 To Access the RTD Sensor the Optional Drop in Grid 8 3 To Access the Electrical Components Inside Panel Box 8 3 Fuse Replacement xoc gal bete ede o eben rtr c Rr er rk 8 3 Printed Circuit Board Replacement 8 3 Optional M emory Card Reader Battery Replacement 8 3 To Access Pump or Motor 8 4 Motor RemoVal a 2e ded Boal nace yas aed Gag oth Rane vedi srl a ofan anc rap teas 8 4 Optional DC Motor Brush Replacement 8 4 Pump Removal doi ce ed atre a a mon cd Ra t atre 8 5 Pump Seal O ring Replacement
3. RATER AUOD E D RO E AT UG 5 16 High Low Temperature Deviation 5 17 Standby Temperatures cat oe esae oie RR ponen Du cota e tutes 5 17 Standby SleepS etU cose sed her sequentem sete qead edo qe Deko ord ees 5 17 Setpoint Limitatlon cepe prete be e pe ure det eta 5 17 Temperature Offset ect velista chs ae nee ely NER EGG eis 5 18 Sequential a ade d Ae d dowd nies ed 5 18 Temperature Scale oci tek vate rA qal NE EAE bes 5 18 Change Security Lock x t dd Een ero Rer t 5 18 Service Page 2 ver wey ree nep ha uet Dedi ep n De ed 5 19 Customer Zone Names iehi aenea a nac av gates cta et d ata he et 5 19 Power On Configuration acne eae eee ae at an ee Zt 5 19 Factory Defaults Paste Cope adams 5 20 Keypad Locking eR ee ein OR DORT na Ru Ag RC 5 20 PC Elke cu Ite pur Veg pu bereiten eun et e bes dd due betas 5 20 Language s ch ee RE RC eae CR a C CRT HR DR DR A oa 5 20 EC D CODtrast ae sed be AUT ei haies aad ae RR Ged i he 5 20 System Logbook erre bue porre teak bee ere betae e d Ra 5 20 Change Security Lock ir vel bea Rig eU UCM EX RR ER 5 20 iTV Dynatec c 2001 Table of Contents Page v D
4. Remove the external pump seal from its groove on the back of the pump adapter plate this is the seal located between the adapter plate and the hopper Install the new seal Re Assembly Procedures Unless noted the M Series ASU s re assembly is simply the reverse sequence of the disassembly procedures H owever the following precautions should be followed whenever they apply for proper re assembly WARNING HOT SURFACE It order to protect personnel and equipment it is important to replace all insulation whenever it is removed from the ASU CAUTION In general all O RINGS AND SEALS should be replaced whenever hot melt equipment is re assembled All new o rings should be lubricated with o ring lube PN 07588 CAUTION TAPERED PIPE THREADS are found on air line fittings used with the pump air supply if applicable and on the outlet filter manifold Apply thread sealant PN N02892 whenever tapered pipe threaded parts are re assembled CAUTION SOME FITTINGS used for adhesive on the ASU have straight threads and o ring seals Use of thread sealant is not necessary with these parts but the o ring seals should be clean and lubricated Tighten straight threaded parts and fittings until their shoulders are firmly seated against the pump body or other surface Excessive torque may damage straight threaded parts and the use of power wrenches is not recommended CAUTION HOT MELT RESIDUE should be cleaned from parts befo
5. 3 11 Calibration of the Optional Voltage Tachometer 3 12 Installation of the Optional Tach Generator or DC Tracking Signal 3 13 Calibration of the Optional Tach Generator or DC Tracking Signal 3 14 evel Controls 12 2 ene Sep tet psu Teen Aas de eiue peg ed Epis 3 15 Field Installation of the Optional Memory Card Reader 3 16 Typical Start Up and Shut Down Procedures 3 18 Storage and Disposal of the Application System 3 19 Chapter 4 DynaControl Controller Set Up Temperature Control Functions in General 4 1 Defining DynaControl Temperature Control 4 1 Error Indicatioriand usc era ru RH AR DER OC CR PAN Re DN a te 4 4 Optional System Status Lights ss oce tem ex er sed aed ne 4 6 Settings for a Typical 4 6 System Values that are Factory Programmed not customer accessible 4 7 Customer Programmable Values Preset at the 4 7 Page iv Table of Contents iTWDynatec 2001 Revised 11 01 DYNAMELT M ASU Manual 20 37 Default Settings of the D
6. 8 5 Re assembly Procedures amp lt 8 5 Chapter 9 Available Options amp Accessories Pressure Gauge E GU RUE EROR RUE PCR E D RO RC UR 9 1 Pre PSI and Post PSI Transducers 9 1 Drop GdS is utet aang preesse PRI 9 1 High Temperature Heater Groups 9 1 Filter Options amp Accessories 9 1 Level Sade hed eh aad has Rade Mee ead Lian 9 1 Pump Options amp 5 9 2 Gear Motor Option S nirna oera a Co egre Peau e ttc OU a ia e ends 9 2 Return Re circulating Hoses 2 2 22 9 3 luteh PEL 9 3 Dual Hopper s ee rt a ide de td 9 3 Higl FIow ASUS ico rot pep mec aed ote Tope eds 9 3 DynaGontrol O ptlons is op Rer tact te ta RO e tU po cee Eau drin a e 9 3 Recommended Service Parts 15 4 9 5 Chapter 10 Component Illustrations amp Bills of Material Chapter dua xo ec p ea aes 10 1
7. Reduced pump efficiency 1 Worn gear s 2 Worn bearings 3 Process conditions changed Remedy Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Increase inlet pressure Replace lip seal Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Consult factory for clearance recommended on new process conditions A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces Appendix 25 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec 2000 6v991 A3H 39 X MV3HM1S SONI 3dAL AVAAAY S3LON 335 AlIOVdvO U3OMON LuYd 931VNAQ AMLI HOLA H3SY NMOHS AJUDO 8672 NOLL 412930 SW3iI SudHSVM Xy ONY Se x ONh GLE SWALI W O NO Q3On NI 51706 ONILNNOW 1 3LDN 310H 1796 ONILNNOW 99v 2 1809 L37NI 197 330H ONTIN vIQ 909 180d L371n0 RRR NI OGG 2 MN 7 227222204 462709 UYd AAA A iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 26 Revised 10 00 REVIS ONS DESCRIPTIONS SECTION C C 010101010101010 TAS NY 4 r al 553 epa ee i D REF 084 E432 1 168 LL DELIVERY YN TUO cC REv PoRT PD A LASER ETCH L 1 13 ITW DYNATEC ANG C
8. not available 38 4 not available 28 8 not available not available not available not available Nominal Filter Manifold Heater optional Resistance in Ohms Page 7 14 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Error Indication Alarm Troubleshooting Guide The operation of error indication alarms is described in Chapter 4 When checking for correct equipment operation in the following guide be aware that all heaters will go off immediately after an error indication alarm occurs if the operator takes no action With the exception of the fuses there are no user replaceable parts on the printed circuit boards If there is a non fuse failure on any of the PCBs the PCB must be replaced DANGER HIGH VOLTAGE Some of the procedures in the following Troubleshooting Guide require poten tially dangerous electricity to be present Only qualified service personnel should perform these procedures Hopper tank 1 Setpoints have been 1 setpoints allowing a Overtemp programmed without larger deviation between the high enough deviation and low limits 2 Hopper sensor 2 Replace hopper sensor if resistance inoperative does not comply with the resistance table in this chapter 3 Hopper control solid state 3 a Verify that the relay is not shorted by relay inoperative removing all of its output wires and verifying that resistance is greater than zero b Ve
9. 4 f necessary select Configuration and change baudrate then re enter Function 5 5 A ddress setting is not used 6 Start Capture Textfile at terminal program 7 Press SAVE F2 8 Stop and close file on terminal program 9 Press RETURN to exit service mode Line Commands page 1 of 2 P remelt No Setpoint Tolerance Offset On Off P rogmelt No Setpoint Tolerance Offset On Off Filterblock No Setpoint Tolerance Offset On Off Hose No Setpoint Tolerance Offset On Off Head No Setpoint Tolerance Offset On Off Aux Zone No Setpoint Tolerance Offset On Off 1 12 50 450 5 50 0 50 ON OFF Pressure No Min P ressure Max Pressure 1 12 0 1500 0 1500 Pump No Mode Manual Automatic Min Automatic Max 1 6 Manu Auto S top 0 100 096 0 100 096 0 100 0 Text No Customer Name Temp 1 48 20 characters Pumps 49 54 Press 55 66 Line Commands page 2 of 2 S ystem 1 Setback Premelt Setback Progmelt Setback Filterblock Setback Hose Setback Head Setback Aux Zone S ystem 2 Setback General Setpoint Heat up Sequence Elect Head Hold C F Spare Limitation 0 1 2 Temp 0 F 1 S ystem 3 Power On Heater Power On Motor Keypad Lock Keypad Lock Mo Configuration Lock Configuration Lock 0 1 1 Start 0 1 1 Start Temp Settings O torSettings O Page 1
10. 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 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 hydraulic pressure e g trigger the heads hand held applicators and or other application devices into a waste container before opening any hydraulic fittings or connections P
11. 4 Entrained particle 5 Possible internal damages Excessive seal 1 Worn seal plate assembly leakage 2 Insufficient inlet pressure 3 Worn lip seal Reduced pump efficiency 1 Worn gear s 2 Worn bearings 3 Process conditions changed Appendix 9 Revised 3 01 Remedy Check temperature sensor and control loop for proper setting operation Allow sufficient heat up time Verify drive is powered Check to assure all alarm circuits are clear Check drive motor current and speed settings Check all drive couplings Check process conditions for proper melt tempera ture pressures viscosities and materials Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Increase inlet pressure Replace lip seal Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Consult factory for clearance recommended on new process conditions A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 10 Revised 10 00 706 5 XC DG S CoXt9036 29 250 OUTLET PORT 2509 OUTLET PORT 1 031 4062 MOUNTING SCREW HOLE 2 HOLES BOLT HOLES 813 INLET PORT NOTES sETCH PART NUMBER amp DISPLACEMENT AT LOCATION SHOWN WITH MINIMUM 125 HIGH CHARCTERS UDE FOUR AP SCREWS
12. BENEFITS High Accuracy Stable repeatable flows are assured even under varying conditions of pressure viscosity and temperature High Temperature C apability Operating temperatures to 450 degrees F 232 degrees C Maximum L ife Only three moving parts components are through hardened tool and die steels to 56 HRc or better The bodies are cast nodular iron Replaceable sleeve bearings for low cost rebuilds High Volumetric Efficiency M aximum efficiency is achieved with optimum operating clearances and assured under pressure by built in alignment pins Minimum Pulsation Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance Precision Construction Ground and lapped components for close control of operating clearances iTV Dynatec 2000 Appendix 3 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating Speed 3 120 rpm depending upon application conditions and fluid viscosity Temperature To 450 degrees F 232 degrees C OPERATION All Dynatec Zenith High Accuracy Pumps are rear ported Fluid enters the pump through a port drilled into the rear side plate the side opposite the drive shaft T he fluid fills the ex posed gear tooth volumes and is transported around the outer diameter of the gear pocket As the gears mesh together the fluid is displaced in a very prec
13. Filter S hutoff Pump Enable Heater Thermostat P ort Terminals Side View Hopper Sensor Port J unction Box Sensor or Thermostat Replacement Remove the junction box cover Over Temperature Thermostat Replacement Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper b Pump Enable Thermostat Replacement Disconnect two wires from the terminal strip and slide the thermostat out C RTD Sensor Replacement Disconnect two wires from the terminal strip and slide the sensor out To Remove the Manifold Cover Unscrew its captive screw and slide cover off Cover allows access to the hose connections on the filter manifold outlet filters heaters and the pressure relief Heater Replacement Cartridge heaters are located underneath the filter manifolds For models DM70 amp 140 Remove the manifold cover see previous page Remove the cover located at the end of the heater retainer plate 4 screws Disconnect heater wires from the terminal rail Loosen the heater retainer plate then allow the cartridge heaters to slide out F or model DM 210 Replace heaters on the outer four manifolds as described above To access heaters on the two inner manifolds remove the two manifold covers then remove the cover located at the end of the heater retainer plate 4 screws Disconnect heater wires from the terminal rail Re move the heat
14. PROG MELT ZONE 35 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 PUMP PUMP 2 PUMP 3 PUMP 4 PUMP 1 PUMP 2 PUMP 3 PUMP 4 MTR 1 MIR 2 J MIR 5 J MIR 4 ER MTR 1 MIR 2 J MIR 3 MTR 4 A PROG MELT ZONE 5 PROG MELT ZONE 19 A PROG MELT ZONE 5 PROG MELT ZONE 19 PROG MELT ZONE 35 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 PUMP 1 2 PUMP 3 PUMP 4 PUMP 5 MIR 1 J MIR 2 MIR 3 MIR 4 ATR 5 E J PROG MELT ZONE 3 PROG MELT ZONE 19 PROG MELT ZONE 35 NOTES FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 FILTERBLOCK ZONE 36 PUMP 1 PUMP 2 PUMP PUMP 4 PUMP 5 PUMP 6 27 MIR 1 MIR 2 J MIR 3 J MIR 4 MIR 5 MTR 6 a P AFIT F Indicates the division line between the two hoppers if Dual hoppers S PROG MELI ZONE 3 PROG MELT ZONES EDGE MESS HUM installed FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 FILTERBLOCK ZONE 36 PN 108534 Rev B INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 2 of 3 40 NOLIVHO9IJNOO INOZ 9 dWNd L33HS NOILOQWLSNI 8 APY 766807 Nd rt 3 522 ne nn gt nn Ic r rama Cr one LO Q 211010 10022 2 1 MSS 1 PREMELI 2 PREMELIS M210 3 PREMELTS Le OG enueiw n sv IN LIAWVNAG PREMELT 1 ZONE 2 PREMELT 2 ZONE 18
15. Page 3 12 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 Calibration of the Optional Voltage Tachometer A voltage tachometer allows the system operator to monitor gear pump motor speed from the controller This information is useful since the amount of glue dispensed per product can be var ied by adjusting the motor rpm an increase in rpm an increase in glue dispensed DANGER WARNING HIGH VOLTAGE T HOT SURFACE Dynamelt systems use electrical power that can be life threatening and hot melt adhesives that can cause serious burns Be sure to read and follow the safety procedures in Chapter 1 of this manual Only qualified persons accustomed to working with live electrical circuits should per form this procedure on the Dynamelt system Calibration Procedure 1 Turn the application system ON and raise the temperatures of all components to normal operating temperatures 2 Turn main power OFF and open the panel box door Restore power to the ASU 3 Atthe controller keypad verify normal operation in AUTO STOP and MANUAL modes refer to M otor Control Programming in Chapter 5 if needed 4 Atthe controller keypad set motor speed to MANUAL mode and to 100 full speed 5 With an external tachometer measure the motor 6 Onthe M otor Control Interface PCB turn the M AX ADJUST potentiometer until the RPM of the external tachometer reads 1800 rpm 7 Calibration of this motor is complete
16. standards as new ones 10 Factory Visit pumps are to be maintained at your plant it can be very worthwtile to have key maintenance people spend a day at the Zenith factory to view manufacturing gauging and assembly techniques Please contact us concerning plans for such a visit or with any questions you may have regard ing the application or maintenance of your Zenith Melt Spinning Pumps Parker Hannifin Corporation Zenith Division 48 Woerd Avenue Box 9115 Waltham MA 02254 617 894 0650 Telex 263905 Appendix 33 iTV Dynatec 2000 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 SdH d WM 7 370415 231VNAU RI NIZ 8262 NAHL 0970 1 0 1 Lud 2023680 roe adi Livy tit THY ear MH AWAD 38 MYu2101 0403100 VAM 004 CSAMARTM VIMPMASOS GLD THY ME mary mengn R 108203 8 JIN M PUTINO gaye 99 Vp Gre dO MAL NAOC 295 WM NO SdW id 3 5NIS HLA ISN 38 NYI AWHISSY WAJlgVUV 08E3980 vov3r8o0 T 6282900 lt 50 3 980 x 9i B C racvazo vov3r0 6263900 or3e8o v e e 91 8 6 8087 cool avon na 39 23 2627 663v80 wor3rao 623790 c x 91 8 991982
17. 0521172 JIONIS 38 22 09 0 2263 80 NIH 82v 0 W3NIVLI3M 7935 2 320164 5NIJV3Q 1015 J308100 v rt dod r6c 04 0057 ATQOE 9150 9556 1 voneayddy 9a euAg MLI spom 901 Houn uy DOUG 8 1 3 NAHL d 909 532 14 2 713404 IK 31DN 33S SITH 062 DNIAV20 A HW3 SV teas 91 0073700 Y 663760 28 390 6963990 90 1902990 LLCI 90 923790 5263 80 94 2 00 CZU3Y90 24523890 Nd 30N3u333U 55009 Sdhinid LAVHI NO NACHS H19N31 3iVISdONddV 41 30 JAIXO NOV B 30 89 JH9S dVJ IV3H 133205 91 B WO04 ININE DL SdH d TW u312VH4VH2J HDIH Ser MWOHINIM HILA NAOHS NOIAIV2O LY 19393274510 1 1 4 HILI 2 did unn WA NO 5131100 0317935935 53108 3 3Hl SdWnd Qiv39 DAI 310 1 NO ATTTWNNSINI 193NN09 SINDH 0549 DAL SALON SBE O Y 529979 2 986 906 906 0061 0051 M M NOLLVAON HIGH ACCURANCY PUMP PERFORMANCE 084E 374 389 584 cc rev VOLUMETRIC EFFICIENCY co enm 100 80 ii ie 084E 436 es 79 Ss Ss 084E376 E 1 752 cc rev zg 60 084E 430 o OBAE 432 lt 50 1 168 cc rev LLI 40 2 gt N N 30 O84E 388 O84E 428 297 cc rev 20 O84E 387 160 cc rev 10 o x
18. 3 way Cord Grip 1 8 1 4 1 8 Hex Nipple Clutch Kit 56C Inline Fitting Elbow 90deg Brass M uffler Pneumatic Exhaust 1 8 N PT Tubing 25 OD 1251D cable 18ga 3C SV Optional Clutch Air anifold Assembly Air manifold Fitting 1 4 tube x 1 8 NPT 1 8 NPT Level Seal Plug M 4 0 7 x 35mm SHC Screw Lockwasher 4mm gt LH oO A o NJ BPP m Revised 12 03 Component Illustrations amp BOM s Page 10 15 DYNAMELT ASU M Manual 20 37 Tw Dynatec c 2001 bs 106660 Front to Base Plate Component Illustration DYNAMELT AC Drive Assembly 106660 amp 106663 Page 10 16 Component Illustrations amp BOM s Tv Dynatec c 2001 Revised 2 03 DYNAMELT M ASU Manual 20 37 Bill of Materials for DYNAMELT M70 Single 106038 M70 Single Hi Temp 804470 M70 Dual 106037 M70 Single Hi Flo109239 M140 Single 106040 M140 Single High Flow 106694 and M140 Dual 106039 Melt amp Grid Assemblies Item No Part Number Description Qty 1 036B 015 Pump Enable Thermostat 2 2 036B 103 Temperature Sensor 4 3 105999 H opper 4 4 105883 Weldment Dual M 70 106037 2 5 105884 Hopper Weldment Dual M 140 106039 2 6 105889 Hopper Weldment M 70 Single 106038 1 7 109238 Hopper Weldment M 70 Single Hi Flo 109239 1 106620 Hopper Weld
19. CRN YEL 14AWG 45 D HEATSINK 2 ORN YEL 14AWG SCREW S W g SCREW a 4 zx y SIDE PLATE LEFT GRN YEL 14AWG 5 2 hx HEATSINK 5 GRN YEL 14AWG SCREW gt NM SCREW E S 1 SIDE PLATE RIGHT CRN YEL 5 ee E OPERATOR PANEL GRN YEL 14AWG e SCREW 239 it lt pia SCR 335 PPR a AVE MOTOR yoror To 6 GRN YEL 16AWC SCREW HT COVER 1 GRN YEL 14AWG PI HOSE HEAD 1 TO 12 GRN YEL 16AWG S 5 S 4 HOPPER LEFT GRN YEL 12AWG PI AUXILARY 1 TO 12 GRN YEL 16AWG o Q m LEVEL PROBE GRN YEL JUNCTION BOX 1 GRN YEL 12AWG S IS SCREW z MA Py D HT COVER 2 GRN YEL 14AWG JUNCTION BOX 2 GRN YEL 12AWG S SCREW gt gt rroommrzio 4 594 805 HT COVER 3 GRN YEL 14AWG PRERE EE a ma lt mod onge SCREW 55901555 258 5 4 oem gt amo HOPPER GRN YEL 12AWG 7 4029 w UL Zztz i OXO SCREW E SOBC LES i Sorti ogQx Z ED M4 2056 Y LEVEL PROBE GRN YEL 250C 2 8 oxA a 92204 SCREW gt o ect d Pr z 2 gt v E GROUNDING DIAGRAM CE MARK PN 804704 REV E Page 11 8 Schematics Revised 12 02 FUSE 452 9 S iTW Dynatec 2001 DYNAMELT M ASU Manual 20 37 VIL 1 PNEUMATIC CLUTCH SCHEMATIC PN 108410 REV A 40 T
20. Chinese ITW Dynatec Manual 20 37 L21 20 37 L 22 20 37 123 20 37 124 20 37 1225 20 37 L 26 20 37 L27 20 37 L 28 20 37 L 29 20 37 L 30 20 37 L31 An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 2001 Table of Contents Page iii DYNAMELT M ASU Manual 420 37 Revised 11 01 TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Electrical a5 Nae D OR a LO AME d AN va E MUN RR za MUNERA Da A 1 1 High Temperatures siars Cose Ron RR eur qi a NUR DUREE GR ar 1 1 High PEeSSUFBc ain dee oma eti oft ned beta oN Ate sedat ena uie RS 1 1 Protective CoVers ise ee edo Ce OR NERO ROC OE cdot Ros 1 1 Eye Protection amp Protective Clothing 1 2 Safe Installation and Operation 1 2 Treatment for Burns From Hot M elt 1 2 SerVICe s Race HU A ROO 1 3 Explosion Fire Hazard aee RC RR TR EON A e OUR S 1 3 LOCKOUT TagoUt come Xe eere as alae Fe BERN Lat ise ed aA UNS 1 3 Chapter 2 Description amp Specifications D escri eruit qu me ded 2 1 Specific
21. DYNAMELT M ASU Manual 420 36 20 37 20 38 Revised 5 01 Controller Setup Below is the step by step process of setting up the controller Note Whenever an Access Code is required enter your individual code The default code is 9999 If you have lost your code call ITW D ynatec Customer Service 1 800 538 9540 in the U SA or con tact your local repsentative Turn the Controller ON Turn the controller ON using the ASUs main On Off switch Language Selection English is the default language If you desire another language choices are German French Ital ian Spanish Swedish Portugese J apanese and Dutch make your selection Press the Service K ey two times to advance to Service Page 2 Press 6 on the numeric keypad followed by Enter I Press the numeric key of your language choice followed by Enter OR Scroll V7 A to your choice then press Enter Note To quickly return to the English language turn the controller OFF Then press both Enter and 9 and hold while turning the controller ON Temperature Scale Selection Press the Service K ey twice to advance to Service Page 1 Press 8 on the numeric keypad followed by Enter Toggle to make your choice between C scale or F scale Press Enter Press Return F4 to Go to the Actual Temperatures Screen Page 5 6 Programming Revised 5 01 ITW Dynatec c 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Actual Temperatures Screen TheActual Temperatures Sc
22. Drawing Hose Schematic ASU to A pplicator A pplicator H ead Schematic Flow Diagram Outlet Filter M anifold Typical Hydraulic Schematic Optional System Status Lights Schematic Optional Level Control Schematic Grounding Diagram CE M ark Pneumatic Clutch Schematic Instruction Sheet for Pump amp Zone Configuration ASU Schematics Schematics Page 11 1 Found on page 11 2 page 11 3 page 11 4 page 11 5 page 11 5 page 11 6 Page 11 7 page 11 8 page 11 9 end of chapter Revised 12 02 Page 11 2 Schematics iTWDynatec 2001 Revised 3 03 DYNAMELT M ASU Manual 20 37 APPLICATOR ASU END SU END END FUNCTION WHITE RED 2C RIGGER WHITE RED 2C E HITE BLACK 20 TRIP TRIGGER 2 2 WHITE BLUE 20 E CENG OD E WHITE BLUE 20 B HEAD SENSOR 5 a 5 GRAY 20 S GRA 0 HEAD SENSOR 6 6 RED 18 HEATER 7 p 3 TERES ES ORANGE 18 HEAD HEATER 8 8 Unei BLUE 20 HOSE SENSOR 9 E eR BLUE 20 HOSE SENSOR 10 BLACK 18 HOSE HEATER 1 HEATER NN D HOSE HEATER 12 n L GREEN YELLOW 16 n 2 BN 2 SN 2NUUND l 2 S HOSE GROUND WIRE HOSE SCHEMATIC PN 101082 REV E ASU to Applicator Dynacontrol iTV Dynatec 2001 Schematics Page 11 3 DYNAMELT M ASU Manual 20 37 Revised 6 01 PLUG HEAD 7 BROWN 22 BROWN 22 GND GRN YEL 18 5005 ACTIVATES HEAD Notes 1 ALL WIRE MIL W 22759 10 OR 12 MINIMUM 600 VOLTS 260 D
23. L e5 D Actuals F Next Page Press Premelt jam SYM DEF Progmelt 1 2 3 Filterblock 300 Hose 274 273 251 Head HOLD HOLD HOLD Aux Zone JKL MNO 4 5 6 Pump PRS TUV WXY 7 8 9 PRESSURE 0 gt ABC 123 e e EE or Symbol use to enter Enter RPM if optional actual a space colon dash 0 toggle from nu RPM readout is installed dot Q or Z into 1 2 3 to alpha text Continued A B C entry lt gt Display amp Function Keypad Numeric Actual Temps Screen shown as example Keypad current software version SYSTEM Alarm N Tue 3 36PM Program gt 5 M C ontrol V5 00c 1 2 orP4 Flashing C indicates optional serial commu nication PC Link is ON Press Enter to activate or confirm 1 23 Enter a numeric value with 0 9 keys Enter a letter on the alpha numeric This item or this screen is locked This item is factory setup only lt gt Press button C to see more zones Factory Setup be HELP Screen F4 on Actual Temperatures Screen modified by ITW Dynatec s technicians only ITW Dynatec c 2000 Programming Page 5 3 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Display Reference cont Condition of Pump Enable Thermostat Black box item is selected for programming Screen continues press
24. NPN Description Drive Shaft Key Woodruff M5 x 12 SHC Screw Seal Retainer amp Bearing Housing Lip Seal Bearing Sleeve Front Plate Assembly Driven Gear Shaft Ball 1 8 Diameter Drive Gear 4 5 cc rev Pump Seal Shaft Retaining Ring Bearing Sleeve Rear Plate Rear Plate Assembly 4 x 25 SHC Screw M10 1 5 x 80mm M10 Flat washer Qty KR A N e N A N N A e e N e e RR T Dynatec c 2001 Component Illustrations amp BOM s Page 10 21 DYNAMELT M ASU Manual 20 37 2 01 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104042 M10 1 5 x 100 All Thread Component Illustration 4 50 cc Rev Single Gear Pump Assembly 100862 Page 10 22 Component Illustrations amp BOM s Revised 2 01 TwDynatec 2001 DYNAMELT M ASU Manual 20 37 Bill of Materials for 1 54 cc Rev Dual Gear Pump Assembly 100863 Item No 0 1 FF t N e e e me me e me o mn ND A UU Ne Part Number 012D083 0781001 101626 069X160 069X061 018X041 100866 012D082 018X031 012C020 069X064 078F017 018X041 100865 101692 NPN 100869 N00198 NPN Description Drive Shaft Key Woodruff M5 x 12 SHCS Seal retainer amp Bearing Housing Lip Seal Bearing Sleeve Front Plate Assembly Driven Gear Shaft Ball 1 8 Dia Pump Gear 1 5 cc Rev O ring 041 Shaft Retaining Ring Bearing Sleeve rear Plate Rear Plate Assembly M4 x 35 SHCS M10 1 5 x 85
25. ON PCB 105095 CPU ar L2 N USE CPU 1 FOR HOPPER 1 BLU USE CPU 3 FOR HOPPER 1 E PESO CRN YE kd 10 on 20 ED 10 JS4 CONNECTOR ON PCB 107440 BLE USE 3 amp 4 FOR HOPPER 2 CONNECTIONS DYNAMELT PUR WIRING DIAGRAM FOR PN 108266 OPTIONAL SYSTEM STATUS LIGHTS TV Dynatec 2001 DYNAMELT ASU Manual 20 37 mi PE pe LEVEL PROB x E VES INS D EN EN ANN gt N E B pes V UMEK LZ VIN ast N See SA OT E NIO D DA uA T Top 5 FIC S L3 A VEA APE d LA OU VUI 2 3 VJ bs f i d IN C 2 4 f L MN 4 4 1 LIT 5AQUJAC 2 TOV EA N YA Ja NADA 3 2 f F3L T 7 IN PANEL BOX wn e VEA rier N LR DOV MOUNTED IN PNL BO 7 Vu ne o gt LEVEL CONTROL SCHEMATIC PN 802972 REV A iTV Dynatec 2001 Schematics Page 11 7 DYNAMELT M ASU Manual 20 37 Revised 10 01 CONDUCTOR SIZE BOTTOM PLATE ACCORDING
26. Two Output Two Filter Manifold PN 102049 Thetwo output two filter manifold is required with a dual gear pump It allows the operator to adjust the two pressure relief valves independently of each other Feinpruf Gear Pumps Feinpruf pumps are commonly used in the European marketplace Gear Pump Repair Kit PN 103151 Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps Description Description N 00198 O ring 069X064 O ring 018X031 Ball Bearing 078F017 Ring Clip 069X061 Seal 0781001 K ey Woodruff iTV Dynatec c 2001 Options amp Accessories Page 9 3 DYNAMELT ASU Manual 20 37 20 38 Revised 9 01 Return re circulating Hoses Available on all models U se of return hoses allows higher adhesive pressures from the head to the substrate because the head is overfed adhesive The overflow adhesive is re circulated to the hop per Pneumatic Clutch PN 106877 A pneumatic clutch is available for the Dynamelt M 70 140 210 505 A clutch relieves adhesive pressure quickly in applications where there are periods of time when adhesive is not being applied Dual Hopper Available DM M 140 and M 210 The adhesive hopper on the dual hopper models is divided into two separate chambers to allow the application of two different adhesives simultaneously E ach chamber is an independent temperature zone allowing them to operate at different adhesive temper atures High Flow ASUs These ASUs are av
27. head auxiliary zones do not begin heating until all hopper zones have reached the low limit of their setpoints Zones which are switched OFF are not applicable c Hold Electric Heads at xxx F for 10 minutes applies to systems utilizing electric applicators only After choosing this selection and programming the temperature to the softening point of your adhesive see your adhesive manufacturer the controller holds all electric heads at the oper ator selected temperature for ten minutes before releasing them to operating setpoint The controller s default heating sequence for the D ynamelt ASU is first all hopper zones This al lows the larger mass of adhesive in the hopper to begin heating immediately Press 8 to program Temperature Scale Program directly on the menu screen by pressing 8 key to choose between Centigrade or Fahrenheit Press Return F4 Press 9 to Change Security Lock for Service Page 1 Enter your access code Press Enter Scroll F1 or F2 to select desired function Press F3 to Lock or Unlock function from programming Re peat for each desired function To Change Y our Access Code Scroll F1 or F2 to select Change Access Code Enter your de Sired new access code Press Enter to Confirm Press Return F4 Press Service ey to advance to Service Page 2 ITW Dynatec c 2000 Programming Page 5 19 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 11 01 Service Functions Screens cont Service Page 2
28. of your melter will be displayed Use this screen to program the quantity of hoses quantity of premelt grids and quantity of pumps installed on your ASU if desired It is o k to leave these items unchanged or with selected Scroll F1 to the line you wish to amend ie hose premelt pump Press Change F2 repeatedly to view the list of possibilities for this line Press Change until your desired quantity is displayed Repeat until all lines are programmed Then Scroll F1 to Configure EU US Press Change F2 to toggle between EU Setup or US Setup for setpoints and parameters if required Press Load Then press Confirm F1 Press Return F4 to return to menu Choosing EU or US reloads all factory setpoints and parameters as follows EU European Setup Temperature scale is Centigrade pressure is measured in BAR pumps are in STOP mode at startup and heaters are active at startup U S United States Setup Temperature scale is F ahrenheit pressure is measured in PSI pumps start in the mode they were left in at shutdown and heaters are active at startup Press 4 to program K eypad Locking Scroll to either Temperature Settings or Pump Settings Press F3 to toggle Locked or Free Scroll to other setting and press F3 to toggle Locked or Free Press F4 to Return to menu Selecting Locked prevents further programming to either temperature setpoints or pumps Select ing F ree allows further programming Pres
29. 0 SetbackOn Off Bit1 Heat up sequence yes no Bit2 Scheduler active yes no Bit3 controller On Off ZZ zone number 01 to max or 00 for all zones four digit data dd two digit data d one digit data or character Programming Page 5 1 ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Chapter 5 PROGRAMMING INSTRUCTIONS FOR DynaControl CONTROLLER WITH EXPANDED KEYPAD V 5 00c amp UP Controller Safety Consideration Never open the control panel without switching off the main disconnect switch to ensure that it is disconnected from its power source i DANGER HIGH VOLTAGE The printed circuit boards should always be carefully removed DO NOT handle the boards except by their edges Read the section on PCBs in Chapter 7 of this manual for further cautions Software Version You can determine the software version of your controller by noting it when it comes up on the Help Screen or on the display at startup ITW Dynatec M Control V 5 00c Current Software Version Page 5 2 Programming ITW Dynatec c 2000 Revised 12 02 DYNAMELT M ASU Manual 50 13 20 36 20 37 20 38 Display amp Keypad Reference Scheduler Key Standby System Status Day Date Clock Ready Scheduler Active Indicator 7 Day Scheduler Heat up Program Recipes Alarm Day of Week Standby Time of Day Service Key On Off Key amp LED Hs rg SYSTEM Alarm 9 Tue 3 36
30. 0103 0143 0123 0110 0114 0512 0113 Males 148 Mi st dm Hers cipt Lii LL E od 0110 0114 942 Models 0420 0124 0122 0123 0120 0121 0122 son r0 Uer tb TIG ant Conclat rc 004 PULL itatoa CLP M Onis Lil Pist ym iTV Dynatec 1999 Appendix 37 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 99 PN 106877 Pneumatic Clutch Kit HORTON CLUTCH MODEL 625 MODULAR UNITS MDU amp MOU ITW Dynetec ASUs use Model 625 MDU amp MOU The following 9 pages from the Horton clutch manual have been edited to include only information on the 625 clutch Read this manual carefully making full use of its explanations and Instructions The Know How of safe continuous trouble iree operation depends on the degree of your understanding of the system and your willingness to keep components in proper operating condition Pay particular attention to all NOTES CAUTIONS and WARNINGS to avoid the risk of personal injury or property damage it is important to understand that these NOTES CAUTIONS and WARNINGS are not exhaustive Horton cannot possibly know or evaluate all conceivable methods in which Service may be performed or the possible hazardous consequences of each method Accordingly anyone who uses a procedure that is not recommended by Horton must first satisfy themselves that neither thelr safety or the safety of
31. 1 8 54 Ready S outputs to MU S LED Hopper 2 Ready supplied Future 9 LED O Future 16 PLC S 15 Solid state relay S Q 14 Q driver outputs System System 1 1 per zone Ready Fl 13 snubbed system2 12 power S 2 11 outputs Future Transformer E 5 Green zone Input L1 S O is heating Power 19 6 240VAC 5 4 53 3 O m E 1 Transformer Fuse 5x20 1amp JF2 Connect to Connect to Connect to CPU lat CPU 2 at CPU 3 at J6 J6 J6 Layout of Components on 48 Zone Power Board Page 7 10 Troubleshooting ITW Dynatec c 2000 Revised 6 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Optional Clutch Printed Circuit Board The Clutch PCB allows installation of up to six optional clutches on the ASU The dip switches SW 1 are turned ON to reflect the number of clutches on the system Relay Green LED clutch is activated Un N Clutch 3 Clutch 4 Green LED System Power ON Clutch Coil Leads Connects Customer Enable S witches for a footswitch hand held applicator etc Connect to 48 Zone Power Board at F1 240 VAC Input Dip Switches 1 clutch switch 1 is ON 2 clutches switch 1 amp 2 are ON 3 clutches 2 switch 1 2 amp 3 are ON Layout of Components on Clutch Board 4 clutches switch 1 2 3 amp 4 are ON 5 clutche
32. 38 Adjustable Adhesive Pressure Relief Valve D ynamelt pumps are outfitted with a high pressure relief valve located on the outlet filter manifold The valve is adjustable and it does not affect adhesive pressure under normal operating conditions The adjustable pressure relief valve is factory set at 34 bar 500 psi for Dynamelt M gear pumps W hen adhesive pressure exceeds the set limit the pressure forces the valve to move away from its seat compressing the spring and allowing adhesive to flow back to the hopper This adhesive flow reduces pressure W hen the pressure falls below the set limit the spring forces the valve against its Seat cutting off adhesive flow The check valve seen below is not instrumental in pressure relief It serves as an overflow valve preventing adhesive from flowing out of the hopper when the filter plug is removed Normally Closed Unrelieved Open Relieved In the drawing below the pressure relief valve is In this drawing pressure has exceeded the setting closed of the valve causing itto open and discharge adhesive to the hopper Adjustment Screw Cap Check Valve Check Valve i Pr r Spring Relief x return Pressure return Valve to Relief to hopper Valve hopper fT Filter from from Basket pump pump to to hose o hose Adhesive flow through Adhesive flow through filter block to hose filter block to hose Operation of the Adjustable Adhesive Pressure
33. 38 Revised 5 01 Use of the 7 Day Scheduler Programming Screen Press This To Function Key Scroll U p Down or Right F1 2 3 Select an individual action day or time Return F4 Return to the M ain Scheduler Screen a Enter Enter a chosen selection Programming 1 Press F3 to scroll to the Action column Then scroll to the first event you desire to program 2 Press Enter lt until the desired A ction Standby Switch On Switch Off or no event is displayed 3 Scroll F3 to the Day column 4 Press Enter until the desired Day ie M on Fri Everyday or any individual day is displayed 5 Scroll F3 to theTime column 6 Press Enter to display the time you desire the event to start Enter hour minutes and am pm in dividually 7 Repeat steps 1 through 6 for each event desired 8 Press F4 to return to M ain Scheduler screen Page 5 26 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Programming of the Optional Memory Card Note Programming of the M emory Card Reader should be performed after all other controller programming is complete This will assure that all of your setpoints are saved to the memory card The optional M emory Card R eader gives convenience and security to your production Tempera ture setpoints and start signals are electronically stored on the memory card and transferred to the controller when the card in inserted into its slot to the right
