ITW Pdf 106806
OPERATIONS & SERVICE MANUAL
Manual # 20-31
Revised 12/15/13
DYNAMELT S SERIES ADHESIVE SUPPLY UNIT
OPERATIONS AND SERVICE MANUAL
with Software Version 5.13S and up
Model #
Serial #
Code #
IMPORTANT ! - READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT
It is the customer’s responsibility to have all operators and service personnel read and understand
this information. Contact your ITW Dynatec customer service representative for additional copies.
NOTICE! Please be sure to include the serial number of your application system
each time you order replacement parts and/or supplies. This will enable us to
send you the correct items that you need.
ITW Dynatec Service Parts Direct Dial: 1-800-538-9540
ITW Dynatec Technical Service Direct Dial: 1-800-654-6711
Page ii
Revised 12/04
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page iii
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
TABLE OF CONTENTS
Chapter 1 Safety Precautions
Chapter - Page #
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eye Protection & Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Treatment for Burns From Hot Melt Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explosion/ Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout/ Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-3
Chapter 2 Description & Specifications
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wattage Capacity Verification Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DYNAMELT Model Designation Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
2-4
2-6
2-10
Chapter 3 Installation & Start Up
Mounting the DYNAMELT ASU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting the ASU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Connections (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Adhesive Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control/ Filter Unit (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover: Hose and Head Electrical and Adhesive Connections (illustration) . . . . . . . . . . . . . . . . . .
Pump Enable (Ready) Thermostat Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Installation of Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of the Optional Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of the Optional Tach Generator or DC Tracking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of the Optional Tach Generator or DC Tracking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of Optional 7-Day Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Start Up and Shut Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and Disposal of the Application System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-2
3-3
3-5
3-5
3-6
3-6
3-7
3-7
3-8
3-9
3-10
3-11
3-12
3-13
Chapter 4 DynaControl Controller Set-Up
Temperature Control Functions in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defining DynaControl Temperature Control Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DynaControl Display During Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Indication Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings for a Typical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Values that are Factory Programmed (not customer accessible) . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Programmable System Values Preset at the Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default Settings of the DynaControl Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Helpful Tips for the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional System Status (Stack) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-3
4-3
4-4
4-5
4-5
4-6
4-7
4-7
Page iv
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Optional Line Speed Tracking for Piston Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Chapter 5 Programming of DynaControl Controller
Controller Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Keypad (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DynaControl Display Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DynaControl Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Your System’s Configuration (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn the Controller On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Opening the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Beeper On/ Off Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Access Code Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Optional Pressure Transducer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Your System’s Parameters (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step A: Setpoint Temperature Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step B: Standby Temperature Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step C: Choosing a Temperature Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step D: Temperature Hi/ Lo Limits Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the Primary (Frequently-Used) Parameters (P1) (illustrated) . . . . . . . . . . . . . . . . . . . . . .
Step E: Customer Setup Access Code Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step F: Choosing the Temperature Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step G: Setback Time Delay Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step H: Sleep Mode Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step I: Sequential Heating Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step J: Head Hold Temperature Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step K: Lock Temperature Setpoints Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step L: Lock Motor Settings Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step M: Pump Enable Temperature Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step N: Setpoint Limitation Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the Secondary (Seldom-Used) Parameters (P2) (illustrated) . . . . . . . . . . . . . . . . . . . . . .
Step O: Customer Setup Access Code Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step P: Measured Temperature Programming (Temperature Zone Offset) . . . . . . . . . . . . . . . .
Step Q: Temperature Zone Enable Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step R: Customer Zone Names Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step S: Choosing Your Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step T: Power On Heater Start Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step U: Power On Input Priority Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step V: Power On Motor Stop Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step W: Level Control Status Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step X: Pressure Sensors Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step Y: Slave Address Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step Z: Gear Ratio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Programming (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Adjust Minimum/ Maximum Speeds for Auto Mode (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual Digital RPM Readout Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming of Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven-Day Scheduler (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control (illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Control Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DynaControl Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ready Light Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-2
5-3
5-4
5-4
5-4
5-4
5-4
5-5
5-5
5-8
5-8
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-12
5-12
5-12
5-13
5-13
5-14
5-14
5-15
5-15
5-15
5-15
5-15
5-16
5-16
5-26
5-26
5-27
5-28
5-28
5-30
5-30
5-31
5-31
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Press On to Start or “Blank” Screen at Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Scan/ Hold Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm/ Error Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Enable Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Motor Quick Stop or Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setback Remaining Time Readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-programming Your System’s Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restoring Factory Defaults (Re-Booting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page v
Revised 4/09
5-31
5-31
5-31
5-32
5-32
5-32
5-32
5-33
5-33
Chapter 6 Preventive Maintenence
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Filter Manifold (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Shaft Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of Preventive Manintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Filter Manifold of Adhesive and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-2
6-2
6-2
6-3
6-4
6-4
6-5
6-5
Chapter 7 Troubleshooting
General Troubleshooting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Components (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Temperature Redundant Overtemp Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Enable Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lithium Battery on CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Power Printed Circuit Boards & Layout Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Control Interface Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Speed Control Drive & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing, Programming & Monitoring Motor Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Trigger Relay Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger Signal Park Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Signal Isolator Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional System Status (Stack) Light Relay Output Printed Circuit Board & Layout Illustration . . . . .
Optional Pressure Transducer (PSI) Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . .
Operator’s Panel Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater and Sensor Resistance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Indication Alarm Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation of the ASU’s Piston Pump (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation of the ASU’s Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Output Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Adhesive Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the ASU Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2
7-2
7-3
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
7-12
7-12
7-13
7-13
7-14
7-15
7-16
7-24
7-25
7-25
7-26
7-27
7-28
7-32
Page vi
Revised 9/11
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Chapter 8 Disassembly & Re-assembly Procedures
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Pump & Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Hopper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Hopper Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lid Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Temperature Redundant Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Enable Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Access the RTD Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTD Replacement for ASU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTD Replacement for Drop-in Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Access the Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main On/ Off Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Access the Pump or Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Pump and Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Seal (O-ring) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note on the Cast-In Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-assembly Procedures & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-1
8-1
8-1
8-1
8-1
8-2
8-2
8-2
8-2
8-2
8-2
8-2
8-2
8-3
8-3
8-3
8-4
8-4
8-4
Chapter 9 Available Options & Accessories
Pressure Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drop-in Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Manifold Assembly w. Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UFD Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APS (Automatic Purge System) Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Resistant Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Enable Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Speed Tracking for Piston Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Pressure Relief Valve Retrofit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DynaControl Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASU Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
9-3
9-3
9-3
9-3
9-3
9-3
9-3
9-3
9-3
9-3
9-3
9-4
9-4
9-5
9-6
Chapter 10 Component Illustrations & Bills of Material
Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DM S05 & DM S10 Filter & Melt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DM S22 & DM S45 Grid, Melt, Filter & Pressure Relief Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2
10-4
10-6
10-8
10-10
10-12
10-14
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page vii
Revised 1/13
Optional Bypass Filter Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Single Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Dual Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10cc Single Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
20cc Single Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
0.55cc Single Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
0.55cc Dual Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
0.15cc Single Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
0.15cc Dual Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Pump Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Single & Dual Swirl Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Optional Filter Manifold with Dump Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Optional Pneumatic Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Pneumatic Pressure Relief Valve Retrofit Kits & Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . 10-40
In addition to the assemblies listed above, this chapter may also contain illustrations for additional options.
Chapter 11 System Schematics & Engineering Drawings
Hose Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Head Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Optional Clutch Kit: Installation, Bill of Material & Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Optional 110/120v GFI Kit: Installation & Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
PN 110331 Pin Connector and Wiring Diagram for Optional DMS w. Nord Connectors Hose Harness . 11-6
Dynamelt S ASU Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . end of chapter
Water-Resistance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . end of chapter
Appendix
Optional Dynatec/ Zenith Standard Accuracy Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 3
Optional Dynatec/ Zenith High Accuracy Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 17
Optional Zenith Melt Spinning Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 31
High Accuracy Pump Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 37
Signal Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 39
Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 47
Optional TSHA High Accuracy Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 51
Ethernet I/P Adapter Option
Internally-Mounted Line Speed Tracking for Piston Pump Models
Dynamelt S V.5 High Temperatures Models (Manual #20-35)
Page viii
Revised 2/09
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 1-1
Revised 1/07
ITW Dynatec c. 1997
ALL MODELS
Chapter 1
SAFETY PRECAUTIONS
All operators and service personnel must read
and understand this manual before operating
or servicing equipment.
All maintenance and service on this equipment must be performed by trained technicians.
Electrical
DANGER
HIGH VOLTAGE
Dangerous voltages exist at several points in this
equipment. To avoid personal injury, do not touch
exposed connections and components while input
power is on. Disconnect, lockout and tag external
electrical power before removing protective panels.
A secure connection to a reliable earth ground is
essential for safe operation.
A disconnect switch with lockout capability must be
provided in the line ahead of the unit. Wiring used to
supply electrical power should be installed by a
qualified electrician.
High Temperatures
WARNING
HOT
SURFACE
Severe burns can occur if unprotected skin comes in
contact with molten adhesive or hot application system
parts.
Safety glasses, gloves and long- sleeved clothing must
be worn whenever working with or around adhesive
application systems.
High Pressure
WARNING
HIGH PRESSURE
PRESENT
To avoid personal injury, do not operate the equipment
without all covers, panels and safety guards properly
installed.
To prevent serious injury from molten adhesive under
pressure when servicing the equipment, disengage the
pumps and relieve the adhesive system’s hydraulic
pressure (e.g., trigger the heads, hand-held applicators,
and/or other application devices into a waste container)
before opening any hydraulic fittings or connections.
IMPORTANT NOTE: Even when a system’s pressure
gauge reads “0” psig, residual pressure and trapped air
can remain within it causing hot adhesive and pressure
to escape without warning when a filter cap or a hose
or hydraulic connection is loosened or removed. For
this reason, always wear eye protection and protective
clothing.
Either of the two High Pressure symbols shown may be
used on equipment.
Page 1-2
Revised 3/97
ITW Dynatec c. 1997
ALL MODELS
Protective Covers
WARNING
DO NOT OPERATE
WITHOUT GUARDS
IN PLACE
Keep all guards in place!
To avoid personal injury, do not operate the application
system without all covers, panels and safety guards
properly installed.
Eye Protection & Protective Clothing
WARNING
EYE PROTECTION
REQUIRED
PROTECTIVE
CLOTHING
REQUIRED
It is very important that you PROTECT YOUR EYES
when working around hot melt adhesive equipment!
Wear safety glasses with side shields which conform to
ANSI Z87.1 or EN166.
Failure to wear safety glasses could result in severe eye
injury.
It is important to protect yourself from potential burns
when working around hot melt adhesive equipment.
Wear protective gloves and long-sleeved, protective
clothing to prevent burns that could result from contact
with hot material or hot components.
Always wear steel-reinforced safety 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 insulation or sheathing.
Read this manual before applying electrical power to
the equipment. Equipment may be damaged by
incorrect electrical connections.
Do not use adhesive that is dirty or that may be
chemically contaminated. Doing so can cause system
clogging and pump damage.
When adhesive hand-held applicators or other movable
applicators are used, never point them at yourself or at
any other person. Never leave a hand-held applicator’s
trigger unlocked when not actually in use.
Do not operate the hopper or other system components
without adhesive for more than 15 minutes if the
temperature is 150 degrees C (300 degrees F) or more.
To do so will cause charring of the residual adhesive.
Never activate the heads, hand-held applicators and/ or
other application devices until the adhesive’s
temperature is within the operating range. Severe
damage could result to internal parts and seals.
Treatment for Burns From Hot Melt Adhesives
Burns caused by hot melt adhesive must be treated
at a burn center.
Care should be used when working with hot melt
adhesives in the molten state. Because they rapidly
solidify, they present a unique hazard.
Even when first solidified, they are still hot and can
cause severe burns. When working near a hot melt
application system, always wear safety gloves, safety
glasses and long-sleeved, protective clothing.
Page 1-3
Revised 1/07
ITW Dynatec c. 1997
ALL MODELS
Always have first-aid information and supplies
available.
Call a physician and/or an emergency medical
technician immediately.
Service
Refer all servicing to qualified personnel only.
Explosion/ Fire Hazard
Never operate this unit in an explosive environment.
Use cleaning compounds recommended by ITW
Dynatec or your adhesive supplier only. Flash points
of cleaning compounds vary according to their composition, so consult with your supplier to determine the
maximum heating temperatures and safety precautions.
Lockout/ Tagout
Follow OSHA 1910.147 (Lockout/ Tagout Regulation)
for equipment’s lockout procedures and other important lockout/ tagout guidelines.
Be familiar with all lockout sources on the equipment.
Even after the equipment has been locked out, there
may be stored energy in the application system, particularly in the capacitors within the panel box. To ensure
that all stored energy is relieved, wait at least one minute before servicing electrical capacitors.
Use of PUR (Polyurethane) Adhesives
PUR adhesives emit fumes (MDI and TDI) that can be
dangerous to anyone exposed to them. These fumes
cannot be detected by the sense of smell. ITW Dynatec
strongly recommends that an exhaust hood or system
be installed over any PUR system.
Consult with your adhesive manufacturer for specifics
about required ventilation.
CAUTION: Because of the nature of PUR
adhesives to strongly bond in the presence
of moisture, care must be taken to prevent
them from curing inside Dynatec equipment. If PUR
adhesive solidifies in a unit, the unit must be replaced.
Always purge old PUR adhesive from the system per
your adhesive manufacturer’s instructions and timetable. ALLOWING PUR ADHESIVE TO CURE IN A
UNIT VOIDS ITW DYNATEC’S WARRANTY.
In This Manual
WARNINGS and CAUTIONS are found throughout
this manual.
WARNINGS mean that failure to observe the specific
instructions may cause injury to personnel.
CAUTIONS mean that failure to observe the specific
instructions may damage the equipment.
Page 1-4
Revised 3/97
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1997
ALL MODELS
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 2-1
Revised 2/09
Chapter 2
DESCRIPTION AND SPECIFICATIONS
Description
The DYNAMELT® S Series adhesive supply unit (ASU) is a computer-controlled hot-melt supply
unit designed on metric standards. Its “all-icon” control panel, with choice of display languages, is
internationally operator friendly. It is available for 120v, 240v or 380v service.
Available in four hopper sizes and with a choice of piston or gear pump, the Dynamelt S ASU uses
a microprocessor temperature control to closely control the temperature of hot-melt adhesive for up
to six hoses and six heads. Temperature setpoints are operator-selected for up to 14 zones and the
system automatically provides warnings and alarms for operator errors and system malfunctions.
The Dynamelt system provides accurate, proportionate temperature control for the hopper, hoses
and applicators. Sequential heating delays may be programmed for turn-on of the hoses and heads.
A “standby” temperature may be programmed so that the temperature zones can be maintained at a
lower temperature when the ASU is not in active use, enabling rapid return to normal operation.
With these flexible temperature programming features, the Dynamelt system increases adhesive life
by eliminating prolonged high adhesive temperatures. It reduces energy consumption and brings the
system up to normal operating temperatures in the shortest possible time.
A four-layered, shielded CPU board protects the microprocessor from external interference. The
temperature control can interlock the parent machine with preselected adhesive temperatures so that
production automatically begins when adhesive temperatures are correct for the application. All
system temperature values can easily and quickly be programmed. An optional remote control panel
gives control and monitoring flexibility.
Digital readout of system conditions is provided. Optional external audible signals or lights which
alert the operator to alarm conditions may be wired in. A security code can restrict access to system
programming and parameters. The CPU monitors the electronic circuitry and provides alarms for
error conditions.
The Dynamelt S ASU uses an extremely dependable, constant-pressure piston pump. This air-operated pump insures a high pressure adhesive output from a low pressure, compressed air input.
Piston pumps are available for either hot-melt or lotion applications. A gear pump is also available
to assure a smoother and higher precision flow. The single or dual pump is driven by a single drive.
To take advantage of ITW Dynatec’s innovative Dynafiber adhesive fiberizing technology, the
Dynamelt S Auxiliary Wattage model has been developed to combine high performance, precise
control and better bond strength with up to 40% adhesive savings.
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 applicators, hand-held applicators and/or special applicators. Options available include pressure gauge,
drop-in grid, pendant control and a seven-day scheduler.
Page 2-2
Revised 8/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Specifications
Environmental:
Storage/ shipping temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40° C to 70°C (-40° F to 158°F)
Ambient service temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7° C to 50°C (20° F to 122°F)
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 60 dbA (at 1 meter)
Physical:
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see dimensional layouts on following pages
Number of heads/ hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 4, or 6 heads/ hoses
Number of hopper temperature zones . . . . . . . . . . . . . . . . . . . . . . . . . 1 or 2 (add 1 for optional drop-in grid)
Number of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Piston pump ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12:1
Gear pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 cc/rev or 4.5 cc/rev standard
Enclosure . . . . . . . . . . . . . . . . . . . . . . . styled, durable metal and high temp plastic,dust and splatter resistant
Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . universal 15-pin Amphenol connectors at asu,
wrench-secured fluid fittings (#6 JIC)
Hopper (tank) capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DM S05 = 4.7 kg/ 10 lb
DM S10 = 9.5 kg/ 20 lb
DM S22 = 22 kg/ 48 lb
DM S45 = 45 kg/ 100 lb
Hopper construction . . . . . . . . . . . . . . . . . . . . . . . . . . welded aluminum, cast-in heaters, TFE Teflon coated
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hopper bottom screen, large pleated pump outlet filter
Weight, empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DM S05 = 43 kg/ 94 lb
DM S10 = 44 kg/ 97 lb
DM S22 = 50 kg/ 110 lb
DM S45 = 54 kg/ 118 lb
Adhesive form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . accepts most forms
Electrical:
Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC S22 = 30 amp/1p/50-60 Hz
200-240 VAC ASUs = 50-60 Hz, see also Wattage Chart pages 2--8 & 2-9
380-400 VAC ASUs = 50-60 Hz, see also Wattage Chart pages 2--8 & 2-9
Power consumption, system maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC system = 3600 watts
200-240 VAC system: DM S05/ DM S10 = 7200 watts
380-400 VAC system: DM S05/ DM S10 = 9650 watts
200-240 VAC or 380-400 VAC system: DM S22/ DM S45 = 11,650 watts
Power consumption, hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC DM22 system = 1800 watts
240/380 VAC system: DM S05 / DM S10 = 1500 watts
240/380 VAC system: DM S22 / DM S45 = 2500 watts
DM S10G = 2250 watts (with drop-in grid)
DM S22G / DM S45G = 5000 watts (with drop-in grid)
Hopper heater type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast-in tubular
Temperature control . . . . . . . . . . . . . . . . . . . . . . microprocessor-based proportional integral derivitive (PID)
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ohm Platinum RTD standard
120 Ohm Nickel RTD optional
Electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . durable, latching connectors
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 hp, alternating current motor, direct drive, horizontal orientation
Maximum current available for hose & head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC system: 600 watts
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 2-3
Revised 5/05
Pressurized Air (Piston Pump Models):
Air pressure supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 to 6.8 bar (20 to 100 psig)
Maximum recommended pump speed . . . . . . . . . . . . . . . . . . . . . . . 60 pump cycles per minute (piston pump)
90 revolutions per minute (gear pump)
Air consumption at 60 pump cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 normal liters/ minute
(3.2 SCFM at 100 psig)
Performance:
Adhesive temperature control range, standard models . . . . . . . . . . . . . . . . . . 10°C to 218°C (50°F to 425°F)
Adhesive temperature control range, optional high-temp models . . . . . . . . . . 10°C to 232°C (50°F to 450°F)
Adhesive temperature control accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 1°C (± 1°F)
Standby adhesive temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . up to 80°C (150°F) lower than setpoint
Hopper ready adhesive temperature deviation (factory set/ field adjustable) . . . ± 20°C (36°F) from setpoint
Over-temperature cutoff for hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218°C (425°F)
Low-temperature cutoff for piston pump (factory set/ field adjustable) . . . . . . . . . . . . . . . . . . 135°C (275°F)
Adhesive viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 to 50,000 centipoise
Warm-up time, full hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 0.5 hour
Adhesive delivery rate, open line . . . . . . . . . . . . . . . . . . . . . . . . . . 0.91 kg/min (2 lb/min)(12:1 piston pump)
0.38 kg/min (0.83 lb/min)(4.5cc gear pump)
Typical adhesive melt rate (depends on adhesive used) . . . . . . . . . . . . . . . . DM S05 = 10.5 kg/hr (23.2 lb/hr)
DM S10 = 10.7 kg/hr (23.6 lb/hr)/ DM S10G = 19.1 kg/hr (42.2 lb/hr)
DM S22 = 22.6 kg/hr (50 lb/hr)/ DM S22G = 41.3 kg/hr (91 lb/hr)
DM S45 = 23.1 kg/hr (50.9 lb/hr)/ DM S45G = 45.6 kg/hr (100.4 lb/hr)
Adhesive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 68 bar (1000 psi) maximum
DynaControl Temperature Control:
Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 zones per board, modular construction
Auxiliary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 zones per board, modular construction
Display type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . long life, bright fluorescent
Temperature control zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 triac-output, can be combined
with solid state relay output (optional)
Solid state relay control signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mA/ 12 volt
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5x20 mm, hose/ head: T6.3AL time delay
Other:
Display languages . . . . . . . . . . . . . . . . . . . . English, French, German, Spanish, Swedish, Italian, Portugese,
Japanese and Dutch
Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . digital display with simplified, all-icon keypad
Temperature standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
High and low temp alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Ready interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Password protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Sequential heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes (hopper, hose, head staged heating)
Sensor open alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
RS232 and RS485 communications capable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
CE approval granted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . all 240v and 380v models
Page 2-4
Revised 8/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
B
G
F
E
A
C
B
D
I
H
Installation Dimensions: DM S05: 5 kg (10 lb) Hopper Capacity
B
G
F
E
A
C
B
D
I
H
Installation Dimensions: DM S10: 9 kg (20 lb) Hopper Capacity
* All Mounting holes are 10mm diameter.