34. 7 2 5 3 312 24 120 13 6 10 1 4 20 150 16 9 12 5 5 16 18 305 33 9 25 3 8 16 into aluminum 360 40 6 30 7116 14 block hopper 480 54 2 40 Table 1 n critical applications where control of bolt preload is important the torque tension relation should be determined by experimenting on the actual parts involved including thread lubricants A t elevated temperatures itis often desirable to reduce screw stress because of deformation creep under sustained loading Screws constructed of type H 11 high temperature alloy steel provide extremely high creep resistance TROUBLESHOOTING GUIDE Trouble Probable Cause Remedy Pump will not turn 1 Low pump temperature Check temperature sensor and control loop for proper setting operation Allow sufficient heat up time 2 Drive malfunction Verify drive is powered Check to assure all alarm circuits are clear Check drive motor current and speed settings Check all drive couplings 3 Process conditions changed Check process conditions for proper melt tempera ture pressures viscosities and materials 4 Entrained particle Return pump to ITW D ynatec for repair cont Appendix 24 iTW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 TROUBLESHOOTING GUIDE continued Trouble Probable Cause 5 Possible internal damages Excessive seal 1 Worn seal plate assembly leakage 2 Insufficient inlet pressure 3 Worn lip seal
35. ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Pump s Programming Screen Each of the pump s is programmed individually by using the function keys as follows Press This To Function Key Scroll Up or Down 1 2 Selecta pump Stop To stop all pumps in system Re Start F 4 To re start all pimps M anual F 1 Choose M anual M ode for the selected pump Automatic F2 Choose A utomatic M ode for the selected pump Stop F3 Choose Stop M ode for the selected pump Clutches F2 Go to the Clutch Programming Screen if clutches are installed Return F4 Return to the A ctual Temperatures Screen Enter Enter a numeric value Programming 1 Scroll to select a pump Press Enter 2 Press M anual A utomatic or Stop as desired pump mode Press E nter 3 If in M anual mode enter pump speed 1 the Set column a Use numeric keypad to enter desired rpm value b Press Enter 4 If in Automatic a Scroll to M in to program minimum pump speed Enter value as described above Note typically at 0 volts this value will be between 0 and 10 default 096 b Scroll to M ax to program maximum pump speed Enter value as described above Note typically at 10 volts this value will be between 0 and 10096 depending on motor installed on ASU default 100 5 Scroll to select next pump to be programmed R epeat steps 2 thru 5 until all pumps are pro grammed 6 If clutches are installed on ASU Press Clutche
36. BitO Bit7 Page 2 BitO Bit7 free 1 locked free 1 locked 1 lock 1 Sock System 4 PI Loop Premelt PI Loop Progmelt Pl Loop Filterblo PI Loop Hose Pl Loop Head PI Loop Aux Zone 1 Low P High l Low P High I Low P 1 Low P High I Low P High l Low P System 5 Gear Ratio GearRatio Mo GearRatio Mo GearRatio Motor Gear Ratio Motor Gear Ratio Motor tor 1 tor 2 tor 3 4 5 6 S ystem 6 Rpm Displayn Pump Clutches Level Control Bar PSI Pressure Sensor Active Recipe 0 1 BitO Bit5 Bit7 0 1 0 51 1 type 1 4 System 7 Zone Premelt 1 Zone Premelt 2 Zone Premelt Zone Premelt 4 Zone Premelt 5 Zone Premelt 6 System 8 Zone Zone Progmelt Zone Progmelt Zone Progmelt Zone Progmelt Zones Progmelt Progmelt 1 2 3 4 5 6 System 9 Zone Filterblo 1 Zone Filterblo 2 Zone Filterblo 3 Zone Filterblo 4 Zones Filterblo 5 Zone Filterblo 6 System 10 Zone Hose 1 Zone Hose 2 Zone Hose 3 Zone Hose 4 Zone Hose 5 Zone Hose 6 System 11 Zone Hose 7 Zone Hose 8 Zone Hose 9 Zone Hose 10 Zone Hose 11 Zone Hose 12 S ystem 12 Zone Head 1 Zone Head 2 Zone Head 3 Zone Head 4 Zone Head 5 Zone Head 6 S ystem 13 Zone Head 7 Zone Head 8 Zone Head 9 Zone Head 10 Zone Head 11 Zone Head 12 System 14 Zone Aux Zo 1 Zone Aux Zo 2 Zone Aux Zo 3 Zone Aux Zo 4 Zone Aux Zo 5 Zone Aux Zo 6 System 15 Zone Aux Zo 7 Zone Aux Zo 8 Zone Aux Zo 9
37. ITEMS 52 GRADE 8 amp BLACK OXIDED 3 25 LONG AND FOUR WASHERS ITEMS 53 FOR MOUNTING GUERA e 2242217 2 EIE REV 25535 SECTION AN 3 85 6 STO A Ed en CAPACITY CC REV AFTER ASS Y MATCH 2 DRILLED HOLES FOR ROLL PINS AR WTC IAT Oe I MRE site APR im Coe Appendix 11 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec 2000 79891 EE Ties s SNId 7108 N04 SAITOH 03711100 HOLYA 55 LON 24768 sg Y Y NOII123S 15272 LA 015 ISNY NON OWNS 4 i A0019 310N 335 ON L13vd 5u3108YH2 HOIH 921 HNMINIW NMOHS NOIIVOO 1Y 1N3432V 14510 9 U3QMTN Luvd 13 SALON LIINI 18 1709 18084 137100 1804 131100 d 6cvi v8e0 A34 J2 ALIOVdv3 1 2 J31VNAQ MAI eo 626661 9 5 29 4 iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 12 Revised 10 00 ITW DYNATEC PART CAPACITY CC REV 2X 250 ROLL PIN 813 INLET PORT BOLT HOLES NOTES ETCH PART NUMBEA amp DISPLACEMENT DE SS ZR EE 1 it 553 9 pM STD NSXS y NN RYAN Pea SECTION 404 WOODRUFF KEYWAY NON ANSI STD Bs AFTER ASS Y MAT
38. NOLIVHAY9IJNOO INOZ 9 dWNd L33HS NOILONULSNI 8 APY 766807 Nd Zone Configuration for Hose Heod Aux M35 M70 140 Head 22 25 2 s Aux Aux 235 26 2 is 25 Hose 21 24 Hose 5 8 11 14 Hose Hose Head 6 9 12 15 4 Head 4 Head Aux 7 10 13 16 Ne Aux ae Aux m Hose Hose 6 Head 6 Head NC Aux Aux 8 G Hose 8 11 14 21 24 27 30 Z CjN Hose Head 8 12 15 22 25 28 31 9 Head P Aux 10 13 16 23 26 29 32 NOEL ERE fon Hose 1 Q Heod 6 o Aux NOTES There are no odd hose numbers in the predefined defaults If for N Hose 2 Head example 5 hoses are installed the default has to be loaded for 6 If m necessary remove hose 6 manually from the zone toble Indicates the division line between the two hoppers if Dual hoppers ore instolled 1 These zone numbers are independent from number of pumps and premelt grids 100 IILU GML 18 0 enuew NSV IN
39. PLC Page 9 2 Options amp Accessories iTV Dynatec c 2001 Revised 6 03 DYNAMELT M ASU Manual 20 37 20 38 Pump Options and Accessories Gear Pumps For higher tolerances and precision several gear pumps are available for the Dynamelt Gear pumps give better service for continuous applications or applications which require more control over the vol ume of adhesive pumped Gear pumps available are Single Pumps PN 100860 1 54 cc rev single standard accuracy gear pump PN 100861 3 2 cc rev single standard accuracy gear pump PN 100862 4 5 cc rev single standard accuracy gear pump PN 109690 10 cc rev single standard accuracy gear pump PN 108875 8 5 cc rev single high accuracy gear pump PN 084E 374 0 584 cc rev single high accuracy gear pump PN 084E 376 1 752 cc rev single high accuracy gear pump PN 084E428 0 297 cc rev single high accuracy gear pump PN 084E430 1 168 cc rev single high accuracy gear pump PN 084E434 2 920 cc rev single high accuracy gear pump Dual Pumps Note all dual pumps require PN 102049 see below PN 100863 1 54 cc rev dual standard accuracy gear pump PN 100864 3 18 cc rev dual standard accuracy gear pump PN 084E 389 0 584 cc rev dual high accuracy gear pump PN 084E432 1 168 cc rev dual high accuracy gear pump PN 108874 2 920 cc rev dual high accuracy gear pump Hi Flow Pumps PN 084E411 20cc rev single gear pump PN 084E412 30cc rev single gear pump PN 084E413 45cc rev single gear pump
40. Pressure Relief amp High Temperature Filter Block Assemblies 10 2 Typical Electrical Panel Box Assembly 10 6 Cabinet ASSen Dll 5 5 nace eon date ER mde 10 10 Drive Assemblies DUERME ROGO UR ROGER n RR RC 10 14 Melt amp Grid Assembligs zc eer ten cR v dederas 10 16 Ar cL 10 18 Pump Adapter Assemblies 10 26 Pressure Gauge Assembly 10 28 In addition to the assemblies listed above this chapter may also contain illustrations for other optional assemblies ordered with your ASU iTV Dynatec c 2001 Table of Contents P age vii DYNAMELT M ASU Manual 20 37 Revised 12 02 Chapter 11 System Schematics amp Engineering Drawings Hose Schematic allimodels Lee e ce ur deni RO Lee a e ok ees 11 2 Head Schematic all 5 11 3 Flow Diagram Outlet Filter M anifold Cross Channel 11 4 Typical Hydraulic Schematic eci ceta resi tete pee dee erbe peek Der ee 11 5 Optional System Status Lights isses me der eee eae 11 5 Optional Level Control 2 2222 dni ae Geena 11 6 Ground
41. Scheduler A ctive display shows that the 7 Day Scheduler is programmed and in use 4 Pump Info Lines indicate pump mode A uto on the illustration on page 5 6 and external refer ence percent or set speed percent 5 f the optional Actual RPM display shown on page 5 3 is installed actual pump rpm may be monitored Page 5 8 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Setpoints Programming Screen SYSTEM Alarm Lo Tue 3 36 PM P d e5 D SETPOINTS F Next Page Press C Premelt SYM ABC DEF Progmelt 2 3 Filterblock 380 Hose 275 Head 215 JKL MNO Aux Zone 5 6 INFO UPPER PREMELT GRID Set 300 F Act 300 F Tol 30 F TUV WXY 8 9 0 gt ABC 123 ITV Dynatec Controller identification number for zone Zone Info Lines ITW Dynatec c 2000 Programming Page 5 9 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Setpoints Programming Screen Each of the temperature zones is programmed individually by using the function keys as follows Press This To Function Key Scroll Up Down or Right F1 2 3 Select each zone s setpoint Return F4 Return to the A ctual Temperatures Screen a Enter Enter a numeric value All F1 zones in a category ie All Hoses Heads etc On Off F3 Toggle a zone on or off Clear F4 Eliminate an error message or alarm Programming 1 Scroll to the first temperature zone setpoint you desir
42. THSA 1 168 cc Single Outlet THSA 2 292 cc Single Outlet THSA 8 5 cc Single Outlet THSA 30 0 cc Single Outlet THSA 584 cc Dual Outlet THSA 1 168 cc Dual Outlet THSA 2 292 cc Dual Outlet Zenith Pump Adapter Assembly Adapter Z Pump O Ring 041 O Ring 021 O Ring 025 Screw Pump M ounting 7 16 ss Washer 3 4 OD Drive Shaft Seal THSA Pump THSA 20 cc Single Outlet THSA 30 cc Single Outlet THSA 45 cc Single Outlet Feinpruef Pump Adapter Assembly A dapter Plate O ring Plate O ring 014 O ring 025 O ring 133 Feinpruef Pump Feinpruef Pump 3 cc Feinpruef Pump 1 2 cc Feinpruef Pump 2 4 cc Coupling Half Not Shown See drive Section O 2 gt HH qq HH T Dynatec 1999 Component Illustrations amp BOM s Page 10 27 DYNAMELT M ASU Manual 20 37 Revised 7 03 THSA Pump Adapter Assembly 084E 406 Page 10 28 Component Illustrations amp BOM s Revised 7 01 Item No 1 2 3 4 5 6 Part Number 806883 101174 104325 805632 102987 00104 Pressure Gauge Assembly 805641 Description Fitting 1 4 NPTM x 6 JIC x 90 Pressure Guage 1000 PSI Fitting Adapter Swivel 6J x 1 4 MPT Fitting 1 4 NPT 1 2 20 Tranducer Insulator Fitting 1 4 NPTM x 6 ST TwDynatec 2001 DYNAMELT M ASU Manual 20 37 iTV Dynatec 2001 DYNAMELT M ASU Manual 420 37 Chapter 11 SCHEMATICS amp ENGINEERING DRAWINGS
43. a flatness of true flat to 0001 convex and a surface finish of 4 to 8 rms to prevent leakage between the pump and block M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to D ynatec s recommended limit for the bolt size used See Table 1 page 26 for torque values The following is a brief standard installation procedure For any special applications con siderations or simply to ask our advice please contact ITW D ynatec cont iTV Dynatec 2000 Appendix 19 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 TO PREPARE THE PUMP FOR USE 1 Always flush out the plumbing system before connecting the pump 2 Filters should be installed prior to the pump inlet that filter ideally to half the pump run ning clearances 3 Turn pumps by hand before running Pumps should turn freely 4 Engage the outer drive shaft carefully making sure that it does not bottom in the slot of the coupling and that itis aligned within one degree angular and 005 parallel with the true pump drive axis Note the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate 5 Tighten the mounting bolts and coupling housing screws to D ynatec recommended torq
44. adjustment follow the programming instructions in Chapter 5 Pump Output Adjustment W hen the adhesive in the A SU s hopper has reached a temperature high enough for the pump to op erate safely the controller will place the hopper in Ready condition and power will be supplied to the pump The pump is self priming Pump output is adjusted by the motor speed control on the controller s keypad However if less pressure is needed maximum pressure of the pump can be decreased or increased by adjusting the pressure relief valve installed on the pump output manifold To change the setting of this valve re fer to instructions in Chapter 3 The relief valve is factory set at 34 bar 500 psi for Dynamelt M gear pumps Page 7 24 Troubleshooting iTVW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Troubleshooting the ASU s Gear Pump No special tools are needed for working on the ASU pump See Chapter 8 of this manual for diaas sembly assembly procedures for the ASU pump and Chapter 10 for locating pump parts on the component illustrations exploded view drawings Gear Pump Priming Start Up The pump is self priming CAUTION DO NOT continue to run the pump if no glue is coming out This could damage the pump since it uses the glue as a lubricant Stop and troubleshoot Troubleshooting Page 7 25 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Gear Pump Troubleshoo
45. any combination of these steels since their coeffi _ cients of thermal expansion are almost identical Zenith Metering Pumps consist of two or more gears housed within center and side plates Power is transmitted to the gears by the drive shaft which is either a through shaft as in the packing gland type of pump or a shaft with a tang that engages a universal seal coupling The coupling is both a connection to external power and the rotating member of mechanical seal In order to develop the high pressures demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow ade quate lubrication Because of these close running clearances in many cases as low 00025 Zenith Pumps require careful maintenance and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure 2 General Operating Requirements i ee Since Zenith Pumps depend upon metered fluids for lubrica tion of their internal bearing surfaces their recommended optimum operating speed range is between 10 and 75 rpm depending upon viscosity and operating pressures Increasing their operating speed improves their efficiency but also pro vides less time to fill the gear tooth spaces Cavitation may occur if sufficient inlet pressure is not pro vided Cavitation or the failure to fill the tooth spaces com pletely causes low deliver
46. flat Head Screws to 22 Lbs 2 50 torque Clean the Bearing Bore of the Housing ttem 3 with fresh solvent making sure all oid Loctite residue is removed Bee Figure 20 Apply an adequate amount of PE QUU idi coat ihe outer race of the Ball Bearing item and press the new Ball Bearing into the 3 See Figure 20 Reinstall the Spacer item 12 and the Retaining Ring tem 39 See Figure 20 Apply an adequate amount of Loctite 680 evenly coat the cuter race of the new Ball Bearing Item 28 and press the new Ball Bearing inte the Housing Item 3 See Figure 20 Support the inner race of the new Ball Bearing Item 28 and press the Disc Joumal ftem 8 inte the Ball Bearings Items 28 and 29 and Housing Item 3 See Figure 20 Side a new Keyed Washer Item 55 onto the Disc Journal Item 8 and reimstaE the Lock Nut Item 56 Bend down the tabs of the Keyed Washer Item 55 the Lock Nut ikem 56 See Figure 20 VR RR mcm ccs mss sms RUD RR RE RR REPLACEMENT PARTS The tem or baBoon number for all Horton products is used for pari identification product parts lists product price lists unit assembly drawings bils of materials and instruction When ordering replacement parts specify mode designation item number part description and quantity Purchase replacement parts through your local Horton Distributor cont
47. followed for installation 1 Make sure that incoming line power to the ASU and that the unit s main disconnect switch are turned OFF Main Disconnect S witch DANGER HIGH VOLTAGE Disconnect and lock out input power to the application system using the lockout safety illustrated above before starting any installation procedures Make sure there is no electrical power on the leads you will be connecting 2 Within the panel box assembly Connect 3 electrical leads with the appropriate voltage to the main circuit breaker and connect one electrical lead to the ground PE terminal see diagram following 380v 505 only In addition to above connect one lead to the neutral terminal 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 cont iTV Dynatec c 2001 Installation Page 3 3 DYNAMELT M ASU Manual 220 37 Revised 11 01 3 Atinstallation the customer must make the following terminal connections into the A SU s printed circuit boards PCBs The boards do not need to be removed from the A SU in order to make connections See the detailed layout on the next page for locations and refer to the detailed layout drawings of the PCBs in Ch 7 if needed Required connections for standard 240 vac ASU Input Power from M ain Power 240vac M ain Power Switch L1 L2 L3 PE Ground Terminal rail Required connections
48. for 380 vac ASU Input Power from M ain Power 380 vac M ain Power Switch L1 L2 L3 N PE Neutral Ground Terminal rail Non essential connections connect if feature is desired R1 R2 Normally Open Ready parent machine interlock Power PCB J5S4 pins 1 amp 2 and Power PCB JS2 pins 1 amp 2 A1 A2 Normally Closed A larm controller display alarms CPU PCB X1 pins 1 amp 2 E1 E2 External Standby controller standby mode CPU X4 connect 5 and 9 or 10 P1 P2 Program Select 1 amp 2 controller program selection CPU X4 connect 1 to 9 or 10 P3 P4 Program Select 3 amp 4 CPU X 4 connect 7 to 9 or 10 Power On Output Power PCB JS1 pins 1 amp 2 Options Make connections for the following if installed on your ASU Tachometer line speed tracking MCI X3 0 ground amp 10 4 Hand H eld A pplicator Footswitch MCI X3 TR Low Adhesive L evel output alarm CPU PCB X1 pins 3 amp 4 D ual Hopper Low Adhesive Level output alarm as above CPU 1 Hopper 1 and CPU2 Hopper 2 Pressure Transducer s 1 to 4 transducers PSI PCB X1 X2 X3 X4 Pressure Transducer s high amp low psi alarms PSI PCB X6 Clutch Customer Enable for motor 1 Clutch PCB JS1 pins 1 amp 2 Clutch Customer Enable for motor 2 Clutch PCB JS1 pins 3 amp 4 Ribboncable RS232 485 Communication Display CPU PCB Program Selection Table User Connections P1 P2 P3 P4 Programi d Pin 1 Pin 7 MCI Con
49. hone in the plate to the original new part specifications 9 After each resurfacing carefully gauge the area between the inlet and discharge ports at the mesh of the gears This area commonly referred to as the throat is the most critical part of the plate Scoring or wear marks here will allow increased slippage from the high pressure discharge port section across the throat to the lower inlet port reducing efficiency Therefore carefully gauge this area for flatness after each resurfacing Appendix 32 Revised 10 00 7 Reassembly NOTE During and between each reassembly step manually tura the metering gears to ensure that they are free turning binding occurs at any time determine the cause and correct it immediately A tiny nick burr or foreign particle can extensively damage a valuable pump component Never use force in reassembling or turning a Zenith Pump H property aligned the pieces will fit easily into place and the pump will turn freely Reassemble the pump as follows 1 After all worn parts have been refinished or replaced all parts should be thoroughly cleaned in a solvent and dried 2 Using the driven gear as an uprighling fixture carefully locate the arbor over its press fit hole in either the front or rear plate Smoothly drive the arbor into its hole with the help of an appropriate arbor press 3 Piace the front side plate with the arbor in position in a softjaw vise or holding fixture 4 Si
50. is open System 1 Status Ready Displayed active System Scheduler Key Heat up Scheduler Active Indicator Day Date Clock etc Alarm Standby System 2 Status SYS 2 READY lo e5 D Next Page Press 4 gt Premelt 300 SYM DEF Progmelt 1 2 3 Filterblock Hose JKL MNO Head 5 6 Aux Zone 7 Stop 96 Hold P SETPOINTS 0 gt ABC 123 T Dynatec All Keypad functions are identical to standard models Dual Hopper Display amp Function Keypad Numeric Actual Temps Screen shown as example Keypad ITW Dynatec c 2000 Page 5 32 Programming DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 10 01 Optional Dual Split Hopper Display amp Keypad Reference cont After Pressing C the Display Changes to Displayed System SYSTEM 1 READY amp SYSTEM 2 READY Actuals F System 1 Next Page Press C 5 7 8 gt Premelt Progmelt Filterblock Hose 275 275 273 274 Head 274 274 215 274 Aux Zone Pump Stop Stop Stop Stop Hold Hold Hold Hold SETPOINTS On the screen shown above additional System 1 temperature zones are displayed After Pressing C again the Display Changes to Displayed System SYSTEM 1 READY amp SYSTEM 2 READY Actuals F System 2 Next Page Press C Premelt Progmelt Filterblock 274 274 273 Hose Head 273 Aux Zone Pump Stop Stop Stop Hold Hold Hold SETPOINTS PRESSURE On the screen shown above Syste
51. is warmed up and that hopper temperature is above the factory set pump enable temperature 4 Faulty M otor Control 4 If the board is faulty it must be Interface B oard replaced Page 7 26 Troubleshooting iTV Dynatec 2000 Revised 6 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 sown Pump doesn toperate 1 Parent machine is not 1 Check parent machine in Auto mode running power lightis ON hopper is at ready 2 A uto motor is set at 2 Re program motor conditon zero at controller keypad e 3 No incoming line 3 Check for presence of 0 to 10 VDC following signal control signal at X 3 of M otor Control Interface PCB If signal is not present s check connection at X 3 and tachometer HE drive connections If control signal is z X3 present there the problem is within the ASU Motor Control Interface PCB 4 Internal A SU connections 4 Check for the presence of 0 to 10 VDC or Motor Control Interface control signal at X 3 of M otor Control PCB inoperative Interface PCB Check ASU connections S1 amp S2 If the signal is not present the problem is in the connection If the signal is present there the problem is most likely a faulty M otor Control Interface B oard 5 System is not ready temp 5 Verify that ASU is warmed up and that eratures are too low hopper temperature is above the low temperature thermostat Pump runs butthereis 1 ASU is out of adhesive 1 A dd adhesive
52. n O1 02 05 10 2 5 1 0 9 as VOLUMETRIC EFFICIENCY FACTOR Aus A P DIFFERENTIAL PRESSURE PSI o UN APPARENT VISCOSITY CENTIPOISES RPM iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 Appendix 35 Revised 10 00 Pressure Transducer PN 800225 Model 0101 1 5T 1 5 18 EN INSTRUCTION MANUAL Models 9100 0104 0102 0103 Modeis 0410 0141 0412 0413 Models 0126 0121 0122 0123 As with ony of electronic or mechanical instrument the 151 Melt Pressure Tronsducer will perform os required if proper attention is green to proven and well estobished handling are provided ond when followed will ensure that the tronsducer will provide the service and perfomance amp expected of this type of instrument Electrical Checklist PROCEDURE Wiring shown Coble Connection Use six wire shielded cables as provided by ISL or equivalent With the extuder ot operaling fernperature ond no presse applied transducer Adjust the zero conto until readout 200 Push the calibration button ond Odjust spon gos unti readout ot 80 of ful range Calibration Calibration Certificate Range 0 1 500 FSI Rcak 1 200 PSI Zero Balance 0 5 foll scale Full Scale Sensitivity 3 320 Excitation Vollage 10 volts recommended 12 volts moximun INDUSTRIAL SENSORS INCORPORATED 1 4 Telephone 617 725 5249 Fox 617 729 1639 Mechanica
53. of the 40 pin ribbon cable supplied into the connection on the Display CPU board cover Memory Card 4 Connectthe ribbon cable from the CPU board to the connection Reader on the Memory Card Reader assembly connection 5 Reinstall the mounting bracket onto the panel box with the four screws 6 Close the panel box and re connect input power to the application system and start up the ASU Display CPU Board 7 Insert the M emory Card into its slot on the control panel with the terminal connection end of the card leading into the housing The card will click into place when it is correctly inserted cont iTV Dynatec 2001 Installation Page 3 17 DYNAMELT M ASU Manual 20 37 Revised 11 01 8 Onthecontroller s keypad display you will be asked to choose either SAV E meaning that data will be transferred from the controller to the card or LOAD meaning that data will be transferred from the card to the controller 9 Press the F1 or F2 button to confirm your choice or Press the F4 button to cancel out 10 Re insert the card and watch the controller s display to see if the card is being read by the controller Page 3 18 Installation iTV Dynatec 2001 Revised 8 02 DYNAMELT M ASU Manual 20 37 Typical Start Up and Shut Down of the DYNAMELT M Application System The following simplified sequence assumes that the D ynaControl Controller has been pro grammed Start Up Procedures 1 Fill the ASU s h
54. pressure transducer 0 0 to 150 0BAR 0 to 1500PSI 2000 open transd 1 transducer all transd 0x50 P zz n dddd ACK NAK write pressure alarm value 0 0 to 150 0BAR 0 to 1500PSI 1 transd multiple transd 0x70 p 22 n dddd read pressure alarm value 0 0 to 150 0BAR 0 to 1500PSI 1 transducer all transd 4 M zz n d ACK NAK write pump mode S Stop M Manual A Automatic 1 pump multiple pumps Ox6d m 77 n d read pump mode S Stop M Manual A Automatic 1 pump all pumps 0x66 f n a sys data 1 read system status 1 see note 1 0x6a j n a sys data 2 read system status 2 see note 2 0x69 i 77 n d read status of temperature zone see note 3 1 zone all zones 0x48 H d ACK Set system mode see note 4 0x52 R d ACK NAK Set active program number 1 to 4 0 72 d read active program number 1 to 4 0x4c L n a ACK NAK reset error message 1 System status Bit0 Setback active Bit1 Controller on Bit2 Enable thermostat active Bit3 Low Level Bit4 Low Temp Bitb High Temp Bit6 always 1 2 System status Bit0 scheduler avtive Bit6 always 1 8 Zone status O off 1 wait 2 heat up ready 4 low temp 5 high temp 62 sensor short circuit 72 sensor open 4 System mode
55. s ITV Dynatec c 2001 Revised 9 01 DYNAMELT M ASU Manual 20 37 Bill of Materials for DYNAMELT M140 Series Cabinet Assembly 106046 Item No Part Number Description Qty 1 101843 Handle Side Panel 4 2 105880 Panel Top Bracket 1 3 105887 Access Cover M140 2 4 105979 Rear Cover M140 1 5 107890 Manifold Cover 2 108128 Manifold Cover Hi Flow Only 6 105891 Base Plate M70 140 1 7 105882 Top Panel M70 140 1 8 105976 Heat Barrier Panel Box M140 1 9 802657 Panel Box 1 10 802102 DCL Mounting Bracket 1 11 105101 M6 x 16mm SHC Screw 4 12 105865 M6 Hex Nut 8 13 009E006 Swivel Caster 2 14 009E009 Rigid Caster 2 15 101074 Receptacle 8 16 103866 Bracket Connector Bank Amphenol 4 17 103516 M8 HHC screw 4 18 8 Star Washer 4 19 078C008 5 16 Flat Washer 4 20 106111 4 x 12 BHC Screw 16 or 64 21 101304 Blank Plate Dual 0 1 or 7 22 104279 Blank Plate Single 4 23 105111 M3 Hex Nut 0 4 or 16 106048 Lid Assembly 2 24 105117 x 8 Pan Head Screw 4 25 106236 4 Star Washer 4 26 106876 Retaining Clip 2 27 106319 M6 Star Washer 4 28 105865 M6 Hex Nut 4 29 106772 Inner Hinge 2 30 106773 Outer Hinge 2 31 105152 M3 x 6mm PHLC Screw 6 32 106892 M3 Flat Washer 6 33 Hinge Hopper Lid 2 34 106770 Heat Deflector 1 35 106771 Collar Hopper 1 36 101842 Handle Hopper Lid 1 37 106769 Lid Hopper 1 38 806399 Lid with level cnt mnt 807141 Lvl Cnt Assm option 1 Revised 11 03 Component Illustrations amp BOM s Page 10 13 DY
56. setting is 0 0096 full scale Turning clockwise increases the minimum RPM above zero RPM when the motor is enabled This adjust ment can be utilized to creep the motor also referred to as auto preload so that positive adhe Sive pressure is always maintained in the system Troubleshooting Page 7 9 ITW Dynatec c 2000 Revised 9 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 48 Zone Power Printed Circuit Board The 48 Zone Power PCB has the capacity to monitor adhesive temperatures for multiple hoses ap plicators hoppers and auxillary zones The LEDs for each temperature zone 1 through 48 illustrated below will flash on and off as their heaters output to maintain setpoint temperature The Power On and Hopper LEDs will light contin uously once the hopper s are up to temperature The settings of theJP1 and JP2 jumpers correspond to the number of hoppers on the ASU For an ASU with one hopper both jumpers must be set to position 1 2 shown For two hoppers JP1 must be set at 1 2 and J P2 must be set at 2 3 JumperJP1 1 amp 2 1 hopper 2 amp 3 3 hoppers Jumper J P 2 1 amp 2 1 hopper 2 amp 3 2 hoppers Low temperature High temperature Connect to thermostats for thermostats for CPU lat Connect to Connect to Hoppers 1 2 Hoppers 1 2 X16 ee om CPU X1 Power ON 1 1 1 D E 1 contactor S JS1 LEDO Power ON LED Hopper 1 Ready System System
57. single Large HiFlo ZKS 084E413 Zenith 45cc single Large HiFlo SPC Special P ump see sales order 16 5 27215 2 D2 P2 F1GC 2 240V 3P Delta no neutral 3 380V 3P Star neutral only Motor Drive Groups 1 pump Total number of drives Drive Setup Drives Front 1 drive Code PN Panel Box Assembly PE 806460 PF 806462 PG 806464 PH 806466 PI 806461 806463 PK 806465 PL 806467 1 drive 2 hose 2 head 2 auxilliary 240v 2 drive 4 hose 4 head 4 auxilliary 240v 3 or 4 drive 4 hose 4 head 4 auxilliary 240v 4 drive 8 hose 8 head 8 auxilliary 240v 1 drive 2 hose 2 head 2 auxilliary 380v 2 drive 4 hose 4 head 4 auxilliary 380v 3 or 4 drive 4 hose 4 head 4 auxilliary 380v 3 or 4 drive 8 hose 8 head 8 auxilliary 380v PM Custom Designed Panel Box Assembly Code PN Options 107793 Memory Card Reader Kit 101563 Additional Memory Card Digital Filter S Pressure Readout election 101246 40 mesh outlet filter 101247 100 mesh outlet filter Standard 106273 150 mesh outlet filter x CDO V2aCT 805641 Analog Pressure Gauge Kit 1 per pump outlet N06642 Signal Isolator 802886 One Point Level Control Assy 806573 Three Point Level Control Assy 107643 Remote Display Kit 108475 RS232 485 Communication 108313 Digital RPM Readout 108445 Pneumatic Clutch Kit 108425 Handgun Trigger Kit 106103 Drain Valve Installation Page 3 1 iTV Dynat
58. teen doing tee ru uae dd 1104 Other Display languages English French German Spanish Swedish Italian J apanese Portugese and Dutch Operator interface multi zone liquid crystal display with alpha numeric keyboard and function keys Temperature roe P ANO US EUR ada ak a wow a e A yes bore and Few s wed co toe a bine ts ble E bU EDEN E EIE DE TRAVERS yes Ready interlock 242 qanm EE ERA Es eee dea aub do qi nd yes Password protection 5 2 aon wry Wien es Ce eee YR Diem eae be PEOR C SER URDU eel yes Sequential heating yes hopper hose head staged heating Sensor ze poi re dy E u A O ATES yes 5232 and RS485 communications Capabl xa ta Yr e tert ee n ac e eet e ee yes SEVEN Gay Schedule aar dere tee ci ce aet er e ene d A es aa ae E yes LLG CER DCCA ded e ee Ee Mee eer oa ita dede n Odd yes Linespeed TRACKING m yes CE approval deor Dora iC COE doe Dou fuoi a osa doo i oe dde yes Page 2 4 Description amp Specifications Revised 2 04 iTW Dynatec 2001 DYNAMELT M ASU Manual 20 37 lr p 1 1 D AOO 1616 6 6 AAAA 1616 6 1002 4 850 39 46 33 4
59. the product will be jeopardized by the service method selected Appendix 38 iTW Dynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont CONNECTING UNITS TO FORM COMBINATIONS MODULAR CLUTCH MDO NOTE The Modutar Drive Unit MDU Ball Bearing Kem 27 Itam 14 unti the iaces of both units are flush See Figure 1 is loose fitting by design Do not allow this Ball ak Bearing to fall off the MDU WARNING 1 Place the Modular Drive Unit MDU on a table with the Head Cap Screws item 31 Ball Bearing Item 27 facing up and property seated against the Retaining Ring on Models 625 75 and 1375 NOTE orthe Hub on Model 1125 See Figure 1 Make sure the air inet ports are property aligned for your mounting requirements 2 Setthe Modular Output Unit MOU onto the MDU making sure the Ball Bearing Item 27 is fully seated into the 5 Using the four Socket Head Cap Screws Item 31 secure bore of the MOU See Figure 1 the MOU to the MDU See Figure 1 3 Rotate the MOU until the four clearance holesarealigned 6 Altemately and eventy tighten the four Socket Head Cap with the four MDU tapped hotes See Figure 1 Screws Item 31 to 50 Ft Lbs E9 Nem torque See Figure 1 4 Press the MOU down against the Compression Spring MOUNTING MODULAR UNITS MODELS 625 AND 875 TO A MOTOR 1 Place the Kay ttem 19 into the motor shaft then sli
60. to the remote computer s COM 1 or COM 2 Download Instructions Download Transfer data from an external PC to DynaControl 1 DynaControl must be connected to a PC via a Null M odem Cable 2 Start the terminal program on PC 3 Start PC Link on DynaControl Function 5 on Service Page 2 4 f necessary select Configuration and change baudrate than re enter Function 5 5 A ddress setting is not used 6 Press LOAD F1 7 Send ASCII file on terminal program 8 DynaControl screen should list all received lines 9 Press RETURN to exit service mode 10 Customer zone text command Text requires the zone number temperatures 1 48 pumps 49 54 pressure 55 66 Download File Format The downloaded A SCII text is line oriented Pages 29 and 30 show all possible line commands Each line starts with and the command following a number of parameters depending on the command E ach parameter must be separated with a horizontal tab char 09h A tab character must be placed after the last parameter in each line Examples 1 Downloading data for the first filterblock zone Filterblock tab 1 tab 325 tab 30 tab 0 tab ON tab This will set the first filterblock to a setpoint of 325 degrees tolerance 30 no offset zone is switched ON 2 Text tab 50 tab Pump 1 Factory Side This will program the customer pump name for motor 2 which could be pump 1 with the string Pump 1 Factory Si
61. under any circumstances Place a layer of 400 Grit Emery Cloth on alapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 1 approximately ten times until a smooth finish appears Turning in a circular fashion or other non uniform motion may cause the ground holes to lose their perpendicularity to the faces Always use clean lint free rags and compressed air to clean components Paper towels are not acceptable they may leave small pieces of paper and dust on the components U se chemical brushes to clean between gear teeth bores and reliefs 8 Replace sleeve bearings as necessary and hone in the plate to the original new part specifications 9 After each resurfacing carefully gauge the area between the inlet and discharge ports at the mesh of the gears T his area commonly referred to as the throat is the most critical part of the plate Scoring or wear marks here will allow increased slippage from the high pressure discharge port section across the throat to the lower inlet port reducing efficiency Therefore carefully gauge this area for flatness after each resurfacing 10 After all components are hospital clean the pump is ready for assembly P ui Appendix 22 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 HIGH ACCURACY PUMP RE ASSEMBLY NOTE During and between each re assembly step manu