DIMENSION
A
B
C
D
E
F
G
H
I
DM S05 mm
DM S05 inches
304,8
12
355,6
14
693,8
27.32
744,6
29.32
304,8
12
419,1
16.50
597,0
23.50
248,9
9.80
381
15
DM S10 mm
DM S10 inches
304,8
12
355,6
14
693,8
27.32
744,6
29.32
304,8
12
610,0
24.0
794,0
31.25
248,9
9.80
381
15
mounting holes*
Page 2-5
Revised 8/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
B
D
G
F
E
A
B
C
D
H
I
Installation Dimensions: DM S22: 22 kg (48 lb) Hopper Capacity
B
D
G
F
E
A
B
C
D
H
I
Installation Dimensions: DM S45: 45 kg (100 lb) Hopper Capacity
DIMENSION
A
B
C
D
E
F
G
H
I
DM S22 mm
DM S22 inches
304,8
12
355,6
14
787,0
31.0
838,0
33.0
304,8
12
610,0
24.0
889,0
35.0
248,9
9.80
381
15
1016,0
40.0
1295,0
51.0
DM S45 mm
DM S45 inches
304,8
12
355,6
14
787,0
31.0
838,0
33.0
304,8
12
mounting holes*
248,9
9.80
381
15
Page 2-6
Revised 5/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Wattage Capacity for 240V and 400V ASUs
In general:
-- Each zone, hose or head, has a maximum wattage capacity of 1200W
-- Each output board has a maximum wattage capacity of 2400W
-- Additional to these zone and board limitations, there is no overall limitation
For all 240V and 400V ASUs:
Hose 1
+
_______
+
_________
1200W max.
+
_______
Head 3
+
1200W max.
Hose 5
+
_______
0
Head 5
+
1200W max.
_________
1200W max.
Hose 2
__________
1200W max.
Hose 3
1200W max.
Head 1
0
+
Hose 4
+
__________
= _____________
1200W max.
2400W max.
Head 4
__________
__________
1200W max.
1200W max.
Hose 6
+
Reset Watts
Head 2
= _____________
0
2400W max.
Head 6
0
_________
__________
__________
= _____________
1200W max.
1200W max.
1200W max.
2400W max.
Reset Watts
Notes on ASU with High Output Power Auxiliary Zones:
2-Hose ASUs can be equipped with 2 High Power Auxiliary Zones.
These zones can provide wattage up to 2400W per zone for each of both.
Using High Power Aux. zones does not reduce the available wattage for hoses and heads (with the
above mentioned limitations).
The Wattage Charts on pages 2-8 and 2-9 show the maximum current of the power service and the circuit breaker size. Use these charts to determine the adequate power service for your ASU.
0
43
100
0
Reset notes
Page 2-7
Revised 12/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Wattage Capacity Verification Chart for 120v S22 ASUs
Fill out this worksheet to assure that your
system will not be overloaded in any area.
CAUTION: To avoid damage to the adhesive application system, DO NOT EXCEED
the maximum wattages listed below.
For Two-Hose S22 120v ASUs Only:
Fill in the wattages for your ASU
Zone:
Hose 1 + Head 1 + Hose 2 + Head 2
=
600W max. 600W max. 600W max. 600W max
*Increased wattage available as special order ASU only.
1200W Maximum*
Notes for 120v ASUs:
1. Assume 33 watts per foot of hose length (i.e. 33 x
feet =
watts).
2. Assume 100 watts per inch of width* for head wattage (i.e. 100 x
inches =
watts).
3. *If applicator width is unknown, assume 1” width per module (for standard heads).
4. ASU will not work when supplied through a GFI circuit breaker with less than 20 ma. fault trip.
CAUTION: The 120v Dynamelt S22 ASU must be installed with a 30 amp service
and adequate 30 amp power wiring (not supplied by ITW Dynatec).
DM-S & DM-S-APS Wattage Chart
S05 / S10
Standard DM-S & DM-S-APS
Hopper
Hose&Head
Hose&Head
1/2
3/4
Hose&Head Premelt Grid Premelt Grid
5/6
S05/10
2 Hoses
1500W
6.25Amp
2400W
10Amp
S05/10
2 Hoses
1 Grid
1500W
6.25Amp
2400W
10Amp
S05/10
4 Hoses
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
S05/10
4 Hoses
1 Grid
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
S05/10
6 Hoses
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
S05/10
6 Hoses
1 Grid
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
1
2
750W
3.1AMP
750W
3.1AMP
750W
3.1AMP
Circuit Breaker
3 PH 400V
Circuit Breaker
3 PH 240V
Max. Amps
SinglePhase
Circuit Breaker
Single-Phase
240V
20A
104100
20A
104100
16
30A
100746
20A
104100
20A
104100
20
30A
100746
20A
104100
30A
100747
26
30A
100746
20A
104100
30A
100747
30
30A
100746
20A
104100
30A
100747
36
50A
100748
20A
104100
50A
109494
40
50A
100748
DM-S & DM-S-APS with High Power Aux-Zones
Hopper
Hose&Head
Aux. Zone
Aux. Zone
1/2
1
2
S05/10
2 Hoses
2 Aux
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
S05/10
2 Hoses
1 Grid
2 Aux
1500W
6.25Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
Premelt Grid Premelt Grid
1
750W
3.1AMP
2
Circuit Breaker
3 PH 400V
Circuit Breaker
3 PH 240V
Max. Amps
SinglePhase
Circuit Breaker
Single-Phase
240V
20A
104100
30A
100747
36
50A
100748
20A
104100
50A
109494
40
50A
100748
DM-S & DM-S-APS Wattage Chart
S22 / S45
Standard DM-S & DM-S-APS
Hopper
Hose&Head
Hose&Head
1/2
3/4
Hose&Head Premelt Grid Premelt Grid
5/6
1
S22/45 2 Hoses
2500W
10.4Amp
2400W
10Amp
S22/45
2 Hoses
1 Grid
2500W
10.4Amp
2400W
10Amp
2500W
10.4Amp
S22/45
2 Hoses
2 Grids
2500W
10.4Amp
2400W
10Amp
2500W
10.4Amp
S22/45 4 Hoses
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
S22/45
4 Hoses
1 Grid
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2500W
10.4Amp
S22/45
4 Hoses
2 Grids
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2500W
10.4Amp
S22/45 6 Hoses
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
S22/45
6 Hoses
1 Grid
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
2500W
10.4Amp
S22/45
6 Hoses
2 Grids
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
2500W
10.4Amp
2
2500W
10.4Amp
2500W
10.4Amp
2500W
10.4Amp
Circuit Breaker
3 PH 400V
Circuit Breaker
3 PH 240V
Max. Amps
Single-Phase
Circuit Breaker
Single-Phase
240V
20A
104100
20A
104100
20
30A
100746
20A
104100
30A
100747
31
30A
100746
20A
104100
50A
109494
41
50A
100748
20A
104100
30A
100747
30
30A
100746
20A
104100
50A
109494
41
50A
100748
20A
104100
50A
109494
51
50A
100748
20A
104100
50A
109494
41
50A
100748
20A
104100
50A
109494
51
50A
100748
20A
104100
50A
109494
61
50A
100748
DM-S & DM-S-APS with High Power Aux-Zones
Hopper
Hose&Head
Aux. Zone
Aux. Zone
1/2
1
2
S22/45
2 Hoses
2 Aux.
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
S22/45
2 Hoses
2 Aux.
1 Grid
2500W
10.4Amp
2400W
10Amp
2400W
10Amp
2400W
10Amp
Premelt Grid Premelt Grid
1
2500W
10.4Amp
2
Circuit Breaker
3 PH 400V
Circuit Breaker
3 PH 240V
Max. Amps
Single-Phase
Circuit Breaker
Single-Phase
240V
20A
104100
50A
109494
41
50A
100748
20A
104100
50A
109494
51
50A
100748
Page 2-10
Revised 8/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Dynamelt S X X X X X X X - X X X X X X X X X
HOPPER SIZE:
5 = 5kg (10 lb)
1 = 10kg (20 lb)
2 = 22kg (48 lb)
4 = 45kg (100 lb)
DROP-IN GRID = G
NO DROP-IN GRID = N
NUMBER OF HOSES:
2, 4, 6 or
U = UFD configuration (2 hose max.)
PUMP:
P12 = Piston pump 12:1 (standard)
PL12 = Piston pump 12:1 (oil or lotion)
LP12 = Piston pump 12:1 (low adhesive pressure)
GGS = Gear pump 0.15cc sngl
GAS = Gear pump 1.5cc sngl
GBS = Gear pump 3.2cc sngl
GCS = Gear pump 4.5cc sngl
GAD = Gear pump 1.5cc dual
GBD = Gear pump 3.2cc dual
GDD = Gear pump 0.55cc dual
GDS = Gear pump 0.55cc sngl
GES = Gear pump 10cc sngl
GFS = Gear pump 20cc sngl
ZDS = Zenith gear pump .297cc sngl
ZES = Zenith gear pump .584cc sngl
ZFS = Zenith gear pump 1.168cc sngl
ZGS = Zenith gear pump 2.92cc sngl
SHS = S&P gear pump 8.5cc sngl
ZED = Zenith gear pump .584cc dual
ZFD = Zenith gear pump 1.168cc dual
SGD = S&P gear pump 2.92cc dual
VOLTAGE:
1 = 115 - 120v/ 1 phase
2 = 200 - 240v/ 1 phase
3 = 380 - 400v/ 3 phase
4 = 200 - 240v/ 3 phase
5 = 480v/ 3 phase
6 = 400v/ 3 phase
OPTIONAL ACCESSORIES:
A = By-pass manifold (single gearpump models)
B = Water Resistant Kit
D = Digital pressure control
E = Pneumatic pressure relief valve
F = 100 mesh/420 micron outlet filter (40 mesh/149 micron is optional)
G = Analog pressure gauge
H = High operating temperature kit
K = KBSI signal isolator (gear pump only)
L = Adhesive level control sensor
M = Ethernet I/P
O = Motor enable relay kit
P = Pendant control & holder
W = Swirl kit, 2 hose
X = Additional drop-in grid (S45 only)
R = Digital rpm readout (gear pump only)
S = Seven-day scheduler
Y = Dump Valve Manifold (piston pump)
V = Swirl kit, 1 hose
Z = Bypass/ Dump Valve Manifold (gearpump)
EXAMPLE:
S1N2P122-GS = Dynamelt S: 10 kg hopper w/ no drop-in grid, 2 hose, 12:1 piston pump, 240 volts/ 1
phase with analog pressure gauge and 7-day scheduler.
DYNAMELT S V.5 SERIES Model Designation Matrix
Page 3-1
Revised 4/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Chapter 3
INSTALLATION
Mounting the DYNAMELT S ASU
The DYNAMELT® S SERIES ASU can be mounted on most flat surfaces, on either an open or a
solid frame (as shown below). Access is needed for the main electrical power and the serial communication connections to come in from below the unit and connect under the DynaControl keypad.
There is a cutout in the baseplate, directly below the pump shaft, which allows adhesive to drain.
The Dynamelt’s hinged hopper lid may be rotated 90 degrees in any direction, so that it can be set
up to open in the most convenient direction.
For installation dimensions, see illustrations on pages 2-4 and 2-5.
Lifting the DYNAMELT S ASU
WARNING
The unit must be lifted by two persons, using proper lifting technique, one
person at either end. Securely hold it under its base plate. No belts or hooks
should be used. Never allow anyone to stand on the ASU.
Hopper Cover
Hopper Lid
Pump & Electronics Cover
Access Cover
DynaControl Keypad
Junction Box
mounting at the
back
Captive Screws
Main ON/OFF
Disconnect Switch
Dynamelt S Stand
Hopper Feeder
Control Box
Mounting plate
Pattern Controller
mounting shelves
DYNAMELT S ASU
Page 3-2
Revised 9/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Installation
Note: Re-read Chapter 1 “Safety Precautions” before performing any installation procedures. All
installation procedures must be performed by qualified, trained technicians.
After the DYNAMELT S SERIES ASU has been properly mounted, the following general sequence
should be followed for installation:
1. Make sure that incoming line power to the ASU and that the unit’s Main Power Switch are
turned OFF.
DANGER HIGH VOLTAGE
Disconnect and lock out input power to the application system before starting any installation procedures. Make sure there is no electrical power on the
leads you will be connecting.
2. Loosen the 2 captive screws on the bottom of each side of the pump and electronics cover.
Remove cover. Select correct plug for your ASU’s amperage. Run the power cord through the
hole in the bottom of the base plate. Open Main Power Switch insulation cover and attach the
power cord at the switch’s connectors. Attach ground wire to ground screw provided in the base
plate.
On the Motor Control Interface printed circuit board (see location illustration on page 3-4), move
Voltage Selection jumper (J3) to its Down position (board is diagrammed on page 7-8).
CAUTION: Grounding conductors never carry electrical current. The use of a
neutral conducting wire as earth ground is incorrect and may cause damage to
the DYNAMELT controller.
Note for 110/120v ASUs only: If your ASU has the optional GFI
Kit (PN 808632), refer to the layout drawing on page 11-5
for kit hookup in-line with supply power.
Pump and
Electronics Cover
Air
Pressure
Regulator
Main Power Switch
Insulation Cover
Main Power Switch
Ground Screw
Power Cord
Hose
Connectors
Page 3-3
Revised 12/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
3. At installation, the customer must make the following terminal connections into the ASU’s
printed circuit boards (PCBs). The boards do not need to be removed from the ASU 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.
Terminal
Circuit
Location
Required connections for standard 120 vac ASU:
-N
PE
Input Power from Main Power, 120 vac
Neutral
Ground
Main Power Switch/ L1
Main Power Switch/ N
PCB Heat Sink Ground Screw
Required connections for standard 240 vac ASU:
-PE
Input Power from Main Power 240vac
Ground
Main Power Switch/ L1, L2
PCB Heat Sink Ground Screw
Required connections for 240 vac 3 PH ASU:
-PE
Input Power from Main Power 240VAC
Ground
Main Power Switch/ L1, L2, L3
PCB Heat Sink Ground Screw
Required connections for 380 vac ASU:
-N
PE
Input Power from Main Power, 380 vac
Neutral, 380 vac
Ground
Main Power Switch/ L1, L2, L3
Power PCB/ X2/ N
PCB Heat Sink Ground Screw
Non-essential connections; connect if feature is desired:
R1, R2
A1, A2
E1, E2
P1, P2
P3, P4
Normally Open Ready (parent machine interlock)
Normally Closed Alarm (controller display alarms)
External Standby (controller standby mode)
Program Select 1&2 (controller program selection)
Program Select 3&4
”
”
”
Power PCB/ X3/ pins 1 & 2
CPU PCB/ X1/ pins 1 & 2
CPU/ X4/ connect 5 and 9 or 10
CPU/ X4/ connect 1 to 9 or 10**
CPU/ X4/ connect 7 to 9 or 10**
Options: Make connections for the following if installed on your ASU:
S1, S2
H1, H2
Tachometer (line speed tracking)
Hand-Held Applicator, Footswitch
Level Control (input)
Low Adhesive Level (output alarm)
Pressure Transducer(s) (1 to 4 transducers)
Pressure Transducer(s) (high & low psi alarms)
System Status Lights
MCI*/ X3/ 0 (ground) & 10 (+)
MCI*/ X3/ TR
CPU PCB/ X4/ 3 to 9 or 10
CPU PCB/ X1/ pins 3 & 4
PSI PCB/ X1, X2, X3, X4
PSI PCB/ X6
Relay Output PCB/ K1 thru K4
** Program Selection Table
P1/P2
Pin 1
open
closed
open
closed
P3/P4
Pin 7
open
open
closed
closed
Program #
= Program 1
= Program 2
= Program 3
= Program 4
* MCI = Motor Control Interface PC Board
Page 3-4
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pressure PCB
Metal
Cover
X6
X1, X2, X3, X4
(numbered left to right)
Motor Control Interface PCB
Trigger Park PCB
or
X1
Trigger Relay PCB
X4
X2
X3
Level Control Amplifier
CPU PCB
X2
Motor Speed Control
Signal Isolator (KBSI) PCB
Operator’s Panel
PCB
Ground
Screw
X1
Power PCB
Power Switch
X3
Auxiliary Power PCBs
(1 - 3)
Power Switch L1 & L2
Pump Enable Thermostat
(see pg. 3-7 for calibration)
Location of PCBs & Customer Connections
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 3-5
Revised 1/00
4. Gear Pump models: omit this step.
Piston Pump models: Install the Air Control/ Filter Unit (containing the air regulator, the
coalescing filter and pre-filter). See illustration on page 3-6. The air control/ filter unit is
mounted directly to the ASU via a threaded hole on the rear cover. Wrap Teflon tape around the
nipple fitting before installing in the ASU. The unit requires clean, dry air. NEVER use lubricated
oil.
For operator convenience, the air pressure gauge can be mounted to either side of the air control
regulator.
With the air pressure regulator, a clockwise turn increases pressure. A counter-clockwise turn
decreases pressure. The recommended pressure is 1.4 to 6.8 bar (20 to 100 psig).
5. The adhesive hoses are connected at the rear cover (see illustration on page 3-6). Make your
electrical hose connections at the six numbered connects on the left side of the cover. Route hoses
so that there is at least an eight-inch radius at any bend. Do not hang hoses without proper
support. Do not crimp, clamp, squeeze or tie hoses.
The hose adhesive ports are located at the bottom of the filter block, to the right of the electrical
connections. There are seven ports for the use of up to six hoses and for the (optional) adhesive
pressure gauge. The seven ports are arranged on two planes (three are on a 45 degree slant from
the other four) in order to give flexibility in mounting the hoses. When making hose connections,
use the numbered guides shown on the illustration (page 3-6) 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.
Refer to the hose and applicator manuals for further details on these items.
6. Install the hose manifold outlet cover by sliding it into place and attaching with the two M4
screws provided.
Adding Adhesive
CAUTION: Using adhesive with viscosity over 50,000 centipoise could cause
motor stall and/ or pump failure.
The adhesive level in the melt tank should be maintained at 13mm to 100mm (1/2” to 4”) from the
top of the hopper. Where applications demand a high output volume of adhesive, add small amounts
of adhesive frequently. Adding large amounts of adhesive to an almost empty hopper will lower the
temperature of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint.