62. up to 48 temperature zones 16 per CPU pcb TheLow Level relay is fixed at normally open TheHigh Low Alarm relay is fixed at normally closed During normal operation the two red indicator lights are always ON Internal connection to Display CPU Board Non volatile Memory Audible Alarm CPU chip Dip switches not used 52 Relay outputs 21 mm 1 amp 2 alarm contacts Lithium battery not 5 xi 3 amp 4 low level contacts O 1 used in M Series Flat cable configuration connect to Software Power PCB chip Flat cable connect xu EPROM to motor interface pcb LED1 monitors DC cutout voltage regulated 5 volts T Terminal connections 1 Program Select 1 1 2 Input 2 4 6 8 412V 3 Low Level Detect Input 5 External Setback Input 7 Program Select 2 3 4 Input 9 amp 10 Ground cutout Flat cable connect to Power PCB Sensor Inputs for Z t ones 6 to 9 Optional RTD Sensor Inputs for Expansion PCB Zones 10 to 15 for ASUs with over 9 zones Sensor Inputs T dif Zones 1 to 5 LED2 monitors DC voltage 12 volts Sensor Inputs for Zone 16 Layout of Components on CPU Board ITW Dynatec c 2000 Troubleshooting Page 7 5 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 2 03 Display CPU Printed Circuit Board The Display CPU PCB contains the controller s CPU module scheduler battery serial ports and op t
63. which is the setpoint plus its high low alarm setting or when it is below its selected under temperature setpoint which is the setpoint minus its high low alarm setting In these cases heater power will not be switched off b When a hopper hose head or auxiliary zone sensor has an open circuit In this case heater power will be switched off Blinking up arrow indicates overtemp Blinking down arrow indicates undertemp SYSTEM Alarm L e5 D Actuals F 2 1 3104 SYM DEF Premelt 2 3 Progmelt Filterblock Hose 213 251 Head HOLD d p Aux Zone Pump MANU TOP STOP 96 HOLD 10LD HOLD b SETPOINTS 0 gt ABC 23 ITV Dynatec indicates no sensor open circuit ITW Dynatec c 2000 Controller Setup P age 4 5 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 11 02 Error Alarms Message Window The display of a message window as illustrated below signifies an error alarm The operator s re sponse to an error alarm is to press F4 and to troubleshoot If a sensor error alarm or an overtemperature alarm occurs during operation the controller will switch off internal power to the heaters and an appropriate error alarm display will appear Pressing the F4 function key acknowledges the error If several zones display alarms each must be acknowledged by pressing F4 The alarm display is switched off and the controller then switches off the faulty zone until the ASU is ready for oper
64. 0 dare 7009 2901 9 waa 38 22 99 96 3b0 7 009 10917 c WAT A38 533 02621 0043780 E 90737090 9903780 90r3v 00 9073760 90 3 00 903709 903760 03 80 909360 6203980 lt 0 3 80 2 X 91 8 6 861 8 0 6601 cw wiwi 38 33 8 0 6863980 0 0 amp zc3vad sorirBo 2 X 91 976 8519870 76624 oooi f seot 9 vna 35 323 620 SUC3 B0 779082960 5153980 S0v3vao 2 X 91 8 6 actvazo 9007 sso x 33 33 0970 2863980 5093960 6ct3vB0 sov3rao X 9 8 t 090820 005 06211223 319815 A38 22 026 2263980 8x X X X X m orJjeso 626360 x o 3r80 2 X 91 8 9 6 840 0627 2 JINIS 33 22 2641 9463 80 vor3r80 _6LE3rB0 cor3rao 8 2 x 91 8 6 9 0 027 cay INIS 34 32 8911 3 80 Or3v 6zt3rB0 S r3v8 8 6 2 X 91 8 9ccvazo 0601 aget FINS 3H 22 vaso r C3v50 0r3ra0 62Ear60 8 2 x 91 8 965 040 3 0NIS 38 29 2620 EcE3v00 vorir n 6 63 80 0 8 S 2 X 91 0 E 9 lt 8 0 226 5 45209 WM L0324 amp 8314 0 17 5 u3lgvavl ASv 8314 4 UBLAVGVE 3215 1706 914 11704 DiW HId 0067 431511 TW NO LND 79001
65. 2 108128 Manifold Cover Hi Flow Only 6 105891 Base Plate M 70 140 1 7 105882 Top Panel M 70 140 1 8 105975 H eat Barrier Panel Box M 70 1 9 802657 Panel Box 1 10 802102 DCL Mounting Bracket 1 11 106110 M5 Hex Nut 8 12 009E 006 Swivel Caster 2 13 009E 009 Rigid Caster 2 14 101074 Receptacle 8 15 103866 Bracket Connector Bank A mphenol 1 16 103516 M 8 HHC screw 4 17 M 8 Star Washer 4 18 078 008 5 16 Flat Washer 4 19 106111 M4 x 12 BHC Screw 16 or 64 20 101304 Blank Plate Dual 0 10r7 21 104279 Blank Plate Single 0or4 22 105111 M3Hex Nut 0 4 or 16 106048 Lid Assembly 2 23 105117 M4x 8Pan Head Screw 4 24 106236 M 4 Star Washer 4 25 106876 Retaining Clip 2 26 106319 M 6 Star Washer 4 2 105865 M 6 Hex Nut 4 28 106772 Inner Hinge 2 29 106773 Outer Hinge 2 30 105152 M3 x 6mm PHLC Screw 6 31 106892 M3 Flat Washer 6 32 105101 M 6 x 16mm HHC Screw 2 33 Hinge Hopper lid 2 34 106770 H eat D eflector 1 35 106771 Collar Hopper 1 36 101842 Handle Hopper Lid 1 37 106769 Lid Hopper 1 38 806399 Lid with level cnt mnt 807141 Lvl C nt Assm option 1 39 808682 O ptional ASU Leg Assembly 5 5 1 40 106321 Washer Flat M8 9x 17 x 1 6 12 41 108297 8 1 25 x 20mm HH Ser FI 12 42 808778 L eg M achine Support 5 5 4 Revised 11 03 Component Illustrations amp BOM s Page 10 11 DYNAMELT M ASU Manual 20 37 TV Dynatec c 2001 Component Illustration DM M70 Cabinet Assembly Page 10 12 Component Illustrations amp BOM
66. 2 SHC Screw 4 4 069X160 Seal Retainer amp Bearing Housing 1 5 069X061 Lip Seal 1 6 018X041 Bearing Sleeve 2 7 100866 100867 Front Plate Assembly 1 8 012D080 012D078 Driven Gear Shaft 1 9 018X031 Ball 1 8 Diameter See illustration for quantity 2 4 10 012C020 012C019 Drive Gear 1 54 cc rev 2 11 069X064 Pump Seal 2 12 078F017 Shaft Retaining Ring 4 13 018X041 Bearing Sleeve Rear Plate 2 14 100865 Rear Plate Assembly 1 15 100908 M4 x 25 SHC Screw 2 16 104775 104776 M10 1 5 x 75mm 80mm 4 17 NPN M10 Flat Washer 4 Tv Dynatec c 2001 Component Illustrations amp BOM s Page 10 19 DYNAMELT M ASU Manual 20 37 Revised 2 01 Pump 100860 has one bearing in this Shaft Pump 100861 has two bearing in this shaft Pump 100861 has two bearing in this Shaft Pump 100860 has one bearing in this shaft In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104042 M10 1 5 x 100 All Thread Component Illustration 1 54 cc Rev Single Gear Pump Assembly 100860 Page 10 20 Component Illustrations amp BOM s Revised 2 01 TW Dynatec 2001 DYNAMELT M ASU Manual 20 37 Bill of Materials for 4 50 cc Rev Single Gear Pump Assembly 100862 Item No oo FF Ut NA FB W NY Part Number 012D072 0781001 101626 069X160 069X061 018X041 100868 012D073 018X031 012C018 069X064 078F017 018X041 100865 100908 104776
67. 251 084E432 Tool Steel Dual High 1 168cc 069X251 084E 434 Tool Steel Single High 2 920cc 069X251 084E436 Tool Steel Dual High 2 920cc 069X251 Thoroughly read and understand this entire manual before installation and operation of pump Note The instructions given herein cover the description installation operation and maintenance of subject equipment D ynatec and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 16 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw pumps Each had problems with pulsation flow inaccura cies multiple seal areas and slippage which required constant calibration high maintenence and extended downtimes Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering The pump s simple design of only three moving parts two metering gears and a drive shaft provided long life and easy
68. 3 Place the gear rear plate 1 with the arbor in position in a soft jaw vise or holding fixture 4 Slip together the driving metering gear 6 drive shaft 4 key 8 and retaining rings 21 Position in the front of the gear rear plate 5 Placethe driven metering gear on its arbor and carefully mesh with the drive metering gear 6 NOTE Repeat steps 3 through 5 for four gear pumps 7 Position the front side plate 3 8 Rotate the gears to ensure free rotation 9 Press the roll pins 41 into place 10 Lubricate the binder screws 23 with DAG dispersion 154 or a similar heat resist ant lubricant and install Torque the screws in even increments to the manufacturer s recom mended limit It is especially important to rotate the gears frequently during this operation 11 Re assemble the seal arrangement making sure the sealing surfaces are perfectly clean and free of scratches nicks or burrs W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 600 grit paper W hen using a carbon seal the coupling housing screws 27 should be torqued to the manufacturer s recommended limit For pumps with a compensation packing seal be sure all old packing is removed cont Appendix 8 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 from the packing housing 12 Inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn Worn shaf
69. 3 on Screen 1 brings up a message screen 00 Recess codes ons O PSI BAR NENNEN System depressurized Pressure Screen 2 SYSTEM Ready Tue L D D Pressure 51 Alarm 51 SYM ape c Sensor Act Low High 100 10 1004 100 q JKL MNO 5 6 1 2 3 4 TUV WXY HIi lt gt LO 19 0 gt 123 ITV Dynatec ITW Dynatec c 2000 Programming Page 5 15 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Optional Pressure Programming Screens Press This To Function Key Pr Limits F2 Go to Pressure Screen 2 to set low and high alarms Setup Enter access code in order to advance to calibration Return F4 Return to the A ctual Temperatures Screen Scroll UporDown FlorF2 Select each sensor transducer Hi lt gt F3 Select the screen s high or low column Bar PSI F1 Choose pressure scale Calibrat F2 Calibrate all transducers Programming 1 The names of the pressure transducers shown on the preceeding page as Pre Filter Pump 1 etc are programmed at Service Page 2 Function 1 see page 5 19 2 On Pressure Screen 1 press Pr Limits F2 to advance to Pressure Screen 2 Use the Scroll keys to select a Low or High limit for the first pressure transducer sensor to be programmed Use the numeric keypad to ent
70. 4852 M 10 x 12 cone Relief Set Screw 2 43 N00199 O ring 114 2 44 107751 Conduit Fitting located in junction box 1 45 N06883 Jam Nut located in junction box 1 46 103570 M5x8x6 SH Set Screw 1 Note These items are included in 108012 Plug Assembly Revised 11 01 Component Illustrations amp P age 10 3 DYNAMELT M ASU Manual All Models T Dynatec c 1999 Plug Assembly 108012 Component Illustration Filter amp Pressure Relief Assembly 102710 Page 10 4 Component Illustrations amp BOM s Revised 2 01 TwDynatec c 2001 DYNAMELT ASU Manual 20 37 Bill of Materials for Pressure Relief amp High Flow Filter Block Assembly 101767 Used On The 106696 High Flow Grid Assembly Item No o 400020 nn Part Number 00185 0030105 006 043 006 072 006 120 006 156 006C135 006G064 006G078 012G001 012G010 048D141 048D142 048J007 048J022 048J117 060E090 069X169 072X093 006G112 078A005 078A030 078A039 078A079 078A099 0784109 078A164 078A178 078A 337 078A379 078C004 078D027 078D037 036B033 036E043 036E079 0786021 0786017 0786013 078 005 072 057 072X262 Description O ring 018 Heater Plate Heat Isolator Block Filter Filter Plug Large Filter Basket Filter Cap Block Pressure Relief Spring Pressure Relief Relief Piston Pressure Relief Screw Junction Box Cover Sna
71. 6 1301 6 342 9 inches 838 2 51 24 13 5 33 B 320 68 1 377 7 12 625 5424 iTV Dynatec 2001 Description amp Specifications P age 2 5 DYNAMELT M ASU Manual 20 37 Revised 2 04 e18 5 8 e Ts T8 8 CIIIS 8 DYNAMELT M140 Installation Dimensions mm 1506 4 850 1301 6 1622 3 177 8 342 9 8382 320 68 1377 7 inches 59 31 33 46 51 24 63 87 7 00 13 5 33 12 625 54 24 Page 2 6 Description amp Specifications iTV Dynatec c 2001 Revised 2 01 DYNAMELT M ASU Manual 20 37 Total System Wattage Capacity Up to 8 Hose Zones 9600 w 9600 w 1200 w each Up to 8 Applicator Zones 9600 w 9600 w 1200 w each Up to 8 AUX Zones 16 000 w 16 000 w 2000 w each Maximum System Wattage pu 57 200 w Main Circuit Breaker Determination M ain circuit breakers vary depending on each unit s system configuration ITW D ynatec typically determines the main circuit breaker by the mains load for a system which by codes should be 12596 to 15096 of the maximum load If a customer later modifies his system by adding heads hoses auxiliary outputs etc the main breaker may need to be upgraded to reflect the increase in load To determine your existing main circuit breaker first determine if the ASU has been modified and the breaker upgraded accordingly If not and the breaker is original to the ASU you will find
72. APAETTY SEE CHART 4 OOOO O 2502 OUTLET PORT 2 HOLES 469 NON STD 40 DEPTH 23064 MOUNTING 13 INLET PORT FRONT VIEW 2 HOLES REAR VIEW REF HPD 5966 HPB 6074 NOTES PUMPS TO BE SHIPPED WITH 4X MOUNTING BOLTS EACH 378 UNC X J 25 ITEMS 52 AND 4X WAGHERS ITEHS 453 pem 1 VARIOUS CC REV l c ESE T Ss 6080 Appendix 27 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Tw Dynatec 2000 19991 80 weet _ 23318 8531 1 15 WS JIVA L LLL mon dWrid WVZHLIS Z 3dAL es L Lm 9NIINDOW 803 z90 X L6L X 89 S SHILI SUSHSVM P ONY CG SWALI 27 X 9 0 8 6 75 01 70 022 HOY3 51208 v HLIM 5 OL ILON GLO9 ddH 996G QdH 334 310H Z M3IA 3015 iT NE 5182 0H 1708 SNILINnOM 9986 LNO HJ tlg 53 or JWH 1708 i SNIINOON 2907 AYMA JH vor E NER 009 1 0 1 9 140d 137400 EE NER SER Ed seis M ra tel y yy ING NIA Bp eel mesos 931vNAU A1I 2 2 U 3 OMddY 31vO ROISIAIY Appendix 28 iTW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhes
73. Appendix 44 iTWDynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont Parts List MODULAR DRIVE UNIT MDU Ball Bearing Hex Head Gap Screw Ring Ext 1 Denotes Repair Kit tem MDU 625 and 875 Repair K amp No 930100 iTV Dynatec c 1999 Appendix 45 DYNAMELT M ASU Manual 20 29 and 20 30 Revised 12 99 Pneumatic Clutch cont MODULAR OUTPUT UNIT MOU 1 Denotes Repair Kit stem MOU amp 25 and 875 Repair Kit No 830300 Denotes Friction Facing item MBU 625 and 875 Friction Facing Kit No 930276 Appendix 46 iTWDynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 2000 Appendix 47 DYNAMELT M ASU Manual 20 36 Revised 10 00 APPENDIX Optional Memory Card Reader The following important instructions pertain to the controller s optional M emory Card R eader For instructions on installation of the memory card see Chapter 3 Installation amp Start U p CAUTIONS 1 When not in use keep the card in its protective case 2 Keep the card away from high temperatures and direct sunlight 3 Do not bend the card or subject it to strong shocks 4 Keep the card dry at all times 5 Avoid direct contact with the connector terminal of the card 6 Keep the card from away from fire Write Protect Function The M emory Card has a write protec
74. C to view SYSTEM Alarm Lo Tue 3 36 System Status Line SETPOINTS F Next Page Press C Temperature Premelt HOLD n priority queue Progmelt 7 299 waiting for release Filterblock l R Zone Status Zone Names Over temp Hose Y Under temp Head 0ff Aux Zone no sensor Zo this is the controller s identifica tion for each zone INFO UPPER PREMELT GRID Set 300 F Act 300 F Tol 30 F Information lines Function keys Scroll Up Down or Right Return to last screen Go to Pressure screen Go to Pump screen Toggle On Off All in category Programming entry 1 2 3 numeric only A B C alpha only A Function keys T Dynatec ABC abc letter case 1 2 3 4 Clear an alarm or message Copy copy word s to a clipboard Paste paste copied words into text Setpoint Programming Screen n Dashed line indicates Progmelts are linked models M70 140 210 only For illustrations of the screens of the Dual Hopper ASUs see pages 5 28 amp 29 SYSTEM Ready Tue 3 36PM Press Enter and Select Mode Actual RPM Set Min Max optional display Pump Mode RPM tach generator required 1 MANU 2 AUTO 5 0 5 0 80 0 RUN 87 3 STOP User chosen INFO RIGHT PUMP Mtr 1 Lock this screen is locked f
75. CH 2 ORILL HOLES FOR ROLL PINS ANG DUAL STREAM HOD METERING PUMP STAINLESS STEEL _ Es 33 1686 ALLGY STEEL Appendix 13 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec 2000 73215 ADVI ONY 5733187001 20 ONY ZY ISIY 114315 SS3 NIV1S 20 ARN JV M ae OTe ee PEP SNId 7108 HO4 53709 O3 IIS G HOLVA 55 9313 ILON sg 015 ISNVY NON Y Y NOILOSS SIA N D In NE HAZ ALY SS NI 1 961 6 6 0020089 Sus ON NOT axopx Sv d 4 9 Teas Se Fe Sev Y HOIH Sci HLIK NADNS NOILYOG LY JN3H3OY IdSIQ 14 HOL3e A38 22 amp iuvd ALIJYdYI IJLYNAOZALI Appendix 14 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 2000 Appendix 15 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 DYNATEC ZENITH HIGH ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL PN 084E 428 084E 430 084E 432 084E 434 084E 436 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 428 Tool Steel Single High 0 297cc 069X251 084E430 Tool Steel Single High 1 168cc 069X
76. Cast H eater 2 40 048 048 1 41D Conduit 4 41 NN00192 O ring 032 2 4 069X 285 O ring 032 kalrez 2 4 42 102446 M 4 0 70 x 10mm SHC Screw 4 43 N 07416 M 8 x 35mm SHC Screw 8 44 078A 055 10 24 x 3 16 SHS Screw 2 084Q 465 Pump Block off Assembly option 45 069X 064 O ring 041 1 46 012G 009 Block off Plate 1 47 N 00834 3 8 16 x 1 25 SHC Screw 4 48 N00754 1 4 Level Seal Plug 2 49 105967 Filter Shutoff Assembly L eft 1 804464 Filter Shutoff Assembly L eft HI Temp Option 1 105968 Filter Shutoff Assembly Right 1 804465 Filter Shutoff Assembly Right HI Temp O ption 1 50 Grid Block Off Assembly 2 51 105149 Block off Plate 1 52 N00192 O ring 032 1 53 108297 M8 x 20mm HH Flange Screw 4 54 N00181 O ring 014 4 Revised 1 03 Component Illustrations amp BOM s Page 10 17 DYNAMELT M ASU Manual 20 37 TwDynatec 2001 Note the dual progmelt for the M70 is identical to the dual M140 with a shorter hopper ngle progmelt for the is identical to the nly one melting Note the S M70 M14 dual with to base plate Page 10 18 Component Illustrations amp BOM s TwDynatec 2001 Revised 2 01 DYNAMELT M ASU Manual 20 37 Bill of Materials for 1 54 cc Rev Single Gear Pump Assembly 100860 Bill of Materials for 3 2 cc Rev Single Gear Pump Assembly 100861 Item No Part Number Description Qty 100860 100861 1 012D079 012D077 Drive Shaft 1 2 0781001 Key Woodruff 1 3 101626 M5 x 1
77. Circuit Board amp Layout Illustration 7 6 M otor Speed Control Printed Circuit Board amp Layout Illustration 7 7 48 Zone Power Printed Circuit Board amp Layout Illustration 7 9 Optional Clutch Printed Circuit Board amp Layout Illustration 7 10 Optional RS232 485 Printed Circuit Board amp Layout Illustration 7 10 Optional Pressure PSI Printed Circuit Board amp Layout Illustration 7 11 Heater and Sensor Resistance 7 12 Resistance Tables s SAN So Se ace ER ce ee Beata oh EON aca N B UNS 7 13 Error Indication Alarm Troubleshooting 7 14 Adjustable Adhesive Pressure Relief Valve 7 22 Operation of the ASU s 7 23 Troubleshooting the ASU Pump 22 2 2 7 24 Gear Pump Troubleshooting Guide 2 1 7 25 Page vi Table of Contents iTWDynatec 2001 Revised 8 02 DYNAMELT M ASU Manual 20 37 Chapter 8 Disassembly amp Re assembly Procedures Disassembly
78. Clutch ON OFF using numeric keys 1 thru 6 ITW Dynatec c 2000 Programming Page 5 13 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Optional Clutch Programming Screen Press This To Function Key Re start F2 Turn ON all clutches at once Stop Turn OFF all clutches Return F4 Return to the Pump Screen Programming 1 To turn individual clutches On or Off toggle individually on the numeric keypad Monitoring 1 On Off status of each clutch is indicated Optional Pressure PSI BAR Programming Screens The two Pressure Programming screens are active only if pressure transducers sensors are installed on your ASU They are reached by Pressing F3 Pressure on the A ctual Temperatures Screen The number of pressure transducers on the ASU will vary per ASU For DM 35 thereis a maximum of four pressure transducers For DM 70 140 there is a maximum of eight pressure transducers For DM 210 thereis a maximum of twelve pressure transducers Pressure Screen 1 cont SYSTEM Ready Tue L 60 D Pressure PSI BAR SYM ABC DEF Sensor Act 1 2 3 100 Pre Filter Pump 1 1004 Post Filter Pump 1 cam pur Pre Filter Pump 2 1004 PostFilter Pump 2 WXY PR LIMITS SETUPrF RETURN 8 9 0 gt ABC 123 ITV Dynatec Page 5 14 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Optional Pressure PSI BAR Programming Screens cont Pressing Setup F
79. EG C 2 SOLENOID S VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION 3 RTD WILL BE PLATINUM 100 OHM HEAD SCHEMATIC PN 103117 REV B Page 11 4 Schematics iTW Dynatec 2001 Revised 6 01 DYNAMELT ASU Manual 20 37 Function of Outlet Filter Manifold s Closeable Cross Channel A Closeable Cross Channel Plug is located inside the Outlet Filter M anifold to prevent adhesive flow between the two outlet filters when a dual pump is in use When a single pump is used ITW D ynatec removes the Cross Channel Plug When changing an ASU from a single to a dual pump or vice versa consult ITW Dynatec for complete instructions D Check Valve 2 Adhesive In P ort Adhesive Return When Cross Channel Plug is removed one adhesive outlet must be plugged 2225 4 22 Cross Channel Plug is removed thru port on side of manifold 2 Closeable Cross x Channel Plug 4C Tj Adhesive Outlet To 4 Hose Adhesive Outlet To Hose The second Adhesive In and Adhesive FLOW DIAGRAM OUTLET FILTER MANIFOLD Return ports are not shown iTV Dynatec 2001 DYNAMELT M ASU Manual 420 37 Transducer p Filter Basket Bypass Schematics Page 11 5 Revised 6 01 TYPICAL HYDRAULIC SCHEMATIC Single Pump Motor Bypass Filter optional Transducer amp optional Pressure Gauge X1 CONNECTOR BLK
80. ITW Dynatec ITW Dynatec GmbH OPERATIONS amp SERVICE MANUAL An Illinois Tool Works Company Industiestrasse 28 Manual 20 37 31 Volunteer Drive D 40822 Mettmann Germany Hendersonville TN 37075 USA Telephone 49 2104 915 0 Revised 5 18 04 Telephone 615 824 3634 FAX 49 210 2104 915 111 FAX 615 264 5222 ITW Dynatec K K Daiwashinagawa Bldg 7 15 Konan 3 Chome Minata Ku Tokoyo 108 J apan iTwDynatec m DM Adhesive Application Solutions ISO 9001 Certified okmarks DYNAMELT M SERIES ADHESIVE SUPPLY UNIT OPERATIONS AND SERVICE MANUAL Model DM M70 140 DCL S oftware V5 11M and up with Expanded DynaControl IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT Itis the customer s responsibility to have all operators and service personnel read and understand this information Contact your ITW Dynatec customer service representative for additional copies NOTICE Please be sure to include the serial number of your application system each time you order replacement parts and or supplies This will enable us to send you the correct items that you need ITW Dynatec Service Parts Direct Dial 1 800 538 9540 ITW Dynatec Technical Service Direct Dial 1 800 654 6711 Page ii Revised 2 01 iTWDynatec 2001 DYNAMELT M70 140 DCL ASU Manual 20 37 This Service Manual is available in the following versions Language English German French Italian Swedish Spanish Dutch Japanese Portugese Finnish
81. Ib DM M 140 140 kg 308 Ib Hopper 5 machined welded aluminum Teflon impregnated PURPA OM ries DC XE hopper bottom screen large pleated pump outlet filter Empleos isa dior uet ha ER E EE TBD Adhesive form tA AE accepts most forms Electrical ARES QR e PEN 200 240 VA C 3p 50 60 Hz 380 VAC 3p Wye Y or 5 wire connection 50 60 Hz M inimum supply amperes see circuit breaker size Power consumption 10 000 watts Power consumption 2 drop in 01105 5 000 watts Hopper heater type n cda a ee qaos en hebt a dey Ry e Prec ke DESEE AT da RY amen cast in Temperature control microprocessor based proportional integral derivitive PID Temperature 5 5 100 Ohm Platinum RTD standard VA detur Seas MERDA CS A Sp EO 120 Ohm Nickel RTD optional Electrical Connectors osi re obe dede sa Cer pef bere E RE CY EAE durable latching connectors os PL phe 1 2 hp alternating current motor TEFC direct drive vertical orientation right angle gearbox M aximum current available for each hose head 10 ampere totally enclosed f
82. If additional motors are used on your application System repeat the above procedure for each motor 8 Close the panel box door and restore application system to normal operation iTV Dynatec 2001 Installation Page 3 13 DYNAMELT M ASU Manual 20 37 Revised 6 01 Installation of the Optional Tach Generator or a DC Tracking Signal The installation of a tach generator or a similar DC tracking signal allows speed tracking of the gear pump through voltage following M ultiple motor boards may be wired in parallel to the tach generator On the controller voltage following is referred to as the AUTO M ode of the motor control Installation Procedure DANGER HIGH VOLTAGE Dynamelt systems use electrical power that can be life threatening Disconnect and lock out input power to the application system before starting any installation procedures 1 Disconnect and lockout input power to the application system 2 Open the panel box and locate the M otor Control Interface B oard see layout illustrtion in Chapter 7 The device will be connected to the 0 and 10 terminals on X3 3 A To install a tach generator i If when facing the shaft on the tach generator the rotation of the shaft is clockwise connect the black lead wire to the 0 terminal and connect the white lead wire to 10 or ii If when facing the shaft on the tach generator the rotation of the shaft is counter clockwise connect the black lead wire
83. LI3AVNAG gt 3 20 Qu U uU Bo Mu ott N iTW Dynatec 2001 Zone Configuration for Prog Melt Filterblock Pumps DYNAMELT M ASU Manual 20 37 Page 11 10 Schematics Revised 12 02 A NA 7C M 0 1 A 2 1 1 PUMP PUMP 1 MIR 1 S MIR 2 on MTR 5 PROG MELT ZONE 3 J PROG MELT ZONE 3 PROG MELT ZONE 19 11 PROG MELT ZONE 3 PROG MELT ZONE 19 PROG MELT ZONE 35 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 PUMP PUMP 2 PUMP 1 PUMP 2 PUMP J oun 2 MIR 1 J MIR 2j qeu MIR 2 J MIR 5j EU MIR 3 MTR 4 PROG MEL ZONE 5 2 PROG MELT ZONE 5 PROG MELT ZONE 19 2 PROG MELT ZONE 5 PROG MELT ZONE 19 PROG MELT ZONE 35 FILTERBLOCK ZONE 4 ducet FILTERBLOCK ZONE 4 FILTERBLOCK ZONE 20 pim FILTERBLOCK ZONE 20 PUMP 1 2 PUMP 3 PUMP P 21 3 MIR 1 MTR 2 MIR j 7N MIR 1 JUL MIR 2 JIL MTR 3 3 PROG MELT ZONE 3 PROG MELT ZONE 19 vo PROG MELT ZONE 3 PROG MELT ZONE 19
84. NAMELT M ASU Manual 20 37 TV Dynatec c 2001 Component Illustration DM M140 Cabinet Assembly Page 10 14 Component Illustrations amp BOM s Revised 12 03 Bill of Materials for DYNAMELT M70 140 AC Drive Assembly 106660 Front 106663 Rear Item No Part Number 106874 106875 104663 106714 106658 108018 106661 106662 109226 106754 106659 103517 106235 106237 801679 106324 106319 N 00732 N 00933 N 00687 106342 078A 183 106341 108313 805095 030A 013 048 184 072X 004 106877 N 00099 N 02745 N 07677 N 08236 110504 110503 N 00093 N 00753 101692 106198 iT Dynatec c 2001 DYNAMELT M ASU Manual 20 37 Description Coupling Half Pump Side Option not part of this assembly Coupling Center Option not part of this assembly Drive Assembly M 70 M 140 M 210 M 6 1 0 x 22mm Coupling Half M otor Side Shaft Gearbox 20 1 Front Drive Assembly 106660 Shaft Gearbox 20 1 Front Drive A ssem 106660 4 5cc pump Shaft Rear Drive A ssembly 106663 Gear Box 20 1 Key 1 4 Sq x 75 Ring Clip M otor M ounting Bracket Bolt M8 x 40mm HHC Screw Washer Flat M8 External Tooth Lock Washer M 8 M otor AC 3P 240v 1HP K 256 Flat Washer M 6 External Tooth Lock Washer M 6 5 16 18 x 3 4 SHC Screw 5 16 Lock Washer 5 16 Flat Washer A dapter Plate 3 8 16 x 1 HHC Screw M 8 1 25 x 40mm SH Set Screw Ring Kit option Optional Pneumatic Clutch Assembly Solenoid 240V
85. PREMELT 1 ZONE 2 PREMELT 2 ZONE 18 PREMELT 3 ZONE 34 2 PREMELIS M 4 PREMELTS M210 6 PREMELIS PREMELT 1 ZONE 1 PREMELT 1 ZONE 1 PREMELT 2 ZONE 17 ET 1 ZONE 1 PREMELT 2 ZONE 17 PREMELT 3 ZONE 5 z PREMELT 4 ZONE 2 PREMELT 5 ZONE 18 PREMELT 6 ZONE 34 PREMELT 4 ONE 18 PREMELT 2 ZONE 2 PREMELT 5 ZONE a gt r the division line between the two hoppers if Dual hoppers ct are installed za on lt v 20 rR Nr Nr Page 11 12 Schematics iTW Dynatec 2001 Revised 12 02 DYNAMELT ASU Manual 20 37 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 2000 Appendix 1 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 DYNATEC ZENITH STANDARD ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL PN 084E 427 084E 429 084E 431 084E 433 084E 435 084E 437 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 427 Nodular Iron Single Standard 069X251 084E 429 Nodular Iron Single Standard 069X251 084E 431 Nodular Iron Dual Standard 069X251 084E 433 Nodular Iron Single Standard 069X251 084E 435 Nodular Iron Dual Standard 069X251 084E 437 Nodular Iron Single Standard 069X251 Thoroughly read and understand this entire manual before installation and operation of pump Note The instruction
86. Programming of the Service Functions on this screen is similar to the programming of Page 1 SYSTEM Ready Tue 3 36PM Service Page 2 Press for Next Page Customer Zone Names PowerOn Configuration Factory Defaults Keypad Locking PC Link Language LCD Contrast System Logbook 4 OY U1 Change Security Lock RETURN Function Press 1 to program Customer Zone Names This function allows the programmer to enter his de sired name for each temperature zone pump and optional pressure transducer This up to 20 character name will be the name displayed in the controller s Info Lines Program following these rules a use the Alpha Numeric keypad to enter letters and numbers When entering letters use one two or three presses of a key to distinguish between the letters Press Enter after each desired letter or number is in place b press the 0 zero key to toggle from letters to numbers C press the SYM key to enter a space colon dash dot 0 2 or other special characters d press F 1 to toggle from upper to lower case e you cannot back up If an error is made press Enter repeatidly to advance through the name loop until you reach the point for correction and re write as desired f press CLR LINE to clear an entire line g you may COPY F2 PASTE F3 and then modify to save time when names are similar h press F4 to advance to the next motor or zone to be named To program Customer Zone N a
87. Relief Valve iTV Dynatec 2000 Troubleshooting Page 7 23 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Operation of the ASU s Gear Pump Manual or Automatic Pump Operation Choose M anual Stop or Automatic gear pump operation via the M otor pushbutton see icon above on the controller s keypad When the Dynamelt s pump is to be operated manually that is without a line following signal the manual mode is used to control pump speed and adhesive output For the gear pump to be operated in the automatic mode a tach generator or equivalent at tached to the parent conveyor line must be provided and the following set up procedure should be performed 1 The tach generator or the signal isolator must be adjusted so that the voltage from the speed controller is 0 to 10 VDC but not more than 10 VDC when the conveyor is at maximum speed This voltage is measured at either on the otor Control Interface PCB for a tach generator or at terminals 9 and 10 of the Signal Isolator B oard 2 The Automatic setting then changes pump speed for any given 0 to 10 VDC incoming tachometer signal Voltage will vary given production speed The motor speed can be adjusted trimmed in automatic mode by setting maximum and minimum percent of full speed values on the controller s keypad MAX of Full Speed will be the true motor speed at 10 volts input This value cannot exceed 100 To make the motor speed
88. Spring 125 x 1 2 14 105099 M8 x 25 SHC Screw 2 15 N07429 M 8 1 25 x 30mm 6 16 006G 112 Cap A djustment Screw 2 17 012 002 Pressure Relief Spring 2 18 109244 Pressure Relief A djustment Screw 2 19 109245 Bullet Hi Pressure 2 20 069X 275 O ring 122 2 21 104733 Plug Pressure Transducer 1 2 20 4 22 078D027 3 4 16 Jam Nut 2 23 101246 Filter Basket 40 M esh 2 24 102711 Filter Block 1 25 102713 Filter Block Heater Retainer Plate 1 26 102714 Pressure Relief Filter Plug 2 27 102715 Filter Plug Retainer Slide 2 28 N04349 Pin Spring 250 x 875 2 29 102716 Slide Housing Frame 1 30 102718 Filter Pull Clip 2 3l 102719 Filter Preload Wave Spring 2 32 103770 O ring 5 005 2 33 103771 O ring 5 254 2 103571 Heater Control Section 240v 1 block 103572 Heater Control Section 240v 2 block 103573 Heater Control Section 240v 3 block 103574 Heater Control Section 240v 4 block 34 036A 170 Heater 5 8 x 5 240v 500w used with 1 Filter Block Assembly 1 036 079 Heater 5 8 x 10 240v 1000w used with 2 Filter Block Assemblies 1 102149 Heater 5 8 x 15 240v 1500w used with 3 Filter Block Assemblies 1 036A 077 eater 5 8 x 20 240v 2000w Used with 4 Filter Block Assemblies 1 35 036E 032 Sensor A dapter 1 36 036B 103 Temperature Sensor 1 37 107754 Cover Hi Temp Sensor amp Heater Section 1 38 107645 Conduit 10 1 39 106156 M4 x 6mm SHSS 1 40 104163 M 6 x 25mm SHC Screw 2 41 101833 10 32 x 1 2 Tamper Proof screw 2 42 10
89. YNAMELT M ASU Manual 20 37 Revised 11 01 Service Page 3 istae x be cia be Tuned tc pe tee bo cma 5 21 Programming at M ain Scheduler Screen 5 22 Use of the Main Scheduler Screen 5 23 Programming of 7 Day 5 5 24 Use of the 7 Day Scheduler Screen 5 25 Programming s sex OC RE 5 25 Programming of the Optional Memory 5 26 U p Downloading Instructions Controller to Remote PC PC Link 5 27 Optional Dual Split Hopper Display amp Keypad Reference 5 31 Chapter 6 Preventive Maintenence General Cleaning oot cte oe ott ed Oa aa A bate oda fug E 6 1 Preventive M aintenance Schedule 6 1 Qutlet Se NOR XC in 6 1 Outlet Filter Manifold illustration 6 2 Replacing the Optional High Flow Outlet Filter Basket 6 3 HOSE Fittings 3 rote S din ctv Ee P CHEER gettin tte nia ee ea uh edat mal eee 6 4 Fasteners iiu imeem ok ei RP APR at og C RAD aaa ne Seb aaa 6 4 Filter Shut
90. Zone Aux Zo 10 Zone Aux Zo 11 Zone Aux Zo 12 System 16 Motor Pump 1 Motor Pump 2 Motor P ump 3 Motor Pump 4 Motor Pump 5 Motor Pump 6 Programming Page 5 31 ITW Dynatec c 2000 Revised 11 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Optional Dual Split Hopper Display amp Keypad Reference Description D ual Hopper models available on DM 140 and DM 210 only contain two hoppers for the purpose of applying two different adhesives or for applying adhesive at two different temperatures On Dual Hopper models each of the A SU s pump motors are assigned to one hopper or the other The DM 210 s pump arrangement is 4 2 illustrated in the following diagrams meaning that hop per 1 System 1 has 4 pumps and hopper 2 System 2 has 2 pumps A 2 2 arrangement is used on the DM 140 D ual Hopper programming and monitoring is identical to the standard models with the exception of having more temperature zones divided among the two systems The controller indicates the active system in the upper status bar The operator moves from system to system in the same man ner that the standard model controller moves from page to page i e by pressing the C key If the operator desires to see the Day Date Clock press the Scheduler key then press 2 Press Return twice to return to the A ctual Temperatures screen As indicated below S ystem 2 temperatures are 5 READY but its low temperature thermostat
91. a heat gun or other controlled heating method is recommended to melt hardened hot melt material Never use a torch or an open flame on any of the components of the application system Once the system is up to temperature disconnect all incoming power before proceeding Remove access door s using the key being careful not to pull off the ground wire attached Turn OFF the filter shutoff valve by turning it to its closed 0 position Motor Removal Open the motor junction box cover 2 screws Inside the junction box dis connect the wires leading to the motor On the outside of the junction box unscrew the hex nut conduit fitting Slide the wires through the conduit fitting Remove the four bolts which attach the motor to the gear box Lift the motor up and out of the ASU For re assembly torque should be approximately 1 8 Nm 16 foot Ibs at room temperature With hopper at 177 C 350 F the maximum allowable torque on screws is 4 1 Nm 36 foot Ibs TW Dynatec c 2001 Disassembly amp Re assembly P age 8 5 DYNAMELT M ASU Manual 20 37 amp 20 38 Revised 6 01 C Pump Removal Verify that the filter shutoff is in its closed 0 position Remove the release pin and retainer clip slide the shaft out of the gear box Slide the coupling off the pump shaft Remove the four pump mounting bolts Release pin amp Retainer clip d Pump Seal O ring Replacement Remove the pump from the A SU see instructions above Coupling
92. a list of the last 1 000 lines of actual temperatures for up to five selected zones The time interval at which these temperatures are recorded is programmable T he first screen of the D ata Logger is the actual data list M ove through the data by pushing F1 Forward or F2 Backward To program press F3 Configure The Data Logger programming screen is seen below Use the ar rows to select a desired function U se the numeric keypad to enter zone numbers or the time interval in 1 10ths of a minute Press Enter to confirm your choices Toggle to select M ode SYSTEM Ready Tue SelectZones 4 12 20 Enter Time Interval 0 1 min Mode Run Stop RUN name of the selected zone Zone 2 RETURN 3 Elapsed Hours the number of hours that the system has been running Not resettable Press 9 to Change Security Lock for Service Page 2 Enter your 4 digit access code Press Enter Press F1 or F2 to select desired function Press F3 to Lock or Unlock function from programming Repeat for each desired function Press Return F4 Press Return F4 again to go to Actual Temp Screen Service Page 3 All of the functions on Service Page 3 ITW D ynatec accessible only No operator programming is possible SYSTEM Ready Service Page 3 Press 3 for Zone Arrangement PI Loop Setup Split Hopper Setup Gear Ratio RPM Display Yes No Pump Clutch Yes No Level Control Yes No 1 O Troubleshooting wo 00 NA ES Change Sec
93. ace this is a DynaControl controller option that allows monitor ing and programming from a customer provided PLC programmable logic controller or a PC per sonal computer P I Loop A temperature control loop which bases heater output proportional P to the difference betweeen setpoint and actual temperature and combines it mathematically with a time I integral factor Power I O PCBs The Power I O printed circuit board PCB provides control signals to and monitoring signals from all the temperature zones in the ASU s system The ASU s hopper hoses and applicators are con trolled by the Power I O PCB Pump Enable Temperature The pump enable temperature protects the pump pump shaft motor and motor control board from damage by not allowing the pump to activate until a low limit the programmed pump enable tem perature is achieved RTD Sensors The standard Dynamelt system uses 100 ohm platinum resistance temperature detector sensors for all temperature controls As an option the unit can be configured for 120 ohm nickel sensors Ready Temperature The programmable temperature on gear pump models which allows the ASU pump to turn ON The default ready temperature range is a deviation of 20 C 36 F from the setpoint The set point minus the deviation is the low limit of the range and the setpoint plus the deviation is the high limit of the range Recipe A program recipe is a set of temperature setpoints and pa
94. ailable as DM M 140 or M 210 units for applications requiring a pump rate up to 2 625 cc min per pump The high flow models are equipped with high flow grid groups including high flow hoppers filter shutoff assemblies filter manifolds and filter baskets DynaControl Options Pendant Control Panel PN 107643 The pendant control option gives the DynaControl keypad mobility via a 9 meter 30 ft 6 meter 20 ft or 3 meter 10 ft cable The Pendant Control Panel replaces the standard display panel Pressure Display PN 108389 DM 70 140 PN 108390 DM 210 The pressure board option enables the controller to read and display adhesive pressure PSI values in the outlet filter manifold The option consists of a PSI printed circuit board which is used with a pressure reading device transducer or gauge mounted on the filter manifold Actual Digital RPM Readout PN 107946 This option provides a controller readout for actual motor or pump revolutions per minute N o addi tional programming is necessary Installation on an encoder is required System Status Lights PN 104280 Remote monitoring of system status is made easier with this tri color light The stack light is mounted on a 6 x 6 box which is itself mounted on a stand with a 10 cable Wired into the con troller the lights illuminate to indicate Power On Ready and Alarm An audible signal ac companies the Alarm light The alarm may be wired to indicate either high low temperatur
95. ally turn the metering gears to en sure that they are free turning If binding occurs at any time determine the cause and correct itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component N ever use force in re assembling or turning a D ynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely Re assemble as follows 1 After all worn parts have been re finished or replaced all parts should be throughly cleaned in a solvent and dried 2 Using the driven gear 7 as an up righting fixture carefully locate the arbor 5 over its press fit hole with the help of an appropriate arbor press 3 Place the rear side plate 3 with the arbor in position in a soft jaw vise or holding fix ture 4 Slip together the driving metering gear 6 drive shaft 4 key 8 and retaining ring Position in the front of the side plate by installing the drive shaft through the bearing 49 5 Placethe driven metering gear on its arbor and carefully mesh with the drive metering gear 6 Carefully lower the center plate 2 over the gears NOTE Repeat steps 5 and 6 for four gear pumps placing the middle plate between gear plates 7 Position the front side plate 1 8 Rotate the gears to ensure free rotation 9 Press the dowels 10 into place moving in the direction of the shortest press distance Usually from the rear side of the pump 10 Lubricate the binder s
96. an cooled iTV Dynatec c 2001 Description amp Specifications P age 2 3 DYNAMELT M ASU Manual 20 37 Revised 6 01 Performance Adhesive temperature control range 40 C to 232 C 100 F to 450 F Standby adhesive temperature range up to 80 C 150 F lower than setpoint Hopper ready adhesive temperature deviation factory set field adjustable 20 C 36 F from setpoint Over temperature cutoff for 232 C 450 F Adhesive viscosity 500 to 50 000 centipoise Warm up time full approximately 0 5 hour Typical adhesive melt rate depends on adhesive used DM M 70 27 95 kg hr 59 209 Ib hr DM M 140 234 115 kg hr 75 253 Ib hr Adhesive D GSSUEG uso sancire Rew ade E OD Eh Ro dca up to 68 bar 1000 psi maximum DynaControl Temperature Control Controller power board 48 zones per board modular construction Display BID uses et cae E Ra a pd Ed NER graphic liquid crystal Temperature control zones DM 70 140 32 maximum with solid state relays Power ODIDUE 2 42 eek tata PE SRR dr RE EN Der MERO ERIT Pd be hopper 10 000 watt hose 1200 watt applicator head 1200 watt auxiliary 2000 watt E 3 15 VDC TILES 2 Dee ae eq He E
97. anual M ode a Press STOP or STOP ALL F3 b Turn OFF the M ain Disconnect Switch 3 If 7 Day Scheduler is in use Turn ON and OFF with the Controller On Off pushbutton Note Except in the case of the 7 Day Scheduler use of the M ain Power Switch to turn the unit OFF will avoid unexpected A SU activation in the event of a power outtage iTV Dynatec 2001 Installation Page 3 19 DYNAMELT M ASU Manual 20 37 Revised 6 01 Storage and Disposal of the DYNAMELT M Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN L 15653 following the instructions detailed in chapter 6 of this manual 2 Clean or replace both the outlet filter and the primary filter following instructions detailed in chapter 6 3 Shut OFF all pressure and power sources 4 Release residual air pressure if applicable 5 Remove all residual adhesive and wipe components clean 6 Remove all air lines if applicable and all power supply cables 7 Pack the unit in a corrosion proof manner 8 Store the unit in such a way that it is protected from damage Disposal of the Unit 1 Shut OFF all pressure and power sources 2 Release residual air pressure if applicable 3 Remove all residual adhesive 4 Remove all air and adhesive hoses and all power supply cables 5 Dismantle all components and sort into mechanical and electrical components 6 Arrange for all components to be recycled Pag
98. ation again W hen the actual temperature exceeds the setpoint limitation plus a tolerance the overtemperature alarm window is displayed and main power is switched off Examples of Error Alarms The Overtemperature A larm indicates that the named zone has exceeded its programmed setpoint limitation Zone Name 4 The controller will shut off power to the heaters Press F4 and troubleshoot the problem Overtemperature The Sensor Failure Alarm can indicate either a sensor open or a sensor short Sensor open is accompanied by Sensor Failure a blinking up arrow on the actual temperatures display screen Sensor short is accompanied by a blinking down Zone Name Ht arrow Press F4 to reset the error message and then either a manually turn the zone OFF via Setpoints F 1 indi cated zone On Off F3 or b troubleshoot the problem The Hopper Overtemp A larm indicates that adhesive temperatures in the A SU s hopper have exceeded the Hopper Overtemp setting of the mechanical redundant thermostat Press F4 and troubleshoot the problem The Communication Error Alarm indicates an internal failure unrelated to zone temperatures Call ITW 22 D ynatec for assistance Communication error Page 4 6 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Optional System Status Lights Audible Alarm This tri color stack light eases remote monitoring of the system s status xi The lower white li
99. ations cse EE Ghi dem ee REDE ERR REGOLE AX ek d Gu RI tek ees 2 2 Installation Dimensions 2 4 Total System Wattage Capacity 2 6 M ain Circuit Breaker Detrmination 2 6 D efinition of ASU Code ira CR ATE 2 7 Chapter 3 Installation amp Start Up Placing the DYNAM EDT ASU i4 ct e t ena eee etw t RU ee RR UN ue 3 1 Open Close Panel Box DOOr 3 2 lationis date dcr ee tme tc Aes a ed rd ca Ns AR 3 2 WISER Connectors ades D dedo ahaa didn ded dolet do i aid d ode act ci dieat ia 3 3 Printed Circuit Board Location Diagram 3 4 Hose Head Electrical amp Adhesive Connections illustration 3 6 Electrical Connections amp Filter M anifold A rrangement M aximum Hose H ead Configuration illus 3 6 Adding AdheSIVG eR Xe ADR A AG na n 3 8 Changing the Adhesive Formula 3 8 Field Installation of Controller Options 4 3 8 Adjusting the Pressure Relief Valve mm 3 9 Pump Enable Ready Thermostat Calibration
100. ators If you are not using a Horton lubricator calibration must replicate the folowing procedure i Close and disconnect the air fine from the unit 2 Tum the Lubrsicator Adjustment Knob clockwise three complete tums 3 Open the air line 4 Close the air fine to the unit when a drop of forme in the Lubricator Sight Gage Connect the air ine to the unit 6 Tum the Lubricator Adjustment Knob counterclockwise ama closed 7 Tum the LubricetorAdjustment Knob clockwise one third um 8 Open the ai line to the uni U aa AIR CONNECTIONS NOTE For quick response Horton recommends a quick exhaust valve and short air lines between the Control Valves and the Modular Units Allan the air intet ports to a down position to allow condensation to drain out of the the air chambers of the Modular Units Adjust the air pressure to approximately 50 psi 3 45 bar when the Modular Unit is installed between a motor and gear reducer When the Modular Unit is mounted using sheaves or Sprockets the air pressure may be regulated between 10 psi 0 7 bar te 80 ps 5 5 bas to ensure air pressure is adequate for torque requirements CAUTION Low air pressure will cause slippage and overheating Excessive air pressure will cause abrupt starts and stops reducing Modular Unit cont iTV Dynatec c 1999 Appendix 41 DYNAMELT M ASU Manual 20 29 and 20 30 Revi
101. bly and of the packing Nichols Copyright 1987 Parker Hannifin Corporation Zenitn Division iTWDynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 H Place the first packing over the shaft and force it firmly and evenly to the bottom of the packing housing Tap it firmly into place 15 Rotate the drive shalt by hand alter each ring is installed to aid seating the packing Continue to install the rings in this manner the proper number of packings have been installed 6 Firmly compress the packing by alternating and evenly tightening up the gland screws then hack off Ye turn Be sure to adjust the gland evenly 8 Some Causes of Pump Failure Problem Cause Seizure foreign particle b mounting block not flat C uneven heating d lack of lubrication interference fit of moving parts Excessive Slippage amp worn gears thickness and out reduced pump side reduced diameter corners etficiency of teeth not square b worn center plate side plates scored at throat amp side plates not flat Seal Leakage pieni or scratched coupling or te b drive shaft bottaming in slot of coup ng C drive shaft misatigned A minor seal leak weep is not abnormal and may be desirable for tubricating the seal surfaces 9 Rehabilitation Pumps may be returned to an authorized repair facility for rehabilitation repaired pumps must pass the same strict
102. c c 2000 Revised 7 02 DYNAMELT M ASU Manual 20 36 20 37 20 38 Service Functions Screens Page 1 cont Press 6 to program Temperature Offset Enter a numeric value for the first zone selected Press Enter Scroll to next desired zone and repeat until all zones are programmed Press R eturn F4 Note to enter a negative value enter the value then press N egative F 3 The Temperature Zone Offset is a mathematical factor which compensates for differences in tem perature between the placement of the system s heaters and sensors An offset is often used for large applicator heads printrolls printwheels or other custom devices U sually no offset is re quired for standard heads The offset may be programmed up to 50 degrees C or F of the zone s temperature Press 7 to program Sequential Heating Scroll to choose one of the three selections No sequence First all hopper zones or Hold electric head Press Confirm F3 Sequential heating allows you to choose the heating order of the temperature zones so that zones requiring more time to heat up to temperature can be programmed to begin heating before others In the case of the Hold Electric Head selection programming of a reduced temperature for ten minutes allows for the stabilization of the electric valves a A No sequence designation means that all temperature zones will begin to heat immediately after the ASU is powered on b Firstall hopper zones means that the hose
103. cal to system pressure to escape 9 Replace or re install the filter basket onto the spring clip Push the filter onto the clip The clip should straddle the wire bar located inside the hole at the top of the filter 10 Lower the filter basket and the filter plug back into the filter cavity 11 Position the two flat surfaces at the top of the filter plug parallel to the movement of the 12 Re tighten the two purge screws slide The slide will not return to its operating locked position unless these flat surfaces are aligned properly If necessary twist the plug to align o 7 Retainer gt Plate Screws SW Filter Plug Replacing the Optional High Flow Outlet Filter Basket 1 The system should be at operating temperature before starting lt Oring this procedure lt lt Filter Before proceeding verify that the motor s is turned OFF and TE ut the applicators have been triggered to relieve pressure Remove the M anifold A ccess Cover Note itis not necessary to remove the Lower M anifold Cover Using insulated gloves and an allen wrench remove the retainer plate screws Lift out the retainer plate filter plug assembly Outlet Filter Manifold cont High Flow Filter Manifold Remove the clogged filter s and install a replacement filter Page 6 4 Preventive Maintenance iTWDynatec 2001 Revised 2 01 DYNAMELT M ASU Manual 20 37 20 38 Note the filter s ma
104. ce table in this chapter X14 Page 7 18 Troubleshooting Revised 10 00 iTWDynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Optional Drop in Grid H eater Open Heater Leads 1 Inspect grid s heater wiring for proper connections 1 Disconnection in grid s heater circuit 2 Verify that the Power PCB is properly connected to the solid state relay 2 Disconnection between Power PCB and solid state relay 3 Refer to the schematic in Chapter 11 to locate the grid s circuit breaker If itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit to ground in the grid s heater circuit This will be limited to between the grid s control relay and the grid s heater 3 Drop in grid circuit breaker tripped 4 Atthe terminal rail use an ohmmeter to measure resistance as follows Forlgrid H1A amp N 380v H1A amp H1B 240v For 2nd grid H2A amp N 380v H2A amp H2B 240v 4 Open drop in grid heater element NOTE TheDM 35 ASU ma have 1 or 2 grids The DM 70 140 ASU may have from 1 to 4 grids For 3rd grid H13A amp N 380v The DM 210 A SU may have H13A amp H13B 240v from 1 to 6 grids For 4th grid H14A amp N 380v H14A amp H14B 240v For 5th grid H25A amp 380v H25A amp H25B 240v For 6th grid H26A amp N 380v See the resistance table in this chapter for normal resistance values Infin
105. cessor Board CPU Circuit Breaker CB 16A 2P 690V ABB CC Circuit Breaker CB 20A 100F 690V 2P ABB Ground Small D ual Side Insert panel Filter RFI EMI M4 x 12 Button head Screw Contact Nor Open Ground BUS 2A mp Fuse 2ND MAIN CB 40 amp Contactor 3P 50A RES 240V COIL Snap on Stand off Fuse Holder Nuetral Block Fuse 15A LP CC Ground Bar Power Board Pressure Board Bus 65A CB L1 L2 L3 Endcap Bus PSB12N 65A Eprom Chip Ribbon Cable A ssm 15PinM 9 PinF Serial 8 conductor crimp on Control A ssembly K ey Pad Label Cable Assembly Bracket M otor Control Interface M otor Choke RFI EMI 30A C M otor Speed Control Stand Off Clutch Board KBSI Board Ground L ug NEU BLK 350M CM 4 14X 12 380V units only Q uanities model driven PoP N LI 1 e gt 1 4 4 16 1 4 Revised 2 03 Component Illustrations amp BOM s Page 10 9 DYNAMELT M ASU Manual 20 37 iTVW Dynatec 1999 or Pendant Control Page 10 10 Component Illustrations amp BOM s iTW Dynatec 2001 Revised 4 03 DYNAMELT M ASU Manual 20 37 Bill of Materials for DYNAMELT M70 Series Cabinet Assembly Base Unit 106045 Item No Part Number Description Qty 101843 Handle Side Panel 4 2 105880 Panel Top Bracket 1 3 105886 Access Cover 2 4 105978 Rear Cover M 70 1 5 107890 M anifold Cover
106. correct pump type 1 Remove the seal arrangement 2 Remove all binder screws 3 Remove dowels 10 and arbor 5 with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Dowels and arbors for the high accuracy pumps are press fit in the rear front plate 1 and slip fitin the center 2 and side plates 3 cont iTV Dynatec 2000 Appendix 21 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 4 Separate the plates by pry slots Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 5 After disassembly clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning Alternative non destructive cleaning methods such as Water jet or solvents are also acceptable 6 Wash components in an ultrasonic cleaning tank and air dry Be careful not to bang parts together 7 Inspect all parts for nicks burrs score marks and other signs of wear The plates and faces of the gears may be hand blocked on 400 600 grit paper and any nicks burrs or sharp edges can be lightly removed with a honing stone Be careful not to round off the edges of the gear teeth while lapping CAUTION Sincethe thickness relationship between the metering gears and the center plate is critical to metering performance and the center plate is non wearing on its sides lap ping these components is not necessary and should not be done
107. crews 47 48 with DAG dispersion 154 or a similar heat re sistant lubricant and install Torque the screws in even increments to the manufacturer s rec ommended limit It is especially important to rotate the gears frequently during this operation 11 Re assemble the seal arrangement making sure the sealing surfaces are perfectly clean and free of scratches nicks or burrs W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 400 600 grit paper W hen using a carbon seal the coupling housing screws 27 should be torqued to the manufacturer s recommended lim it For pumps with a compensation packing seal be sure all old packing is removed from the packing housing 12 Inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn Worn shafts will result in premature seal leakage and should be replaced 13 Pack lip seals 15 with a silicone based grease and lubricate with Parker Super O L ubricate or an equivalent silicone based oil 14 Install lip seals into seal housing 22 as shown 15 Tighten seal housing screws to 60 Ibs in Check for rotation iTV Dynatec 2000 Appendix 23 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread Torque L ubricated T hreads UNC Alloy Steel L bs in Nxm Lbs ft 10 24 w carbon seal gasket 50 57 4 2 10 24 w o carbon seal gasket 64
108. d not customer programmable Minimum setpoint value 10 C 50 Maximum setpoint value Setpoint limitation 218 C 425 F for high temp mode enabled ASUs 232 C 450 F Maximum alarm deviation 50 C or F Minimum alarm deviation 5 C or F Maximum standby temperature 150 C or F less than setpoint Minimum standby temperature 30 C or F less than setpoint Actual temperature indication range 0 C to 260 C 32 F to 500 F Customer Programmable Values Preset At The Factory ITW Dynatec can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the DynaControl con troller at the factory They may be changed by reprogramming through the keypad These are not the default settings see following section Applicator head and hose setpoints varies from 138 to 149 C 280 to 300 F Hopper setpoint 143 C 290 F All zones are switched off except for the hopper and the optional drop in grid Motor rpm 0 in the OFF mode Standby 80 C 140 F under setpoint Hi and low alarms 12 C 20 F from setpoint Pump enable temperature 132 C 270 F Page 4 8 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Default Settings of the DynaControl Controller Default settings are the manufacturer s preset values to which the system wil
109. de cont Page 5 28 Programming ITW Dynatec c 2000 Revised 10 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Important Note the last command in the download file must be End Notes The command lines may be arranged in random order M aximum file length is 5000bytes Each data field may have a comment text tab Setpoint 325F tab tab 325 tab The DynaControl list screen indicates the commands in abbreviated form A after the command on the D ynaControl list screen indicates a wrong parameter indicates unknown command or syntax error If downloading system info using the System command the controller does not check for validity of the parameters Upload Instructions The upload function will send an ASCII fileto the external PC PL C The file contains all zone related information The size of the file depends on the number of zones pumps and pressure transducers The data format is similar to the download file Example PREME 1 41035 5 PUMP 2 M 850 100 900 Premelt 1 setpoint 410 tolerance 35 offset 5 zone is ON Pump 2 manual mode with 85 0 min speed for automatic 10 0 max speed 90 0 Customer zone names will be indicated with TXT TE for temperature zones TXT PU for Pumps TXT PR for Pressure transducers 1 DynaControl must be connected to a PC via a Null M odem Cable 2 Start terminal program on PC 3 Start PC Link on DynaControl Function 5 on Service Page 2
110. de the motor shaft into the Modular Unit See Figure 7 2 Rotate the Modular Unit until the clearance holes in the Modular Unit are aligned with the tapped holes in 1he Moior then using the four Hex Head Cap Screws Item 33 and Lock Washers item 24 secure the motor to the Modutar Uni See Figure 7 3 Altemately and evenly tighten the four Hex Head Cap Screws to 20 Ft Lbs 27 Nem torque cont iTV Dynatec 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont ALL MODELS AND MOTOR TO A REDUCER CAUTION When mounting sheaves or sprockets refer to Table 1 for overhung load data Exceeding the data in Table 1 will result in premature failure to the Modutar Unit 1 Placethe Key Hem 19 output shaft of the Modular Uni and side the output shaft of the Moduiar Unit and motor into the reducer 2 Rotate the Modular Unit and motor until the hotes in the Moduler Unit are aligned with the holes m the veducer flange and the air inlet ports of the Modular Unit are facing down 3 Using four Hex Head Screws secure the Modular Uni and motor w the reducer 4 Altemately and evenly tighten the tour Head Cap Screws making sure the Modular Unit and reducer faces are flush with each other HOUSING GUARD INSTALLATION WARNING Always have the Housing Guard in place when operating Modular Units See Figure 9 Each Modular Unit is provided with Housing Guard After combini
111. deviation and low limits 2 Grid sensor inoperative 2 Examine grid sensor assembly for intermittent break in sensor lead Remove sensor bulb from grid Replace grid sensor if resistance does not comply with the resistance table in this chapter iTV Dynatec 2000 Troubleshooting Page 7 17 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 3 Grid control solid state 3 Use a clamp on ammeter to monitor relay inoperative current R eplace inoperative solid state relay Optional Drop In 1 Sensor cable has become 1 Verify that grid sensor cable is Grid Sensor O pen unplugged from CPU properly connected at X 14 on the CPU PCB 2 Disconnection between 2 Verify that all connections are properly Power PCB and the CPU made on the CPU PCB PCB 3 Drop in grid sensor 3 Replace sensor if resistance does inoperative not comply with the resistance table in this chapter Optional Drop in 1 Short circuit caused by 1 Verify that sensor plug is clean and Grid Sensor Short debris where sensor plugs correctly connected at X 14 on the into CPU PCB CPU PCB 2 Pinched sensor lead wire 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the sensor lead to the plug at X 14 on the Power PCB Repair or replace any damaged wire 3 Drop in grid sensor 3 Replace sensor if resistance does inoperative not comply with the resistan
112. dling Printed Clrcuit Boards in this chapter before handling or attempting service on Dynamelt s PCBs The Dynamelt s DynaControl includes malfunction self diagnostics alerts and error indication alarms The error indication alarms the alarms displayed on the D ynaControl readout are triggered whenever there is a sensor failure and whenever there is an over temperature condition T he opera tion of the error indication alarms is described in Chapter 4 of this manual Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 TheASU is supplied with power 3 TheASU is supplied with pneumatic air 4 Pneumatic and electrical connections are correct 5 Adhesive is in the hopper Error Messages See Ch 4 for complete instructions on Error Alarms and M essages Sensor Failure on Zone temperature zone has an open or shorted sensor Overtemperature on Zone temperature zone has exceeded setpoint limitation Communication Error indicates a serious problem which requires service by Dynatec Hopper Overtemp hopper temperatures have exceeded their thermostat s setting Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the A SU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunction does not move
113. ducer position Page 5 16 Programming ITW Dynatec c 2000 Revised 7 02 DYNAMELT M ASU Manual 20 36 20 37 20 38 Service Functions Screens The three Service Function Screens are designated Service Page 1 Service Page 2 and Service Page 3 They are accessed by pressing the Service K ey 1 2 or 3 times Functions coded are active and require no code to program Functions coded with key 7 are locked and require entry of a code before programming For example as seen on the diagrammed screen below Setpoint Limitation is locked from further programming Functions coded m6 are ITW D ynatec factory setups and are not user accessible Program the Service Functions as described on the following pages M any functions are pro grammed simply by a toggle or by a single numeric entry Service Page 1 Service Key SYSTEM Ready Tue 3 36 PM 4 Service Page 1 Press S for Next Page Hi Lo Temperature Standby Temperature Standby Sleep Setup Setpoint Limitation N A Temperature Offset Sequential Heating C S 00 NA ES Change Security Lock RETURN 0 gt 123 T Dynatec Alpha Numeric Enter Keypad ITW Dynatec c 2000 Programming Page 5 17 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 7 02 Service Functions Screens Page 1 cont Function Press 1 to program High Low Temperature Deviation Enter a numeric value for the first zone selected Press Enter to conf
114. e low adhesive level or open short sensor cont Page 9 4 Options amp Accessories iTV Dynatec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 20 38 Memory Card Reader PN 107993 The M emory Card Reader is an option which gives the ability to store and transmit system parame ters start signals and setpoints on credit card sized card It is useful for systems which utilize multiple D ynamelt units Production security is assured since with the keypad locked the card reader prohibits unauthorized changes to the production process except for a 5 C flexibility adjustment For example if a 175 C production setpoint is programmed the card reader allows the operator to make adjustments only between 170 and 180 C Line Speed Tracking Options Line speed tracking is a standard feature of the M Series 505 which allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage input W hen operated as the standard feature a 0 10v signal from a PLC or a similar line speed output device is utilized However it may also be operated utilizing one of the following optional devices PN 0150050 Tach Generator a mechanically operated device which produces a reference voltage that allows the A SU s gear pump to track a parent machine s production line speed PN N06642 Signal Isolator a device which conditions a parent machine s production line s DC speed reference voltage to allow the ASU s gear pu
115. e 3 20 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions ITW Dynatec c 2000 Controller Setup Page 4 1 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Chapter 4 DynaControl CONTROLLER SET UP Temperature Control Functions in General The DynaControl microprocessor based proportional temperature control in the ASU performs a number of functions that help to maintain adhesive setpoints in all temperature zones of the DYNA MELT system It maintains permanent system values fixed proportional and integration values that have been programmed at the factory such as the maximum temperature setpoint It enables the user to program temperature settings and heater on off sequencing that are appropriate to a specific ap plication It displays all programmed values and it includes self diagnostic malfunction alerts and failure alarms Note Some D ynaC ontrol functions are direct temperature conversions between de grees Celsius and Fahrenheit Other parameters are independently selected values Defining DynaControl Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained CPU Module The central processing unit CPU of the microprocessor temperature control Cold Start When the ASU resets itself to default set
116. e Setpoints Programming 5 5 9 Programming si oce terea pant es Mm dr cd Ant b qe D Ra tb ata c MU 5 9 A Na Retos Ae efe due 5 9 Motor Programming 5 5 10 Use of the M otor Programming Screen 5 11 Programming 3 it Dacos cia ede UT Ram Eas intern sees deed 5 11 MONITORING 72 Bossi fo edite e og oth han host d anton te p Df e 5 11 Optional Clutch Programming Screen 5 12 Use of the Optional Clutch Programming Screen 5 13 Program MING s uo ed den es reti e Bed D lect eret Don at dy Kein Mae Rer oS 5 13 MOMITOFING RR RO Ee 5 13 Optional Pressure PSI BAR Programming Screen 5 13 Use of the Optional Pressure PSI BAR Programming 5 5 15 Programming uiu dee iy AUTO COE RO nas 5 15 MONITORING cocto cto etr ru doceas a s MUT c Lot Dr A ata Mice caf ate ge 5 15 Service Functions Screens 4x34 a O A a da tete ERR NEA 5 16 ServicePagel sour
117. e dictates 1 Check all hose fittings for tightness 2 Check all fasteners for tightness 3 Inspect filter shutoff Clean or replace as required Flushing the System Contaminated adhesive accumulation of residue in the system and hopper or changing the adhesive formulation may require the system to be flushed To flush the system have at least 6 liters 1 5 gal lons of flushing fluid on hand PN L 15653 per hopper Repeat this procedure for each hopper of a dual hopper ASU WARNING The flushing fluid will splash easily Wear protective clothing gloves and a face shield to prevent severe burns 1 Pump out as much of the molten adhesive from the hopper as possible 2 Reduce A SU s pump pressure to zero Note the hose used in the following process is merely for the convenience of depositing flushing fluid This procedure does not have to be repeated for each hose in the system 3 Disconnect one of the supply hose s adhesive feed from its applicator head Do not cont Page 6 6 Preventive Maintenance iTWDynatec 2001 Revised 2 01 DYNAMELT M ASU Manual 220 37 20 38 disconnect the electrical power to the head since that would disable the pump Put the hose in a secured position within a container which will catch the used flushing fluid 4 Addflushing fluid to the hopper and allow approximately fifteen minutes for it to reach hopper temperature Carefully stir the flushing fluid to mix with any adhesive re
118. e maintained at 13mm to 100mm 1 2 to 4 from the top of the hopper W here applications demand a high output volume of adhesive add small amounts of adhe sive frequently A dding large amounts of adhesive to an almost empty hopper will lower the tempera ture of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint Changing the Adhesive Formula If a different adhesive formulation from the one being currently used is needed the system will haveto beflushed if thetwo formulations areincompatible See Chapter 6 of this manual forthe proper flushing procedure W hen in doubt about adhesive compatibility flush your system Field Installation of Controller Options Customers who choose to modify their adhesive supply unit with ITW D ynatec manufactured options should assure that only qualified technicians perform such installations The installation of options that require specific procedures and or calibration are outlined in this chapter Before controller options are installed always turn the controller s main power switch OFF In most cases turning the controller OFF will assure that the controller will retain its programmed parameters and configuration R e booting is not necessary iTV Dynatec c 2001 Installation Page 3 9 DYNAMELT M ASU Manual 220 37 Revised 6 01 Adjusting the Pressure Relief Valve Thefunction of the pressure relief valve is to protect the gear pump s and the pump drive compo nents fro
119. e temperature programming features the Dynamelt system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time A four layered shielded CPU printed circuit board protects the microprocessor from external inter ference The temperature control can interlock the parent machine with preselected adhesive tem peratures so that production automatically begins when adhesive temperatures are correct for the application All system temperature values can easily and quickly be programmed A n optional re mote control panel gives control and monitoring flexibility Digital readout of system conditions is provided A security code can restrict access to system pro gramming and parameters The CPU monitors the electronic circuitry and provides alarms for error conditions The Dynamelt M ASU uses an extremely dependable gear pump s to assure a smoother and higher precision flow The single or dual pumps are driven by individual drives The Dynamelt s teflon coated hopper accepts adhesive in all popular forms including pellets slugs and blocks The ASU can accomodate air actuated automatic applicators heads electric applica tors hand held applicators and or special applicators Options available include pressure gauge two drop in grids dual hopper pneumatic clutches digital pressure readout and adhesive level con