Changing the Adhesive Formula
If a different adhesive formulation from the one being currently used is needed, the system will have
to be flushed if the two formulations are incompatible. See Chapter 6 of this manual for the proper
flushing procedure. When in doubt about adhesive compatibility, flush your system.
Page 3-6
Revised 3/00
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pressure adjustment (clockwise increases)
Pressurized Air In
Air Flow
1/4 NPT female
Air pressure gauge
Coalescing filter
Pre-filter
Air Control/ Filter Unit
Maintain adhesive level
13mm-100mm (1/2”-4”)
from top of hopper.
Air Control/ Filter Unit
Adjustable Pressure
Relief Valve
Pressure Gauge (optional)
Hose/ Head Electrical
Connections
(6 hose/ head model
shown)
Filter Outlet Manifold
Hose/ Head Adhesive Port
Adhesive Port Connections
Electrical #1
Electrical #2
Electrical #3
Electrical #4
Electrical #5
Electrical #6
Note the difference
in appearence between
120v and 240v
Adhesive Supply
Hose
#1
#5
#3
#4
#6
Rear Cover: Hose and Head Electrical and Adhesive Connections
#2
#7
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 3-7
Revised 4/07
Pump Enable (Ready) Thermostat Calibration
The Pump Enable (Ready) Thermostat is preset to 135°C (275°F), unless the customer has specified a
different preset temperature on his original ASU order. Generally, the pump enable is set approximately
30°C (50°F) lower than the application setpoint.
If a different temperature other than the factory preset temperature is desired, use the following procedure to re-calibrate the thermostat. Note: The thermostat must be re-calibrated and the controller’s
pump enable temperature must be re-programmed.
CAUTION: DO NOT set the pump enable thermostat lower than the softening
point of your adhesive or pump damage may result.
As an example: the operator desires to lower the preset Pump Ready temperature to 107°C (225°F).
1. At the controller keypad, set the hopper temperature to the temperature at which you want the
pump to start, i.e. 107°C (225°F).
2. Remove the hopper access cover and locate the thermostat (refer to illustration on page 3-4).
3. Wait for the hopper temperature to stabilize at 107°C (225°F), then:
For thermostats with purple & black wire leads or with tan wire leads: turn the thermostat’s
adjustment screw counter-clockwise to increase the temperature (or clockwise to decrease it) until
you hear the pump’s solenoid switch on. Adjust no further.
4. Replace the hopper access cover.
5. At the keypad, re-set the hopper’s temperature to its correct “run” temperature.
6. Re-program the controller’s pump enable temperature to 107°C (225°F) (refer to Ch. 5).
Field Installation of Controller Options
Customers who choose to modify their adhesive supply unit with ITW Dynatec 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. Re-booting is not necessary.
However, in the case of field installation of the 7-Day Scheduler, the controller must be re-booted. Then
the system configuration and all system parameters must be re-programmed (refer to Chapter 5). Note:
any time that the controller is re-booted it will be restored with the controller’s defaults.
Page 3-8
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Adjustment of the Optional Level Control
To adjust the adhesive level sensitivity: access the control’s
amplifier, located on the panel mount under the pump and
Sensor
electronics cover (see page 3-4). On the amplifier (diagrammed Connect
at right) 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. When
the LED goes out, the audible and visible alarms will activate.
1
2 3
4 5 6
min
max
S
7 8 9 10 11 12
Sensitivity
Adjustment
Screw
Yellow Light
Page 3-9
Revised 4/07
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
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. Multiple motor boards may be wired in parallel to the tach
generator. On the DynaControl controller, voltage following is referred to as the “AUTO” Mode 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. Remove the pump and electronics cover and locate the Motor Control Interface Board (see layout illustration 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 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% Manual).
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. Re-install the ASU’s pump and electronics cover.
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”.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 3-10
Revised 2/09
Calibration of the Optional Tach Generator or DC Tracking Signal
After installation of a tach generator (or a similar DC tracking signal), the device must be calibrated at the DynaControl controller.
Prior to calibration, turn the application system ON and allow all components to warm up to
normal operating temperatures (above ready temperatures).
1. Perform the following sequence at the controller keypad:
Press the Motor icon.
Press Enter to select the mode; the mode will flash.
Scroll to AUTO mode.
Press Enter to save the selected mode.
Press Set Up to verify the factory setup of “MIN % = 0”.
Press Set Up to verify the factory default of “MAX % = 100”.
Press Set Up to return to AUTO.
2. Energize the parent line (tracking signal) to its full speed (at least 10 VDC at the “0” and “10”
terminals at X3 on the Motor Control Interface printed circuit board).
3. On the Motor Control Interface printed circuit board (see illustration in Chapter 7) locate and
adjust the web speed scaling potentiometer (VR1) clockwise until the “SET %” is below 99.8.
Then adjust counter-clockwise until it equals 99.8%.
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 “MAX %” value down from the factory default of 100%.
Adjusting the “MIN %” 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 (MIN % = 0) is
used.
Page 3-11
Revised 4/07
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Installation of Optional 7-Day Scheduler
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.
CAUTION: Printed circuit boards (PCBs) and their components are extremely static
sensitive. Observe the cautions listed on page 7-3 when handling these items.
These instructions are provided for field installation of the 7-Day Scheduler (all units).
1. Remove the pump and electronics cover of the adhesive supply unit (ASU) (reference page 8-1) .
2. Locate the CPU pcb behind its metal cover. The cover has cutouts over the chips to facilitate their
removal and installation. Reference the board’s layout drawing in Chapter 7.
3. When removing the scheduler chip, the pcb’s metal cover may need to be removed. The
scheduler chip is installed on the upper right-hand side of the CPU board at IC5. Note the
orientation of the scheduler chip to the board; it has a black dot on its upper edge.
4. If replacing a chip, insert a small screwdriver under it, and slowly begin to lift the chip from its
socket using a rocking motion. Carefully work the screwdriver under the length of the socket,
until the chip releases from the socket. Remove the old chip.
5. Carefully align the new chip to the socket, orienting the chip in the same manner as the
old chip. Note: be sure that all the pins are directly over their corresponding sockets before
pushing the chip into position.
6. Slowly insert the new chip by pushing it directly down onto the sockets.
7. Visually inspect to assure that all pins are in their corresponding sockets.
8. Replace the pump and electronics cover.
9. Re-connect input power to the application system and start up the ASU.
10. Re-boot the controller. The DynaControl controller must now be re-programmed using
instructions for the 7-Day Scheduler.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 3-12
Revised 2/09
Typical Start-Up and Shut Down of the DYNAMELT S Application System
The following simplified sequence assumes that the DynaControl Controller has been programmed.
Start Up Procedures
1. Fill the ASU’s hopper with clean hot-melt adhesive to within a couple of centimeters (inches)
of the top of the hopper. Close the hopper lid immediately to prevent contaminants from
falling in. (Cover your bulk supply of adhesive to prevent contaminants also.)
2. Switch ON the Main Power Switch at the DynaControl keypad. The controller display will
come on and the ASU will begin to heat up.
3. If it is not ON, depress the controller’s On/Off Switch. Its green LED will illuminate.
4. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the temperatures
of the temperature zones to stabilize. Monitor the display to see when “H” (Heating) changes
to “R” (Ready). The Undertemp arrow (see page 5-2) will blink and the Temperature Control
Selector’s LED will blink until the temperature zones are up to ready temperature.
5. When temperatures are ready, the motor is enabled to pump adhesive.
a. If Motor is in Auto Program: Adhesive will begin to pump when the production line begins
to operate.
b. If Motor is in Manual Program:
i. Depress Motor button.
ii. Scroll to “Manual”.
iii. Depress Enter.
iv. Scroll to desired speed.
v. Adhesive will begin to pump after “R”
(Ready) condition is attained.
Temperture Control
Selector/ LED
Overtemp-Undertemp
Display Arrow
Readout
Display
Main
Power
Switch
I
O
Shut Down Procedures
1. If Motor is in Auto Program: Turn OFF the
Main Power Switch.
Motor Button
Enter
Scroll
Buttons
2. If Motor is in Manual Program:
a. Turn OFF the motor by depressing the Motor button, then scroll to STOP.
Controller On/Off
Switch/ LED
b. Turn OFF the Main Power Switch.
3. If 7-Day Scheduler is in use: Turn ON and OFF with the Controller On/Off Switch.
Note: Except in the case of the 7-Day Scheduler, use of the Main Power Switch to turn the unit
OFF will avoid unexpected ASU activation in the event of a power outtage.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 3-13
Revised 4/07
Storage and Disposal of the DYNAMELT S Application System
Temporary Storage of the Unit
1. Flush the adhesive application system with flushing fluid (PN L15653), following the
instructions detailed in chapter 6 of this manual.
2. Clean or replace both the outlet filter and the primary filter, following ithe nstructions
detailed in chapter 6.
3. Shut OFF all pressure and power sources.
4. Release residual air pressure.
5. Remove all residual adhesive and wipe components clean.
6. Remove all air lines and all power supply cables.
7. Pack the unit in a corrosion-proof manner.
8. Store the unit in such a way that it is protected from damage.
Disposal of the Unit
1. Shut OFF all pressure and power sources.
2. Release residual air pressure.
3. Remove all residual adhesive.
4. Remove all air and adhesive supply hoses and all power supply cables.
5. Dismantle all components and sort into mechanical and electrical components.
6. Arrange for all components to be recycled.
Page 3-14
Revised 2/09
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 4-1
Revised 6/03
Chapter 4
DynaControlä 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 DYNAMELTÒ 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 application. It displays all programmed values, and it includes self-diagnostic malfunction alerts and
failure alarms. Note: Some DynaControl functions are direct temperature conversions between degrees Celsius and Fahrenheit. Other parameters are independently selected values.
Defining DynaControl Temperature Control Terms
Adhesive Temperature Control Range
The temperature limits within which the ASU, hoses and applicators may be programmed and maintained.
CPU Module
The central processing unit (CPU) of the microprocessor temperature control.
Cold Start
When the ASU resets itself to default setting 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 values. See page 4-6 for the controller’s defaults.
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.
Power, Aux & Grid PCBs
The Power printed circuit board (PCB), Auxiliary PCBs and Grid PCBs provide control signals to,
and monitoring signals from, all the temperature zones in the ASU’s system. The standard unit’s hopper, hoses and applicators are controlled by the Power PCB. Additional hoses and applicators are controlled by the Aux PCB(s). Optional pre-melt grids are controlled by the Grid PCB.
Mechanical High-Temperature Protection
A mechanical, redundant thermostat located on the hopper which turns OFF the system at 232°C
(450°F) [or 276°C (529°F) for optional high temperature units].
Page 4-2
Revised 8/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Microprocessor-based Proportional Temperature Control
The built-in control system that controls, monitors and displays all system temperature values.
Over-Temperature Setpoint
The programmable temperatures that will cause 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.
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 temperature) is achieved.
RTD Sensors
The standard Dynamelt system uses 100-ohm platinum resistance temperature detector sensors for
all temperature controls.
Ready Temperature
The programmable temperature, on gear pump models, which allows the ASU pump to turn ON.
Or, on piston pump models, the adjustable hopper temperature which allows the pump to turn ON.
The default ready temperature range is a deviation of ± 20°C (± 36°F) from the setpoint. The setpoint minus the deviation is the low limit of the range, and the setpoint plus the deviation is the high
limit of the range.
Sequential Heating
The heating sequence which allows the slower-heating hopper to reach operating temperature without unnecessary use of electricity for faster-heating hoses and applicators. Sequential heating is the
time period during which the hoses and applicators remain OFF while the hopper (and optional
drop-in grid) heats up. Hoses and applicators may be independently programmed. If hopper temperature is above ready temperature when the ASU is turned ON, the hose and applicator sequence is
bypassed and they will be turned ON. Sequential heating is restored after Standby is turned from
ON to OFF Sequential heating is not needed for most applications and can delay total system warmup time.
Setpoint
A programmable temperature that has been selected for hopper, hoses and applicators.
Setpoint Limitation
This is a universal maximum temperature for all zones. The programmer cannot program a temperature setpoint higher than the setpoint limitation.
Standby Condition
The system condition where the ASU, hose and head temperatures are maintained at predetermined
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. When standby mode is activated or de-activated, the controller will sound a short alarm (beep).
Page 4-3
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
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
Due to the separation between the heaters and sensors in some systems, the controller can be programmed to display a temperature for a zone which is different from the sensor’s actual temperature. The temperture zone offset mathematically corrects for these temperature differences. Each
zone may have an individual offset.
DynaControl Display During Normal Operating Mode
Zone #
Overtemp/ Undertemp Alarm
Zone Condition (A = Hi/Lo Alarm)
Zone Description
A
1: HOPPER
Set: 420°F Act: 450°F
Setpoint
Temperature in
Celsius or
Fahrenheit
Scan Mode is ON
Actual Temperature
Error Indication Alarms
The following illustrations show the display screens that will be activated when one or more error indication alarm conditions occur. The conditions that will trigger an alarm are:
· When a hopper, hose or head has exceeded its selected over-temperature setpoint, which is
the setpoint plus its Hi/Lo alarm setting (see example 1 below), or when it is below its
selected under-temperature setpoint, which is the setpoint minus its Hi/Lo alarm setting
(see ex. 3).
· When a hopper, hose or head sensor has an open circuit (see ex. 2).
When an alarm condition occurs, the current display will be interrupted only if a sensor failure
occurs. This is accompanied by an continuous audible alarm signal (if the beeper is “active”). If
more than one alarm condition occurs simultaneously, all alarm conditions will be displayed sequentially.
Error Indication Alarm Display Examples
Example 1
Example 3
11:
HEAD 4
SET: 110°C
ACT: 100°C
10:
HOSE 4
SET: 40°C
ACT: 100°C
Message: Blinking up arrow indicates overtemp.
Message: Blinking down arrow indicates undertemp.
Example 2
2
HOSE 1
ERROR ON CHANNEL 2
Message: Hose 1 Sensor is Open
After pressing “C”
2:
Set: - - - °C
HOSE 1
Act: ? °C
Message: Zone is switched Off, no sensor detected.
Page 4-4
Revised 12/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Operator Response to Error Indication Alarms
If an alarm occurs during operation, the audible alarm (beeper) will sound if enabled. The controller
will switch off the internal power to the heaters and an appropriate error indication display will appear.
Pressing the “C” (clear) key resets the error and turns off the audible alarm. If several zones display
alarms, each must be acknowledged by pressing key “C”. The alarm display is switched off. The
operator must either switch OFF the indicated temperature zone(s) (via the DynaControl keypad) or
troubleshoot the problem.
Low temperature alarms will not open the main contactor and are only indicated by the up and
down blinking display arrows and auxilary alarm output contacts.
A sensor failure is displayed and the main contactor opens and the audible alarm sounds.
When the actual temperature exceeds the setpoint limitation plus a tolerance of 15°C (30°F), a sensor open is displayed and main power is switched off. When the actual temperature falls below the
minimum allowed temperature value 10°C (50°F), there is a sensor short alarm.
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. 1999
DYNAMELT S ASU Manual 20-31
Page 4-5
Revised 10/99
System Values That Are Factory Programmed (not customer programmable)
·
Minimum setpoint value: 10°C (50°F).
·
Maximum setpoint value (Setpoint limitation): 218°C (425°F).
·
Maximum alarm deviation: 50° (C or F).
·
Minimum alarm deviation: 5° (C or F).
·
Maximum standby temperature: 150° (C or F) less than setpoint.
·
Minimum standby temperature: 30° (C or F) less than setpoint.
·
“Actual” temperature indication range: 0°C to 260°C (32°F to 500°F).
Customer Programmable System Values Preset At The Factory
ITW Dynatec can set the controller’s system values to customer’s specs, if provided.
If customer’s specs are not provided, the following values will be entered into the DynaControl controller at the factory. They may be changed by reprogramming through the keypad. (These are not
the “default” settings, see following section).
·
Applicator (head) and hose setpoints: 177°C (350°F).
·
Hopper setpoint: 150°C (300°F).
·
All zones are switched off, except for the hopper and the optional drop-in grid.
·
Motor rpm: 0 in the “Manual” 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 4-6
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DYNAMELT S ASU Manual 20-31
Default Settings of the DynaControl Controller
Default settings are the manufacturer’s preset values to which the system will 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.
To cause an internal memory reset (re-boot), do the following:
1. Turn the DynaControl power switch OFF, and
2. Turn the main power ON again while pressing both the “Scroll Up” and “Scroll Down”
keypad buttons simultaneously until the temperature icon’s LED lights.
Defaults
·
Language: English
·
Audible alarm (beeper): “2” (beeps for a failure/ error only).
·
Setting for Customer Access Code: “9999”.
·
Temperature setpoint for each zone: -- -- -- (Off)
·
Hopper ready temperature: 79°C (174°F).
·
Over-temperature limit: Your chosen setpoint limitation + 15°C (30°F).
For example: if your setpoint limitation is 218°C (425°F), then your over-temp limit = 233°C (455°F).
·
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: #1 = first hopper, then hose/ head.
·
Setpoint limitation: 218°C (425°F).
·
Pump enable temperature: 135°C (260°F).
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DYNAMELT S ASU Manual 20-31
Defaults, cont.
·
Minimum pump speed: 0% of full speed (gear pump models only).
·
Maximum pump speed: 100% of full speed (gear pump models only).
Helpful Tips for the User
·
When the ASU is turned ON, all temperature setpoints and other operating parameters will
be exactly where they were when the ASU was turned off.
·
When the ASU is turned ON, all system heaters go ON unless they have previously been set
below 40C (100F) (in which case they will be turned OFF) or if sequential heatups have
been set. However, if hopper temperature is above ready temperature when the ASU is
turned on, all hose and head sequential heatups will be bypassed and hoses and heads will be
turned ON.
·
If the system is turned off and then on again, the standby condition will be disabled.
Optional Line Speed Tracking for Piston Pump Models
Line speed tracking allows the controller to control adhesive volume by adjusting pressure. For programming instructions of this option, see the Motor Control Programming section of Ch. 5. For details on the internally-mounted line speed tracking kit, see special section at end of manual.
Optional System Status (Stack) Lights
Stack lights ease remote monitoring of the system’s status. On the basic,
tri-color stack light, the lower, clear light illuminates when the system is
turned ON. The middle, green light indicates that the system has warmed up
to temperature setpoints (“ready”). The upper, red light illuminates only in an
alarm condition and is accompanied by an audible alarm. The audible alarm is
housed within the upper (black) section of the stack. This setup is shown on
the illustration to the near right.
An alternative is a five-light status light, as illustrated to the far right. On this
status light, the previously described red (“alarm”), green (“system ready”)
and clear (“power ON”) are supplemented by blue (“standby”) and amber
(“low adhesive level”) lights.
Red
(Alarm)
Red
(Alarm)
Green
(Ready)
Green
(Ready)
Clear
(ON)
(Standby)
Blue
Amber
(Low
Level)
Clear
(ON)
Page 4-8
Revised 1/01
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 5-1
Revised 12/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Chapter 5
PROGRAMMING INSTRUCTIONS
FOR DynaControl CONTROLLER, V.5.13S & up
Controller Safety Consideration
DANGER HIGH VOLTAGE
Never open the control panel without switching off the main disconnect switch
(item “N” on page 5-2) to ensure that it is disconnected from its power source.
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 display at startup:
* * * ITW Dynatec * * *
DynaControl V 5.xx S
Current Software Version
Page 5-2
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
DynaControl Keypad
A.
N.
I
B.
C.
D.
E.
F.
Keypad Layout (as diagrammed above):
A.
B.
C.
D.
E.
F.
G.
Readout Display
Temperature Control
Gear Pump Motor Control
Pressure Readout (Option)
Pattern Control (Option)
Set Up
Clear/ Cancel
G.
H.
K.
I.
J.
L.
H.
I.
J.
K.
L.
N.
O
Vertical Scroll, UP
Enter
Vertical Scroll, DOWN
Seven-Day Scheduler (Option)
DynaControl On/Off Switch
Main Power Switch On (I) /Off (O)
Each keypad pushbutton has an LED which lights when selected. When main power is ON, the LED
for the DynaControl’s On/Off Switch (item “L” above) is continuously ON.