120. e to program 2 On the numeric keypad enter the desired setpoint value 3 Press Enter 1 4 Scroll to the next setpoint to be programmed and repeat steps 2 and 3 N otes a To turn a zone OFF scroll to zone press Enter to select press ON OFF F3 b When turning a switched off zone back ON it will retain its previous setpoint c To change all zones in a category ie all hoses or all aux zones etc scroll to one item in that category enter desired value then press F1 this does not apply to zones which are turned OFF Monitoring 1 Zo the number which appears here is the controller s identification number for this zone This number cannot be changed by user 2 The Zone Info L ines indicate the user defined zone name programmed on Service Page 2 menu item 1 the zone s setpoint the zone s actual temperature the zone s tolerance programmed on Service Page 1 menu item 1 and the zone s identification number Page 5 10 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Pump Programming Screen cs Optional RPM Display SYSTEM Ready 36 4 e5 D Press Enter and Select Mode Min SYM DEF Pump Mode 96 2 3 1 MANU 2 JKL 3 STOP 5 6 INFO RIGHT PUMP 2 3 my wy 0 gt ABC 123 ITV Dynatec Alternative programming function keys EEA EUN E7778 ITW Dynatec c 2000 Programming Page 5 11 DYNAMELT M
121. ean all components in a non destructive solvent 6 Wash components in an ultrasonic cleaning tank and air dry Be careful not to bang parts together 7 Inspect all parts for nicks burrs score marks and other signs of wear The plates and faces of the gears may be hand blocked on 600 grit paper and any nicks burrs or sharp edges can be lightly removed with a honing stone Be careful notto round off the edges of the gear teeth while lapping CAUTION Sincethe thickness relationship between the metering gears and the gear rear plate is critical to metering performance and the gear rear plate is non wearing on its sides lapping these components is not necessary and should not be done under any circum stances Place a layer of 600 Grit Emery Cloth on a lapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 1 approximately five times until a smooth finish appears Turning in a circular fashion or other non uniform motion may cause the ground holes to lose their perpendicularity to the faces Always use clean lint free rags and compressed air to clean components Paper towels are not acceptable they may leave small pieces of paper and dust on the components U se chemical brushes to clean between gear teeth bores and reliefs 8 Replace sleeve bearings as necessary and hone in the plate to the original new part specifications 9 After each resur
122. earance between the metering gears and their housing must be as small as possible yet large enough to allow adequate lubrication All parts are ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances cont iTV Dynatec 2000 Appendix 5 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 these pumps require careful maintenence and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure T hese pumps are precision instruments you can t keep them too clean Please treat them with care and if it s at all possible set aside a separate clean area for pump maintenance To clean High Accuracy M etering Pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer Time at temper ature will be related to the pump size and the degree of polymer contamination and should be determined by trial Note Careful control of he furnace temperature 700 degrees F max and atmosphere is critical Should the temperature exceed the original tempering temperature the steel hardness will draw back and the dimensional stability of the pump may be upset A nother acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath shold be heated to a temperature that is sufficient t
123. ec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 Chapter 3 INSTALLATION Placing the DYNAMELT M ASU The DY NAMELT M SERIES ASU can stand alone on flat surfaces T he main electrical power and the serial communication connections in from below the unit and connect under the Dy naControl keypad so access is needed there For installation dimensions see illustration on page 2 4 Hopper Lid Controller Keypad Hose Head Electrical Connections Main Disconnect S witch Manifold Keylock Cover Panel Box Va Keylock 0 Door Keylock Panel Box The DYNAMELT M70 140 DCL ASU Page 3 2 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT ASU Manual 20 37 Re read Chapter 1 Safety Precautions before performing installation procedures All installa tion procedures must be performed by qualified trained technicians lt ON To Open Close Panel Box Door Position 1 With the key supplied unlock the panel box door 2 Turn the main disconnect switch counterclockwise to Reset while pushing the tab clockwise with your thumb 3 Pull door open 4 To close Turn switch to ON Hold door closed while turning swith to Reset and then back to ON 5 Lock the panel door with the key Installation After the DY NAM ELT M SERIES ASU has been properly positioned the following general sequence should be
124. ed to the pump size and the degree of polymer contamination and should be determined by trial Note Careful control of he furnace temperature 950 degrees F max and atmosphere is critical Should the temperature exceed the original tempering temperature the steel hardness will draw back and the dimensional stability of the pump may be upset A nother acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath shold be heated to a temperature that is sufficient to carburize the polymer T he car burization process usually takes between 3 and 12 hours depending on the polymer type temperature pump size and furnace load cont Appendix 20 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning A fter gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent It may be necessary to disassemble the seal arrangement to remove polymer ash If present always replace the carbon seal plate after pump burnout If the pump was perform ing satisfactorily when removed from service and still turns freely after burnout pressure test it and add a high temperature lubricant to prepare it for return to service To store for future use simply add a rust preventative oil It is recommended that pump users institute a program of dimensional inspection of critical parts in order to
125. ee illustration on page 3 6 Each hose is connected at both an adhesive port and an electrical connect M ake your electrical hose connections at the numbered connects above the filter manifolds R oute hoses so that there is at least an eight inch radius at any bend Do not hang hoses without proper support Do not crimp clamp squeeze or tie hoses Two feed hose adhesive ports are located at the bottom of each filter manifold When making hose connections use the numbered guides shown on the illustration to coordinate ie when using one hose make your hookup to electrical connection 1 and adhesive port 1 When using two heads hoses hookup hose head 1 to electrical connection 1 and adhesive port 1 then hookup hose head 2 to electrical connection 2 and adhesive port 2 etc Two return hose adhesive ports are located at the top of each filter manifold U se the illustration to coordinate adhesive port and electrical connections as above Return hoses are designated as auxiliary ports 5 Connect optional PSI transducers at the PSI ports labeled on the filter manifold Position them from left to right across the manifolds as shown in the lower illustration on page 3 6 Transducers measuring adhesive pressure before it enters the filter use the ports stamped Pre PSI and transducers measuring pressure after the filter use the ports stamped Post PSI Transducers must be wired into the pressure printed circuit board Units not us
126. er and D ynatec should be notified immediate ly W hile the pump is composed of steel it is a precision instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat cont Appendix 4 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 them as you would any other precision gauging instrument D ynatec Zenith pumps are shipped filled with a rust preventive oil Flush the oil throughly with a cleaning solvent It may be necessary to disassemble the seal arrangement to remove all traces of the oil but disassemble only if necessary After flushing the pump should be lubricated internally for start up purposes Pour a suitable high temperature lubricant silicone oil into the inlet port Rotate the metering gears until lubricant appears at the discharge port M ount the pump to a block with a flatness of true flat to 0001 convex and a surface finish of 4 to 8 rms to prevent leakage between the pump and block M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to Dynatec s recommended limit for the bolt size used See Table 1 on page 10 for torque values The following is a brief standard installa
127. er retainer plate then remove the heater s H eater plates are kocated underneath the hopper s Remove the access door Use a hex head socket wrench to remove the six heater plate bolts through the holes drilled in the base plate Disconnect the heater wires Slide the old heater plate out Connect heater wires to new plate Slide new plate in place and fasten with the six bolts Note the DM 70 amp 140 models have two heater plates the DM 210 model has three heater plates TW Dynatec c 2001 Disassembly amp Re assembly P age 8 3 DYNAMELT M ASU Manual 20 37 amp 20 38 Revised 6 01 To Remove Rear Cover No customer replaceable components are behind the rear cover To remove remove the two ac cess doors in order to access and remove the five screws which hold the rear cover in place Two screws are located in the upper corners of the rear cover Three screws are located across the bot tom of the cover To Access the RTD Sensor in the Optional Drop in Grid Remove the access door Remove the screws on the drop in grid s junction box cover in order to remove the cover Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter To Access Electrical Components inside the Panel Box DANGER HIGH VOLTAGE Dynamelt systems use electrical power that can be life threatening Disconnect and lock out input power to the application system before starting any disassembly procedure Verif
128. er your desired value Press Enter R epeat until all desired pressure transducers are programmed with Low and High pressure limits Use Hi lt gt Lo F3 to move be tween columns as necessary 3 Press Return F4 to return to Pressure Screen 1 Press Setup F3 On the first message screen enter your four digit access code On the second message screen enter the maximum ar PSI val ue of the pressure transducer s installed on your ASU 4 Press Bar PSI F1 to choose display in Bar or PSI 5 Press Calibrat F2 to calibrate all the pressure transducers installed The controller will ask System depressurized press Confirm F3 Note Before confirming verify that all transducers are at 0 pressure Pumps must be turned OFF and time allowed for system pressure to drop to 0 The controller will display Waiting After a few seconds the Pressure Screen will appear and in its last column will list if each pressure transducer has Passed or Failed the calibration Note Failed indicates a problem with the transducer or the Pressure PCB 6 Press Return F4 to return to Pressure Screen 7 Press Return F4 again to return to A ctual Temperatures Screen Monitoring 1 Actual pressure values may be monitored for each transducer on either screen 2 Over pressure or Under pressure arrows indicate conditions 3 A question mark indicates that no transducer is installed or that installation is not complete for this trans
129. es Setpoint Limitation This is a universal maximum temperature for all zones The programmer cannot program a tem perature setpoint higher than the setpoint limitation System Logbook This is the controller s record keeping function It contains the D ynaControl s list of the last 1 000 controller events its Data Logger which records the last 1000 lines of selected actual tem peratures and a counter which records the system s elapsed hours Temperature Zone Enable The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not ever appear on the controller s display and heating is switched OFF Temperature Zone Offset D ue to the separation between the heaters and sensors in some systems the controller can be pro grammed to display a temperature for a zone which is different from the sensor s actual tempera ture The temperture zone offset mathematically corrects for these temperature differences E ach zone may have an individual offset Page 4 4 Controller Setup ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Error Indication amp Alarms Error Indication Blinking Up and Down Arrows The following illustration shows the display screen when one or more error indication conditions occur The conditions that will trigger an error indication are a When a hopper hose head or auxiliary zone has exceeded its selected over temperature setpoint
130. ess C to reset it You then have five minutes to refill the hopper before the alarm reactivates and the ASU s pumps stop The single point level control monitors a low adhesive level The capacitive sensor is mounted in the hopper The sensor cable is plugged into an amplifier DO NOT CUT the sensor cable Adjustment of the Single Point Level Control To adjust the adhesive level control s sensitivity access the control s amplifier located inside the panel box assembly On the amplifier diagrammed below is a sensitivity adjustment screw Turn the screw clockwise to increase sensitivity or counter clockwise to decrease The yellow LED lights to indicate the presence of adhesive W hen the LED goes out the alarm will acti vate 1234 56 Sensor 4 Sensitivity Adjustment Screw Connect min max T lt Yellow LED 1 11 OO O OO OO Amplifier Multi Point Level Control Refer to the level control manufacturer s manual for complete instructions on its setup and op eration The multi point level control is used with customer controlled devices not the D ynacontrol controller It has the capability for three separately calibrated outputs H owever for most ap plications one output calibrated with a high and a low level is sufficient The two other outputs may be used as safeties such as critica
131. et to tell whether the problem is in the hose or the Power PCB Sensor C If head to hose and hose to A SU plugs and sockets are okay head sensor may have an intermittent short or open circuit Examine connections inside the service block area of the head and monitor head sensor resistance with an ohmmeter while flexing sensor leads Repair or replace as appropriate Plug Sensor amp Heater 1 Disconnection between hose and ASU ose Head No Sensor Open Im Visually examine connection where hose plugs into ASU socket for proper contact and seating If pins or housings are damaged repair or replace hose or hose harness in ASU Page 7 20 Troubleshooting iTVW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Note Vertical configuration is for 2 Hose sensor harness DM 35 only Larger ASUs are unplugged from Power arranged horizontally PCB 2 Verify that effected hose is properly connected to Power PCB Replace or repair damaged hose harness as necessary 3 Disconnection between the 3 Verify that all PCBs are properly Power PCB s and the CPU mounted inside the panel box PCB s flat cables 4 Hose H ead sensor circuit 4 Replace head sensor if resistance does inoperative not comply with resistance table in this chapter Use hose schematic to check hose sensor at ASU socket Repair or replace hose hose harness or Po
132. facing carefully gauge the area between the inlet and discharge ports at the mesh of the gears T his area commonly referred to as the throat is the most critical part of the plate Scoring or wear marks here will allow increased slippage from the cont iTV Dynatec c 2000 Appendix 7 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 high pressure discharge port section across the throat to the lower inlet port reducing effi ciency Therefore carefully gauge this area for flatness after each resurfacing 10 After all components are hospital clean the pump is ready for assembly o 7 D STANDARD ACCURACY PUMP RE ASSEMBLY Figure 1 EE NOTE During and between each re assembly step manually turn the metering gears to en sure that they are free turning If binding occurs at any time determine the cause and correct itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component Never use force in re assembling or turning a D ynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely Re assemble as follows 1 After all worn parts have been re finished or replaced all parts should be throughly cleaned in a solvent and dried 2 Using the driven gear 5 as an up righting fixture carefully locate the arbor 7 over its press fit hole in the gear rear plate Smoothly drive the arbor into its hole with the help of an appropriate arbor press
133. fferent preset temperature on his original ASU order Generally the pump enable thermostat is set approximately 30 C 50 F lower than the application setpoint If a different temperature is de sired use the following procedure to re calibrate the thermostat CAUTION DO NOT setthe pump enable thermostat lower than the softening point of your adhesive or pump damage may result As an example the operator desires to lower the preset Pump Ready temperature to 107 C 225 F 1 Atthe controller keypad set the hopper temperature setpoint to the temperature at which you want the pump to start i e 107 C 225 F Hopper 2 Usethe key to unlock the side door then remove it being carefull not to pull out the ground wire attached 3 Waitfor the hopper temperature to stabilize at 107 C 225 F then a For thermostats with purple amp black wire leads or tan leads turn the thermostat s adjustment screw counter clockwise to increase pe the temperature or clockwise to decrease it until the pump s AG mtor begins turning A djust no further b For thermostats with tan with tracer wire leads turn the thermostat s adjustment screw clockwise to increase the temperature or counter clockwise to decrease it untilthe pump s motor begins turning A djust no further 96 4 Replacethe side door Pump EnableThermostat 5 Atthe keypad re set the hopper temperature setpoint to its correct run temperature
134. fitted housing that is comprised of three plates The center gear plate fits closely around the outside diameter of the metering gears The front and rear plates sandwich the center plate and restrict axial movement of the gears Power is transmitted to the gears by the drive shaft which is a through shaft Shaft sealing is accomplished with a high tempera ture cup seal High accuracy pumps are precision instruments requiring skilled and careful maintenence Constructed of high quality tool and die steels such as AISI 02 M2 M 4 and CPM M 4 or other high performance alloys they are tempered after heat treatment to hardnesses ranging from HRc 58 to HRc 64 Sincethe thermal expansion rates for all three steels are almost identical and are otherwise entirely compatible it is possible to combine them so as to take advantage of their best qualities in the most economical way TheType D2 tool steel is often selected for the side and center plates as it offers good abra sion resistance and it is the most economical of the three steels we most commonly use Type D2 will also provide a higher degree of corrosion resistance than M 2 or M 4 The portion of the side plate subject to the most wear is the shaft bearing hole which has an easily replaceable inexpensive sleeve bearing that can be made of the extremely wear resist ant Type M 4 tool steel Types M 2 and CPM M 4 steels are commonly used for the metering gears drive shaft and universal seal coup
135. g counter clockwise decreases it T he current limitis factory preset so no adjustment is necessary ACC and DEC B adjusting pots These pots change the time required for the pump motor to accelerate A CC or de accelerate Turning full counter clockwise equals 0 3 seconds Turning full clockwise equals 20 0 seconds Factory default for either pot is 10 0 seconds cont J 1 umper A M J umper Auto Manual PWR Power LED Green unitis ON FSR J umper amp connection to drive enable of Motor Interface PCB Interface PCB 5 Potentiometers Factory Set Do Not Adjust Line L2 Spade connectors CL Current Limit 2 to incoming AC L1 Main Power MAX inactive MIN Minimum RPM DEC B Decelerate gt ACC Accelerate COMP IR Comp W Spade Connectors Motor V 3 to Motor U ST Status Led Red yellow green See table below ST LED Color Function ST LED Color Function Green Slow Flash Normal Operation Red Yellow Quick Flash Undervoltage Red ON Current Limit Red Yellow Slow Flash Overvoltage Red Quick Flash Overload Yellow ON Stop Red Slow Flash Short Circuit Layout of Components on Motor Drive Board Page 7 8 Troubleshooting ITW Dynatec c 2000 Revised 7 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 MIN adjusting pot This pot adjusts the minimum speed of the pump motor when it is enabled The pot is factory preset to exactly zero RPM when the speed
136. gency medical technician immediately ITW Dynatec c 2001 DYNAMELT M ASU Manual 20 36 20 37 20 38 Service Refer all servicing to qualified personnel only Page 1 3 Revised 9 98 Explosion Fire Hazard Never operate this unit in an explosive environment Use cleaning compounds recommended by ITW D ynatec 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 R egulation for equipment s lockout procedures and other impor tant lockout tagout guidelines Be familiar with all lockout sources the equipment Even after the equipment has been locked out there may be stored energy in the application system partic ularly in the capacitors within the panel box To ensure that all stored energy is relieved wait at least one min ute before servicing electrical capacitors 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 Dynatec c 2001 Revised 3 97 DYNAMELT M ASU Manual 20 36 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solution
137. ght illuminates when the system is turned ON The arm middle green light indicates that the system has warmed up to temperature setpoints ready The upper red light illuminates only in an alarm ea condition and is accompanied by an audible alarm The audible alarm is ada housed within the upper black section of the stack m Power O N n The status lights may be wired to indicate either high low temperature low adhesive level or open short sensor See Chapter 11 for wiring diagram Settings for a Typical Operation Note The values given here are approximate settings for a typical packaging operation The values you choose will be based on the type of equipment and adhesive you are using and the nature of your particular operation If Application Temperature is 177 C 350 F Hose and head temperature 177 C 350 F Hopper setpoint temperature 163 C 325 F Hi Lo limit deviation 12 C 20 F ASU operating range 149 C to 177 C 300 F to 350 F Standby condition temperature deviation 30 C 50 F Hopper over temperature setpoint 177 C 350 F Mechanical thermostat for the hopper over temperature 219 C 425 F For most operations temperature fluctuations will be very small and of short duration For these reasons the settings above are recommended ITW Dynatec c 2000 Controller Setup Page 4 7 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 System Values That Are Factory Programme
138. gives values for several different head wattages A suspected head heater problem can be isolated by measuring head heater resistance and comparing itto the resistance for the appropriate wattage of your system The Nominal Hopper Heater Resistance table gives heater resistance for the hopper heaters of each Dynamelt M Series model and for the optional drop in grids The Nominal Filter M anifold Heater Resistance table gives heater resistance for the heater located in the optional filter manifold pressure relief block The heater inside the manifold varies depend ing on the number of filter manifolds mounted on the A SU therefore resistance varies also iTV Dynatec 2000 Troubleshooting Page 7 13 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Temperature Resistance Hose Length Resistance F C in Ohms Meters Feet in Ohms 323 358 201 223 155 172 120 133 102 114 75 84 51 57 Nominal Hose Heater Resistance for DynaF lex Hoses Watts Resistance in Ohms Nominal Head Heater Resistance N ote Resistance is measured at ambient temperature 20 C 68 F Temperature Sensor Resistance 0 00385 PT 100 RTD m mmm Qty Hopper Heaters 1 2 3 Max Drop in Grids 2 4 6 Resistance Ohms for each Hopper Heater 11 5 11 5 11 5 Resistance Ohms for each Drop in Grid Heater 23 23 23 Nominal Hopper Heater Resistance in Ohms of Filter Manifolds M70 140 on ASU 115 2 115 2 51 6 51 6
139. her pressures smaller adjustments to the screw will make larger changes to actual pressure 1 CAUTION Approach desired pressure with caution DO NOT TURN THE ADJ USTMENT 10 After desired pressure is achieved tighten the jam nut down onto the adjustment screw and lock itin place 11 Replace and tighten the adjustment screw cap 12 While the motor is operating at maximum speed observe the adhesive flow from the applicator s 13 Reduce the motor speed in increments of about 1096 until the adhesive flow begins to decrease Note Though the speed of the motor is reduced there will beno changein theamount of adhesiveflow coming out of the applicator This is because the pressure relief is designed to allow only a maximum adhesive pressure regardless of the motor speed past a certain point Then increase motor speed in smaller increments 1 to 596 until adhesive flow returns to the desired amount Note Thisistheoptimum pointof operation for the motor pump and pressure relief It will also facili tate the best system performance and reduce wear on these components The application system is now adjusted for normal operation 14 Re tighten the two purge screws and re install the access cover iTV Dynatec 2001 Installation Page 3 11 DYNAMELT M ASU Manual 20 37 Revised 6 01 Pump Enable Ready Thermostat Calibration The Pump Enable Ready Thermostat is preset to 132 C 270 F unless the customer has specified a di
140. hutoff out 5 a Replace the clogged filter shutoff assembly or b Emerse the assembly in flushing fluid PN 1 15653 to loosen contaminants Remove assembly from fluid and use a hot air gun if necessary and rags to clean all contaminants from it 6 Apply a coat of anti sieze compound onto the threads of the filter shutoff nut before re inserting into the ASU iTV Dynatec c 2001 Preventive Maintenance Page 6 5 DYNAMELT M ASU Manual 20 37 20 38 Revised 2 01 7 Replace the filter shutoff o ring Lubricate the new o ring with lube PN N 07588 8 When re installing the filter assembly turn the filter s cut out hole toward the pump Align the filter shutoff knob in its open position N ote each filter shutoff is stamped I open and 0 closed to show position 9 Close the access doors Restore the ASU to normal operation Pump Shaft Leak There is a cutout in the baseplate directly below the pump shaft s which will allow adhesive from a leaking pump to exit the ASU Inspect the area under the baseplate cutout every month for adhe sive A leaking pump shaft indicates a worn pump seal See instructions in Chapter 8 for replace ment of this seal Summary of Preventive Maintenance Schedule Monthly or as experience dictates 1 Inspect outlet filter basket Replace as required 2 Check for leaking adhesive under the baseplate caused by a worn pump seal Replace as re quired Every Three Months or as experienc
141. ifold Page 9 6 Options amp Accessories iTV Dynatec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions TW Dynatec 2001 Component Illustrations amp BOM s Page 10 1 DYNAMELT M ASU Manual 20 37 Revised 6 01 Chapter 10 COMPONENT ILLUSTRATIONS amp BILLS OF MATERIAL Chapter Format This chapter contains the component illustrations exploded view drawings for each assembly of the DYNAMELT M SERIES ASU These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Page 10 2 Component Illustrations amp BOM s T Dynatec c 1999 Revised 1 04 DYNAMELT M ASU Manual All Models Bill of Materials for Pressure Relief amp High Temp Filter Block Assembly 102710 Items from Heater Control Groups 103571 103572 103573 103574 are also Included in this illustration and bill of material Item No Part Number Description Qty 102710 Filter Block Top Assembly 1 1 N00181 O ring 014 6 2 N00185 O ring 018 2 3 N00753 1 8 NPT Level Seal Plug 1 4 N00187 O ring 020 2 5 N00754 1 4 NPT Level Seal Plug 3 6 103626 3 8 BSPP Plug 2 7 102712 Filter Block Insulator Plate 1 8 102717 Check Valve 655 Cart 1 way 2 9 NPN M 8 1 25 x 90 SHC Screw 6 10 103623 Straight Fitting BSPP 2 108928 Manifold Sub Assembly 1 11 A69X 133 O ring 124 2 12 78 282 30 x 1 8 Drive Screw 6 13 N02969 Pin
142. ing D iagFalmi s 42 4 i Gothic Male cebat ed Abe dta 11 7 Pneumatic Clutch Schematic 11 8 Instruction Sheet for Pump amp Zone Configuration 11 9 Dynamelt ASU Schematics end of chapter Appendix Optional Dynatec Zenith Standard Accuracy Gear PUMPS Appendix 1 Optional Dynatec Zenith High Accuracy Gear PUMPS Appendix 15 Optional Zenith M elt Spinning A ppendix 29 High Accuracy Pump Performance Chart A ppendix 34 Pressure 0 oret cob ue m cu detect ee el a aN A ppendix 35 Pneumatic aic eel KCN ae ha elec Appendix 37 Optional Memory Card Reader Appendix 47 Page viii Table of Contents iTV Dynatec 2001 Revised 11 01 DYNAMELT M ASU Manual 20 37 ITW Dynatec An Illinois Tool Works Company ITW Dynatec Adhesive Application Systems ITW Dynatec c 2001 DYNAMELT M ASU Manual 20 36 20 37 20 38 Page 1 1 Revised 9 98 Chapter 1 SAFETY PRECAUTIONS All operators and service personnel must read and understand this manual before operating or servicing equipment
143. ing transducers may use either a PSI port or a feed hose port to mount a optional pressure gauge If all ports are in use the pressure gauge may be installed in line with a hose Refer to the hose and applicator manuals for further details on these items Page 3 6 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 Electrical Connections Fl OQ 1 Closeable Cross Channel Tamper Proof Screw Bleed Valve Port Heater Channel RTD Sensor Channel Purge Drain Hose Head Electrical and Adhesive Connections Head Hose mre 00 9 Connects ALI Rd Return Hose Electrical Al A2 Connects 511 512 F1 F2 Adhesive supplied Adhesive supplied Adhesive supplied Adhesive supplied by motor pump 1 by motor pump 32 by motor pump 3 by motor pump 4 Up to Four Filter Blocks with up to 16 Adhesive Ports Note Always connect Auxiliary Return Hose 1 A1 to Auxiliary Electrical Connect 1 A1 Feed Hose 1 F1 to Feed Electrical Connect 1 F 1 etc as described on page 3 3 Dynamelt M70 amp M140 Electrical Connection and Filter Manifold Arrangement for Maximum Head Hose Configuration iTV Dynatec c 2001 Installation Page 3 7 DYNAMELT M ASU Manual 20 37 Revised 11 01 This page is intensionally blank Page 3 8 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 Adding Adhesive Theadhesivelevel the melt tank should b
144. ion between 2 Verify that all connections are properly Power and CPU PCB made on the CPU PCB 3 Hopper circuit breaker 3 Refer to the schematic in Chapter 11 tripped to locate the hopper circuit breaker If itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit to ground in the hopper heater TH POPE circuit This will be limited to between eater Wire Ries the hopper control relay and the hopper heater 4 Open hopper heater 4 Atthe terminal rail use an ohmmeter element to measure resistance across H3A and 380v or across and H 3B P 240v See the resistance table Hopper Circuit Breaker in this chapter for normal resistance values Infinitely high reisistance values indicate an open heating element which must be replaced NOTE A DM 70 140 models If the ASU has a second heater measure may have up to two hopper this heater s resistance across H 15A and heaters 380v or across H 15A and 15B 240v as outlined above NOTE B DM 210 models If theASU has a second heater see Note may have up to three hopper If the ASU has a third heater measure heaters this heater s resistance across H27A and N 380v or across H27A and H27B 240v as outlined above Optional Drop in 1 Setpoints have been 1 Re program setpoints allowing a Grid eater programmed without larger deviation between the high 2500w 6805 enough
145. ional connections It is located directly behind the controller s display panel within its mounting bracket or within the remote pendant assembly option if applicable W hen downloading software updates use the download serial port seen at the lower right of the il lustration W hile downloading the J 1 jumper is moved temporarily to its 1 position To configure the number of optional pressure transducers on an ASU use the dip switches shown below beneath the expansion board and the following chart There are four transducers per PSI PCB and a maximum of three PSI PCBs per ASU Note PSI not available on APS models Switch 1 On the RS Com board both the 1 and 2 jumpers must be in upper position for Connect to opt o 1 2 Expansion Board for Serial Commu 485 and both in lower position for 232 2 nication CAUTION FOR Dip Switches to configure i BOUND CON of opt PSI PCBs only Optional RS232 Serial Connect Optional RS485 Serial Con NECT ONLY switches 1 amp 2 are used use for PLC PC Link nect use for PLC PC Link or APS model Scheduler Download Optional Memory Card Reader connect Software Download P ort Connect to CPU PCB Layout of Components on Display CPU PCB Page 7 6 Troubleshooting ITW Dynatec c 2000 Revised 1 03 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Motor Control Interface Printed Circuit Board For each motor on the A SU there is a M otor Cont
146. ip together the driving melering gear drive shaft and key Position in the front of the side plate by installing the drive shaft through the hearing 5 Place the driven metering on its arbor and careful ly mesh with the driving melering gear 6 Carefully lower the center plate over the gears 7 Position the rear side plate 8 Rotate the gears to ensure free rotation 8 Press the dowels into place moving in the direction of the shortest press distance Usually from the rear side of the pump 10 Lubricate the binder screws with DAG Dispersion 154 or a similar heat resistant lubricant and install Torque the screws in even increments to the manufactutrer s recom mended limit It is especially important to rotate the gears frequently during this operation 11 Reassemble the seal arrangement making sure the seal ing surfaces are perfectly clean and free of scratches nicks or burrs When a carbon seal plate is used always use a new carbon seal that has been lightly polished on 400 600 grit paper When using a carbon seal the coupl ing housing screws should be torqued to 3 the manufac turer s recommended torque limit For pumps equipped with a compression packing seal be sure all old packing is removed from the packing housing 12 Inspect the drive shaft at the sea area making sure that it is nat scored shouldered or worn 13 Dip the packing rings into high temperature oil and graphite This aids assem
147. irm Scroll to next desired zone and repeat until all zones are pro grammed Then Press Return F4 to return to menu Note after entering one value in any catego ry you may press All xxx F1 to change all the items in that category TheHigh Low Temperature Deviation is a range representing the high and low temperature limits of each setpoint D uring operation these limits activate the error alarms which alert the op erator to over temp and under temp conditions in the temperature zones The smallest deviation programmable is 5 C or F and the largest is 50 Press 2 to program Standby Temperature Enter a numeric value for each category Press E nter Press Return F4 Note if the same Standby Temperature is desired for all zones enter the value in the first row then press Enter The Standby Temperature is a reduction in temperature by which all the temperature zones will be reduced in a standby condition F or example if the hopper setpoint is 275 and you program a 100 degree standby temperature the controller will reduce the hopper temperature to 175 Numerical ly the controller will accept any standby temperature within the range of 30 C and 150 C 30 F and 150 Press 3 to program Standby Time Delay and Sleep M ode Enter a numeric value for the time delay Press Enter Toggle press F1 or F2 to Sleep M ode Enter a numeric value for Sleep M ode Delay Press Enter Press Return F4 The Standby Ti
148. isconnection between 2 Check connection Verify that solid solid state relay and _ state relay is operative check schematic Power PCB or inoperative Chapter 11 for relay location Use relay clamp on ammeter to monitor hose Head current If current does not cycle on and off the relay has failed and must be replaced 3 Disconnection between 3 Visually inspect wiring inside head cartridge heater and cable verify that cartridge heater leads are assembly inside head properly connected in the service block area Sensor 4 noperative hose head 4 Refer to schematic in Chapter 11 for Heater circuit breaker location of circuit breaker If itis Dim found to be tripped do not re set it TN without first finding cause Visually inspect and use an ohmmeter to check for a possible short circut to ground in the hose head heater circuit Plug Sensor amp Heater 5 Open hose head heater 5 Use an ohmmeter to measure hose element head heater resistance See resistance table in this chapter for resistance values Infinitely high resistance indi cates an open heater element 6 Open wiring inside ASU 6 Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate open wires in head heater circuit Repair or replace ASU hose head harness or other ASU wiring as necessary Page 7 22 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20
149. ise amount out through the discharge port that is drilled alongside the inlet port in the rear plate Since these pumps are not self priming a flooded suction is usually the minimum inlet pres sure required However when high viscosity fluids are used more time is required to fill the tooth volumes As a result the inlet pressure must be increased or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation D ynatec Zenith pumps rely on the metered fluid for lubrication of internal bearing areas The pump should never be allowed to run dry or be allowed to run with non lubricating fluids such as water B ecause of the close clearances in the bearing areas lack of sufficient lubrication can cause pump seizure or some other catastrophic failure Slippage will occur across the faces of the gears from the high pressure side to the low pres sure side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate The Standard A ccuracy Pumps are designed for high temperature and high pressure opera tion As such operating temperatures to 450 degrees F can be achieved INSTALLATION Pumps should be carefully unpacked to make sure that the shipment is complete If any items are missing or damaged the freight carri
150. itely high reisistance values indicate an open heating element which must be replaced iTV Dynatec 2000 Troubleshooting Page 7 19 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 ose Head 1 Hose Head setpoints No Overtemp incorrectly programmed 1 setpoints to allow a larger deviation 2 or shorted hose head triac or dual solid state relay 2 Refer to the schematic in Chapter 11 to locate the correct head hose triac or relay Use clamp on ammeter to mon itor hose head current If current does not cycle on and off then the triac or relay has failed and must be replaced Note Vertical configuration is for DM 35 only Larger ASUs are arranged horizontally 3 Disconnection between thd 3 Verify that all PCBs are properly 2 Power PCB s and the CPU mounted inside the panel box A board s flat cables 4 Hose Head sensor circuit 4 Visually examine socket connect inoperative ion where hose head attaches to ASU Verify that pins are properly seated If pins or plug housing are damaged repair or replace hose If socket is damaged repair or replace harness b If hose to A SU plug and socket are okay hose may have intermittent short or open circuit Repair or replace hose hose harness or Power PCB as appropriate Alternately problem can be isolated by connecting the effected hose to a different ASU hose sock
151. ive Application Solutions iTV Dynatec c 2000 Appendix 29 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 ZENITH MELT SPINNING PUMPS MANUAL Covers ITH Dynatec part numbers 084 374 0845276 84E387 O84E388 AHAHAHAHA Ext pi EEL LT Mamtenanceeo LENNA THH EL mE tt Femperature H Metering EN Eyes esee mg HERBST Pump PNs 084E 374 thru 084E 389 use PN 069X 251 pump shaft seal Pump PNs 084 411 thru 084E 413 use PN 069X 289 pump shaft seal Appendix 30 Revised 10 00 iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 This maintenance manual is as specific as possible but please remember that there are many varieties of Zenith pumps in service If you have any questions about specific parts and their orientation always refer to the drawings and parts lists for your exact pump by type If you still have questions refer them to us at the factory 1 Introduction Zenith Spinning Purnps are precision instruments requiring skilled and careful maintenance Constructed of high quality tool and die steefs such as AIS types D 2 M2 and M 4 or other high performance alloys they are tempered after heat treatment to hardnesses ranging from Rockwell Sale 58 to 64 A Zenith Pump may be constructed from any one or
152. keep maintenence and operting costs at a minimum By noting the perfor mance of a pump immediately before removing it from service and correlating the perfor mance to measured component wear the user can establish the maximum wear limits for the pump s critical components Further he can predict the service life of the pump and schedule his down time accordingly As with any other Dynatec pump high accuracy pumps may be returned to D ynatec for com plete rehabilitation as necessary This procedure may be desirable if only a few pumps are involved If a large number of pumps are to be maintained at the user s plant it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing gauging and assembly techniques involved in producting the pumps Please contact D ynatec at 1 800 538 9540 for further information on these items HIGH ACCURACY PUMP DISASSEMBLY If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt pumps If maintenence is required due to low delivery or seizure the following procedure is recom mended for disassembly NOTE note the location and orientation of all parts to ensure correct re assembl y Refer to assembly drawing located in the back of this manual for your
153. l Mounting Checklis PROCEDURE Prolecfive Cop on Remove only when ready to instol Sensing tronsducer Diaphrogm Mochined Hole Snouid be s shown Exirude Transducer threads with Never Preparation Seez by Bostik o CSA by feipro Transducer locate in less thon 140 ombent Housing temp Transducer Clear mounting hole of plastic Instollation resdue Mounting Torque 50 inch pounds recommended 500 inch pounds max cont Appendix 36 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 Start up Trouble and Removal Shooting Checklist Guilde PROCEDURE SYMPTOM TYPICAL CAUSE Start Up Make swe thot tha extruder is of Indicotor ot Ful n open cicuit Perform Ihe desred temperature before or Unstable continuity checks with ohm ihe extruder drive is operated indication metet Removal of Always remove the transducer of zero instrument Replace ond Transducer pror fo cleoning Ihe exkuder but use of tepa of ratum to fS ond remove only while the coitxotion extuder is ot termperature procedure Pracuces no Cleaning of Wipe the transducer fip with o Change in reoding Transducer Tip Cloth while Ihe transducer is sti hot Do not use sharp tools on responds Tronsducer is damaged Rehan fip fo col retion to procedure bot does not indicate pressure Installation Wiring Diagrams R ded fi ion Modais 0100 0104 0102 0103 Models
154. l high and critical low for multi ASU systems with bulk feeders Page 3 16 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 Field Installation of the Optional Memory Card Reader If ordered as an option with a new Dynamelt A SU the M emory Card Reader will be factory installed To add a M emory Card Reader to a unit in the field follow these installation instructions IMPORTANT A D ynatec factory formatted Memory Card PN 107994 is required for the control ler to function properly Do not attempt to use any other card DANGER HIGH VOLTAGE Dynamelt systems use electrical power that can be life threatening Disconnect and lock out input power to the application system before starting any installation procedures In addition disconnect ALL incoming power to the ASU POWER TO THE MAIN CIRCUIT BREAKER MUST BE DISCONNECTED T Main 1 Switch OFF the ain Disconnect this is the circuit breaker lever QD DUAL located on the panel box and open the panel box door 2 Removethe DynaControl mounting bracket from the ASU via Dynacontrol four screws accessed from inside the panel box assembly Mounting 3 Ontheinside of the mounting bracket remove the two nuts from the cover over the card reader slot Place the M emory Card R eader assembly into the cut out window with its ribbon cable connector facing inside U se the two screws supplied to mount the assembly to the bracket 3 Install either end
155. l return if the Dyna Control is subjected to an internal memory reset also referred to as a re boot While you can change your programmed values to anything within the system s limits the default settings cannot be changed Defaults Language English Setting for Customer Access Code 9999 Temperature setpoint for each zone Hopper ready temperature 135 C 270 Over temperature limit Your chosen setpoint limitation 10 C or F For example if your setpoint limitation is 218 C 425 F then your over temp limit 228 C 435 Standby temperature for all zones 80 C 140 F lower than programmed setpoints Hi lo limit deviation for all temperature zones 20 C 36 F Temperature zone offset 0 C 0 F Sequential heating first hopper zones then hose head zones and auxiliary zones Setpoint limitation 218 C 425 F Minimum pump speed 0 of full speed Maximum pump speed 100 of full speed Proportional Integral values P I values for Premelt Hopper and Filterblock temperature zones P 15 and I 3 For all other zones P 12 and I 2 ITW Dynatec c 2000 Controller Setup P age 4 9 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 11 01 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 if the auto
156. late 2 Pump seal inoperative 2 Remove seal from pump inspect it Ss O ring and replace it if worn or damaged Be sure there are no burrs or other sharp edges on pump shaft or on installation tools that could damage a new seal A dhesive leak at pump 1 O ring in pump s rear 1 Remove seal from pump inspect it to hopper interface plate is inoperative and replace it if worn or damaged Be sure there are no burrs or other sharp edges on the rear plate o ring groove that could damage a new o ring 2 Pump assembly screws 2 Verify that all four pump screws are missing or loose tightly assembled to the hopper 3 Helicoil insert pulled out 3 Remove pump and inspect hopper of hopper Repair or replace hopper as necessary Page 7 28 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions TW Dynatec c 2001 Disassembly amp Re assembly P age 8 1 DYNAMELT M ASU Manual 20 37 amp 20 38 Revised 6 01 Chapter 8 DISASSEMBLY amp RE ASSEMBLY PROCEDURES Note Re read Chapter 1 Safety Precautions before performing any disassembly procedures All disassembly and repair procedures must be performed by qualified trained technicians Disassembly Procedures Note Use the exploded view drawings referenced with each procedure in conjunction with the in structions outlined in this cha
157. ling due to their superior torsional strength and abrasion resistance for these items that are the most critical to proper metering performance OPERATION All Dynatec Zenith High A ccuracy Pumps are rear ported Fluid enters the pump through a port drilled into the rear side plate the side opposite the drive shaft The fluid fills the ex posed gear tooth volumes and is transported around the outer diameter of the gear pocket As the gears mesh together the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate cont Appendix 18 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 Since these pumps are not self priming a flooded suction is usually the minimum inlet pres sure required However when high viscosity fluids are used more time is required to fill the tooth volumes As a result the inlet pressure must be increased or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation D ynatec Zenith pumps rely on the metered fluid for lubrication of internal bearing areas pump should never be allowed to run dry or be allowed to run with non lubricating fluids Such as water B ecause of the close clearances in the bearing areas lack of sufficient lubrica tion can cause pump seizure or some other catastrophic failure Slippage will occur across the faces of the gears from the high p
158. ls for 10cc Single Gear Pump Assembly 109690 Item No Part Number Description Qty 1 018X031 Ball bearing 1 8 Dia 6 078F 017 Snap ring 1 2 4 3 0781001 Key Woodruf 404 1 4 069X061 S haft Seal 1 5 069X064 O ring 041 2 6 100908 M4 0 7 x 25mm SHC Screw 2 7 101626 M5 0 8 x 12mm SHC Screw 4 8 109685 Pump 10 Rev 1 9 109686 Rear Bearing Plate 10cc Rev 1 10 109689 Gear 10cc Rev 2 11 109687 Drive Shaft 10cc 20cc 1 12 109688 Driven shaft 10cc 20cc 1 13 069X160 S haft seal retainer 1 14 0010002 Dow Corning 112 Lubricant Not Shown Page 10 26 Component Illustrations amp BOM s Revised 7 03 TW Dynatec 1999 DYNAMELT M ASU Manual 20 37 Bill of Materials for Assorted Pump Adapter Assemblies Item No A WYN 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 084E 406 012G 024 069X 058 N 00179 069X 274 N 00190 078C 130 NPN 084E 428 084E 374 084E 430 084E 434 108875 084E 438 084E 389 084E 432 108874 084E 419 0126027 069 064 069 230 069 270 078 618 078 141 069 289 084 411 084 412 084 413 103923 103624 103924 00181 069 270 102927 103917 103918 103919 104351 Description TSHA Pump Adapter Assembly Pump A dapter O Ring 28 O Ring 12 Seal Dual Pump to Progmelt not part of this assembly O Ring 24 3 8 Washer 3 4 OD M10 x 85mm SHC screw Zenith Pump THSA 297 cc Single Outlet THSA 584 cc Single Outlet
159. m 2 temperature zones are displayed iTV Dynatec c 2001 Preventive Maintenance Page 6 1 DYNAMELT M ASU Manual 20 37 20 38 Revised 2 01 Chapter 6 PREVENTIVE MAINTENANCE Note Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance procedures must be performed by qualified trained technicians General Cleaning The DY NAM ELT9 M SERIES ASU enclosure is finished with an extremely durable polyurethane paint The enclosure may be cleaned with a variety of industrial cleaners following manufacturers directions To prevent discoloration or deterioration of the ASU s finish avoid prolonged contact with strong solvents The molded plastic handles may be cleaned with mineral spirits Preventive Maintenence Schedule The Dynamelt M ASU requires little maintenance T he hopper is fitted with a coarse screen to pre vent large debris from entering the system Normally this screen does not require cleaning The ASU parts that require regular periodic maintenance are as follows Replacing the Outlet Filter Basket The outlet filter should be replaced monthly during the first few months of operation A fter you gain experience with your system you can determine how often you need to replace it The outlet filter is located on the outlet filter manifold on the hose connection panel of the ASU See illustra tion of theoutlet filter on page 6 2 Use the following procedure to replace the standard o
160. m overload and to protect other components from potentially damaging pressure levels The system will allow pressures up to 1000 PSI however typical factory settings are 500 PSI WARNING HIGH PRESSURE NOTE The following procedure sleeved protective clothing must be worn will require the hot melt adhesive to prevent the possibility of serious injury to be at a high temperature and from the molten adhesive Refer to the application system to have Chapter 1 and the section entitled substantial pressure Safety SAFETY PRECAUTIONS for further glasses insulated gloves and long details and First Aid information To Adjust Pressure Relief Note This adjustment should be done with a melt pressure gauge or a pressure transducer installed Failure to use proper equipment can result in excessive pressure levels 1 Turn the application system ON and raise the temperatures of all components to normal operating temperatures Note Position a bucket or other waste receptacle under the applicator s so that adhesive will be collected during the adjustment procedure 2 Atthe controller set the motor speed to 0 so that the gearmotor is not turning 3 Locate the pressure relief assembly on the filter manifold where the hoses attach to the A SU and remove the access cover 4 Position a heat resistant container below the manifold With a hex key screwdriver allen wrench slowly loosen the manifold s two purge set screws do not attemp
161. maining in the hopper 5 Slowly increase the pump pressure Pump about half of the fluid through the hopper pump and adhesive supply hose into the flushing container WARNING Avoid splashing the flushing fluid from the end of the hose 6 Reduce the pump speed to zero 7 Remove the outlet filter and replace the basket following the procedures outlined in the Outlet Filter section of this chapter 8 Add new adhesive to the hopper and allow it to reach application temperature 9 Slowly increase motor speed to the pump 10 Actuate each of the heads until all the flushing fluid is removed and a steady stream of new adhesive flows T Re adjust the pump speed for the desired flow 1 Re fill the hopper with adhesive system is now ready for production ITW Dynatec c 2000 Troubleshooting Page 7 1 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes DANGER WARNING HIGH VOLTAGE 25 7 HOT SURFACE Dynamelt systems use electrical power that can be life threatening and hot melt adhesives that can cause serious burns Re read Chapter 1 Safety Precautions before performing any trou bleshooting or repair procedures All troubleshooting and repair procedures must be per formed by qualified trained technicians CAUTION Printed circuit boards PCBs are prone to damage from static electrical charges during handling Read Han
162. maintenance For years since chemical engineers have relied on Zenith to provide precision fluid han dling solutions for their most difficult pumping applications Zenith gear pumps can be found wherever precise pulseless repeatable metering of fluids is required BENEFITS High Accuracy Stable repeatable flows are assured even under varying conditions of pressure viscosity and temperature High Temperature C apability Operating temperatures to 550 degrees F 288 degrees C Maximum L ife Only three moving parts components are through hardened tool and die steels to 62 HRc or better Replaceable sleeve bearings for low cost rebuilds High Volumetric Efficiency M aximum efficiency is achieved with optimum operating clearances and assured under pressure by built in alignment dowels Minimum Pulsation Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance Precision Construction Ground and lapped components for close control of operating clearances iTV Dynatec 2000 Appendix 17 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating Speed 3 120 rpm depending upon application conditions and fluid viscosity Temperature To 550 degrees F 288 degrees C DESIGN D ynatec Zenith High A ccuracy M etering Pumps consist of two gears rotating in mesh with in a closely
163. matic heater startup is enabled and if setpoints are programmed unless sequential heatups have been set However if hopper temperature is above ready temperature when the ASU is turned ON all hose and head sequential heatups will be bypassed and hoses and heads will be turned ON If the system is turned OFF and then ON again the standby condition will be disabled Page 4 10 Controller Setup ITW Dynatec c 2000 Revised 9 02 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Serial Protocol for RS232 and RS485 Options V5 00 d amp up Specifications RS232C no handshake RS485 4 wires baud rate 1200 57600 baud character format 8 databits 1 startbit 1 stopbit parity no parity check General information DynaControl is always slave The controller is only reacting when addressed by a master DynaControl is only responding when own slave address is received Slave address is programmable via front panel PC LINK Setup Multi digit values are transferred most significant digit first each digitis ASCII coded Used control characters STX 02 Start of Text ETX 03 End of Text EOT 04 End of Transmission ENQ 05 Enquiry ACK 06 Positive A cknowledge NAK 15 Negative A cknowledge Structure of commands Master transmits to D ynaControl EOT addr opcode 0 n data bytes ENQ DynaControl responds STX 1 n data bytes ETX Address Setting Each telegram sent to the D ynaControl contains the slave address D ynaCont
164. me Delay allows programming of a delay from the time the external standby ter minals for connection see Chapter 3 are connected until the ASU enters its standby mode The time delay selected must be in the range from 0 00 which represents an immediate entry into standby i e no delay to 18 0 hours The Sleep Mode may be activated only during Standby It becomes activated after a programmed length of time 0 1 to 18 0 hours During Sleep M ode all heaters are turned OFF and the motors are stopped The display reads F 1 to Start Heating when in Sleep Mode To disable the Sleep M ode press Disable F 3 Standby and Sleep M ode work together For example if you program a Standby of 1 hour anda Sleep M ode of 3 hours the ASU enters Standby one hour after the external contact is closed The ASU enters Sleep M ode three hours after entering Standby Press 4 to program Setpoint Limitation Enter a numeric value Press Enter Press Return F4 The Setpoint Limitation is a universal maximum temperature for all temperature zones ie the overtemperature limit The controller will not allow the operator to program a higher setpoint than the value of the setpoint limitation The default setpoint limitation is 218 C 425 F The se lectable range for the setpoint limitation is 40 C 232 C 100 F 450 F Function 5 is not active in the present controller configuration No programming is possible Page 5 18 Programming ITW Dynate
165. ment M 140 Single High Flow 106694 1 8 105881 Heater Plate M 70 140 2 9 L 00006 Spacer 12 10 101156 M 6 x 20mm SHC Screw 24 11 103517 M8 x 30 HHC Screw 12 12 N 00686 Flat Washers 1 4 48 13 N 00697 Lock Washer 1 4 48 14 103749 Filter Shut off plug fits in place of or opposite Filter shut off 2 4 15 N 00210 O ring 912 fits in place of or opposite Filter shut off 2 4 16 Filter Block A ssembly See Your order for part Number and Qty 17 106103 Ball Valve Assembly O ption 2 J unction Box Assembly 2 18 105885 Junction Prog M elt M 70 140 1 19 106001 Cover Junction B ox 1 20 078C021 Flat Washer 88X 1 0X 13 2 21 048 018 Bushing Plastic Cap 1 2 2 22 048F 125 Terminal Rail 11 5 one of each 2 23 048F 136 Block Terminal 35 Amp 44 24 048F 137 Cover End 6 25 048F 021 Ground Terminal 2 26 048F 069 End E 2 27 107751 5 16 Conduit Fitting 4 28 N 06883 Jam Nut 4 29 107645 107646 5 16 Conduit 12 25 one for each conduit fitting 2 30 048J 014 3 4 45 deg Connector 2 108829 108830 1 2 Sealtite Conduit 36 1 2 Sealtite Conduit 40 opposite side lea 104166 Over Temp Switch Assembly Sold as an assembly only 2 3l 104165 Insulator Over Temp Thermostat 2 32 104164 Overtemp R eset Thermostat 2 33 103538 M4 X 6mm Pan Head 2 Grid Group 2 34 N 00181 O ring 014 8 16 N 007081 O ring 014 K alrez 8 16 35 104696 Flange 2 36 003E 023 Cover 1 37 036E 103 Temperature Sensor 2 38 160174 Sensor A dapter 2 39 104802
166. mes Press F1 to program Temperature zones F2 to program Pumps or F3 to program Pressure Transducers Scroll to the first item to be named Press Enter to allow naming Using the A Ipha N umeric keypad and following the rules given above spell out name as desired Press F1 F2 or F3 to select another item to name Repeat until all items are named as desired Press F4 again to Return to Service Page 2 screen Press 2 to program Power On Configuration This function gives the user the choice of having the heaters and pumps come on or remain off whenever the ASU is powered on USA default is both On European default is Heaters On Pumps Off Note programming here overrides programming made at the next Service Function Function 3 Factory Defaults Press 1 to toggle the heaters On or Off Press 2 to toggle the pumps On or Off Press 3 to toggle the external inputs On or Off Note if you select heaters Off the controller will remind you at power on to press F1 to turn the heaters On Page 5 20 Programming ITW Dynatec c 2000 Revised 12 02 DYNAMELT M ASU Manual 50 13 20 36 20 37 20 38 Service Functions Screens Page 2 cont Press 3 to program Factory Defaults CAUTION Factory Default programming is not essential If done improperly it can cause re pro gramming of setpoints to be necessary If you are satisfied with your ASU s setup you may leave Factory Defaults unprogrammed Upon entering this screen the ASU Type model
167. mm SHC Screw Middle Plate O ring 113 M10 Flat Washer Qty FN e A N e N FW A Wo RFP RFP Ne RF A e eR iTV Dynatec 2001 Component Illustrations amp BOM s Page 10 23 DYNAMELT M ASU Manual 20 37 2 01 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread Component Illustration 1 54 cc Rev Dual Gear Pump Assembly 100863 Page 10 24 Component Illustrations amp BOM s T Dynatec c 1999 Revised 8 02 DYNAMELT M ASU Manual 20 37 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread Bill of Materials for 3 2 cc Rev Dual Gear Pump Assembly 100864 Item No Part Number Description Qty 1 0120088 Drive Shaft 1 2 0781001 K ey Woodruff 1 3 101626 5 12 SHCS 4 4 069X 160 Seal retainer amp Bearing Housing 1 5 069 061 Lip Seal 1 6 018X 041 Bearing Sleeve 2 7 100867 Front Plate A ssembly 1 8 012D 087 Driven Gear Shaft 1 9 018X 031 Ball 1 8 Dia 5 10 012C019 Drive Gear 4 5 cc R ev 4 11 069 064 O ring 041 3 12 078F017 Shaft Retaining Ring 4 13 018X 041 Bearing Sleeve rear Plate 2 14 100865 Rear Plate Assembly 1 15 101691 4 40 SHCS 2 16 NPN M 10 1 5 x 85mm 4 17 100870 M iddle Plate 1 18 N 00198 O ring 113 2 19 NPN M 10 Flat Washer 4 iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 25 DYNAMELT M ASU Manual 20 37 8 02 Bill of Materia
168. mp Shaft 1 8 107641 Block off Plate U sed with pendant control 1 9 104384 M echanical O perator Circuit B reaker 1 10 103075 Circuit Breaker See PN Unique to your system IBOM 1 11 802657 Panel Box 1 12 802658 Insert Panel Layout 108583 1 13 048H 384 SSR Dual 40 240VA C 6 32 14 107993 Memory Card Assembly option 1 15 102326 Cover Memory Card 1 16 109770 Pendant Control Assembly option 1 Continued on pages 6 thru 7 Revised 2 03 Component Illustrations amp BOM s Page 10 7 DYNAMELT M ASU Manual 20 37 iTW Dynatec 1999 Optional Pendant Control Page 10 8 Component Illustrations amp BOM s Revised 2 03 TW Dynatec 2001 DYNAMELT M ASU Manual 20 37 Bill of Materials for Typical Electrical Panel Box Assembly 806465 Cont from pg 4 Item No 17 18 19 20 21 22 23 24 25 26 21 28 29 30 3l 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Part Number 102762 103183 103184 106093 103069 103070 104193 108306 106978 106111 048H 212 103663 107466 806512 806555 108144 0481126 104780 804535 805198 107440 106147 804691 804696 107893 107922 108256 107891 110090 107033 107853 048E 162 107438 TBD 804890 Description lAmpFuse Fuse Block Lever Open Fuse GDC4 250VAC Terminal Rail Control Pro
169. mp to track line speed Serial Communication PC Link Remote I O Interface PN 108475 Bi directional data transfer to a remote computer is available for the controller The ASU s standard RS232 serial port connection allows remote interface up to 50 meters from the D ynaControl con troller The RS485 serial port connection offers remote interface over a much longer distance Either connection enables all system parameters to be monitored and or controlled from the remote sta tion iTV Dynatec c 2001 Options amp Accessories Page 9 5 DYNAMELT M ASU Manual 20 37 Revised 6 03 Recommended Service Parts List Deere 9 Electrical 102762 Fuse 1 amp motor control interface pcb 104117 Fuse T6 3A Lx 5x20 pcbs 103184 Fuse GDCA terminal rail 804535 Fuse 15a LP CC 036B 103 RTD Sensor PT heater control 104166 Over Temp Thermostat amp Insulator 036B 015 Pump Enable Thermostat 102411 B oot Insulator 048H 384 Solid State Relay D ual 109857 CPU Printed Circuit Board V 5 108258 Display CPU PC Board 107440 48 Zone Power 1 0 PC Board 106149 Auxiliary RTD PC Board optional 107853 M otor Speed Control AC Drive Board 110090 M otor Control Interface PC Board 107438 Clutch PC Board optional 106147 Pressure PC Board optional 036A 170 Heater 500w for 1 filter block 036A 079 Heater 1000w for 2 filter blocks 102149 Heater 1500w for 3 filter blocks 036A 077 Heater 2000w for 4 filter blocks O rings N00181 O ri
170. mpress the packing then back off turn of the screws Be sure to adjust the gland properly Do not over tighten Adjustment may be made during operation to control excessive leakage Time Saving Heating Alternative Maintain the clean and ready to use pump in an oven at operating temperature This avoids thermal shock and saves valuable beating time 4 Startup 1 Ensure that the pump is free turning and lubricated Engage the outer drive shaft carefully making sure that it iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 does not bottom in the slot of the coupling and thal it is aligned within 1 angular and 005 parallel with the true pump drive axis The coupling is the rotating member of the seal and depends on the internal operating pressure of Ue pump to force it forward and affect a seal against the carbon or melal seal plate In pumps with a through shaft and compression packing seal the pump to driver axis may shift unevenly due to pump healing expansion Jo remedy this we recom mend connecting the pump driver to the pump shaft with a double universa joint arrangement This type of joint will prevent bending loads from being transmitted to the pump shaft when misaligned This greatly reduces the possibility of premature shaft failure due to fatigue To prevent seizure be sure to apply adequate high temperature lubrication to the universal joints 2 After startup take up gradually and evenl
171. ng 014 outlet filter manifold A 69X 133 O ring 124 outlet filter manifold PRP Ea pa pa pa pa ka QJ OU Ui Ui 8 6 per manifold 2 per manifold N00187 O ring 020 outlet filter manifold 2 per manifold 069X 275 O ring 122 outlet filter manifold 2 per manifold N 00199 O ring 114 outlet filter manifold 2 per manifold 103770 O ring 5 005 outlet filter manifold 2 per manifold 103771 O ring 5 254 outlet filter manifold 2 per manifold N00192 O ring 032 6 807729 Pump Shaft Seal Zenith TSHA pump models 2 per pump 069X 061 Pump Shaft Seal ITW Dynatec pump models 2 per pump 069X 289 Pump Shaft Seal Hi Flow pump models 2 per pump 069X 064 O ring 041 optional pump block off assembly 1 see Pump A dapter O rings 1 of each per pump 101247 Filter Basket 100 mesh 2 per manifold 101246 Filter Basket 40 mesh optional 2 per manifold 109482 Filter Basket 200 mesh optional 2 per manifold 006C 156 High Flow Filter Basket optional 2 per manifold 105968 Filter Shutoff A ssembly Right 105969 Filter Shutoff A ssembly N 07588 L ubricant O ring L 15653 Kit Flushing Fluid 1 gallon 001U 002 Hi Temp Lubricant tube 102717 Check Valve pressure relief 101340 M otor B ushes Baldor optional DC motor 2 per motor 106313 M otor Bushes optional Lenze motor 2 per motor 108012 Filter Pressure Relief Plug ssembl 1 N 00185 O ring 018 outlet filter manifold 2 per man
172. ng the Modular Units install the Housing Guard 50 one of the ribs of the Modular Unit housing is directly beneath the clamp on the Housing Guard Waterproof guards are also available Purchase waterproof guards your focal Horton Distributor Appendix 39 Revised 12 99 OVERHUNG LOAD DATA Load 1 25 4 from Pilot Face ex ws nz 455 1200 281 Lbs 281 Lbs 1544 Lbs 610 Lbs 1800 321 Lbs 321 Lbs 636 Lis 700 Lbs 1200 1281 Lbs 281 Lbs 544 Lbs 610 Lbs 1800 1321 Lbs 321 Lbs 636 Lbs 700 Lbs 1200 244 Lbs 244 t bs 570 Lbs 570 Lbs 1800 279 Lbs 279 ibs 655 Lbs 655 Lbs Based on 10 000 hrs average and using 50 psi air TABLE 1 Appendix 40 Revised 12 99 Pneumatic Clutch cont LUBRICATION NOTE iTWDynatec 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumaticaliy actuated devices require clean pressure regulated and lubricated air for maximum performance and long The most effective and economical way to lubricate Horton Clutches and Brakes is with an Alr Line Lubricator which injects oil into the pressurized nir forcing an oil mist into the air chamber Locate the lubricator above and within ten fest of the Clutch or Brake and use a low viscosity such as SAE 10 Synthetic Lubricants are not recomended 1 UBRICATOR DRIP RATE SETTINGS NOTE These settings are for Horton supplied lubric
173. ngs the operator can determine if the filter basket is clogged Drop in Grids PN 104802 The drop in grid is an extra heated grid s which is installed near the bottom of the A SU s hopper The additional grid s allows faster melting of adhesive for applications requiring higher melt rates and higher volumes of adhesive W hen installed the drop in grid becomes an auxiliary temperature zone on the controller High Temperature Heater Groups M ore accurate temperature control may be gained by using a High Temp Heater Group in the filter manifold pressure relief block A heater and sensor are contained inside the block and become their own temperature zone on the controller Six groups are available depending on the number of filter manifolds on the ASU Filter Options and Accessories 40 Mesh Outlet Filter PN 101246 Some situations do not call for a fine mesh outlet filter A clean adhesive or one with along pot life are examples Systems utilizing lower temperatures or systems running in a clean environment can also utilize a 40 mesh filter Standard equipment on D ynamelt is a 100 mesh filter PN 101247 Level Control Single Point Level Control PN N08122 Available on all models Multi Point Level Control PN 0840192 DMM140 amp DMM210 only These devices inform the operator via a message on the controller that the hopper s adhesive level is low They may also be wired to stop production turn on an alarm light or signal or signal a
174. nt Again it is usually necessary to disassemble only the seal arrange ment to remove polymer ash 3 Always replace the carbon seal plate after pump burnout If the pump was performing satisfactorily when removed from service and still turns freely after burnout pressure test it and add a high temperature lubricant to prepare it for return to service store Jor future use simply add a rust preventative oil Appendix 31 Revised 3 01 el 6 Disassembly If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt purnps If maintenance required due to low delivery or seizure the following procedure is recommended for disassembly NOTE Be sure to note the location and orientation of all parts to ensure correct reassembly 1 Remove the sea arrangement 2 Remove all binder screws 3 Remove dowels and arbors with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Most dowels and arbors press fit in the front side plate and slip fit in the center and rear side plates When this is the case it is preferable to press from the front drive side Separate the plates by lightly tapping them with a soft head hammer If pry slots are available the pump you may use them instead of o