DynaControl Display Reference
Overtemp
Zone #
Zone Description
or Undertemp
Alarm (Blinking Indicator)
Zone Condition: R = Ready
H = Heating
W = Waiting for release
O = Off
A = Hi/Lo Alarm
E = Electric Head Hold
A
1: HOPPER
Set: 420°F Act: 450°F
Scan Mode is ON
or
Hold Mode is ON (no icon)
Temperature Offset Programming Display ONLY
Setpoint
Temperature
in Celsius or
Fahrenheit
Actual Temperature
2 HOSE 1
=
Measured Temp: 325° F
Equals sign = no offset
Up arrow = positive offset
Down arrow = negative offset
Page 5-3
Revised 4/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
DynaControl Menu Structure, V5.13S and up
Standby Temperature
--140°F
*
Temperature Program
1
*
1 HOPPER
Hi/Lo Alarm ± 36°F
*
Customer Setup P1
Access Code: 9999
*
Customer Setup P2
Access Code: 9999
*
1. To Acknowledge an Error
Press
Message or go to Custorer Setup:
2. To Activate or De-activate a
Temperature Zone:
Press
and
then press
3. To Exit Programming at Any Time:
simultaneously.
Press
Factory Setup
Access Code: xxxx
Primary Parameters
°C
Secondary Parameters
> °F <
Setback Time Delay
Automatic Sleep Mode
> Not Active < Active
1: HOPPER
Heating Sequence 1
Head Hold Temp:XXX°F
> Not active <
active
Lock Temp. Settings
> Not Active < Active
Lock Motor Settings
> Not Active < Active
*
*
*
*
*
*
.
Pump Enable Tempera.
260 °F
*
Setpoint Limitation
425 °F
*
1: HOPPER
Measured Temp: 201°F
NOTE: Factory Setup Is Not
Customer Accessible, call
ITW Dynatec for assistance
1: HOPPER
Temp. Zone Enable: 1
1 HOPPER
PI-Loop: P=20
Customer Zone Names
Not Active > Active <
I =2
High Temp. Setpoints
> Not Active < Active
*
*
1: HOPPER
Change Zone Text
Customer Setup
Change Acc Code:9999
*
Poweron Heater Start
> Not Active < Active
Poweron Input Prior.
> Not Active < Active
*
Poweron Motor Stop.
> Not Active < Active
*
Level Control
> Not Active <
*
Active
Pressure Sensors: 4
Type: 1500 PSI
*
Slave Address:
*
Gear Ratio:
M: 1 18.0
1
*
* These screens are shown
with their defaults.
Page 5-4
Revised 6/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Setting Your System’s Configuration
Below is the step-by-step process of setting up the controller with your system configuration. Press
the buttons in the sequence illustrated and follow the arrows through the configuration. For notes on
each step, see pages 5-6 through 5-7.
Note: Whenever an Access Code is required, enter your individual code. When a wrong code is entered, the controller will take you back to the beginning of the setup process. If you have lost your
code, call ITW Dynatec Customer Service: 1-800-538-9540 (in the USA) or contact your local repsentative.
Turn the Controller On (see also pg. 5-6)
Press the DynaControl ON/ OFF button.
If your ASU was shipped from the ITW Dynatec factory and you specified desired settings, then
the controller has been pre-programmed accordingly. The controller will automatically proceed
to Temperature Setpoint Programming and a screen such as the one illustrated below (“2. Hose
1”) will be displayed. The programmer should proceed to program desired temperature setpoints.
However, to verify or modify programmed setpoints, the programmer should bypass this screen
(“2. Hose 1”) and follow the entire programming sequence starting with Step 1.
2. HOSE 1
Set: 135 °F
Act: 82°F
Step 1: Opening the Menu (see also pg. 5-6)
x2
Press Clear twice, then press Set Up.
Step 2: Language Selection (see also pg. 5-6)
Use Scroll buttons to select desired Language.
(DEFAULT = English).
Step 3: Beeper Selection (see also pg. 5-6)
x2
Press Set Up twice.
Use Scroll buttons to select Beeper “ON” or “OFF” as follows:
0 = OFF
1 = Beeps on key strokes only.
2 = Beeps for a failure (error) only (DEFAULT).
3 = Beeps on both key strokes and failures.
Page 5-5
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Step 4: Access Code Required (see also pg. 5-7)
x3
Press Set Up three times,
Scroll to allow access to system parameters:
Enter your 4 digit Access Code (DEFAULT = 9999).
Press Enter.
No
Is
Code Correct?
Note: The correct code allows you to proceed. The wrong code takes
you to the beginning of the program.
Yes
Step 5: Optional Pressure Transducer Calibration (see also pg. 5-7) If option is not installed, press Set Up
to bypass.
x6
Press Set-Up to initiate Pressure Transducer Calibration.
NOTE: To calibrate, all transducers must be at “0” pressure. Motors
must be turned OFF and time allowed for system pressure to drop
to “0”.
Pressure Sensors
1: OK 2: OK 3: ? 4: ?
Press Enter. The controller will calibrate all transducers.
When completed, the screen will read “OK!”
You will then see this screen. It indicates if the sensors are either “OK” or “?”.
A “?” appears if there is no transducer present. If a transducer is present,
the “?” indicates the transducer may be: defective, not correctly connected
or out of range.
Press Clear, the Temperature icon or the Motor icon to end Calibration.
Page 5-6
Revised 6/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Configuration Set Up Steps
Turn the Controller On
The controller is turned On or Off by pressing the DynaControl On/ Off button (button is illustrated
on page 5-2, item “L”).
If your controller has been pre-programmed and you wish to program your temperature setpoints,
you may begin with the temperature zone screen that appears now, ie “2. Hose 1”.
Bypass the “Setpoint Temperature Programming” display which appears by proceeding to Step 1.
If you wish to progress through the entire programming sequence, proceed with Step 1.
Step 1: Opening the Configuration Menu (see illustration pg. 5-4)
The Basic Configuration menu is opened by pressing the “Clear” button twice, followed by pressing
the “Set Up” button.
Step 2: Language Selection (see illustration pg. 5-4)
The unit is capable of displaying several alphabets and several languages. Use the Scroll buttons to
select a language.
Languages available are: English, German, French, Spanish, Swedish (Svenska), Italian, Japanese,
Portugese and Dutch.
Step 3: Beeper On/ Off Selection (see illustration pg. 5-4)
The DynaControl has a built-in beeper (alarm) which serves to confirm settings that have been
keyed in and which serves as an alarm signal for error indication. The beeper can be activated or
de-activated.
Press “Set Up” twice, then use the Scroll buttons to select “On” or “Off” as follows: 0 = OFF; 1 =
beeps only on key strokes; 2 = beeps only for a failure and 3 = beeps on either key strokes or failures.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 5-7
Revised 2/09
Step 4: Access Code Required to Proceed to System Parameters (see illustration pg. 5-5)
To prevent unauthorized changes to DynaControl’s basic configuration and system parameters,
your access code must be entered at this point in order to continue.
Press “Set Up” three times, then press “Scroll Down” and enter your four digit access code. Then,
either press “Enter” to confirm or “Set Up” to return to the beginning of the menu.
An incorrect code takes you back to the beginning of the configuration menu.
Step 5: Optional Pressure Transducer Calibration (see illustration pg. 5-5)
Press “Set Up”. After assuring that all transducers are at zero pressure, motors are OFF and system
pressure is at “0”, calibrate the pressure transducers by pressing “Enter”.
After calibration a “Pressure Sensors” screen indicates the status of each transducer. If the transducer connected to a numbered port is not “OK”, a “?” appears. The “?” indicates one of the
following:
1. no pressure transducer is present,
3. the transducer is not correctly connected, or
2. the transducer is defective,
4. the transducer is out of range.
Press “Clear”, the “Motor” icon or the “Temperature” icon to end the configuration sequence.
YOUR SYSTEM’S CONFIGURATION IS NOW SET UP AND COMPLETE.
PROCEED TO PARAMETER SETUP.
Page 5-8
Revised 6/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Setting Your System’s Parameters
Parameter Setup refers to the process of setting up the controller to meet the specific temperature
requirements of your production. Temperature setpoints for each temperature zone must be programmed as well as a standby temperature and high/ low alarm limits. Choices must be made for
program selection and motor conditons. If desired, temperature zone offsets and/ or a temperature
zone enable may be selected.
For ease of programming, the controller’s parameters are divided into three categories: basic, primary (frequently-used) and secondary (seldom-used) parameters. After programming the basic parameters, your access code is required to enter the menus of the primary and secondary parameters.
On the following pages is the step-by-step process for setting up the DynaControl with your system’s parameters. Press the buttons in the sequence illustrated and follow the arrows through the
menus. The sequence is continuous, so follow it in the given order. Refer to pages 5-17 through
5-25 for notes on each step.
Note: If your controller does not respond to temperature setpoints programming, a previous
user may have locked the temperature setpoints and motor settings to further programming.
If this is so, before programming any parameters is possible, the “Lock Temperature Setpoints”
and “Lock Motor Settings” parameters must be de-activated. Follow these steps to de-activate:
Advance to the Lock Temperature Setpoints screen: press the Temperature icon, press Set Up four
times, enter your access code and press Enter, press Set Up five times to advance to “Lock Temperature Settings”, then Scroll to “Not Active” to allow programming. Now advance to “Lock Motor Settngs”
by pressing Set Up once and scroll to “Not Active”. (Complete programming instructions for these steps
are found on page 5-11, Steps K & L). Then press the Temperature icon to return to Step A.
Step A: Setpoint Temperature Programming (see also pg. 5-17)
Press the Temperature icon to initiate programming.
If Scan Mode is active, press Enter to disable the Scan Mode.
Press Enter to program Temperature Zone 1.
Scroll to your desired Temperature Setpoint (to turn a zone OFF, see page
5-15). DEFAULT = Off (-- -- --).
Press Enter to confirm and save your new Setpoint value.
Scroll to the next Temperature Zone to be programmed and repeat the
sequence.
Press Temperature Icon to end Temperature Setpoint Programming and to
enable the Scan Mode.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 5-9
Revised 6/02
Step B: Standby Temperature Programming (see also pg. 5-18)
x1
Press Set Up to initiate Standby programming.
Press Enter to initiate a change.
Scroll to your desired Standby Temperature. Select a value between -30°C
and -150°C (-30°F and -150°F) from setpoint. DEFAULT = 80°C/ 140°F
Press Enter to confirm and save your new Standby value.
Step C: Choosing a Temperature Program (see also pg. 5-18)
x2
Press Set Up.
Press Enter to initiate a change.
Scroll to your desired Program (4 choices are possible). DEFAULT = 1
Press Enter to confirm and save your new Program.
Step D: Temperature Hi/ Lo Limits Programming (see also pg. 5-18)
x3
Press Set Up to initiate Hi/ Lo Limits programming.
Scroll to choose a Temperature Zone.
Press Enter to initiate a change.
Scroll to your desired Hi/ Lo Limit (all values represent a range (+ or -) from
the zone’s temperature setpoint). The programmable range is ± 5° to ± 50° (C
or F). DEFAULT = ± 20°C/ 36°F
Press Enter to confirm and save your new Hi/ Lo Limit.
Scroll to the next Temperature Zone and repeat the sequence.
Programming the Primary (Frequently-Used) Parameters (P1)
Step E: Customer Setup Access Code Programming (see also pg. 5-19)
x4
Press Set Up.
Scroll to enter your Access Code. (Or enter the DEFAULT access code “9999”.)
Press Enter to confirm. Note: an incorrect code takes you back to Step B.
A correct code will allow you to enter the Primary Parameters Menu (P1).
Page 5-10
Revised 4/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Step F: Choosing the Temperature Scale (see also pg. 5-19)
Scroll (toggle) to choose Celsius or Fahrenheit.
Press Enter.
Step G: Setback Time Delay Programming (see also pg. 5-19)
x1
Press Set Up.
Setback Time Delay:
After Motor Stop *
or
Setback Time Delay:
After Extern. Contact
is displayed
Press Enter.
Scroll to the desired hour (0 to 7). DEFAULT = 0:00
Press Enter to save your choice.
Scroll to the desired minute (:00 to :59).
Press Enter to save your choice.
Scroll to choose either “Setback in (hour: min.): After Motor Stop” *
or “Setback in (hour: min.): After External Contact”.
Press Enter to save your choice.
* Selection available for gear
pump models only.
Step H: Sleep Mode (see also pg. 5-19)
x2
Press Set Up.
Scroll to activate the Sleep Mode. DEFAULT = Not Active
Press Enter to save your choice.
Scroll to the desired Sleep Mode duration (0.1 to 9.9 hours). DEFAULT = 4
Press Enter to save your choice.
When the ASU is in Sleep Mode, the display will read as follows:
Press ON to Start
To override Sleep Mode: press the DynaControl ON/ OFF key
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 5-11
Revised 6/02
Step I: Sequential Heating Programming (see also pg. 5-20)
x3
Press Set Up to initiate Sequential Heating Programming.
Scroll to choose a Temperature Zone.
Press Enter to initiate a change.
Scroll to your desired Priority for this zone. Number “1” indicates highest
priority (zone turns on immediately). Number “5” is lowest priority (zone waits
until other zones are up to setpoint). DEFAULT = 1
Press Enter to confirm and save your Priority.
Scroll to the next Temperature Zone to be programmed and repeat the sequence.
Step J: Head Hold Temperature (see also pg. 5-20)
x4
Press Set Up to initiate Head Hold Temperature programming.
Scroll to choose either ACTIVE (this zone is an electric applicator and a ten
minute stepped heat-up sequence is desired) or NOT ACTIVE (DEFAULT).
If ACTIVE is choosen, press Enter to select a holding temperature.
Scroll to choose a holding temperature (the holding temperature will equal the
softening point of your adhesive). PRESET = 200°F/ 100°C
Press Enter to save your choice.
Step K: Lock Temperature Setpoints (see also pg. 5-21)
x5
Press Set Up to program Temperature Setpoint Locking.
Scroll to choose either ACTIVE (temperature setpoints are locked and cannot be
changed) or NOT ACTIVE (temperature setpoints are unlocked and programmable = DEFAULT). Choose Not Active to continue programming setpoints.
Step L: Lock Motor Settings (see also pg. 5-21)
x6
Press Set Up to program Motor Setting Locking.
Scroll to choose either ACTIVE (motor settings are locked and cannot be
changed) or NOT ACTIVE (motor settings are unlocked and programmable =
DEFAULT). Choose Not Active to continue programming the motor settings.
Page 5-12
Revised 6/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Step M: Pump Enable Temperature Programming (see also pg. 5-21)
x7
Press Set Up.
Press Enter to initiate a change.
Scroll to your desired pump enable temperature (i.e., the lowest temperature at
which the pump will safely operate). DEFAULT = 135°C/ 260°F
Press Enter to confirm and save.
Step N: Setpoint Limitation Programming (see also pg. 5-21)
x8
Press Set Up.
Press Enter to initiate a change.
Scroll to your desired maximum temperature (i.e., the setpoint limitation).
DEFAULT = 218°C/ 425°F
Press Enter to confirm and save.
or
Press the Temperature icon to return to the temperature setpoints screen or
press Clear to program the Secondary Parameters (P2).
Programming the Secondary (Seldom-Used) Parameters (P2)
Step O: Customer Setup Access Code Programming (see also pg. 5-22)
Scroll to enter your Access Code (or enter the DEFAULT access code “9999”.)
Press Set Up to select P2.
Scroll to enter your Access Code.
Press Enter to enter the Secondary Parameters Menu (P2).
The controller will now display the “Measured Temp.” screen.
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Step P: Measured Temperature Programming (Temperature Zone Offset) (see also pg. 5-22)
x1
Press Set Up to initiate Temperature Zone Offset programming.
Scroll to choose a Temperature Zone.
Press Enter to initiate a change.
Scroll to the desired Measured Temp for this zone. The value must be
between ± 50° C (± 100° F) of the temperature. DEFAULT = 0
Press Enter to confirm and save your Measured Temp value.
Scroll to the next Temperature Zone and repeat the programming sequence
until all zones are programmed.
Upon completion of this step, the display will indicate the type of offset (or lack of such) as illustrated below:
2 HOSE 1
Measured Temp:
=
325° F
2 HOSE 1
Measured Temp:
325° F
2 HOSE 1
Measured Temp:
325° F
Equals sign (=) indicates no offset.
Upward arrow indicates a positive-value offset.
Downward arrow indicates a negative-value offset.
Step Q: Temperature Zone Enable Programming (see also pg. 5-22)
x1
Press Set Up to initiate Temperature Zone Enable programming.
Scroll to choose a Temperature Zone.
Press Enter to initiate a change.
Scroll up once for 1 = ON.
Scroll down once for 0 = OFF.
Press Enter to confirm and save your enable value.
Scroll to the next Temperature Zone and repeat the programming sequence
until all zones are programmed.
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Step R: Customer Zone Names (see also pg. 5-23)
x2
Press Set Up to initiate Customer Zone Names.
Customer Zone Names
not activ
activ
You will see this screen.
Scroll to choose “Active” (you name the temperature zones) or “Not Active”
(controller will use default zone names). DEFAULT = Not Active.
The default names are: HOPPER, HEAD, HOSE and GRID.
If you choose to name the zones (”Active”):
Press Set Up.
Scroll to the desired zone.
Customer Zone Names
not activ
activ
Press Enter to initiate a change. The cursor will appear below the first alpha/ numeric
character to be modified.
Scroll through the alpha/ numeric characters until the character desired is above
the cursor.
Press Enter to move the cursor to the next character to be modified and repeat the
previous step to change it. (Press “C” to create a space between characters.)
Repeat the last two steps until all characters in the selected zone are modified as
desired.
Press Clear to end changes for the selected zone.
Scroll to the next desired temperature zone and repeat the sequence.
Step S: Changing Your Access Code (see also pg. 5-23)
x3
Press Set Up.
Press Enter to initiate a change.
Scroll to choose an Access Code (DEFAULT = 9999).
Press Enter to save your choice.
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Step T: Power On Heater Start Programming (see also pg. 5-23)
x4
Press Set Up to initiate Poweron Heater Start.
Toggle to select “Active” (DEFAULT for European setup) or “Not Active” (DEFAULT for US setup).
Step U: Power On Input Priority Programming (see also pg. 5-24)
x5
Press Set Up to initiate Poweron Input Priority.
Toggle to select “Active” (input contacts set priority) or “Not Active” (keypad programming sets priority/ DEFAULT).
Step V: Power On Motor Stop Programming (see also pg. 5-24)
x6
Press Set Up to initiate Poweron Motor Stop.
Toggle to select “Active” (motor Off at poweron) or “Not Active” (motor On at poweron/ DEFAULT).
Step W: Level Control Status Programming (see also pg. 5-24)
x7
Press Set Up to initiate Level Control Status.
Toggle to select “Active” (level control in use) or “Not Active” (level control not in
use/ DEFAULT).
Step X: Pressure Sensors Programming (see also pg. 5-25)
x8
Press Set Up to initiate Pressure Sensors programming.
Toggle to select the number of pressure transducers on the ASU. DEFAULT = 4
Press Enter to activate transducer Type.
Scroll to select the PSI rating of the pressure transducers on the ASU.
(DEFAULT = 1500 PSI/ 1000 BAR)
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Step Y: Slave Address Programming (see also pg. 5-25)
x9
Press Set Up to initiate Slave Address programming.
Press Enter to activate.
Scroll to select the slave address of this ASU. DEFAULT = 1
Press Enter to save your choice.
Step Z: Gear Ratio Programming (see also pg. 5-25)
x10
Press Set Up to initiate Gear Ratio programming.
Press Enter to activate.
Scroll to select the ASU’s gear ratio (DEFAULT = 18).
Press the Temperature icon to end parameter programming and return to the setpoints screen.
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DYNAMELT S ASU Manual #20-31
Basic Parameters Setup Steps
If programming locks are active: advance to
“Lock Temperature Setpoints” and “Lock Motor Settings” screens and select “Not Active” at each. Then press the Temperature icon to return to setpoint
temperature programming.
Step A: Setpoint Temperature Programming (see illustration pg. 5-8)
Each temperature zone must be programmed with a temperature setpoint.
1. Hopper
Set: _ _ _ °C
1. Hopper
Set: 130 °C
Act: 122°C
Act: 122°C
Press “Enter” to program Temperature Zone 1. To program or
change a setpoint, use the “Up Scroll” or “Down Scroll” buttons to
find the desired setpoint, then save the new value by pressing “Enter”. Scroll to the next temperature zone and repeat this process until
each zone has a temperature setpoint programmed. Switch off any
unused zones by following the procedure outlined in the following
section.
Switching Temperature Zones On and Off
1. Hopper
Set: 123°C Act: 122°C
Press
simultaneously
1. Hopper
Set: _ _ _°C
Act: 122°C
Any temperature zone which is not being used in a given program
should be switched OFF so that it will not display “Error”. To do this,
activate a setpoint change by pressing “Enter”, then simultaneously
press both the “Up Scroll” and “Down Scroll” buttons. Once this is
done, “_ _ _” appears as the setpoint value. When the zone is later
switched ON, its formerly programmed setpoint will be retained.
To turn a temperature zone ON, activate the setpoint value by pressing
“Enter”, then change the value by using the “Up Scroll” and then
“Down Scroll”. Save your change by pressing “Enter” once more.
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Step B: Standby Temperature Programming (see illustration pg. 5-8)
It is possible to reduce the temperatures of all the temperature zones to a “Standby” condition. The
amount of the temperature reduction is programmed via the temperature parameter setup menu.
Only one standby temperature is accepted for the entire system; all zones will be lowered to it.
A “typical” standby temperature is approximately 30°C (50°F) lower than setpoint, depending on
adhesive used and customer preference. Numerically, the controller will accept any standby temperature within the range of -30°C and -150°C (-30°F and -150°F).
Press “Set Up”, then press “Enter”. Scroll to desired Standby temperature. Press “Enter” to save.
Activating the Temperature Standby
Press for 5
seconds
1.
STANDBY MODE
Set: 123°C Act: 122°C
To activate a standby, press the “Temperature Control” button for at
least five seconds. You will see the words “STANDBY MODE”
alternating on the display, which indicates that the ASU is in
standby. To de-activate standby, once again press the “Temperature
Control” button for at least five seconds. The standby display will
then disappear.
Step C: Choosing a Temperature Program (see illustration pg. 5-9)
Up to four separate temperature programs can be programmed into the controller, though only one
program is active at any given time. Setpoints may differ from one program to another. When
switching between programs, the new program’s setpoints take over, so there may be error alarms if
the new program’s unused temperature zones are turned ON.
The programs are referred to as: Program 1, Program 2, Program 3 and Program 4.
Press “Set Up”, then press “Enter”. Scroll to desired program. Press “Enter” to save.
Step D: Temperature Hi/ Lo Limits Programming (see illustration pg. 5-9)
For each temperature zone setpoint, an individual high and low limit can be set. During operation,
these limits activate the error alarms which alert the operator to over-temp and under-temp conditions in the temperature zones of the adhesive application system. They also cause over-temp zones
to be automatically turned OFF.
Each hi/ lo limit is a range (+ and -) from setpoint. Thus a setpoint of 150°C which has been programmed with a 10° hi/ lo limit will activate an under-temp alarm when the zone’s temperature falls
below 140° and will activate an over-temp alarm when the zone’s temperature rises above 160°. Refer to Display Reference illustration on page 5-2.
The smallest hi/ lo limit programmable is ± 5° (C or F) and the largest hi/ lo limit programmable is
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Page 5-19
Revised 12/04
± 50° (C or F).
Press “Set Up”, then Scroll to choose a temperature zone. Press “Enter”. Scroll to the desired Hi/
Lo Limit value. Press “Enter” to save. Scroll to the next temperature zone and repeat.
Step E: Customer Setup Access Code Programming (see illustration pg. 5-9)
To prevent unauthorized changes to the primary and secondary parameter programming, your Access Code is required at this point in order to continue to the Primary Parameter Menu (P1).
Press “Set Up”, then Scroll to the value of your access code (or enter the default access code
“9999”). Press “Enter”. A wrong access code will take you back to Step B.
Step F: Choosing the Temperature Scale (see illustration pg. 5-10)
Toggle to choose either Celsius or Fahrenheit with the Scroll arrows, then press “Enter”.
Step G: Setback Time Delay Programming (see also pg. 5-10)
The Setback Time Delay allows programming of a delay from the time the “external standby” terminals (for connection, see Chapter 3) are connected or automatically by a motor stop (this option
available for gear pump models only) until the ASU enters its standby mode.
Note: this step bypasses Step J: Head Hold Temperature (used on electric applicators only).
The time delay selected must be in the range from 0:00 (which represents an immediate entry into
standby, i.e. no delay, although in actuality, it may take up to a minute for a 0:00 setback to activate) to 7:59 (seven hours and 59 minutes).
Press “Set Up”. Press “Enter” to program. Scroll to the desired hour (0 to 7), press “Enter” to
save. Scroll to the desired minute (0 to 59), press “Enter” to save. Scroll to choose “Setback in
(hour: minute): After Motor Stop” (this option is available to gear pump models only) or “Setback
in (hour: minute): After External Contact” (this option is available to either gear pump or piston
pump models), press “Enter” to save.
Factory default for setback time delay is “external contact” and no time delay.
Step H: Sleep Mode (see also pg. 5-10)
To use the Sleep Mode, the ASU must be in Setback. During Sleep Mode, all heaters are turned
OFF and all motors are stopped.
Sleep Mode and Time Delay Setback can work together. For example, if you program a Time
Delay Setback of one hour and Sleep Mode of three hours, then the ASU is going into Setback one
hour after the external setback is activated and it will go into Sleep Mode three hours after the setback begins.
The minimum programmed Sleep Mode duration is 0.1 hour (six minutes) and the maximum is
9.9 hours.
Press “Set Up”, scroll to activate, then press “Enter”. Scroll to the desired hours duration (0.1 to
9.9), press “Enter” to save.
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Step I: Sequential Heating Programming (see also pg. 5-11)
The controller allows you to choose the heating order of the various temperature zones, so that
zones requiring more time to heat up to temperature can be programmed to begin heating before
others. This is done by programming each zone with a sequential heating priority.
A “Priority 1” designation means the temperature zone will begin to heat immediately after the
ASU is powered on. Zones with higher priority numbers (Priority 2 through Priority 5) do not
begin heating until all zones with lower priority values have reached the low limit of their setpoints. Zones which are switched OFF are not applicable.
The most common heating sequence for the Dynamelt ASU is first hopper, then hose/ head. This
allows the larger mass of adhesive in the hopper to begin heating first. This sequence (hopper,
then hose/ head) is also the controller’s default heating sequence.
The current status of a temperature zone in the heating sequence can be seen on the LED display
(see pg. 5-2 Display Reference for illustration). The status is designated by a letter in the upper
right of the screen, as follows:
O
= Temperature zone is switched OFF.
W
= Temperature zone is waiting for release; zones with lower priority values
have not yet reached setpoint.
H
= Temperature zone is ON and in initial heating sequence, but has not
reached setpoint.
R
= Temperature zone is ON and has reached setpoint. It is ready.
A
= Temperature zone is ON and alarm condition (high or low) has been
reached.
E
= For electric applicators only: the controller holds electric applicators at
an operator-selected temperature for ten minutes before releasing to the
operating setpoint.
By changing setpoints and/ or switching off zones, zones may be released earlier.
Press “Set Up”, Scroll to choose a temperature zone, press “Enter”. Scroll to desired priority and
press “Enter”. Scroll to next zone and repeat sequence.
Step J: Head Hold Temperature (see illustration pg. 5-11)
Head Hold Temperature applies to systems utilizing electric applicators only. After programming
the temperature (to the softening point of your adhesive, see your adhesive manufacturer), the
controller holds all electric heads at the operator-selected temperature for ten minutes before releasing them to operating setpoint. This feature allows for the stabilization of the electric valves.
When using this feature, the electric applicators must be programmed to priority 2 or higher in
Step I.
Press “Set Up”. If an electric applicator is installed, Scroll to “Active” programming, press “Enter” to initiate holding temperature programming, Scroll to select a holding temperature, press
“Enter” to confirm and save the chosen temperature.
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Page 5-21
Revised 6/02
Step K: Lock Temperature Setpoints (see illustration pg. 5-11)
Temperature Setpoints Locking is a safety feature which allows the programmer to turn the keypad
off to further temperature setpoint programming. Selecting the “Active” mode locks in your programmed setpoints and turns off the keypad. Selecting “Not Active” unlocks the keypad and allows
programming (this is the default). Before Parameter Programming can begin, Temperature Setpoint
Locking must be made “Not Active”.
Press “Set Up”, then Scroll to choose either “Active” or “Not Active”.
Step L: Lock Motor Settings (see illustration pg. 5-11)
Motor Settings Locking is a safety feature which allows the programmer to turn the keypad off to
further motor programming. Selecting the “Active” mode locks in your programmed settings and
turns off the keypad. Selecting “Not Active” unlocks the keypad and allows programming (this is
the default). Before Parameter Programming can begin, Motor Settings Locking must be made
“Not Active”.
Press “Set Up”, then Scroll to choose either “Active” or “Not Active”.
Step M: Pump Enable Temperature Programming (see illustration pg. 5-12)
The Pump Enable Temperature serves as a low limit value. The controller will not allow the pump
to come on until its enable temperature is achieved. By doing so, it protects the pump, pump shaft,
motor and motor control board. The default pump enable temperature is 121°C (250°F). The selectable range for the pump enable temperature is 40°C - 196°C (100°F - 385°F).
Press “Set Up”, press “Enter”, then Scroll to your desired Pump Enable Temperature. Press “Enter”
to save.
Step N: Setpoint Limitation Programming (see illustration pg. 5-12)
The Setpoint Limitation is a universal maximum temperature for all temperature zones. The controller will not allow the operator to program a higher setpoint than the value of the setpoint limitation. The default setpoint limitation is 190°C (375°F). The selectable range for the setpoint limitation is 40°C - 218°C (100°F - 425°F).
Press “Set Up”, press “Enter”, then Scroll to your desired Setpoint Limitation. Press “Enter” to
save.
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DYNAMELT S ASU Manual #20-31
Step O: Customer Setup Access Code Programming (see illustration pg. 5-12)
To prevent unauthorized changes to the secondary parameter programming, your Access Code is
required at this point in order to continue.
Press “Set Up”, then Scroll to the value of your access code (or enter the default access code
“9999”). Press “Set Up” to select the Secondary P2 Menu, then Scroll to enter your Access Code
(or enter the default access code “9999”) again. Press “Enter”.
Step P: Measured Temperature Programming (Temperature Zone Offset) (see illustration pg. 5-13)
The Temperature Zone Offset is a mathematical factor which compensates for differences in temperature between the placement of the system’s heaters and sensors. The offset may be up to ± 50
degrees (C or F) of the temperature. An offset is often used for large applicator heads, printrolls,
printwheels or other custom devices. Important Note: Usually no offset is required on standard equipment.
Each temperature zone may be programmed with a different offset. If a zone is programmed with
a positive-valued offset, an “Up” arrow will appear on the display. If a zone is programmed with a
negative-valued offset, a “Down” arrow will appear. If a zone is programmed with no offset, an
equals sign (“=”) will appear on the display.
Press “Set Up”, then Scroll to choose a temperature zone. Press “Enter”, then Scroll to the desired
offset value (anywhere between ±50 degrees C or ±100 degrees F). Press “Enter” to save. Scroll
to the next temperature zone and repeat.
Step Q: Temperature Zone Enable Programming (see illustration pg. 5-13)
The Temperature Zone Enable allows you to eliminate inactive temperature zones from the DynaControl display, in order to make scrolling from one zone to another less time consuming. It is especially useful for small systems with fewer zones.
Press “Set Up”, then Scroll to choose a temperature zone. Press “Enter”, then Scroll up to “1” to
turn the zone ON, or Scroll down to “0” to turn the zone OFF. Press “Enter” to save. Scroll to the
next temperature zone and repeat.
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Page 5-23
Revised 6/02
Step R: Customer Zone Names (see also pg. 5-14)
Customer Zone Names allows the programmer to change the name of any temperature zone to any
word up to 14 or 15 characters in length.
Note: the temperature zone number and the last three characters on the line cannot be changed.
Press “Set Up”. Choose “Not Active” to use the controller’s default zone names. Choose “Active”
to write your own temperature zone names.
Press “Set Up”. Scroll to the temperature zone whose name you desire to modify. Press “Enter”. A
cursor (^) will appear under the first position (character) which can be changed. Scroll through the
alpha/ numeric characters until your desired character is in the selected position. Press “Enter” to
save your choice and to move to the next position in the word. Repeat the “Scroll”/ “Enter” sequence until your new name is spelled out. Press “Enter” to save the new name.
To modify the name of another temperature zone, press “Clear” then Scroll to the deisred zone.
Repeat the above sequence, spelling out new names for as many zones as you desire. Press “Clear”
to end Customer Zone Names programming.
Note on selecting characters: When scrolling to the desired alpha/ numeric character, use the “up”
scroll button to access the characters rapidly in ascending order. Use the “down” scroll button to
access the characters more slowly in decending order. Use the “Clear” button to remove the character. Use the “Enter” button to move the cursor to the next position in the name.
Step S: Changing Your Access Code (see illustration pg. 5-14)
Press “Set Up”, press “Enter”, then Scroll to choose the desired access code. Press “Enter” to save.
Step T: Power On Heater Start Programming (see illustration pg. 5-15)
With this programming step you choose to turn the ASU’s heaters ON (be active) or OFF (be inactive) whenever the controller is powered ON. If you choose “Not Active”, you will need to manually turn the heaters ON, via the controller, after each power ON.
Note: an active Seven-Day Scheduler (option) overrides this parameter. See “Seven-Day Scheduler” in this chapter for more details.
Press “Set Up”, then Scroll to choose “Active” or “Not Active”. Press “Set Up” to continue.
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Step U: Power On Input Priority Programming (see illustration pg. 5-15)
Programming at this step affects both Standby programming and Temperature Program programming.
Choosing “Active” allows an external contact (input) to take priority over keypad programming of
both of these functions. This priority becomes apparent after the ASU is powered OFF and then
ON again.
So, for example, if “active” is chosen here, the selections for standby (On or Off) and temperature
program (program #1, 2, 3, or 4) will revert to the choice made at the external contact once the
ASU is powered ON.
Choosing “Not-Active” allows keypad programming of the two functions to take priority. In this
case, the temperature program last used will be retained after the ASU is powered ON and standby
condition will remain as programmed.
Press “Set Up”, then Scroll to choose “Active” or “Not Active”.
Step V: Power On Motor Stop Programming (see illustration pg. 5-15)
Programming at this step determines if your motor is ON (select “not active”) or OFF (select “active”) when the ASU is turned On. If you choose “Active”, you will need to manually turn the motor ON, via the controller, after each power ON.
Press “Set Up”, then Scroll to choose “Active” or “Not Active”.
Step W: Level Control Status Programming (see illustration pg. 5-15)
Programming at this step lets the controller know if a level control device is in use on the ASU. Select “Active” if there is a level control device in use or select “Not Active” if there is not a level
control device in use.
Press “Set Up”, then Scroll to choose “Active” or “Not Active”.
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Page 5-25
Revised 6/02
Step X: Pressure Sensors Programming (see illustration pg. 5-15)
Programming at this step lets the controller know how many pressure transducers and the PSI rating of the transducers installed on the ASU. Default = 1500 PSI/ 1000 BAR
Press “Set Up” and Scroll to choose the number of transducers installed. Press “Enter” and Scroll
to select the PSI rating of the transducers.
Step Y: Slave Address Programming (see illustration pg. 5-16)
Slave addresses are used for serial communication. If a user has multiple ASUs and desires to control them all through a PLC, each ASU needs a numeric slave address for identification.
Press “Set Up” and press “Enter”. Scroll to choose a slave address for this ASU. Press “Enter” to
save.
Step Z: Gear Ratio Programming (see illustration pg. 5-16)
The gear ratios of a gear motor need to be programmed only when a CPU board is replaced. Typically, ITW Dynatec ships gear motor ASUs with an 18 to 1 gear ratio, though a special application
may require a special gear ratio.
Press “Set Up” and press “Enter”. Scroll to select a gear ratio for this ASU. Press the Temperature
icon to end parameter programming and return to the temperature setpoint screens.
PARAMETER PROGRAMMING IS COMPLETE. PROCEED TO MOTOR CONTROL PROGRAMMING (if applicable).
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Page 5-26
Revised 5/07
Motor Control Programming
Motor control programming is required on ASUs which utilize:
1. Gear pumps, or
2. Piston pump units equipped with an optional Line Speed Tracking kit.
(Standard piston pump-equipped ASUs use an air regulator to increase or decrease adhesive volume
and pressure and therefore do not require programming.)
Motor Control Programming (see also pg. 5-27)
Press the Motor icon to initiate a change.
Press Enter to select the mode; the mode will flash.
Scroll (toggle) to choose between the three modes: Manual, Automatic or Stop.
Press Enter to save the selected mode.
If “Stop” is selected, the menu ends here.
If “Manual” is selected:
Scroll to change the “SET %”.
Press Enter to save.
If Manual is selected, the menu ends here.
If “Auto” is selected, follow instructions listed below:
To Adjust Minimum/ Maximum Speeds for Auto Mode (see also pg. 5-27)
The Auto Mode is used when a tach generator is employed.
Press Set Up to program the Auto Mode.
Scroll to desired maximum motor speed. The maximum speed is used to scale
the input signal (tach generator) to the pump’s percent of maximum speed.
DEFAULT= 100%.
Press Enter to confirm your value.
Press Set Up.
Scroll to desired minimum motor speed. DEFAULT = 0.0%
Press Enter to save.
Press Motor icon to end programming.
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Revised 6/02
Actual Digital RPM Readout Option
Units installed with the optional Digital RPM Readout require no additional programming to display the pump’s acutal rpm value (0 -90 rpm)..
Press the Motor icon to view the readout. You will then see this screen:
Motor 1: Manual (or Auto)
Set: xx.x%
xxxx rpm
Motor Control Programming (see illustration pg. 5-26)
The ASU’s motor can be programmed to run in manual or automatic modes or it can be switched
off. When the Motor icon is pressed, the LED displays “Manual”, “Auto” or “Stop” to indicate
which mode is currently programmed.
In “Auto” mode, the display reads the value of minimum speed until production begins. Then the
readout will begin to accelerate automatically as it reads a DC signal and tracks production speed.
Auto mode requires that a maximum input signal of 10 VDC (customer supplied) be connected to
the ASU. See Chapter 3 for more details.
In “Manual” mode, the readout displays the “SET” % (of Full Speed) to the percent of full speed
value programmed into the controller. If a tachometer (option) is connected to the motor, the readout will also display the actual motor RPM.
Press Motor icon. Press Enter. Scroll to desired mode (Auto, Manual or Stop). Press “Enter” to
confirm. If Stop is selected, menu ends here. If Manual is selected, Scroll to desired setpoint. Press
Enter to save.
If Auto is selected, follow instructions in the next programming sequence.
To Adjust Minimum/ Maximum Speeds for Auto Mode (see illustration pg. 5-26)
The ASU’s motor must be programmed with a minimum and maximum percent of full (maximum) speed when Auto mode is used. The maximum speed is used as a scaling factor between the
input signal (tach generator) and the percent of full speed value of the pump.
The minimum speed is necessary to keep the pump turning in order to maintain a minimum
amount of adhesive pressure throughout the hose and applicator head.
For instance, if the input signal is 10VDC at 100 meters per minute and the pump percent of full
speed is 100% (maximum speed), but the system is putting out too much adhesive, adjusting the
“MAX %” to 50% will allow the pump to slow down and adhesive output will decrease by 50%.
Press “Set Up” to program the maximum motor speed value, Scroll to desired value, press “Enter”
to save. Press “Set Up” again to program minimum motor speed, Scroll to desired value, press
“Enter” to save. Press Motor icon to end.
PROGRAMMING IS NOW COMPLETE FOR THE STANDARD DYNAMELT ASU.