175. nted circuit boards PCBs should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is notavailable frequently touch a bare metal part of the ASU unpainted frame mounting screw etc to safely discharge any electrostatic buildup on your body 2 Handle a PCB by its edges only Don t grip a PCB across its surface 3 When removed from the ASU each PCB must be individually packaged inside a metallized static drain envelope Do not place the removed PCB on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or 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 PCBs for shipment use only static drain bubble pack Do not use foam peanuts or bubble pack not known to be static draining The following pages detail the Dynamelt M Series PCBs Page 7 4 Troubleshooting ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 CPU Printed Circuit Board The CPU board s contains the controller s software chip EPROM CPU chip and non volatile memory It also contains the optional RTD Expansion PCB for ASUs with 10 or more zones Up to three CPU boards may be installed on an ASU corresponding to up to three hoppers and
176. nter c Scroll to M in and enter a value of 0 Press Enter d Scroll to M ax 96 and enter a value of 100 Press Enter 2 Energize the parent line tracking signal to its full speed at least 10 V DC at the 0 and 10 terminals at X 3 on the M otor Control Interface printed circuit board 3 On M otor Control Interface printed circuit board see illustration in Chapter 7 locate and adjust the web speed scaling potentiometer V R 1 clockwise until the SET 96 is below 99 8 Then adjust counter clockwise until it equals 99 896 4 The system is now calibrated so that full parent machine speed corresponds to full speed of the gear pump The amount of adhesive dispensed can now be adjusted by trimming the pump RPM at the AUTO menu of the controller by adjusting the M AX value down from the factory default of 10096 A djusting the MIN 96 value corresponds to the pump speed when the parent line is stopped 0 0 volts at the 0 and 10 terminals In most applications the factory default M IN 96 0 is used iTV Dynatec 2001 Installation Page 3 15 DYNAMELT M ASU Manual 20 37 Revised 11 02 Optional Level Controls Single Point Level Control The level control device informs the A SU s operator via a Level Low message on the Dyna control controller s System Status display that the A SU s hopper needs to be refilled or that it is overfull It may also be wired to stop production W hen the alarm activates pr
177. o carburize the polymer The car burization process usually takes between 3 and 12 hours depending on the polymer type temperature pump size and furnace load CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning After gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent t may be necessary to disassemble the seal arrangement to remove polymer ash If present always replace the carbon seal plate after pump burnout If the pump was perform ing satisfactorily when removed from service and still turns freely after burnout pressure test it and add a high temperature lubricant to prepare it for return to service To store for future use simply add a rust preventative oil It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum By noting the perfor mance of a pump immediately before removing it from service and correlating the perfor mance to measured component wear the user can establish the maximum wear limits for the pump s critical components Further he can predict the service life of the pump and schedule his down time accordingly As with any other Dynatec pump high accuracy pumps may be returned to D ynatec for com plete rehabilitation as necessary This procedure may be desirable if only a few pumps are involved If a large number of pumps are to be main
178. of the keypad Programming 1 Insert the M emory Card in its slot on the control panel Y ou will then see this screen SYSTEM Ready Tue Load From Memo Card to this Controller Save From this Controller to Memo Card RETURN 2 Choose Load F1 or Save F2 After a few seconds you will see this message Transmission Done 3 Remove your memory card from its slot Y ou will return to the A ctual Temperatures Screen ITW Dynatec c 2000 Programming Page 5 27 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 10 01 Up Downloading Instructions Controller to Remote PC PC Link The U pload Download functions are used to transfer system information and data from or to the D ynaControl To do this the DynaC ontrol must be connected to an external PC or PLC viaa se rial cable The data format is an ASCII text with TA B delimited data This text can be created with standard word processing programs or spreadsheet applications and up or downloaded via terminal programs B oth functions are on demand functions i e they must be started on the D ynaControl keypad Hardware Hookup Remove the controller mounting bracket from the ASU via four screws accessed from inside the panel box assembly U sing a standard serial extension cable M ale F emale DB 9 if necessary utilize a DB25 to DB9 adapter connect either of the D ynaControl controller s serial ports on the Display CPU PCB see illustration on page 7 5
179. off Cleaning or 6 4 P rmp ShafE ooo EU ear beam ale ae ask ng ERN ne RR n Rae es 6 5 Summary of Preventive Manintenance 6 5 Elushing theSystem desir d Rit heeft Rea ah Bata dota belua aft Rack ae S de 6 5 Chapter 7 Troubleshooting General Troubleshooting Notes 7 1 Preliminary Checks cca ach S ET XR Rue EXE E RE E Tub bese M 7 1 Error M essages is osse eigen tah dee tan Acc nter dac dede acp edite sao aod 7 1 Hose Applicator Troubleshooting 7 1 M otor Speed Control PC Board Re set 7 1 High Temperature Redundant Overtemp Thermostat 7 2 Pump Enable Thermostat 1 toe Pre ecce et ee ped dept cs 7 2 Lithium Battery on Cer eer o ap d pede gati 7 2 Handling Printed Circuit Boards 7 3 CPU Printed Circuit Board amp Layout Illustration 7 4 Display CPU Printed Circuit Board amp Layout 7 5 M otor Control Interface Printed
180. on or sheathing Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections Do not use adhesive that is dirty or that may be chemically contaminated Doing so can cause system clogging and pump damage When adhesive hand held applicators or other movable applicators are used never point them at yourself or at any other person Never leave a hand held applicator s trigger unlocked when not actually in use Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until the adhesive s temperature is within the operating range Severe damage could result to internal parts and seals Treatment for Burns From Hot Melt Adhesives Burns caused by hot melt adhesive must be treated at a burn center Care should be used when working with hot melt adhesives in the molten state B ecause 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 emer
181. opper with clean hot melt adhesive to within a couple of centimeters inches of the top of the hopper Close the hopper lid immediately to prevent contaminants from falling in Cover your bulk supply of adhesive to prevent contaminants also 2 Switch ON the M ain Disconnect the circuit breaker located on the panel box 3 Atthe DynaControl keypad press the controller s F1 button if prompted to do so 4 Allow adequate time approximately 20 30 min for the adhesive to melt and the temperatures of the temperature zones to stabilize M onitor the System Status display to see when H eat U p changes to Ready Undertemp arrows will blink until the temperature zones are up to ready temperature 5 When temperatures are ready the pump and motor are enabled to pump adhesive Atthe pump screen Select A uto or M anual M ode Select desired pump press Enter a If Pump is in Auto M ode Adhesive will begin to pump when the production line begins to operate b If Pump is in M anual M ode i Press M anual F1 Press Enter ii Enter desired speed value Press Enter iii Scroll to select next pump if applicable R epeat steps i thru iii until all pumps are programmed Adhesive will begin to pump once the pump enable thermostat closes and Ready condition is attained Shut Down Procedures Atthe pump screen 1 If Pump is in Auto M ode a Press STOP or STOP ALL F3 b Turn OFF the M ain Disconnect Switch 2 If Pump is in M
182. ows the operator to program main power ON and OFF times which coincide with his daily production schedule throughout the work week U p to ten events may be scheduled A n event is a specific day and time or every day at the same time AnASU which has an active seven day scheduler should be turned ON at the main power switch It should not be turned off by the main power switch while the scheduler is active To turn the ASU OFF temporarily overriding the scheduler use the D ynaControl On Off keypad icon In the event of a power outage or a manually switched main power ON an active scheduler over rides the Power On Heater Start parameter That is if the scheduler is in Switch ON at the time of a power ON the heaters will be turned ON Likewise if the scheduler is in Switch OFF at the time of a power ON the heaters will be turned OFF W hen the seven day scheduler is programmed and active the scheduler icon on the controller screen flashes continuously 7 Day Scheduler Screen 7 Day Scheduler Active Indicator Keypad On Off SYSTEM Ready Tue 3 36PM L DOD Event Action Day Time 1 Standby El SYM DEF 2 Switch On Mon Fri 1 2 3 3 Standby Mon Fri 4 on Mon F ri 5 S witc Mon Fri 2 Everday GHI JKL No 7 Monday 8 Tuesday 3 PRS WXY RETURN 71819 e 0 gt ABC 123 T Dynatec Enter ITW Dynatec c 2000 Programming Page 5 25 DYNAMELT ASU Manual 20 36 20 37 20
183. p In Hole Plug 3 8 St Conduit Fitting Grommet Hose Support Bracket O Ring 039 1 2 NPT Level Seal Plug Cap Nut Adjustment Screw 10 24 x 1 2 SHCS 1 4 20 x 1 SHCS 3 8 16 x 1 FHSCS 1 4 20 x 1 2 HHCS 3 8 16 x 1 3 4 SHCS 5 16 18 x 1 SHCS 10 24 x 1 2 HHSMS 3 8 16 x 4 1 4 SHCS 3 8 16 x 5 1 2 SHCS 1 4 20 x 4 1 2 SHCS Flat Washer 1 4 SAE 3 4 16 Jam Nut 3 8 16 Eye Nut Temperature Sensor Sensor Adapter Heater 5 8 x 10 240v 1000w Flat Washer Lock Washer 3 8 USS Flat Washer 3 8 SAE Flat Washer 48 3 8 NPT x 3 4 16 JIC Hex Nipple 3 4 NPT x 3 8 NPT Reducer Bill of Materials 9 Sr ct aaa at proc CES Gl Ae qi den TwDynatec c 2001 Component Illustrations amp BOM s Page 10 5 DYNAMELT M Manual 20 37 Revised 2 01 Component Illustration for Pressure Relief amp High Flow Filter Block Assembly 101767 Used on the 106694 High Flow Grid Assembly Page 10 6 Component Illustrations amp BOM s Tv Dynatec 2001 Revised 2 03 DYNAMELT M ASU Manual 20 37 Bill of Materials for Typical Electrical Panel Box Assembly 806465 Item No Part Number Description Qty 1 802102 M ounting Bracket 1 2 107625 Bezel 1 3 802626 Heat Sink 2 4 102328 Panel Box Lock K it 2 5 103377 Wire duct 1 5 W x 3 H 103378 Wire duct 2 w x 3 H 6 103439 Wire Duct Cover 1 5 103438 Wire Duct Cover 2 25 7 104382 104383 Rotary Handle a
184. pter Read the cautions on page 8 5 before re assembling the ASU To Remove the Access Doors There are two access doors one on either side of the ASU Use the key to unlock the door then lift it off being careful not to pull off the ground wire attached Remove the ground wire and re attach when the door is re installed These doors allow access to the motor pump junction boxes op tional drop in grids filter shutoffs and optional ball valves To Open J unction Boxes There are two junction boxes one on either side of the hopper s A junction box cover is removed by two screws at the bottom of the box Within the juction boxes are thermostats heater terminals and the hopper sensor See also the detailed illustration on the following page Panel Box Assembly Access Door Filter S hutoff Keylock Thermostat Pump Enable Thermostat Filter Shutoff Assembly LT Ball Valve J Nie Assembly n SS option B z d ZA Pump Enable Thermostat Manifold Cover 4 Over Temp Reset Thermostat Over Temp Reset Page 8 2 Disassembly amp Re assembly iTV Dynatec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 amp 20 38 J unction Hopper Box cover BAN J unction Box Cutouts for conduit connectors for filter manifold heater and sensor Over Temp Reset Cutouts for drop in grid assembly Ko o
185. r in conjunc tion with the above method In either case great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 4 After disassembly clean ai components in a glass bead blast cabinet to remove any debris remaining after heat cleaning Wash components in an ultrasonic cleaning tank and air dry 6 Inspect all parts for nicks burrs score marks and other signs of wear plates and sides of the gears may be hand blocked on 400 600 grit paper and any nicks burrs or sharp edges can be lightly removed with an Arkansas stone CAUTION Since the thickness relationship between the metering gears and center plate is critical to metering performance and the center plate is non wearing on its sides lapping these components not necessary and should not be done under any circumstances T To keep maintenance costs to a minimum the following procedure is recommended A Measure used parts and compare their dimensions with new part standards This will provide you with precise information on the wear of the pump parts and aid in maximizing the useful life of each component B Replace worn gears shafts bearings and center plates C Side and middle plates may be refinished by grinding and or lapping them to remove wear markings and return them to flatness within 0001 convex and surface finish of 4 to 8 rms 8 Replace the sleeve bearings as necessary and
186. rameters which the user has programmed and wishes to store in the controller for future use Up to four recipes may be stored in the Dyna Control controller Sequential Heating The heating sequence which allows the slower heating hopper to reach operating temperature with out unnecessary use of electricity for faster heating hoses and applicators Sequential heating is the time period during which the hoses and applicators remain OFF while the hopper and optional drop in grids heats up Hoses and applicators may be independently programmed If hopper tem perature is above ready temperature when the ASU is turned ON the hose and applicator ITW Dynatec c 2000 Controller Setup P age 4 3 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 5 01 sequence is bypassed and they will be turned ON The heat up sequence is restored after Standby is turned from ON to OFF Sequential heating is not needed for most applications and can delay total system warm up time Standby Condition The system condition where the A SU hose and head temperatures are maintained at predeter mined reduced temperature values Standby temperatures are set lower than setpoint temperatures in order to reduce adhesive degradation and energy consumption when the system is temporarily inactive and to permit rapid system warm up when run condition is selected Setpoint A programmable temperature that has been selected for hopper hoses applicators or auxiliary Zon
187. re installed on ASU A fter setting limits for all pressure transducers return to the A ctual Temperatures Screen 4 Press Scheduler K ey to program the following functions Standby Time amp Date Clock 7 Day Scheduler and or Program Recipes 5 Press Help to view the Help screen illustrated on page 5 2 Monitoring 1 System Status display describes system status as one of the following a System Heat up power is ON but zone temperatures have not risen to setpoint range b System Ready all zones have reached setpoint temperatures c Alarm a temperature zone is out of its setpoint tolerance range A n overtemp alarm is indi cated by an upwards arrow next to a temperature A n undertemp alarm is indicated by a down wards arrow next to a temperature d Alarm Lo the pump enable thermostat undertemp thermostat is preventing operation due to a low temperature condition e Standby the system is in a programmed standby state 2 Actual Temperatures or Zone Status of all zones is displayed a 3HHE a three digit number indicates a zone s actual temperature b HOLD zone is waiting for release Temperatures have not risen to setpoint range C Arrow up zone is over temperature d Arrow down zoneis under temperature there is no sensor Zone needs troubleshooting f gt there are more temperature zones not seen on the current display To view them press C on the numeric keypad bottom row first key 3 7 Day
188. re they are re assembled particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts should always be re tightened at operating temperature Page 8 6 Disassembly amp Re assembly iTV Dynatec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 amp 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec c 2001 Options amp Accessories Page 9 1 DYNAMELT ASU Manual 20 37 20 38 Revised 10 01 Chapter 9 AVAILABLE OPTIONS amp ACCESSORIES Pressure Gauge Assembly PN 805641 A n optional analog pressure gauge can be mounted on the outlet filter manifold Reading the adhe Sive pressure at the manifold rather than in line on a hose allows for more precise monitoring of System pressure It is also useful for troubleshooting and maintenance The gauge is installed at one of the adhesive ports on the manifold Fittings and adapter are included in the assembly Pre PSI amp Post PSI Transducers PN 800225 Transducer Assembly PN 108825 A pressure transducer is an electronic probe that allows the melted adhesive s pressure to be pro cessed by the ASU s control system They are used to monitor system operating pressures and their limits The Pre PSI transducer measures adhesive pressure in the filter manifold before the filter basket The Post PSI transducer measures the pressure after the filter basket By comparing the two readi
189. reen serves as the controller s main menu From here you can go to any other screen The A ctual Temperatures Screen is also the most useful screen to display for monitoring purposes Scheduler Key Controller t t 7 D heduler Acti System Status ay Scheduler Active On Off Key E mum SYSTEM Alarm Actuals F e Premelt C SYM DEF Progmelt 2 3 Filterblock V Tue 3 36 PM Next Page Press C 2 Hose 2 Head a 55 Aux Zone 7 TUV WXY 8 9 0 gt ABC 123 11 Pump Info Lines Use of the Actual Temperatures Screen Press This To Function Key On Off Toggle display pumps and heaters power ON or OFF Setpoints F 1 Pumps F2 Pressure F3 Help F4 Service Scheduler Go to the setpoints programming screen Go to the pumps programming screen Go to the pressure screen Go to the Help screen Go to the first of the three service screens Go the the M ain Scheduler screen ITW Dynatec c 2000 Programming Page 5 7 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Actual Temperatures Screen cont Programming Sequence details on following pages 1 Press Setpoints After programming all of your temperature setpoints return to the A ctual Tem peratures Screen 2 Press Pumps A fter programming all pumps and optional clutch es return to the A ctual Tem peratures Screen 3 Press Pressure if optional pressure transducers a
190. ressure side to the low pres sure side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate The High Accuracy Pumps are designed for high temperature and high pressure operation As such operating temperatures to 550 degrees F can be achieved INSTALLATION Pumps should be carefully unpacked to make sure that the shipment is complete If any items are missing or damaged the freight carrier and Dynatec should be notified immediately While the pump is composed of steel it is a precision instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat them as you would any other precision gauging instrument Dynatec Zenith pumps are shipped filled with a rust preventive oil Flush the oil throughly with a cleaning solvent It may be necessary to disassemble the seal arrangement to remove all traces of the oil but disassemble only if necessary After flushing the pump should be lubricated internally for start up purposes Pour a suitable high temperature lubricant silicone oil into the inlet port Rotate the metering gears until lubricant appears at the discharge port M ount the pump to a block with
191. rify condition of relay by discon necting then re connecting properly Then when Temperature Zone is OFF use a VOM AC voltmeter to verify that 240 volts are not present at the heater terminal Solid State Relay Relay iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Troubleshooting Page 7 15 Revised 10 00 1 Sensor cable has become unplugged from CPU PCB Hopper Sensor Open 2 hopper sensor Hopper Sensor Hopper Sensor Short 1 Short circuit caused by debris where sensor plugs into CPU PCB 2 Pinched sensor lead wire 3 Inoperative hopper sensor 1 Verify that hopper sensor cable is properly connected on X 14 on the CPU PCB 2 Replace hopper sensor if resistance does not comply with resistance table in this chapter 1 Verify that sensor plug is clean and correctly connected on X 14 on the CPU PCB 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the sensor lead to the plug at the CPU PCB Repair or replace any damaged wire 3 Replace hopper sensor if resistance does not comply with resistance table in this chapter Page 7 16 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Hopper H eater O pen 1 Disconnection in hopper 1 Inspect hopper heater wiring for heater circuit proper connections 2 Disconnect
192. rol Interface PCB and a M otor Speed Control PCB TheM otor Control Interface PCB diagrammed below connects directly to the CPU PCB The M otor Speed Control PCB diagrammed on the following page connects via a spade connector to the M otor Control Interface PCB Up to two motor s pcbs may be connected to one CPU PCB Each M otor Control Interface PCB s jumpers should be set as follows the 1 and J 2 jumpers should always be set in the M 1 position diagrammed below for motor 1 3 and 5 For motor 2 4 and 6 jumpers 1 and 2 are set in the M 2 position opposite from those diagrammed below The M S selection jumper must be set in the M position The 3 jumper is always set as shown below MAX speed adjusting pot This pot adjusts the maximum output voltage of the motor speed con trol board It is factory preset to full pump motor rpm 10096 Normally this pot does not need ad justment Turning clockwise increases the voltage To verify adjustment set the motor to manual mode and to 100 speed Then adjust the pot to desired maximum speed 5 NOTE Do not attempt to use the MAX pot adjustment to trim the line speed to a given value Proper automatic line speed following is accomplished with correct motor programming into the controller see Chapter 5 ENCODER connections the optional Digital RPM Readout s encoder is installed onto these board connections MAX Speed Adjustment potentiometer X2 connections are in
193. rol is only responding if the received address matches the programmable address Examples Controller address 2 37 1 Write temperature setpoints Zone 3 250 F Zone 4 280 F Zone 5 300 Zone 6 350 F but temporarily not in use EOT 3 7 F 0 3 0 2 5 0 0 2 8 0 0 3 0 0 1 3 5 0 ENQ 37 3 250 280 300 350 Off note adding 1000 to the setpoint will deactivate this zone 2 R ead actual temperatures EOT 3 7 d 0 0 ENQ 37 00 note zone number 00 will request information of all available zones ITW Dynatec c 2000 Controller Setup Page 4 11 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 7 01 Return String 517 0 2 3 5 0 2 4 4 1 9 0 90 2 3 5 zonelis235 zone 2 is 244 F zone 3 has no sensor attached Note 1999 indicates open sensor 0999 indicates sensor short circuit 3 R ead actual pump speed EOT 3 7 e6 0 0 ENQ request the speed of all pumps Return String STX 0 8 5 0 0 6 6 4 ETX gt System has 2 pumps pump1 85 0R pm pump2 66 4R pm 4 R ead System Status EOT 3 7 f ENQ Return String STX gt F 46hex Bit wise 07 16 05 04 05 1 li 00 Always No setback normal mode Controller is on Enable thermostat closed Hopper not empty No low temper _ No high temper Rany 5 Read status of all temperature zones EOT 3 7 1 0 0 ENQ Return String STA 022 zone 1 is not used 0 zone 2 amp 3 heating but below
194. rom further Function key gt MANUAL AUTOMATIC STOP RETURN programming Manual Automatic or Stop pump modes Restart pump F1 All Stop stop all pumps T Dynatec Pump Programming Screen Page 5 4 Programming ITW Dynatec c 2000 Revised 7 02 DYNAMELT M ASU Manual 20 36 20 37 20 38 Basic Programming Sequence Quick Reference Follow the screen by screen steps outlined in the remainder of this chapter for complete setup and programming instructions Thereafter use this page as a quick reference Press Turn Controller On x2 6 Language Selection x1 8 Temperature Scale Selection Actual Temperatures To Program Setpoints To Program Pump Motor s a3 To Program Optional Clutch es Program Optional Pressure Transducers 1 Service Page 1 1 High Low Temperature Deviation 6 Temperature Offset 2 Setback Temperature 7 Sequential Heating 3 Setback Sleep Setup 8 Temperature Scale 4 Setpoint Limitation 9 Security Lock or Access Code x2 Service Page 2 1 Customer Zone Names 6 Language 2 Power On Configration 7 LCD Contrast 3 Factory Defaults 8 System Logbook 4 Keypad Locking 9 Change Security Lock 5 PC Link ay To Program Scheduler 1 Manual Standby Activation 4 Select Program Recipes 2 Time amp Date Clock 5 Manual Scheduler Activation 3 Program 7 Day Scheduler ITW To Program Optional Memory Card End ITW Dynatec c 2000 Programming Page 5 5
195. rotective Covers WARNING DO NOT OPERATE WITHOUT GUARDS IN PLACE K eep 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 3 97 Eye Protection amp Protective Clothing WARNING EYE PROTECTION REQUIRED PROTECTIVE CLOTHING REQUIRED Itis very important that you PROTECT Y OUR EYES when working around hot melt adhesive equi pment ITW Dynatec c 2001 DYNAMELT M ASU Manual 20 36 20 37 20 38 Wear safety glasses with side shields which conform to ANSI Z87 1 or EN 166 Failure to wear safety glasses could result in severe eye injury Itis important to protect yourself from potential burns when working around hot melt adhesive equi pment Wear protective gloves and long sleeved protective clothing to prevent burns that could result from contact with hot material or hot components Always wear steel reinforced safety shoes Safe Installation and Operation To avoid possible failure of 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 insulati
196. rs for TE TED o High Low Alarms Normally Open default no alarm no continuity Normally Closed no alarm has continuity Flat cable to CPU PCB Transducer 1 gt Green LED Board logic power is OK Layout of Components on Pressure Board Page 7 12 Troubleshooting ITW Dynatec c 2000 Revised 5 02 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Heater and Sensor Resistance Values The resistance values given in the four tables on the following page will aid in troubleshooting when a sensor or heater malfunction is suspected The Temperature Sensor Resistance table gives values for various temperatures If you know the approximate temperature of the suspected sensor you can check to see if the sensor resistance approximates the value given in the table by unplug ging the affected head or hose connection and measuring resistance across the affected pins see wiring diagram in Chapter 11 for pin numbers DANGER HIGH VOLTAGE Disconnect input power to the application system before disconnecting re connecting electrical connections Make sure there is no electrical power on the leads you will be connecting The Nominal Hose Heater R esistance table gives the heater resistance for hoses A suspected hose heater problem can be quickly isolated by measuring hose heater resistance and comparing it to the correct resistance for your hose length and voltage as shown The Nominal H ead H eater Resistance table
197. s iT Dynatec c 2001 Description amp Specifications Page 2 1 DYNAMELT M ASU Manual 20 37 Revised 6 01 Chapter 2 DESCRIPTION AND SPECIFICATIONS Description The DY NAM ELT M Series adhesive supply units A SU are computer controlled hot melt supply units designed on metric standards Utilizing ITW Dynatec s DynaControl temperature controller their control panels with choice of display languages provide comparative data of all setpoints motors etc on a few convenient comprehensive display screens The Dynamelt M Series 505 are available in three cabinet sizes and offer four hopper sizes The D ynamelt 70 amp 140 models use microprocessor temperature controls to closely control the tempera ture of hot melt adhesive for up to 8 hoses and 8 heads Temperature setpoints are operator selected for up to 32 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions The Dynamelt D ynaControl system provides accurate proportionate temperature control for the hopper hoses and applicators Sequential heating delays may be programmed for turn on of the hoses and heads A standby temperature may be programmed so that the temperature zones can be maintained at a lower temperature when the A SU is not in active use enabling rapid return to normal operation The seven day scheduler allows programmable automatic startup and shutdown of the ASU throughout the workweek With these flexibl
198. s switch 1 2 3 4 amp 5 are ON 6 clutches all switches are ON Optional RS232 485 Printed Circuit Board Pin Configuration RS232 RS485 5 Ribboncable connect to 5 Gnd 8 RxB Display CPU PCB S Shield 9 RxA S Shield Pins not listed are not used Layout of Components on Communication Board Input connections from Transducers ITW Dynatec c 2000 Troubleshooting Page 7 11 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Optional Pressure PSI Printed Circuit Board Each Pressure PSI PCB on the ASU allows the controller to monitor up to four pressure transduc ers The DM 35 ASU can accept one PSI PCB four transducers the DM 70 140 ASUs can accept up to two PSI PCBs up to eight transducers and the DM 210 ASU can accept up to three PSI PCBs up to 12 transducers Each CPU board can accomodate one PSI PCB The 8 pairs of terminals at the top edge of the board as seen below are for the high and low alarm outputs of the relays The eight jumpers for the high low alarm output relays E1 thru E8 are facto ry set to Normally Open default and are illustrated below in default position The leads from the pressure transducers are connected at the left of the board as seen below Note the quantity of pressure transducers on an ASU is configured at the dip switches on the Dis play CPU PCB High amp Low Alarm Outputs 4High 4Low 3High 3Low 2High 2Low 1High 1Low 200009000 0009000090 J umpe
199. s 5 to program optional PC Link serial communication Scroll to select either Load from Computer to this Controller or Save From this Controller to Computer Press F1 to Load Press F2 to Save Press F3 to Configure BAUD rate or FIFO The message Waiting indicates the controller computer is processing data message Transmission Done indicates the computer controller has completed transmission Press F4 to Return to menu The D ynaControl is capable of bi directional data transfer of all system parameters to a remote computer If this option is installed on your ASU program it at this step To program your remote computer see page 5 27 When PC Link is installed and the external serial communication is ON a flashing C appears at the upper right of the HELP screen Press 6 to program Language Scroll to desired language Press F4 to Return to menu Press 7 to program LCD Contrast Press F1 to increase contrast or F2 to decrease contrast of display Press F4 to Return to menu ITW Dynatec c 2000 Programming Page 5 21 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Service Functions Screens Page 2 cont Press 8 to program System L ogbook The System Logbook has the following functions 1 System Logbook a list of the last 1 000 controller events Use F1 and F2 to move forward or backward thru the logbook U se F3 Configuration to choose to log all system data or errors only 2 Data Logger
200. s F2 to program see next page Monitoring 1 RUN indicates the pump motor is enabled 2 HOLD indicates that the controller is preventing the pump motor from running due to a low temperature a standby condition etc 2 The Info Line indicates the user defined name for the selected pump programmed on Service Page 2 menu item 1 3 If the optional Actual RPM display is installed actual pump rpm may be monitored With this option the RUN HOLD column is eliminated The Actual RPM display is also seen on the A ctual Temperatures Screen Page 5 12 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Optional Clutch Programming Screen The Clutch screen is active as a subset of the Pump Programming Screen only if clutches are installed on your ASU It is reached by Pressing F2 Clutches on the Pump Screen seen on pre vious pages The number of clutches on the ASU will equal the number of motors For DM 35 thereis a maximum of two pumps clutches For DM 70 140 there is a maximum of four pumps clutches For DM 210 thereis a maximum of six pumps clutches SYSTEM Ready Tue 3 36 PM L e Press Enter and Select Mode Switch Clutches ON OFF with button 1 SYME AECI 2ST Pump Clutch 1 Pump Clutch 2 Pump Clutch 3 i Pump Clutch 4 Pump Clutch 4 Pump Clutch 6 TUV WXY RE START STOP ALL RETURN 2 F3 F4 0 gt 123 Turn
201. s programs can be programmed and stored in the controller though only one recipe is active at any given time Setpoints may differ from one recipe to another When switching between recipes the new recipe s setpoints take over so there may be error alarms if the new recipe s unused temperature zones are turned on The program recipes are referred to as Recipe 1 Recipe 2 Recipe 3 and Recipe 4 To create a Recipe advance to the M ain Scheduler Screen and press 4 Use F1 or F2 to choose recipe number for this example say 2 Press to confirm Press F4 then press F4 again to go to the A ctual Temperatures Screen Program all controller setpoints and functions as outlined on page 5 4 W hen all programming is completed Recipe 2 is created Press 5 to activate or deactivate the 7 Day Scheduler Press F4 to return to the M ain Scheduler screen Press 4 to return to the Actual Temperatures Screen Shortcuts 1 To activate or de activate the Scheduler from the the A ctual Temperatures Screen M ain M enu toggle by pressing and holding the Service wrench K ey for five seconds 2 To activate or de activate Standby from the the A ctual Temperatures Screen M ain M enu toggle by pressing and holding the Scheduler clock K ey for five seconds Page 5 24 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Programming of 7 Day Scheduler 7 Day Scheduler The Seven D Scheduler all
202. s given herein cover the description installation operation and maintenance of subject equipment D ynatec and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 2 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw pumps Each had problems with pulsation flow inaccura cies multiple seal areas and slippage which required constant calibration high maintenence and extended downtimes Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering T he pump s simple design of only three moving parts two metering gears and a drive shaft provided long life and easy maintenance For years since chemical engineers have relied on Zenith to provide precision fluid han dling solutions for their most difficult pumping applications Zenith gear pumps can be found wherever precise pulseless repeatable metering of fluids is required