IF YOUR ASU HAS OPTIONAL CONTROLLER FEATURES, CONTINUE WITH THE
PROGRAMMING INSTRUCTIONS ON THE FOLLOWING PAGES.
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DYNAMELT S ASU Manual #20-31
Programming of Other Optional Features
Seven-Day Scheduler
The Seven-Day Scheduler allows the operator to program main power ON and OFF times which
coincide with his daily production schedule throughout the work week. Up to ten “events” may be
scheduled. An event is a specific day and time or every day at the same time.
An ASU which has an active seven-day scheduler should be turned ON at the main power switch
(item “N” on page 5-2). It should never be turned off by the main power switch while the scheduler
is active. To turn the ASU OFF (temporarily overriding the scheduler), use the DynaControl on/ off
keypad icon (item “L” on page 5-2).
In the event of a power outage, or a manually switched main power ON, an active scheduler overrides the “Power On Heater Start” parameter (see Parameter Setup “Step T”). 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.
When the seven-day scheduler is programmed and active, the green LED on the scheduler icon on
the controller keypad (item “K” on page 5-2) flashes continuously and the controller screen is blank
(ie, no display). Time-of-day is indicated on a 24-hour day/ 60-minute hour clock; i.e. 12:00 pm =
12:00 and 12:00 am = 24:00.
Seven-Day Scheduler Programming
Press the Seven-Day Scheduler icon to initiate programming.
Time and day will be displayed as illustrated below. The time display will flash to
indicate the active mode.
00 : 00
x1
Friday
Press Set-Up.
Step a: Time-of-Day Programming
Program the controller’s clock with the correct time of day:
Scroll to the current “hour” (numerically: 00:00 to 23:00).
Press Enter to confirm.
Scroll to the current “minutes” (:00 to :59).
Press Enter to confirm.
Scroll to the current day of the week (Sunday thru Saturday).
Press Enter to confirm. On the display, the colon (:) will flash.
Page 5-29
Revised 6/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Step b: Event Programming
Note: a scheduler “event” is either a “Switch ON” or a “Switch OFF” time.
Press the Seven-Day Scheduler icon. The first event number will flash, as seen below.
S. 1
00:00
-- -- -- -- -- -Every day
Press Enter. “ -- -- -- -- -- -- ” will flash, indicating that the scheduler is not in use.
Scroll to select “Switch ON”, “Switch OFF” or “ -- -- -- -- -- -- (not in use)” for this event.
Press Enter. The hour will flash.
Scroll to choose the hour of the event (00:00 to 23:00).
Press Enter. The minutes will flash.
Scroll to choose the minutes of the event (:00 to :59).
Press Enter. The day-of-the-week will flash.
Scroll to choose either “Every day”, “Mon. - Fri.”, or any individual day.
Press Enter. The event number will flash.
Scroll to choose another event number to continue.
Repeat Step b for each event you wish to schedule.
Step c: Turning Seven-Day Scheduler ON or OFF
Press the Seven-Day Scheduler icon.
Scroll to choose the scheduler to be either “Active” (ON) or “Inactive” (OFF).
If the scheduler is active, the display will be as illustrated below and, after programming is complete, its icon’s green LED will flash continuously.
7-Day Scheduler
Not active
active
Press the Temperature icon to exit the 7-Day Scheduler programming menu.
Page 5-30
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pressure Control Programming
System pressure, as read by optional pressure transducers, may be monitored at the controller by
pressing the pressure control icon. Up to four transducers may be monitored per pressure board.
Pressure is measured in “psi” if your system setup is “US” or in “bar“ if your setup is “EU”.
Press Pressure Control icon. You will then see this screen:
Pressure Readout
System 1: xxxx psi
Press Set-Up.
Scroll to select the low alarm pressure value for your first transducer (DEFAULT = 0).
Press Enter to confirm and save your choice.
Scroll to select the high alarm pressure value for your first trandsducer
(DEFAULT= 1000).
Press Enter to confirm and save your choice.
Repeat to program each “system” (transducer) on your ASU.
Press Clear or the Temperature icon to end.
Level Control Prompt
The DynaControl’s screen is automatically interrupted and an audible alarm sounds to prompt the
operator to re-fill the ASU’s hopper with adhesive. If the hopper is not refilled, the alarms repeat
every two minutes.
Low Tank Level
Press C to Clear
When you see this screen and hear the alarm -- -Press “C” to clear alarm.
Re-fill the hopper.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 5-31
Revised 2/09
DynaControl Features
Ready Light Display
Each button (icon) on the keypad has a light diode (LED) in its upper left corner. A constant light indicates that the button has been pressed (selected). A flashing light on the
Temperature Control button (as in the example at right) indicates that a zone(s) is not
up to ready temperature. A flashing light on the Seven-Day Scheduler (optional) button indicates
that the scheduler is programmed and active.
Press On to Start or “Blank” Screen at Startup
If a controller screen reading “Press On to Start” is the first screen to come up after powering on,
this indicates that your ASU will not begin heating until you manually turn its heaters on (by
pressing ON). This condition is a default of the EU setup. This condition may be re-programmed at
Step “T” of the programming sequence to allow automatic heating at power on.
If the first screen to come up after powering on is “blank” (ie, no display message) this indicates
that your ASU has an active Seven-Day Scheduler (option) and the scheduler is in a “Switch Off”
event. See Seven-Day Scheduler programming in this chapter for more details.
Temperature Scan/ Hold Modes
At any time during production, the operator may choose to “scan” through all the temperature
zones, or to “hold” the display of one particular zone on the LED readout.
In Scan mode, each of the temperature zones are displayed (in numeric order) at intervals, one after
the other. Scan mode is indicated on the display by a small triangle in the upper right corner (see
illustration below). In the Hold mode, one temperature zone is displayed constantly (and no triangle
appears). Pressing the Temperature Control button (illustrated above right) activates the Scan mode.
The Scan mode is de-activated, and the Hold mode activated, by any
1. Hopper
of the following buttons: “Up Scroll”, “Down Scroll”, “Clear” or
Set: 123°C Act: 122°C
“Enter”. After any controller power on, the controller will start up in
the Scan mode.
Alarm/ Error Indication
If an alarm condition occurs during operation, the ASU’s main power
output (internal relay) will be switched off and an appropriate error
indication will appear in the display (see example at left; for more
examples, see Chapter 4). If the controller is in Scan mode at the time of the alarm, the Scan mode
will be de-activated and the temperature zone which has the alarm condition will appear in the
display.
2 TEMP ZONE HOSE 1
ERROR ON CHANNEL 2
To acknowledge the error and clear the error indication message, press the “Clear”
button (illustrated at right). By doing this, the faulty zone is switched off and the ASU
is again ready for operation. If several zones show alarm conditions, each error must
be acknowledged by pressing “Clear”.
cont.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 5-32
Revised 2/09
Pump Enable Indication Arrow on Motor Display
MOTOR 1:
0 RPM
STOP
A flashing down arrow on the motor display indicates that the actual
temperature is too low for the motor to turn on. This indication may
occur in any of the three motor modes: Manual, Auto or Stop.
A flashing LED on the motor button indicates that zones with temperature priority #1
have not reached pump enable temperature.
Gear Motor Quick Stop or Quick Start
To Stop: If the ASU is running in either Manual or Auto mode, it can be quickly stopped by first
pressing the “Motor” button, followed by pressing “Enter”.
To Start: If the ASU is stopped and Manual mode is flashing, press the “Motor” button, then scroll
to select either “100%” (fast start), “50%” (half-speed start) or “0%” (very slow start), then press
Enter.
Models equipped with piston pumps do not have this feature.
Hour Meter
Press “Clear”, then press the “Clock” key for at
least five seconds to display the Hour Meter. The
hour meter counts the total elapsed hours the electronics of the
Dynamelt ASU have been running. The counter begins with the first Power On of the ASU and
cannot be reset. Any time the ASU is in standby is not counted. Any time the ASU is powered on
for less than 30 minutes is not counted. If the CPU printed circuit board is replaced with a new
board, the counter will start over at “0”.
Setback in (hour: minute)
Elapsed Hours: 1234
Setback Remaining Time Readout
Setback in 1:30 (h:m)
Elapsed Hours: 1234
Press “Clear”, then press the “Clock” key to read
a display of the remaining time of a setback (in
hours: minutes) which has a programmed time delay.
Page 5-33
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Re-programming Your System’s Parameters
It is not necessary to re-boot the DynaControl in order to change your system’s parameters (setpoints). Use the following procedure:
Note: If Lock Temperature Setpoints and Lock Motor Settings are not active, begin at step 4 and
omit step 7.
1. Start at the temperature zone display.
2. Press “Set Up”
1. Hopper
Set: _ _ _ °C
Act: 122°C
until you advance to “Customer Setup”. Enter your four-digit access code.
3. Press “Set Up” until you advance to “Lock Temperature Setpoints”. Choose “Not Active”. Press
“Setup” once to advance to “Lock Motor Settings”. Choose “Not Active”.
4. Press “Temperature” icon
. Then follow either “a” or “b” below:
a. To re-program a temperature zone: scroll “Up” or “Down”
to the desired zone.
b. To re-program any other parameter: press “Set Up” until you advance to the parameter’s
screen. If desired parameter has multiple screens, scroll “Up” or “Down” until the desired screen
is displayed.
5. Press “Enter”
. The setpoint will flash.
6. Scroll “Up” or “Down” to the new desired setpoint. Press “Enter” to confirm and save.
7. Press “Set Up” until you advance to “Lock Temperature Setpoints”. Choose “Active”. Press
“Setup” once to advance to “Lock Motor Settings”. Choose “Active”.
8. Press “Temperature” icon to exit.
9. If desired, press “Temperature” icon again to enter Scan Mode.
Restoring Factory Defaults (Re-Booting)
Rebooting your DynaControl controller will restore its factory defaults and wipe out all programmed setpoints. To perform this sequence, first turn the controller’s On/Off switch OFF, then:
Power
ON
Turn ON the controller’s On/Off switch while pressing and holding both the Scroll Up
and the Scroll Down buttons for approximately five or six seconds. Release buttons.
The screen will read “SYSTEM SETUP”.
Use Scroll buttons to choose desired system:
US = English language, Fahrenheit temperature scale and heaters powered ON at
startup.
EU = English language, Celsius temperature scale and heaters powered OFF at
startup.
Press Enter to confirm and save your chosen System Setup.
Page 5-34
Revised 2/09
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 6-1
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
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 DYNAMELTÒ S 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 lid and control and hose panels may be cleaned with mineral spirits.
Preventive Maintenence Schedule
The Dynamelt S ASU requires little maintenance. The hopper is fitted with a coarse screen to prevent large debris from entering the system. Normally this screen does not require cleaning. The
ASU parts that require regular, periodic maintenance are as follows:
Output Filter
The output (pump) filter should be replaced monthly during the first few months of operation. After
you gain experience with your system, you can determine how often you need to replace it. The output filter is located on the output filter manifold on the hose connection panel of the ASU. See illustration of the output filter on page 6-2.
Use the following procedure to replace the output filter.
cont.
WARNING
HIGH PRESSURE
Use the output filter manifold’s bleed valve to relieve adhesive pressure before
performing any pump filter maintenance. See page 6-5 for detailed instructions.
HOT ADHESIVE
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’s purge drain before proceeding.
Page 6-2
Revised 8/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Brass Filter Nut
PN 006C024
O-ring
PN 069X058
Filter Basket
PN 101246/ 40 mesh
PN 101247/ 100 mesh
Output Filter
Manifold
Bleed Valve port
Purge Drain
Output Filter Manifold (located on the Hose Connection Panel)
1. The system should be at operating temperature before starting this procedure.
2. Before proceeding, follow instructions to “Purge the Filter Manifold of Adhesive and
Pressure” on page 6-5. Leave purge screw open for this procedure.
3. Unscrew and remove the brass filter nut (15.8 mm or 5/8” nut).
4. With needle nose pliers, pull the filter basket out of the manifold body.
5. The filter basket is replaced as needed. Note the char and debris inside the filter basket.
6. Before replacing the filter basket, replace the o-ring on the filter nut. Apply o-ring lubricant
(PN N07588) to the new o-ring.
7. Apply a coat of anti-seize to the threads of the filter nut. Re-install the filter basket and the
filter nut. Tighten the filter nut until it is seated firmly against the manifold body, taking care
not to cut the o-ring as it enters the manifold. Tighten purge screw.
Hose Fittings
All hose fittings should be checked for tightness after every three months of operation.
Fasteners
After the first ten hours of operation, check all set screws, socket head and cap screws for tightness.
Thereafter, re-check all fasteners after every three months of operation.
Page 6-3
Revised 4/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Primary FIlter Cleaning
See the illustration below for location of the primary filter.
1. Pump all the adhesive out of the hopper.
2. Lower the temperature of the application system to the adhesive’s softening point.
WARNING HOT SURFACE
The ASU will still be hot when this procedure is being done. Use insulated
gloves and protective clothing when removing the primary filter.
3. Remove the access cover via two captive screws. Do not pull out the ground wire attached.
4. Wearing gloves, unscrew the filter retaining nut and pull the primary filter out.
5. Emerse the clogged filter in flushing fluid (PN L15653) to loosen contaminants. Remove
filter from fluid and use a hot air gun (if necessary) and rags to clean all contaminants from
the filter.
6. Apply a coat of anti-sieze compound onto the threads of the filter retaining nut before
re-inserting into the ASU.
7. When re-installing the filter assembly, turn the filter’s cut out hole toward the pump.
Align the filter shutoff knob in its “open”, vertical position (as shown in the diagram).
Note: the filter shutoff knob is closed when it is positioned horizontally.
8. Replace the access cover and restore the ASU to normal operation.
Access Cover
Ground Wire
Access Cover
Primary Filter
Location of Captive Screws
(2)
Filter Shutoff Knob
Hose Connection Panel
Page 6-4
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pump Shaft Leak
There is a cutout in the baseplate, directly below the pump shaft, which will allow adhesive from a
leaking pump to exit the ASU. Inspect the area under the baseplate cutout every month for adhesive.
A leaking pump shaft indicates a worn pump seal. See instructions in Chapter 8 for replacement of
this seal.
Summary of Preventive Maintenance Schedule
Monthly (or as experience dictates)
Inspect output filter basket. Replace as required.
Check for leaking adhesive under the baseplate, caused by a worn pump seal. Replace as required.
Every Three Months (or as experience dictates)
Check all hose fittings for tightness.
Check all fasteners for tightness.
Inspect primary filter. Clean or replace as required.
Page 6-5
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Purging the Filter Manifold of Adhesive and Pressure
As a safety precaution, the Dynamelt system should be purged of pressure and adhesive before attempting to change the output filter or before removing any of the hoses or applicators from their
manifold port.
Refer to the illustration on page 6-2 while following these instructions.
WARNING
HIGH PRESSURE
During the purging procedure, hot adhesive can come out of the manifold under
high pressure. Wear a face shield, gloves and protective clothing. Stand clear of
the ASU until all pressure is relieved.
HOT ADHESIVE
Avoid splashing hot adhesive. Position a heat-resistant container under the
manifold’s purge drain before proceeding.
The ASU should be at operating temperature. Turn the ASU’s pump/ motor OFF.
1. Locate the bleed valve on the output filter manifold.
2. With a hex key screwdriver (allen wrench), slowly loosen the purge screw (do not attempt to
remove it) which is in the bleed valve’s port. Allow the adhesive and pressure to escape out
of the manifold. The adhesive will flow into the heat-resistant container positioned below the
manifold.
3. After all adhesive has run out, re-tighten the purge screw.
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 gallons) of flushing fluid on hand (PN L15653).
WARNING HOT ADHESIVE
The flushing fluid will splash easily. Wear protective clothing, gloves and
a face shield to prevent severe burns.
1. Pump out as much of the molten adhesive from the hopper as possible.
2. Reduce the ASU’s pump pressure to zero.
cont.
Page 6-6
Revised 8/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Note: the hose used in the following process is merely for the convenience of depositing flushing
fluid. This procedure does not have to be repeated for each hose in the system.
3. Disconnect one of the supply hose’s adhesive feed from its applicator head. Do not
disconnect the electrical power to the head (since that would disable the pump). Put the hose
in a secured position within a container which will catch the used flushing fluid.
4. Add flushing fluid to the hopper and allow approximately fifteen minutes for it to reach
hopper temperature. Carefully stir the flushing fluid to mix with any adhesive remaining in
the hopper.
5. Slowly increase the pump pressure. Pump about half of the fluid through the hopper, pump
and adhesive supply hose into the flushing container.
WARNING HOT ADHESIVE
Avoid splashing the flushing fluid from the end of the hose.
6. For Piston Pumps: Reduce the pump pressure to zero.
For Gear Pumps: Reduce the pump speed to zero.
7. Add new adhesive to the hopper and allow it to reach application temperature.
8. For Piston Pumps: Slowly increase air pressure to the pump.
For Gear Pumps: Slowly increase motor speed to the pump.
9. Actuate each of the heads until all the flushing fluid is removed and a steady stream of new
adhesive flows.
10. Remove the output filter and replace the basket. Install a new o-ring on the filter nut
(lubricate the new o-ring with o-ring lubricant prior to installation) and tighten the brass nut.
11. For Piston Pumps: Re-adjust the pump air pressure for the desired flow.
For Gear Pumps: Re-adjust the pump speed for the desired flow.
12. Re-fill the hopper with adhesive. The system is now ready for production.
Page 7-1
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Chapter 7
TROUBLESHOOTING
General Troubleshooting Notes
DANGER
HIGH VOLTAGE
WARNING
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
troubleshooting or repair procedures. All troubleshooting and repair procedures must be
performed by qualified, trained technicians.
CAUTION: Printed circuit boards (PCBs) are prone to damage from static
electrical charges during handling. Read “Handling Printed CIrcuit Boards” on
page 7-3 before handling or attempting service on Dynamelt’s PCBs.
The Dynamelt’s DynaControl includes malfunction self-diagnostics, alerts and error indication
alarms. The error indication alarms (the alarms displayed on the DynaControl readout) are triggered
whenever there is a sensor failure and whenever there is an over-temperature condition. The
operation of the error indication alarms is described in Chapter 4 of this manual.
Preliminary Checks: Verify the following before proceeding:
1. The ASU is switched on.
2. The ASU is supplied with power.
3. The ASU is supplied with pneumatic air (if applicable).
4. Pneumatic and electrical connections are correct.
5. Adhesive is in the hopper.
Error Messages:
ERROR ON CHANNEL X = temperature zone “X” has an open or shorted sensor.
EEPROM ERROR = new software installed. Re-boot controller.
HOPPER OVERTEMP = indicates a serious problem which requires service by ITW Dynatec.
Hose/ Applicator Troubleshooting Tip
Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an
alternate socket on the ASU. If the malfunction goes with the applicator and hose, the problem will
usually be in the applicator or hose that was moved. If the malfunction does not move with the
applicator and hose, the problem is probably in the ASU.
Page 7-2
Revised 2/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pressure PCB
Metal
Cover
Motor Control Interface PCB
Trigger Park PCB
Trigger Relay PCB
or
CPU PCB
Motor Speed Control
Signal Isolator (KBSI) PCB
Operator’s Panel
PCB
Power PCB
Auxiliary Power PCB(s)
Overtemp
Thermostat Re-Set
Primary Filter
Pump Enable Thermostat
Location of Components
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 7-3
Revised 6/03
High-Temperature Redundant Overtemp Thermostat
The Dynamelt S Series ASU includes a mechanical (redundant) overtemp thermostat that acts as a
safety backup. If the ASU’s hopper temperature should exceed 232°C (450°F) [or 276°C (529°F)
for optional high temperature ASUs], the thermostat will cause the ASU’s circuit breaker to open
and power to the hopper and all hoses and heads will be cut off. The mechanical thermostat must be
manually re-set after the hopper temperature falls below 204°C (400°F).
The overtemp thermostat is located on the front side of the hopper, behind the access cover (see illustration on previous page). To reset: turn OFF the ASU’s main power switch; loosen the two captive screws to remove the access cover; 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, located to the right of the overtemp thermostat (see illustration on previous page) and it is factory set
at 135°C (275°F). The thermostat is adjustable so that operators using adhesives with extraordinarily high or low melting points can tailor the low-temp setting to their production’s needs.
Refer to Chapter 3 for instructions on calibration of this thermostat.
Lithium Battery on CPU PCB
The CPU Printed Circuit Board contains a lithium battery which powers the optional seven-day
scheduler’s clock. The normal life of this battery is about ten years. When the battery needs replacement, the scheduler’s clock does not function, but other controller features remain intact. Return the
board to ITW Dynatec for battery replacement.
Page 7-4
Revised 1/00
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Handling Printed Circuit Boards (PCBs)
The Dynamelt ASU and DynaControl controller utilize several printed circuit boards (PCBs). These
boards are extremely sensitive to electrostatic charges. When 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 removing and replacing connectors.
CAUTION: Printed circuit boards (PCBs) should be handled using the following
procedures:
1. Wear a wrist grounding strap. If a grounding strap is not available, frequently touch a
bare metal part of the ASU (unpainted frame, mounting screw, etc.) to safely discharge
any electrostatic buildup on your body.
2. Handle a 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 S Series PCBs.
Page 7-5
Revised 11/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
CPU Printed Circuit Board
The CPU board contains the controller’s CPU chip (built into the board) and optional 7-Day
Scheduler chip. The CPU chip (EPROM) can only be reprogrammed at ITW Dynatec’s factory.
The CPU board is mounted directly behind the Operator’s Keypad PCB, behind a protective, metal
cover. All of the user terminals are located outside of the protective cover.
The Low Level relay is fixed at normally open. The High/ Low Alarm relay is fixed at normally
closed. During normal operation, the two red indicator lights are always ON.
Set the dip switches as follows: (a.) for standard piston pump models: set all switches (S1 - S4) to
OFF, or (b.) for gear pump models and for piston pump models utilizing the DCL-controlled line
speed tracking option: set S1 to ON; set S2, S3 & S4 to OFF
Solid state relay control for Hopper, Head/ Hose 1 & 2
EPROM (not removable or programmable by user)
PC/PLC Serial Channel
BT1
X5 X6
X10
Relay outputs:
1&2 = alarm contacts
3&4 = low level contacts
Audible
Alarm
+
Scheduler Battery
--12A
+12A
+12D
+ 5D
Connect to Operator
Panel PCB
1
2 X1
3
4
Flat cable connect to
Auxiliary PCB or
Relay Output PCB
U1
X11
J2
S4
S3
S2
S1
J1
X4
1 = Program Select 1 (1/2) Input
2, 4, 6, 8 = +12V
3 = Low Level Detect Input
5 = External Setback Input
7 = Program Select 2 (3/4) Input
9&10 = Ground
1
2
3
4
5
6
7
8
9
10
Flat cable connect
to Power PCB
(cutout)
(cutout)
J6
X3
Sensor Inputs for
Head/ Hose 3 & 4
X2
Sensor Inputs for
Head/ Hose 5 & 6
and Aux 1, 2 & 3
X7
Sensor Inputs for
Hopper &
Head/ Hose 1 & 2
(Dynatec factory use)
Dip switches
X16
ON
Terminal connections:
LEDs
Optional Scheduler chip
X14
Sensor Input for channel 16
Layout of Components on CPU Board
Flat cable connect
to optional motor board
Page 7-6
Revised 6/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Power Printed Circuit Board
The DynaControl has one power board and, depending on the number of hose/ heads on your
Dynamelt ASU, up to three auxiliary zone boards. If the ASU has 1 or 2 hose/ heads, it will have
only the main power board pictured below (for zones 1 to 5). If the ASU has more hoses/ heads, up
to three auxiliary zone PCBs are employed to accomodate additional temperature zones. The
Auxiliary (AUX) PCBs connect to the power board as diagrammed below.
The Power PCB is mounted to the ASU’s base plate, in the pump and electronics compartment.
The green LEDs 3 thru 7 cycle on and off as individual zones come up to temperature. LED 8
indicates that the relay power supply is ON; it lights continuously.
All power board fuses are 6.3AF amp.
1&2: Auxiliary ready contacts (closed = ready)
3&4: TH2 Low-temp thermostat
5&6: TH1 Overtemp thermostat
LED7 = Head 2
LED6 = Hose 2
LED5 = Head 1
LED4 = Hose 1
LED3 = Hopper
X3
654321
Flat cable connect
to CPU Board
Pump/ solenoid &
power supply fuse
Connect to Aux PCB #2
for Hose/ Head 5 & 6
Connect to Aux PCB #3
for Premelt Grid 1 or 2
J5
Transformer
X4
LED7
LED6
LED5
LED4
LED3
Pump/ solenoid connect
Head 2 fuse
F5
Hose/ Head 2 heater connect
X10
LED8
F1
X23
L3 N3
X22
L2 N2
Hose 2 fuse
F4
X21
L1 N1
Head 1 fuse
Connect to Aux PCB #1
for Hose/ Head 3 & 4
Hose/ Head 1 heater connect
F3
X8
Hose 1 fuse
F2
Hopper heater connect
Line power input
X2
L3 N3 L2 N2 L1 N1
PE PE PE
X13
Main Ground
X5 X6 X1
X7
Protective earth grounds
for Auxiliary Power PCBs
Layout of Components on Power Board
Page 7-7
Revised 3/06
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Auxiliary Power Printed Circuit Boards
When the adhesive supply unit employs more than three hoses and three heads and/ or drop-in
grids, Auxiliary Power (AUX) PCBs are added to the system to accomodate the additional temperature zones.
The addition of hose/ head 3 and 4 requires Auxiliary PCB #1. The addition of hose/ head 5 and 6
requires Auxiliary PCB #2. The addition of a grid requires Auxiliary PCB #3. AUX PCB 2 & AUX
PCB #3’s basic layouts are identical to AUX PCB #1 (detailed below), however their fuses and connects are seen in the two smaller illustrations below.
Jumpers: Each AUX board has a JMP 2 jumper. Only AUX #1 and AUX #3 have a JMP 1 jumper.
Important Note: if a jumper exists in the JMP 1 position on AUX #2, it must be removed. The factory configuration for each board’s jumpers is diagrammed below.
All board fuses are 6.3 amp, AF. The green LEDs 4 thru 7 cycle on and off as individual zones are
heating.
Location of AUX PCBs
on ASU Base Plate
D
I
V
I
D
E
R
P
A
N
E
L
N = Neutral (blue) wire from Power PCB
Connect to Solid State Driver
Outputs for Auxiliary Zone
L1, L2 or L3 = Black wire from Power PCB
PE = Ground (green) wire
from Power PCB
Auxiliary Boards
#3 #2 #1
LED4
JMP 1
Flat cable
connect to
CPU board
X8
LED7
F4
F5
PE
X10
Head 3 Fuse
Connect to
Head 3/ Hose 3
Hose 3 Fuse
Head 4 Fuse
Connect to
Head 4/ Hose 4
Hose 4 Fuse
Layout of Components on Auxiliary Power PC Board #1
JMP 1
L2
F3
X8
F3
N
Power PCB
CONTROL PANEL
LED6
L1
F2
JMP 2
set to
6 -13
F2
LED5
L3
Auxiliary Power PC Board #2
JMP 2
set to
14-21
F5
F4
X8
X10
JMP 2 Hose 5
Head 5
Head 6 Fuse
set to Fuse
Fuse
Connect to
6 -13
Connect to
Head 6/ Hose 6
Head 5/ Hose 5
Hose 6 Fuse
F3
F2
F5
F4
X10
spare
spare
fuse
fuse
not used
spare fuse
not used
spare
fuse
Auxiliary Power PC Board #3
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 7-8
Revised 8/11
Motor Control Interface Printed Circuit Board
Note: Only gear pump ASUs require this board. Piston pump units have no motor control PCB.
The Motor Control Interface PCB is located on the back of the metal cover which protects the CPU
board, facing the motor.
The three jumpers (J1, J2 and J3) should always be set in the positions diagrammed below. The
M/S selection jumper must be set in the “S” position.
“MAX” speed adjusting pot: This pot adjusts the maximum output voltage of the motor speed control board. It is factory preset to full pump motor rpm (100%). Normally, this pot does not need adjustment. 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.
Voltage Selection (J3): UP position (for KB drive) = 0-5V, DOWN position = 10v (for Yaskawa drive)
MAX Speed Adjustment potentiometer
Motor
J2
Flat cable connect to
CPU PCB at J1
J1
X1
Transformer Fuse
F1
X2
10
0
5V
10v
En
En
J3
M
S
X4
Web
Transformer
X5
L1
240 VAC input
VR1
X3
N
P
0
5
TR
TR
10
0
X2 connections are internal and not
for customer’s use:
Speed reference voltage set by J3
Ground
not used
Pump enable
Pump enable
Encoder pulse
not used
Ground
Encoder supply voltage
Handgun trigger input &
pump enable
Handgun trigger input &
pump enable
0-10 VDC input, web speed,
max. 40v
Ground
Web Speed Scaling potentiometer
Factory Set, Do Not Adjust
Layout of Components on Motor Control Interface Board
Page 7-9
Revised 3/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Motor Speed Control Drive
The Motor Speed Control is located on a bracket mounted on the divider panel within the pump
and electronics compartment of the ASU. This variable-frequency drive is factory-set and normally
does not require adjustments. The following is a list of parameters that Dynatec programs to
optimize performance, but which differ from the drive’s default parameters.
Parameter
Value
Description
B1-17
L1-01
L2-01
1
2
2
E1-09
E2-01
E1-04
0.5
1.5
62*
Starts the motor even when the enable signal precedes power up.
Prevents false tripping at low speeds.
Does not stop the motor when under-voltage is detected (power up after
short interruption).
Allows the motor turn down to 1% minimum.
Full load amperes, maximum motor current.
Calibrates the maximum speed. See note below for details.
* Due to component tolerances, the maximum speed of the pump might vary. In order to calibrate
the maximum speed, parameter E1-04 can be fine-tuned. Valid range is 61 to 63.
Set motor speed to 100% and adjust parameter E1-04 so that the pump is turning exactly 90rpm.
The acceleration and deceleration times are factory set
to 10 seconds. If an application requires faster acceleration/deceleration, corresponding parameters can be
changed:
Parameter
Value
Description
C1-01
10.0
C1-02
10.0
The time it takes to ramp the
pump speed up from 0 to
maximum.
The time it takes to ramp the
pump speed down from maximum to 0.
S1 S2 S3 S4 S5 SC A1 +V AC AM AC
BLU
BLU
+ OR
-- GRAY
Corrupted Memory
If the memory becomes corrupted:
1. Restore the factory default settings by entering
2220 at parameter A1-03.
2. Re-enter the ITW Dynatec parameters specified in
the chart at the top of this page.
cont.
Layout of Motor Control Drive
Page 7-10
Revised 3/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Accessing, Programming and Monitoring Motor Control Parameters
To Access and Change Parameter Values
Step 1.
Step 2.
Step 3.
Note: On the Motor Interface PC board, change Voltage Selection jumper J3 to 10V (down
position).
To access other drive signals, refer to the Yaskawa technical manual, available at:
http://www.yaskawa.com/site/products.nsf/productGroup/ACDrives.html
Page 7-11
Revised 9/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Optional Trigger Relay Circuit Board
When hand-held applicators are utilized in a Dynamelt S system, the optional Trigger Relay PCB
replaces the standard Trigger Parking PCB. The trigger switches of the hand-held applicator(s)
terminate on the Trigger Relay PCB.
2.5 amp fuse
X5
F1
Solenoid 1
Solenoid 1
Solenoid 2
Solenoid 2
Enable
Enable
X4
PE
N
L1
X1
X3
Trigger Parking
Terminal
X2
Trigger Parking Terminals
Layout of Components on Optional Trigger Relay Board
Page 7-12
Revised 3/06
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Trigger Signal Parking Printed Circuit Board
When hand-held applicators are utilized in a Dynamelt S system, their trigger switches terminate
on the Trigger Relay PCB. When hand-held applicators are not used, these trigger switches terminate on the Trigger Signal Parking PCB, which is mounted onto the unit’s heat shield.
There is one trigger switch per hose/ applicator.
Ground
X3
X1
X2
Trigger Parking Terminals
Layout of Components on Trigger Signal Parking Board
Optional Signal Isolator Printed Circuit Board
The Signal Isolator (KBSI) Board is detailed in the appendix of this manual.
Optional System Status (Stack) Light Relay Output Extension Board
The System Status Light Relay Output Extension Board is used with the system status lights option.
The board occupies the slot near the Power PCB normally occupied by the third Auxillary Power
PC Board. It requires software V5.13S or higher. Its contacts are rated for 250VAC/ 2 amps max.
Its functions operate according to customer connections (K1, K2, K3 and K4).
K1: N.O. contact will close when all installed motors are in automatic mode.
K2: (for future use)
K3: N.O. contact will close when standby is active.
K4: N.O. contact will close when the power is on.
K4
K3
K2
K1
J1
Ribboncable
to CPU X16
Layout of Components on System Status Light Board
Page 7-13
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Optional Pressure (PSI) Printed Circuit Board
The Pressure (PSI) PCB allows the controller to monitor up to four psi transducers. It is located on
the back of the metal cover which protects the CPU board, mounted above the Motor Interface
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
factory 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).
High & Low Alarm Outputs
4 High 4 Low 3 High 3 Low
2 High 2 Low 1 High 1 Low
X6
E6
E5
E4
E3
E2
NO
NC
E8
E7
Jumpers for
High/Low Alarms:
Normally Open (default)=
no alarm/ no continuity
Normally Closed =
no alarm/ has continuity
E1
Input connections
from Transducers:
X1
Transducer #1
Flat cable to
CPU PCB
X2
Transducer #2
Transducer #3
Transducer #4
Green LED = Board
logic power is OK
X3
X5
X4
Layout of Components on Pressure Board
Operator’s Panel Printed Circuit Board
The Operator’s Panel PCB is located behind the DynaControl keypad (see illustration on page 7-2) On
ASUs which employ the optional Pendant Control, it
is located within the pendant. The Operator’s Panel
PCB connects to the CPU board. There are no adjustors, jumpers or user-replaceable parts on this board.
DYCO-PA
Connection to CPU PCB
X5
Page 7-14
Revised 1/00
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Heater and Sensor Resistance Values
The resistance values given in the four tables on the following page will aid in troubleshooting
when a sensor or heater malfunction is suspected. The “Temperature Sensor Resistance” table gives
values for various temperatures. If you know the approximate temperature of the suspected sensor,
you can check to see if the sensor resistance approximates the value given in the table by unplugging the affected head or hose connection and measuring resistance across the affected pins (see
wiring diagram in Chapter 11 for pin numbers).
The “Nominal Hose Heater Resistance” table gives the heater resistance for hoses. A suspected hose
heater problem can be quickly isolated by measuring hose heater resistance and comparing it to the
correct resistance for your hose length and voltage as shown.
The “Nominal Head Heater Resistance” table gives values for several different head wattages. A
suspected head heater problem can be isolated by measuring head heater resistance and comparing
it to the resistance for the appropriate wattage of your system.
The “Nominal Hopper Heater Resistance” table gives heater resistance for the hopper heaters of
each Dynamelt S Series model and for the (optional) drop-in grids.
DANGER HIGH VOLTAGE
Before unplugging connectors from the PCBs, ground yourself to the
ASU by touching any available unpainted cool metal surface, mounting
screws, etc. This will avoid electrical discharge to the PCB assembly when you are removing and replacing connectors.
Page 7-15
Revised 11/10
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
F
Temperature
C
Resistance
in Ohms
32
50
68
86
104
122
140
158
176
194
212
230
248
268
284
302
320
338
356
374
392
410
428
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
100
104
108
112
116
119
123
127
131
135
139
142
146
150
154
157
161
164
168
172
176
180
183
Hose Length
Meters Feet
1.2
1.8
2.4
3
3.7
4.9
7.3
4
6
8
10
12
16
24
Resistance
in Ohms
466-544
279-326
236-275
189-221
155-181
118-137
77-90
Nominal Hose Heater Resistance
for #6 DynaFlex Hoses
Temperature Sensor Resistance
Watts
Resistance in Ohms
200
270
350
500
700
288
213
165
115
82
Nominal Head Heater Resistance
(0.00385 PT 100 RTD)
Model Number
Qty. Heaters
Resistance in Ohms
for each heater
S05 & S10
S10G
Drop-in Grid
S22 & S45
S22G & S45G
Drop-in Grid
2
1
2
1
76.8
76.8
46
32.9
Nominal Hopper Heater Resistance
Note: Resistance is measured at ambient temperature (20C/ 68F).
Page 7-16
Revised 5/13
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
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 potentially dangerous electricity to be present. Only qualified service personnel should
perform these procedures.
Problem
Possible Cause
Solution
Hopper (tank)
Overtemp
1. Setpoints have been
programmed without
enough deviation.
1. Re-program setpoints, allowing a
larger deviation between the high
and low limits.
2. Hopper sensor inoperative. 2. Replace hopper sensor if resistance does not comply with the resistance table in this manual.
Sensor
3. Power PCB is inoperative. 3. Use a clamp-on ammeter to monitor
current. If the PCB is functioning, it
will read 0 if LED 3 (Hopper) is OFF.
If LED 3 is ON, the ammeter should
read 6 amps for S05/S10 or 10.4 amps
for S22/S45. If not working properly,
replace Power PCB.
4. Hopper control triac
on Power PCB is
inoperative.
4. In an over-temperature condition,
the DC voltage from the hopper LED
on the Power PCB should be OFF.
If it is not OFF, the triac is inoperative
and should be replaced.
Page 7-17
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Hopper Sensor Open
1. Sensor cable has become
unplugged from CPU
PCB.
1. Verify that hopper sensor cable is
properly connected at X14 on the
CPU PCB.
2. Hopper sensor inoperative. 2. Replace hopper sensor if resistance
does not comply with resistance table.
Sensor
Hopper Sensor Short
1. Short-circuit caused by
debris where sensor plugs
into CPU PCB.
1. Verify that sensor plug is clean and
correctly connected at X14 on the
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 the CPU PCB. Repair or
replace any damaged wire.
3. Hopper sensor inoperative. 3. Replace hopper sensor if resistance
does not comply with resistance table.
Page 7-18
Revised 8/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Hopper Heater Open
1. Disconnection in hopper
heater circuit.
1. Inspect hopper heater wiring for
proper connections.
2. Disconnection between
Power PCB and the
CPU PCB.
2. Verify that all connections are
properly made between the Power
and CPU boards.
3. The ASU circuit breaker
(on the front panel) is
inoperative.
3.Visually and electrically inspect for a
short circuit to ground in the hopper
heater circuit. This will be limited to
between the hopper triac on the Power
PCB and the hopper heater.
4. Open hopper heater
element.
4.Remove all lead wires form both
hopper heater elements. Use an ohm
meter to measure resistance across
each element. Infinitely high
reisistance values indicate an open
heating element which must be replaced.
Heater
OHMS
S10
70-81
S22/S45
41.5 - 48.2
(Optional) Drop-in Grid 1. Setpoints have been
Overtemp
programmed without
enough deviation.
Sensor
1. Re-program setpoints, allowing a
larger deviation between the high
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 resistance table.
3. Grid control solid state
relay inoperative.
3. Use a clamp-on ammeter to monitor
current. A functioning relay will read
3.2 amps (for S10) or 7.3 amps (for
S22 or S45) or 10.4 amps (for the
S022G/S45G Drop-in Knife Grid).
Replace inoperative solid state relay.
Solid State
Relay
Page 7-19
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
(Optional) Drop-In Grid 1. Sensor cable has become
Sensor Open
unplugged from CPU
PCB.
CPU PCB
Solution
1. Verify that grid sensor cable is
properly connected at X7 on the
CPU PCB.
2. Disconnection between
Power PCB and the
CPU PCB.
2. Verify that all connections are properly
made between the Power PCB and the
CPU PCB.
3. Drop-in Grid sensor
inoperative.
3. Replace grid sensor if resistance
does not comply with resistance table.