203. sed 12 99 Pneumatic Clutch cont TROUBLESHOOTING contaminated Friction Facings Replace the Friction Facings Appendix 42 iTVW Dynatec 1999 Revised 12 99 DYNAMELT M ASU Manual 20 29 and 20 30 iTV Dynatec c 1999 DYNAMELT M ASU Manual 20 29 and 20 30 Pneumatic Clutch cont MODULAR OUTPUT UNIT MOU FIGURE 20 Models 1125 and 1375 1 Bend back the tabs on the old Keyed Washer Item 55 and remove the Lock Nut 56 and Keyed Washer See Figure 20 Fully support the Housing item 3 and press the Disc Journal Item 8 out of the Housing See Figura 20 Using a beating puller remove the old Ball Bearing Hem 28 trom the Housing ttem 3 See Figure 20 WARMING attention should be exercised when working Special with retaining rings Always wear safety goggles when working with spring of tension loaded fasteners or devices Remove the Spacer Item 12 and Retaining Ring Item 39 from the Housing ftem 3 Sea Figure 20 Press old Bearing Item 29 out of the Housing Item 3 See Figure 20 Remove the six old Fiat Head Screws Item 25 securing the old Friction Facing 9 to the Disc Joumal Item 8 and remove the oki Friction Facing See Figure 20 Using six new Flat Head Screws Item 25 secure a new Friction Facing ttem to the Disc Journal Item 8 See Figure 20 16 11 12 13 14 15 Appendix 43 Revised 12 99 Tighten the six
204. setpoint window 2 zone 4 heating and ready 3 zone5 amp 6 waiting due to heat up sequence 1 zone 7 amp 8 sensor attached 7 D D D D cont Dynatec deese Application Sysrems Parameter opcode Syntax DynaControl Version V5M Serial Protocol Return String Function Option 0x41 A zz n dddd ACK NAK write temperature setpoints C 10 to 232 will switch to Celsius 1 zone multiple zones 0x46 F zz n dddd ACK NAK write temperature setpoints F 50 to 450 will switch to Fahrenheit 1 zone multiple zones 0x61 a 77 n dddd read temperature setpoints 1 zone all zones 0x64 d 77 dddd n dddd read actual temperature 1999 open sensor 0999 shorted sensor 1 zone all zones 0x42 B zz n dd ACK NAK write temperature tolerance window 5 to 50 degree 1 zone multiple zones 0x62 b 77 dd n dd read temperature tolerance window 1 zone all zones 0x43 C zz n dddd ACK NAK write pump speed setpoint 0 0 to 100 0 1 pump multiple pumps 0x63 c 77 dddd n dddd read pump speed setpoint 0 0 to 100 0 1 pump all pumps 0x65 e 77 dddd n dddd read actual pump speed 0 0 to 150 0 Rpm 1 pump all pumps 0x6c l 77 dddd n dddd read line speed input 0 0 to 100 0 1 pump all pumps 0x67 g 72 dddd n dddd read
205. sing adhesives with extraordinarily high or low melting points can tailor the low temp setting to their production s needs To access the pump enable thermostat follow the instructions given in Chapter 8 Refer to Chapter 3 for instructions on calibration of this thermostat Lithium Battery on CPU PCB The CPU Printed Circuit Board contains lithium battery which serves no function in the Dynamelt M Series controller configuration Lithium Battery on Display CPU PCB The Display CPU Board contains a lithium battery The normal life of this battery is about ten years When the battery needs replacement the scheduler s clock does not function but other con troller features remain intact Return the board to ITW Dynatec for battery replacement ITW Dynatec c 2000 Troubleshooting Page 7 3 DYNAMELT ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Handling Printed Circuit Boards PCBs The Dynamelt A SU and D ynaControl controller utilize several printed circuit boards PCBs These boards are extremely sensitive to electrostatic charges W hen working near or with any PCBs the following procedures must be followed to avoid damage to them DANGER HIGH VOLTAGE Before unplugging connectors from the I O PCBs ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the PCB assembly when you are remov ing and replacing connectors CAUTION Pri
206. sure to escape out of the manifold A dhesive will drain into the container 5 Wearing insulated gloves push down on the adjustment screw cap with sufficient force to release the slide While holding the cap down pull the slide forward until the groove stops the roll pin Note If the cap moves up before the slide opens fully this is an indication that there is iTV Dynatec c 2001 Preventive Maintenance Page 6 3 DYNAMELT ASU Manual 20 37 20 38 Revised 2 01 still pressure in the system Stop and verify that the motor pump is turned OFF and the applicator s valves are open before proceeding Then repeat step 5 Pull the cap and the filter plug up and out of the filter cavity Due to adhesive and the o ring seals there will be some resitance before the plug exits the cavity Note the filter basket hangs from the plug by a spring clip If the filter pulls free of the spring clip and remains in the cavity use a hooked tool to extract it Pull the filter basket free from the spring clip The filter should be inspected and replaced as needed Note the char and debris inside the filter basket Before replacing the filter basket inspect the two o rings on the filter plug Replace any cut or damaged o ring A pply hi temp lubricant PN 001U 002 to a new o ring before installing maintaining system pressure A cut or scuffed scratched o ring can allow 1 CAUTION The condition of the lower o ring PN 069X275 is especially criti
207. t fun ction The write protect switch is set to OFF when it is shipped from the factory in order to allow data writing W hen the write protect switch is set to the W P arrow protection is ON and it will not allow data to be written Battery cover Connector terminal Parts Reference Initial Installation of the Lithium Battery The M emory Card s battery is installed at the factory prior to shipment To Replace the Lithium Battery CAUTION When replacing the battery the Memory Card MUST BE INSERTED INTO ITS SLOT ON THE CONTROL PANEL SO THAT YOUR CONTROLLER DATA IS RETAINED 1 Insert the M emory Card into its slot on the control panel 2 With your finger pull the hook downward and remove the battery cover 3 Remove the old battery 4 Confirm the position of the new battery s polarity as shown in the illustration and insert the battery 5 Replace the battery cover Replacement Battery The lithium battery may be obtained locally Specify CR 2330 Battery Installation Appendix 48 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions
208. t to remove them Allow adhesive and pressure to escape out of the manifold A dhesive will drain into the container 5 Remove the adjustment screw cap see diagrams below and loosen the jam nut Turn the adjustment screw counter clockwise until itis two turns from being completely out of the filter plug Note if the adjustment screw comes out of the filter plug be prepared for some adhesive to flow out of the screw hole cont P Screw cap gt Turning the adjustment screw counterclockwise opens the outlet and decreases the j 4 g pressure to the hose am nut gt gt and increases the pressure to the hose Turning the adjustment screw Adjustment screw clockwise closes the outlet Page 3 10 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 6 Atthe controller turn the motor ON to its maximum operating speed 7 Actuate open the valves on the applicator s in order to fill them with adhesive and purge air from the system 8 Closethe valves those openend in the last step to stop the flow of adhesive 9 Using a wrench turn the adjustment screw clockwise to increase the pressure to the applicator s SCREW COMPLETELY CLOCKWISE BOTTOMING IT INTO THE PLUG since this would shut off the pressure relief channel and could cause extensive damage to the pump motor and seals Be aware that the higher the adjusted pressure the more sensitive the adjustment is i e at hig
209. tained at the user s plant it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing gauging and assembly techniques involved in producting the pumps Please contact D ynatec at 1 800 538 9540 for further information on these items Appendix 6 iTWDynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 STANDARD ACCURACY PUMP DISASSEMBLY If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt pumps If maintenence is required due to low delivery or seizure the following procedure is recom mended for disassembly NOTE sure to note the location and orientation of all parts to ensure correct re assembl y Refer to assembly drawing located in the back of this manual for your correct pump type 1 Remove the seal arrangement 2 Remove all binder screws 3 Remove pins 10 and arbor 5 with an arbor press in the direction which disengages the press fit in the shortest distance NOTE Dowels and arbors for the standard accuracy pumps are press fit in the gear rear plate 4 Separate the plates by pry slots that are available in the pump Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 5 After disassembly cl
210. ternal and not for customer s use lt 0 5 VDC speed reference Flat cable connectto lt ne CPU PCB atJ1 Pump enable lt Pump enable X1 Encoder pulse z ME S not used Transformer Fuse gt lt Ground Encoder supply voltage Transformer p Handgun trigger input amp pump enable lt Handgun trigger input amp K pump enable 0 0 10 VDC input web speed NES msx 40v 240 VAC input Web Speed Scaling potentiometer Factory Set Do Not Adjust Layout of Components on Motor Control Interface Board ITW Dynatec c 2000 Troubleshooting Page 7 7 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 1 03 Motor Speed Control Printed Circuit Board The M otor Speed Control PCB is connected to the M otor Control Interface B oard via spade connc tors P1 and P2 P3 is not used The three jumpers FSR J1 and are factory set do not change The 1 jumper is always set in the upper position The A M Jumper is always present CL adjusting pot The current limit CL adjustment will limit the maximum current available to the AC pump motor during overload This will protect the motor from damage The setting is facto ry set to deliver 100 of the rated horsepower for the ASU When the motor load exceeds the cur rent limit value the Status LED light will illuminate red indicating an overload condition Turn ing clockwise increases the current limit value turnin
211. the main circuit breaker listed in the Panel Box Assembly PBA section of the indented bill of materials inserted at the back of this manual The main circuit breaker is the largest amperage cir cuit breaker listed in that bill of materials iTV Dynatec c 2001 DYNAMELT M ASU Manual 20 37 Description amp Specifications P age 2 7 Revised 6 03 Definition of Code DYNAMELT DM 70 amp 140 ASUs w DynaControl ASU Code M XX D X X D PX XX X X M 14 DN Code PN Base Unit 70 106051 70kg 154 Ib Hopper 14 106053 140kg 308 Ib Hopper 7D 106050 70kg 154 Ib Dual Hopper 1D 106052 140kg 308 Ib Dual Hopper 1H 106696 140kg 308 Ib Hopper HiF lo D DynaControl Controller Code PN Grids N n a Standard 804634 Add Drop in Grids O n a Omit Drop in Grids Qty Code PN Pump s 3t Quantity of each Type of Pump GAS 100860 Dynatec 1 54cc single GBS 100861 Dynatec 3 18cc single GCS 100862 Dynatec 4 5cc single GAD 100863 Dynatec 1 54cc dual GBD 100864 Dynatec 3 18cc dual ZLS 084E372 Zenith 0 160cc single ZDS 084E 428 Zenith 0 297cc single ZES 084E 374 Zenith 0 584cc single ZFS 084E 430 Zenith 1 168 single ZGS 084E 434 Zenith 2 92cc single SHS 108875 S amp P 8 5cc single ZLD 084E 387 Zenith 0 160cc dual ZDD 084E 388 Zenith 0 297cc dual ZED 084E 389 Zenith 0 584cc dual ZFD 084E432 Zenith 1 168cc dual SGD 108874 S amp P 2 92cc dual ZIS 084E411 Zenith 20cc single Large HiFlo ZJ S 084E412 Zenith 30cc
212. ting 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 v and use proper tools for handling hot melt components Note Each motor and M otor Interface PCB in the system can run independently or dependent y Each Motor Interface PCB may have its own operating parameters Therefore each motor and Motor Interface P CB should be troubleshot independently Pump doesn toperate 1 Motor On Off is OFF at 1 Check keypad setting in M anual mode the controller keypad power light doesn t light 2 Hopper temperature is 2 Pump cannot operate until hopper has ON OFF Led below ready setpoint reached ready condition Verify that hopper has reached ready R e program Y hopper operating setpoint and ready setpoint if necessary 3 No incoming electrical 3 Check to see if ASU temperature power control is operating If not check for presence of incoming supply voltage Pump doesn t operate 1 M anual motorissetat 1 Re program motor in M anual mode zero at the keypad power lightis ON hopper is at ready condition 2 1f pump On Off is being 2 Check condition of the remote switch controlled by a remote the hand held applicator switch i e a hand held applicator the switch or switch circuit may be open 3 Low temp alarm 3 Verify that ASU
213. ting due to either a malfunction or to a deliberately initiated cold start procedure When the ASU is turned ON via the Main Power Disconnect Switch Default Settings The factory set programmable system values that will be in effect if the user does not enter new val ues The controller will revert to its defaults whenever it is reset The DynaControl controller s de faults are listed in this chapter Error Indication Alarms Alarms which indicate that the programmed over temperature values have been exceeded for one or more hopper hose or head zones Alarms may also indicate an open or short circuited sensor Mechanical High Temperature Protection A mechanical redundant thermostat located on the hopper which turns OFF the system at 232 C 450 F Microprocessor based Proportional Temperature Control The built in control system that controls monitors and displays all system temperature values cont Page 4 2 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Over Temperature Setpoint The programmable temperatures that will cause alarms blinking up and down display arrows to occur when those temperatures are exceeded Power is not disconnected the READY contact opens and the alarm contact opens If an external alarm has been connected it will activate The over temp setpoint is the upper limit of the ready temperature range of each zone PC Link Also referred to as remote I O interf
214. tion procedure For any special applications con siderations or simply to ask our advice please contact D ynatec TO PREPARE THE PUMP FOR USE 1 Always flush out the plumbing system before connecting the pump 2 Filters should be installed prior to the pump inlet that filter ideally to half the pump run ning clearances 3 Turn pumps by hand before running Pumps should turn freely 4 Engage the outer drive shaft carefully making sure that it does not bottom in the slot of the coupling and that itis aligned within one degree angular and 005 parallel with the true pump drive axis Note the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate 5 Tighten the mounting bolts and coupling housing screws to D ynatec recommended torque at room temperature 6 Make sure fluid is in the pump before starting 7 Start pump slowly and if possible run it with a lubricating fluid 8 When satisfactory operation is achieved the pump and system may be gradually brought up to normal process speeds and pressures 9 If at any time during operation the pump does not appear to be running smoothly stop the pump immediately to avoid any serious internal damage CLEANING INSPECTION AND REPAIR REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op the high pressure demanded the cl
215. to hopper no adhesive output 2 f pump has been serviced 2 Check pump wiring to schematic and leads reversed pump will run with no output Low or inconsistent 1 Filter s clogged 1 and inspect filter basket adhesive output and primary filter 2 Adhesive used is too 2 Verify that system components are viscous at appropriate temperatures and that the selected adhesive is correct for the application Filter Basket 3 Clogged hose 3 Inspect hose for kinks or internal plugs of debris or char Clean or replace hoses as necessary 4 Clogged applicators 4 nspect applicators for plugged nozzles or filters Clean or repair applicators as necessary iTV Dynatec 2000 Troubleshooting Page 7 27 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 5 The fixed pressure relief 5 When fully closed clockwise and valve is opening all applicators are off adhesive pressure should be around 34 bar 500 psi If itis significantly less the pressure relief valve should be replaced 6 Inoperative lower o ring 6 Replace o ring Follow diagram and in filter plug is allowing instructions in Chapter 6 for Outlet pressure to escape Filter to locate the o ring Adhesive leak at pump 1 Pump seal is incorrectly 1 seal and bearing from pump shaft seal positioned inside the seal Verify that all components are and bearing assembly correctly positioned Seal Assembly Rear P
216. to the 10 and connect the white lead wire to 0 iii Verify that the gear pump motor is running at full speed when set to 100 in MANUAL mode The output of the tach generator can be adjusted depending on the application but it must be at least 10 VDC to obtain full adhesive gear pump speed Note under no conditions will the motor ever run faster than this speed 100 M anual B To install a similar DC tracking device not a tach generator Connect the DC tracking voltage signals to the terminals so that the negative lead is connected to 0 and the positive lead is connected to 10 Note the tracking voltage must be at least 0 10 VDC but not more than 0 25 VDC 4 Close the ASU s panel box door 5 Re connect input power and restore the application system to normal operation Procede to Calibration of the Optional Tach Generator or DC Tracking Signal Page 3 14 Installation iTV Dynatec 2001 Revised 6 01 DYNAMELT ASU Manual 20 37 Calibration of Optional Tach Generator or DC Tracking Signal A fter installation of a tach generator or a similar DC tracking signal the device must be cali brated at the D ynaControl controller Prior to calibration turn the application system ON and allow all components to warm up to nor mal operating temperatures above ready temperatures 1 Perform the following sequence at the controller keypad for each motor a Go to M otors screen b Choose AUTO mode Press E
217. trol The DM 70 1405 are also available in high flow models Page 2 2 Description amp Specifications iTV Dynatec 2001 Revised 6 03 DYNAMELT ASU Manual 20 37 Specifications Environmental Storage shipping temperature 40 C to 70 40 F to 158 F Ambient service temperature 7 C to 50 20 F to 122 F Noise CAISSON Kean croatia 60 dbA at 1 meter 39 inches Physical cce Creed dec e EE EE FT see dimensional layouts on following pages Number of heads 5 5 1108 Number of return hoses auxillary ZONES 108 Number of hopper temperature ZONES 102 N mber of pmp p DUX te bebe RE DU TRE CEPE IER 1104 Number of optional drop in gridS ors hi eines abe 2 N mber ds DE 2 Gear DUITIDS chad ak eic Pe CRI dU aes 2 92 cc rev standard Enclosure cssc PER voa ex rer jax nb es styled durable metal dust and splatter resistant Hose connections universal 15 pin Amphenol connectors at asu wrench secured fluid fittings 6 JIC Hopper tank DM M 70 70 kg 154
218. trol Interface PC Board open Program 1 closed Program 2 open Program 3 closed Program 4 Page 3 4 Installation iTV Dynatec 2001 Revised 2 03 DYNAMELT M ASU Manual 20 37 Printed Circuit Board Location Diagram The printed circuit boards PCBs are located within the main panel box assembly Note When multiple PCBs are installed to accomodate multiple components ie four motor speed control PCBs and four motor control interface PCBs to accomodate four motors as illus trated below make connections to all PCBs Note On Split Hopper M odels DM 140 only CPU PCB 1 controls Hopper 1 and CPU PCB 2 controls Hopper 2 Motor Control interface Board CPU Boards 4 shown 2 shown Motor S peed Control Drive Board Main Ground 4 shown Lug PE Ter Pressure Boards Main Circuit minal 3 shown Breaker Side Panel o e o 9 LJ L1 L2 L3 o o o qp o o o X1 6 X2 o ojj o 4 219 O Contactor Neutral 380v only RS232 485 Communication JS1 Circuit 154 nons Breaker 152 Power Board Breaker Neutral 380v only TM Level Circuit Control Breakers Clutch Signal Isolator Board Board Typical Panel Box Layout DM140 shown iTV Dynatec c 2001 Installation Page 3 5 DYNAMELT M ASU Manual 220 37 Revised 6 01 4 The adhesive hoses are connected at the rear cover s
219. ts will result in premature seal leakage and should be replaced 13 Inspect lip seals for wear cracks and abrasions Replace if needed 14 Pack lip seals 15 with a silicone based grease and lubricate with Parker Super O L ubricate or an equivalent silicone based oil 15 Install lip seals 15 into seal housing 9 as shown 16 Tighten seal housing screws 22 in a cross pattern to 60 Ibs in Check for free rota tion SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread Torque L ubricated T hreads UNC Alloy Steel L bs in Nxm Lbs ft 10 24 w carbon seal gasket 50 57 4 2 10 24 w o carbon seal gasket 64 7 2 5 3 312 24 120 13 6 10 1 4 20 150 16 9 12 5 5 16 18 305 33 9 25 3 8 16 into aluminum 360 40 6 30 7116 14 block hopper 480 54 2 40 Table 1 n critical applications where control of bolt preload is important the torque tension relation should be determined by experimenting on the actual parts involved including thread lubricants A t elevated temperatures itis often desirable to reduce screw stress because of deformation creep under sustained loading Screws constructed of type H 11 high temperature alloy steel provide extremely high creep resistance iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 TROUBLESHOOTING GUIDE Trouble Probable Cause Pump will not turn 1 Low pump temperature 2 Drive malfunction 3 Process conditions changed
220. ubricant ap pears at the discharge port 3 Mount the pump to a block with a flatness of true flat to 0001 convex and a surface finish of 4 to 8 rms to pre vent leakage between the pump and the block Make sure mounting bolts are lubricated with DAG Dispersion 154 for example and alternately torqued in even in crements up to the manufacturer s recommended limit for the bolt size used see Table Screw Torque Values Standard Alloy Steel Screw Size amp Torque Ib in Thread UNC Lubricated threads 024 w Carbon Seal Gasket 50 10 24 Carbon Seal Gasket 80 1224 asap iine seta das 120 TEM C ausvsees eiae rx ra 160 WIES S doses orba Vna 325 3 816 wee rar nn 360 E2d3 s 900 in critical applications where control of bolt preload is important the torque tension relation should be determined by experimenting on the actual parts involved including thread lubricants At elevated temperatures it is often desirable to reduce screw stress because of deformation creep under sustained loading Screws con structed to type 11 high temperature alloy steel provide extremely high creep resistance 4 Heat the pump thoroughly and evenly including the seal arrangement i S Tighten the mounting bolts and coupling housing screws to the manufacturer s recommended torque at that operating temperature If your pump has a packing seal take up firmly and evenly on the seal gland screws to co
221. ue at room temperature 6 Make sure fluid is in the pump before starting 7 Start pump slowly and if possible run it with a lubricating fluid 8 When satisfactory operation is achieved the pump and system may be gradually brought up to normal process speeds and pressures 9 f at any time during operation the pump does not appear to be running smoothly stop the pump immediately to avoid any serious internal damage CLEANING INSPECTION AND REPAIR REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op the high pressure demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow adequate lubrication All parts are ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances these pumps require careful maintenence and handling especially of component parts slightest burr nick or particle of foreign matter can cause scoring or even seizure These pumps are precision in struments you can t keep them too clean Please treat them with care and if it s at all pos sible set aside a separate clean area for pump maintenance To clean High Accuracy M etering Pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer Time at temper ature will be relat
222. urity Lock RETURN Page 5 22 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Programming at Main Scheduler Screen The M ain Scheduler Screen functions include Standby Date amp Time Clock 7 Day Scheduler and Program R ecipes Press the Scheduler K ey to advance to the M ain Scheduler Screen Main Scheduler Screen Scheduler Key SYSTEM Ready Tue 3 36PM L 60 D Activate Deactivate Standby Change Time amp Date 1 SYM DEF 2 Program Scheduler 3 4 5 2 3 Select Recipes Activate Deactivate Scheduler JKL MNO 5 6 TUV WXY RETURN 8 29 F4 0 gt ABC 123 ITV Dynatec ITW Dynatec c 2000 Programming Page 5 23 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 11 01 Use of the Main Scheduler Screen Function Press 1 to manually activate or deactivate Standby Press Press F4 to return to the M ain Scheduler screen N ote use of this key will override a programmed Standby Press 2 to program the time of day and date of year clock Press F1 or F2 to change a selected item press F3 to select another item Press Press F4 to return to the M ain Scheduler screen Press 3 to program the 7 Day Scheduler See programming details and screen on following page Press 4 to select an active recipe 1 4 Use 1 or F2 to select recipe 1 2 3 or 4 Press F3 to Con firm Press F4 to return to the M ain Scheduler screen U p to four separate setpoint recipe
223. utlet filter cont WARNING HIGH PRESSURE Turn the motor OFF and trigger the applicators to relieve adhesive pressure before performing any outlet filter maintenance WARNING Avoid splashing hot adhesive The filter screen will be covered with hot adhesive and must be handled with proper tools Position a heat resistant container under the manifold before proceeding Page 6 2 Preventive Maintenance iTWDynatec 2001 Revised 2 01 DYNAMELT M ASU Manual 20 37 20 38 Adjustment Screw Cap O ring PN A69X133 N Filter Plug pcm Spring Clip gt Filter Basket PN 101246 40 mesh H NE PN 101247 100 mesh Roll Pin in Groove Slide in Open Position Outlet Filter Manifold Purge Set Screw Purge Drain 3 Purge Set Screw Purge Drain Standard Outlet Filter Manifold located at the Hose Connection Panel 1 The system should be at operating temperature before starting this procedure 2 Before proceeding verify that the motor s is turned OFF and the applicators have been triggered to relieve pressure 3 Remove the M anifold Access Cover by unscrewing its screw and lifting it up and off 4 Position a heat resistant container below the manifold With a hex key screwdriver allen wrench slowly loosen the manifold s two purge set screws do not attempt to remove them Allow adhesive and pres
224. wer PCB as appropriate lt lt 2 2 1 Debris at connection between hose head and ASU 1 Visually inspect hose plug and A SU Socket for cleanliness and proper contact and seating of pins Hose H ead No Sensor Short 2 Hose H ead sensor circuit 2 Using the hose schematic check hose inoperative sensor resistance at ASU socket An ohmmeter can be used to isolate a pinched wire in the hose harness When cause is isolated replace hose hose harness or Power PCB as appropriate b If head to hose and hose to A SU plugs and sockets are okay head sensor may have an intermittent short or open circuit Examine connections inside the service block area of the head and monitor head sensor resistance with an ohmmeter while flexing sensor leads Repair or replace as appropriate iTV Dynatec 2000 Troubleshooting Page 7 21 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 reme sm _ Hose Head No 1 Disconnection between 1 Visually examine effected hose plug H eater O pen hose head and ASU and A SU socket for cleanliness and proper contact and seating Refer to the wiring diagram for pin identifica tion The problem can be isolated by plugging the effected hose head into another A SU socket If the new hose number is then displayed as malfunct ioning the problem is in the hose that was moved Repair or replace hose head or ASU hose harness as appropriate 2 D
225. with the ap plicator and hose the problem is probably in the ASU Motor Speed Control PC Board Re set Anytime the AC drives s M otor Speed Control printed circuit board must be re set due to line Surges or over currenting the motor turn the ASU OFF by the main power switch and wait at least 20 seconds before attempting to re start This will allow the pcb to re set See the table on page 7 7 to troubleshoot Page 7 2 Troubleshooting ITW Dynatec c 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 High Temperature Redundant Overtemp Thermostat The ASU includes a mechanical redundant overtemp thermostat that acts as a safety backup If the ASU s hopper temperature should exceed 232 C 450 F the thermostat will cause the A SU s cir cuit breaker to open and power to the hopper and all hoses and heads will be cut off The mechani cal thermostat must be manually re set after the hopper temperature falls below 204 C 400 F The overtemp thermostat is located behind the motor access door see Chapter 8 To reset turn OFF the ASU s main power switch push the center of the thermostat s insulator to re set restart the ASU Pump Enable Thermostat The pump enable thermostat is a low temperature safety feature of the Dynamelt ASU designed to prevent the pump from powering on before the adhesive is molten It is a cartridge thermostat and it is factory set at 135 C 275 F The thermostat is adjustable so that operators u
226. y again that the main power is OFF On the outside of the panel box use the main disconnect switch to open the panel box door see Chapter 3 for instructions on opening door a Fuse Replacement F uses are located in the upper right corner of the inside of the panel box assembly following printed circuit boards are fused M otor Control Interface Power 1 0 and the optional Clutch board b Printed Circuit Board Replacement Reference the section entitled Handling Printed Cir cuit Boards in Chapter 7 The PCBs are located in the panel box assembly R efer to detailed lay out in Chapter 3 The PCBs snap into and out of their standoffs To remove place your fingertips under one corner of the PCB and pull out firmly from the standoff Repeat for each corner of the PCB Note aside from fuses and the Lithium battery on M Series CPU PCB see Chapter 7 there are no replaceable parts on the PCBs Optional Memory Card Reader Battery Replacement Refer to instructions outlined in the A ppendix of this manual See Ch 3 for installation of M emory Card Reader Page 8 4 Disassembly amp Re assembly iTV Dynatec c 2001 Revised 6 01 DYNAMELT M ASU Manual 20 37 amp 20 38 To Access the Pump or Motor DANGER HOT SURFACE amp HIGH VOLTAGE If the pump is notoperable but the heating system will function raise the temperature of the application system to the operating temperature to aid in the pump disassembly process Otherwise
227. y and excessive wear It also encourages the introduction of air through seals Under ideal conditions speeds up to 200 r m have been maintained over long periods of time You can however expect accelerated wear in such instances depending on the lubricity of the solution and the differential pressure in the application Another cause of low through put is slippage across the sides of the gears from the high pressure discharge section to the lower pressure inlet section when thin fluids are metered against a substantial differential pressure This slippage is dependent on three factors viscosity of the material speed of the and the differential pressure Therefore even though the clearance between the gears and their housing may be as little as 00025 high slippage may still occur from high to low pressure ports if viscosity is low and pressure high i 3 Preparing Your Zenith Pump for Use Assembly itea vin Acetone o MEK Since Zenith Pumps are precise instruments their assembly requires detailed attention to every step 1 Zenith Pumps are shipped filled with a rust preventative oil Flush the oil out thoroughly with a cleaning solvent may be necessary to disassemble the seal arrangement to remove all traces of the oil but disassemble only if necessary 2 After flushing the pump should be lubricated internally Pour a suitable high temperature lubricant into the inlet port Rotate the metering gears until the l
228. y be cleaned or replaced If cleaning a filter use only solvents recommended by your adhesive supplier 7 Inspect the o ring Replace if flat or damaged 8 Apply a coat of silicone lubricant onto the filter plug before re inserting it into the manifold 9 Apply a coat of anti seize compound onto all screws before re inserting 10 Restore application system to normal operation Hose Fittings All hose fittings should be checked for tightness after every three months of operation Fasteners A fter the first ten hours of operation check all set screws socket head and cap screws for tightness Thereafter re check all fasteners after every three months of operation Filter Shutoff Cleaning or Replacement See the illustrations in Chapter 10 M elt amp Grid Assembly for location of the filter shutoff s DM 70 DM 140 and DM 210 models have two filter shutoffs 1 Pump all the adhesive out of the hopper 2 Lower the temperature of the application system to the adhesive s softening point WARNING HOT SURFACE The ASU will still be hotfor this procedure Use insulated gloves and protective clothing when removing the filter shutoff 3 Open the two access doors located at the sides of the ASU Do not pull out the ground wires attached The filter shutoff assemblies are located on either side of the hopper R epeat this procedure for each assembly 4 Wearing gloves use a wrench to unscrew the filter shutoff nut and pull the filter s
229. y on the pack ing gland screws until slight weepage Occurs 3 Be sure to follow up closely throughout the running in period of the packing unti the seal is thoroughly seated Do not completely seat the packing in one adjustment 5 e Cleaning 1 clean melt spinning pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initia hour to prevent flashing of the polymer Time at temperature will be related to pump size and degree of polymer contamination and should be determined by trial NOTE Careful control of the furnace temperature and atmosphere is critical Should the temperature exceed the original tempering lemperature the steel hardness may draw back and the dimensional stability of the pump may be upset Consult Table for proper tempering temperature Rockwell AISI Tempered At Hardness D 2 Ohio Air Die 8509 50 58 60 M 2 1050 566 61 64 M 4 Neatro 1050 F 556 C 61 64 Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath should be heated to a temperature that is sufficient to carburize ihe polymer The carburization process usually takes between 3 12 hours depending on the polymer type temperature pump size and furnace load CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning 2 After gradually cooling to room temperature the pump should be thoroughly flushed in a clean solve
230. ynaControl 4 8 Helpful Tips for the User cesso ae ele esa els da OR GEEREGUCR RR CR b EG E E IRURE 4 9 Serial Protocol nenni Reci n e e aded agii face ada vire Aet 4 10 Chapter 5 Programming of DynaControl Controller Controller Safety Consideration 5 1 Software Version ocu tre t ect not epo alae cu tton cab eee e e n vu ca S Y d 5 1 Display amp Keypad 5 2 Basic Programming Sequence Quick 5 4 Controller Setup teme bore cbr AAAS eee Tee UP AERE 5 5 Turning the Controller te tme d aba ERR gea ot conde 5 5 Language Selections eia de edt ete eee t e eden s tei na efi e 5 5 Temperature Scale Selection 5 5 Actual Temperatures 5 5 6 Use of the Actual Temperatures Screen 5 6 Programming Sequence 5 7 eas dat tre SG er inna Web at EAD Med EN ER a EN et ata Nee AT A 5 7 Setpoints Programming Screen 5 8 Use of th

dynamelt m series adhesive supply unit operations and service

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