X7
(Optional) Drop-in Grid 1. Short-circuit caused by
Sensor Short
debris where sensor plugs
into CPU PCB .
Sensor
1. Verify that sensor plug is clean and
correctly connected at X7 on the
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 X7 on the CPU PCB. Repair or
replace any damaged wire.
3. Drop-in Grid sensor
inoperative.
3. Replace grid sensor if resistance does
not comply with resistance table.
Page 7-20
Revised 6/00
Problem
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Possible Cause
Solution
(Optional) Drop-in Grid 1. Disconnection in grid’s
Heater Open
heater circuit.
1. Inspect grid’s heater wiring for
proper connections.
2. Disconnection between
2. Verify that the Power PCB or Aux
Power PCB or Aux Power
Power PCB is properly connected
PCB and solid state relay.
to the solid state relay.
Heater Wire
3. Main circuit breaker
tripped.
3. Refer to the schematic in Chapter 11 to
locate the main circuit breaker. If it
is 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.
4. Open Drop-in Grid heater
element.
4.Remove all lead wires from both
grid heater elements. Use an ohm
meter to measure resistance across
each element. Infinitely high reisistance
values indicate an open heating element
which must be replaced.
OHMS
S10
70-81
S22/S45
21.9-25.3
Page 7-21
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Hose/ Head
(No.) Overtemp
1. Hose/ Head setpoints
incorrectly programmed.
1. Re-program setpoint to allow a
larger deviation.
2. Hose/ Head triac on
Power or Aux PCB is
inoperative.
2. Use a clamp-on ammeter to monitor
hose current. If hose current does not
cycle on and off, then triac is inoperative and Power or Aux PCB must be
replaced.
3. Disconnection between
Power and/ or Aux PCB
and the CPU PCB.
3. Verify that Power and Aux PCBs are
properly connected to the CPU PCB.
4. Hose/ Head sensor circuit
inoperative.
4. a. Visually examine hose/ head
socket connections. Verify that pins
are properly seated. If pins or plug
housings are damaged, repair or replace
hose. If socket is damaged, repair
or replace harness.
ASU Socket and Hose Plug
Sensor
Heater
Plug
Sensor &
Heater
b. If hose-to-ASU plug and socket are
okay, hose may have intermittent short
or open circuit. Repair or replace hose,
hose harness, Power PCB or Aux PCB
as appropriate.
Alternately, problem can be isolated by
connecting the affected hose to a
different ASU hose socket to tell
whether the problem is in the hose or
in the Power or Aux PCB.
c. If head-to-hose and hose-to-ASU
plugs and sockets are okay, head
sensor may have an intermittent short
or open circuit. Examine connections
inside the service block area of the head
and monitor head sensor resistance
with an ohmmeter while flexing sensor
leads. Repair or replace an inoperative
sensor.
Page 7-22
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Hose/ Head
(No.) Sensor Open
1. Disconnection between
hose and ASU.
1. Visually examine connector for proper
contact and seating. If pins or housings
are damaged, repair or replace hose or
hose harness (in ASU).
2. Hose sensor harness unplugged from Power or
Aux PCB.
2. Verify that affected hose is properly
connected to Power or Aux PCB.
Replace or repair damaged hose harness
as necessary.
ASU Socket and
Hos/ head Plug
Sensor
Heater
3. Disconnection between
3.Verify that all PCBs are properly
Power or Aux PCB and the
inserted in their connections on the
CPU board.
CPU board.
Plug
Sensor &
Heater
4. Hose/ Head sensor circuit
inoperative.
Hose/ head (No.) Sensor 1. Debris at connection
Short
between hose/ head and
ASU.
4. Replace head sensor if resistance
does not comply with resistance table.
Use hose schematic to check hose
sensor resistance at ASU socket, repair
or replace hose, hose harness, Power
PCB or Aux PCB as appropriate.
1. Visually inspect hose plug and ASU
socket for cleanliness and proper
contact and seating of pins.
2. Debris at connection
between hose/ head
harness and Power or Aux
PCB.
2. Visually inspect that the affected hose
plug at Power or Aux PCB is clean
and properly installed.
3. Hose/ Head sensor circuit
inoperative.
3.Using the hose schematic, check hose
sensor resistance at ASU socket. An
ohmmeter can also be used to isolate a
pinched wire in the hose harness.
When cause is isolated, repair or replace
sensor, hose, hose harness, Power PCB
or Aux PCB as appropriate.
Page 7-23
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Hose/ Head (No.) Heater 1. Disconnection between
Open
hose/ head and ASU.
ASU Socket and
Hos/ head Plug
Sensor
Heater
Plug
Solution
1. Visually examine affected hose/ head
plug and ASU socket for cleanliness
and proper contact and seating. Refer
to wiring diagram for pin identification. The problem can be isolated by
plugging the affected hose/ head into
another ASU socket. If the new hose
number is then displayed as malfunctioning, the problem is in the hose that
was moved. Repair or replace hose or
head or ASU hose/ head harness as
appropriate.
2. Disconnection between
hose/ head harness and
Power PCB or Aux PCB.
2. Verify that the hose harness is properly
inserted into its Power or Aux PCB
plug. Check for loose leads, debris
and proper contact.
3. Disconnection between
cartridge heater and cable
assembly inside head.
3. Visually inspect wiring inside head.
Verify that cartridge heater leads are
properly connected in the service
block area.
4. Open head heater element.
4. Use an ohmmeter to measure resisitance of head cartridge heater. Refer
to resistance table for resistance
values. Infinitely high resistance indicates an open heater. Replace cartridge
heater as appropriate.
5. Head fuse on Power PCB
or Aux PCB inoperative.
5. If fuse is found to be blown, do not
replace it without first finding cause.
Look for a short circuit to ground
in the head heater circuit, particularly
inside the head at the connections in
the service block area.
If replaced fuse also blows, Power or
Aux PCB may be the cause. However,
fuse failure is usually due to a problem
in the head heater circuit, not the
Power or Aux PCB.
6. Open wiring inside ASU.
6. Visually inspect ASU wiring and use
an ohmmeter and the wiring diagram
to locate open wire in head heater circuit. Repair or replace ASU hose harness or other ASU wiring as necessary.
Sensor &
Heater
Page 7-24
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Operation of the ASU’s Piston Pump
The pump is double-acting and provides constant pressure. However, the pump does not provide the
same volume of adhesive with each piston stroke. When operating, the pump shaft will move more
slowly during the forward stroke (into the pump body) and more quickly during the reverse stroke
out of the pump body.
During the forward stroke of the pump in the first drawing below, the piston moves to the right.
This forces the input check valve to close. The pressure generated by the piston opens the output
check valve. During the forward stroke, the adhesive pressure is uniform within the pump and in the
output line, as shown by the dark gray area.
During the reverse stroke in the lower drawing, the piston moves to the left and low-pressure
adhesive (light gray area) pushes the input check valve open and fills the cylinder. At the same time,
the higher back-pressure from the pump output (dark gray area in drawing) holds the output check
valve closed.
OUT
Forward Stroke:
Input valve closed,
output valve open.
OUT
Reverse Stroke:
Input valve open,
output valve closed.
IN
Operation of the Piston Pump
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 7-25
Revised 10/99
Operation of the ASU’s Gear Pump
Manual or Automatic Pump Operation
Choose “Manual”, “Stop” or “Automatic” gear pump operation via the “Motor” pushbutton (see
icon above) on the DynaControl keypad. When the Dynamelt’s pump is to be operated manually
(that is, without a line following signal), the manual mode is used to control pump speed (and adhesive output). For the gear pump to be operated in the automatic mode, a tach generator, or equivalent, (attached to the parent conveyor line) must be provided and the following set-up procedure
should be performed:
1. The tach generator or the signal isolator must be adjusted so that the voltage from the speed
controller is 0 to10 VDC (but not more than +10 VDC when the conveyor is at maximum
speed). This voltage is measured at either X3 on the Motor Control Interface Printed Circuit
Board (for a tach generator) or at terminals 9 (+) and 10 (-) of the (optional) Signal Isolator
Board.
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 speed can be adjusted (trimmed) in automatic mode by setting maximum and minimum RPM
values on the DynaControl keypad.
To make speed adjustments, follow the programming instructions on pages 5-18 and 5-19.
Pump Output Adjustments
When the adhesive in the ASU’s hopper has reached a temperature high enough for the pump to operate 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 DynaControl 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, follow the procedure outlined on the next page. The relief valve is factory set at 27 bar (400 psi) for
gear pumps and 68 bar (1000 psi) for piston pumps.
Output can also be adjusted by using the (optional) flow control valve located between the outlet
filter manifold and the hose. This valve will operate as long as adhesive pressure is below the pressure setting of the pressure relief valve. To adjust: using the knob on top of the valve, turn counterclockwise to open the valve, allowing more adhesive to flow or turn clockwise to close the valve,
deceasing the amount of adhesive flow.
Thus adhesive output volume and pressure can be fine-tuned for a particular application by coordinating the settings of the motor speed control (at the keypad) and the pressure relief and (optional)
flow control valves on the outlet filter manifold.
Page 7-26
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Adjustable Adhesive Pressure Relief Valve
Dynamelt pumps are outfitted with a high-pressure relief valve located on the outlet filter manifold.
The valve is adjustable and it does not affect adhesive pressure under normal operating conditions.
The adjustable pressure relief valve is factory set at 27 bar (400 psi) for Dynamelt gear pumps and
68 bar (1000 psi) for piston pumps.
When adhesive pressure exceeds the set limit, the pressure forces the valve to move away from its
seat, compressing the spring and allowing adhesive to flow back to the hopper. This adhesive flow
reduces pressure. When the pressure falls below the set limit, the spring forces the valve against its
seat, cutting off adhesive flow.
Normally Closed (Unrelieved):
Open (Relieved):
In the drawing below, the valve is closed.
In this drawing, pressure has exceeded the setting
of the valve, causing the valve to open and discharge adhesive to the hopper.
Adjustment screw
Lock nut
Mounting nut
return to
hopper
from
pump
Adhesive flow through
filter block to hose
to
hose
from
pump
Adhesive flow through
filter block to hose
to
hose
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.
2. At the controller, set the motor speed to “0” so that the gearmotor is not turning.
3. Locate the pressure relief assembly on the manifold (where the hoses attach).
4. At the controller, turn the motor ON to desired operating speed.
5. Locate the valve’s adjustment screw and loosen its lock nut.
6. Actuate (open) the valves on the applicator(s) in order to fill them with adhesive and purge air
from the system.
7. Close the valves (those opened in the last step) to stop the flow of adhesive.
8. Using a wrench, turn the adjustment screw clockwise to increase the pressure to the
applicator(s) (or counter-clockwise to decrease pressure) until desired pressure is achieved.
CAUTION: DO NOT adjust the adjustment screw fully clockwise (closed).
Maximum operating pressure should not exceed 1000 PSI.
9. After desired pressure is achieved, tighten the lock nut. The system is now adjusted.
Page 7-27
Revised 7/02
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Troubleshooting the ASU Pump
NOTE: Before troubleshooting your pump, first determine if your DYNAMELT ASU is equipped
with a piston pump or a gear pump. This chapter contains separate Troubleshooting Guides for
each.
No special tools are needed for working on the ASU pump. See Chapter 8 of this manual for diaassembly/ 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.
Caution for 20cc/rev Standard Accuracy Gear Pumps
CAUTION: DO NOT exceed the 400 psi pressure relief valve factory setting on 20
cc/rev gear pumps. Motor overload will result if 400 psi is exceeded.
Note: the RPM readout will not operate when used with the 20cc/rev standard pump.
Piston Pump Priming/ Start-Up
WARNING HIGH PRESSURE
To avoid accidental splashing of hot melt adhesive, always relieve pressure by
opening the filter drain on the pump manifold before working on the pump.
WARNING
Observe manufacturer’s procedures for selecting and using cleaning solvents.
Be sure to read and comply with the safety procedures outlined in Chapter 1
of this manual before proceeding, particularly the section entitled, “Preventing
Explosions and Fire”.
The pump is self priming. Before starting the pump, make sure a hose is attached with an open line.
WARNING HOT ADHESIVE
Use a stable, deep container to collect hot-melt adhesive while priming the
pump.
Begin with ASU electrical power OFF and the Air Control/ Filter Unit adjusted to zero air pressure.
Turn the ASU power switch ON and slowly increase air pressure to the pump and the Air Control/
Filter Unit.
Increase air pressure until the pump begins to stroke very slowly. By allowing the pump to stroke
very slowly it will gradually purge itself of air. As the pump begins to run smoothly, gradually increase the air pressure to normal operating pressure (1.4 to 5.4 bar or 20 to 80 PSIG).
Page 7-28
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Piston Pump Troubleshooting Guide
WARNING HOT SURFACE & ADHESIVE
Some of the procedures in the following Troubleshooting Guide require working
near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing
and use proper tools for handling hot melt components.
Problem
Possible Cause
Solution
Pump Will Not Stroke
1. No air pressure.
1. Verify system has been provided
with at least 0.5 SCFM of air at
20-100 PSIG (.014 std. cubic meters/
minute at 6.8 bar).
2. Hopper temperature is
below ready setpoint.
2. Air valve cannot pass air until hopper
has reached ready condition. Verify
that hopper has reached ready. Reprogram hopper operating setpoint and
the ready temperature of the pump
enable thermostat as necessary.
3. 3-way solenoid valve is
closed.
3. Verify that valve is properly connected (electrically) inside ASU.
Verify that valve is properly connected to Air Control/ Filter Unit.
Disconnect valve electrical leads
and verify that air is passed through
when 240 VAC is applied to the
valve terminals. Replace valve if
defective.
4. Fault in compressed air
fitting on ASU.
4. Inspect the system for improper
connections, loose tubing or fittings, or kinked tubing. Repair or
replace tubing or fittings as
necessary.
5. Inoperative air valve (on
back end of pump air
cylinder).
5. Remove air valve from pump.
Inspect, clean and repair as necessary.
6. Inoperative air cylinder
4-way valve.
6. Remove 4-way valve. Inspect,
clean and repair as necessary.
Regulator
Air Tubes
Solenoid
Air fittings
Air
valve
Page 7-29
Revised 9/11
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Pump Quick-Strokes in
Both Directions
1. No adhesive in hopper.
1. Verify that hopper has an adequate
level of hot melt adhesive.
molten
adhesive
2. Adhesive is too cold to
flow into pump.
2. Check ready temperature of the
pump enable thermostat to
make sure there has been enough
time for the adhesive to rise to the
hopper setpoint temperature.
3. Adhesive used is too
viscous.
3. Verify that adhesive selection and
hopper setpoint temperature are
compatible and that both are
appropriate for your application.
4. Pump needs priming.
4. Prime the pump by removing the two
o-ring plugs on its top and inserting
molten adhesive.
5. Problem with pump shaft
piston.
5. Remove the shaft and piston from
the pump. See Chapter 8 for disassembly/ assembly procedures.
Verify that piston diameter is
correct: 19.63mm to19.66mm
(0.773” to 0.774”) and that piston is
tightly assembled to end of shaft.
6. There is a large opening
in the system downstream
of the pump.
6. Inspect system for open filter drain,
disconnected or ruptured hose, or
disconnected head. Repair as
necessary.
Loosen
set screw
Open
drain
Inlet check valve
Outlet
check valve
Pneumatic
pressure
relief valve
Purge
drain
Pump Quick-Strokes
on the Forward-Stroke
Only (shaft moving
into pump body)
7. Malfunctioning pneumatic 7. Open the purge drain and insure the
drain has some adhesive flow to show
pressure relief valve.
pressure is being released. Remove the
hose and close the purge drain. Slowly
raise the pump pressure to check for
flow directly from the manifold. If
there is no flow, replace the pneumatic
pressure relief valve.
1. Inlet check valve is
blocked open.
1. Clean inlet check valve. This may
be possible without removing the
pump by cleaning debris through
the pump inlet hole at bottom of
hopper.
Page 7-30
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Pump Motion on the
Forward Stroke (shaft
moving into pump) is
very slow or stopped.
1. Outlet check valve is
blocked closed.
1. Clean outlet check valve.
Pump Quick-Strokes on 1. Outlet check valve is
the Reverse Stroke
blocked open.
(shaft moving out of
pump)
1. Clean outlet check valve.
Low or Inconsistent
Adhesive Output
1. Outlet filter is clogged.
1. Remove and inspect outlet filter.
Clean or replace as necessary. See
Chapter 6 “Preventive Maintenance”
for procedure.
2. Adhesive used is too
viscous.
2. Verify that system components are
at proper temperature and that
selected adhesive is correct for your
application.
3. Blocked hose.
3. Inspect hose for kinks, internal plugs
of debris or char (degraded adhesive).
Clean or replace hoses as required.
4. Blocked applicator heads.
4. Inspect heads for plugged nozzles,
proper air valve operation or plugged
filters. Clean or repair heads as
needed.
5. Pressure relief valve in
outlet block is opening.
5. Verify that air supplied to pump is
less than 6.8 bar (100 PSIG). If
relief valve is opening with air pressure less than 6.8 bar (100 PSIG),
adjust or replace pressure relief valve.
1. Filter drain valve not
tightly closed.
1. Close and tighten filter drain valve.
2. Filter drain valve blocked
open.
2. Remove filter plug assembly from
pump. Disassemble plug assembly,
clean and re-install.
Inlet check valve
Outlet
check valve
Pressure
Relief
Valve
Outlet
filter
Output
Manifold
Adhesive Leak at
Filter Drain Spout
Loosen
set screw
Open
drain
Page 7-31
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Adhesive Leak at Pump 1. Pump seal out of proper
Shaft Seal
position inside seal and
bearing assembly.
Seal assembly
2. Seal inoperative.
Adhesive Leak at Pump- 1. Adapter plate o-ring
Hopper Interface
inoperative.
Pump
Pump
adapter
O-ring
Solution
1. Remove seal and bearing assembly
from pump. Verify that all components are correctly assembled.
2. Remove seal from pump and inspect
it. Replace worn or damaged seal.
Be sure there are no burrs or other
sharp edges on pump shaft or on
installation tools that could damage
the new seal.
1. Remove o-ring from adapter plate and
inspect. Replace it if worn or damaged.
Be sure there are no burrs or sharp
edges in the adapter plate o-ring groove
that could damage the new o-ring.
2. Pump assembly nuts
are missing or loose.
2. Verify that all four pump nuts are
tightly assembled to the hopper with
the proper hi-collar washer.
3. Helicoil insert pulled out
of hopper.
3. Remove pump and inspect bottom
of hopper. Repair or replace hopper
as necessary.
Page 7-32
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Gear Pump Troubleshooting Guide
WARNING HOT SURFACE & ADHESIVE
Some of the procedures in the following Troubleshooting Guide require working
near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing
and use proper tools for handling hot melt components.
Problem
Possible Cause
Solution
Pump doesn’t operate
in “Manual” mode,
power light doesn’t
light.
1. Motor On/Off is OFF at
the controller keypad.
1. Check keypad setting.
2. Hopper temperature is
below ready setpoint.
2. Pump cannot operate until hopper has
reached “ready” condition. Verify that
hopper has reached ready. Re-program
hopper operating setpoint and ready
setpoint if necessary.
3. No incoming electrical
power.
3. Check to see if ASU temperature
control is operating. If not, check
for presence of incoming supply
voltage.
1. “Manual” motor is set at
zero (at the keypad).
1. Re-program motor.
Motor Button
Power Light
Pump doesn’t operate
in “Manual” mode,
power light is ON,
hopper is at “ready”
condition.
2. If 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 is warmed up and that
hopper temperature is above the factoryset pump enable temperature.
4. Faulty Motor Control
Interface Board.
4. If the board is faulty it must be
replaced.
Page 7-33
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Possible Cause
Solution
Pump doesn’t operate
in “Auto” mode,
power light is ON,
hopper is at ready
conditon.
1. Parent machine is not
running.
1. Check parent machine.
2. Re-program motor.
2. “Auto” motor is set at
zero (at controller keypad).
3. No incoming line
following signal.
X3
Motor Control Interface PCB
3. Check for presence of 0 to 10 VDC
control signal at X3 of Motor Control
Interface PCB. If signal is not present,
check connection at X3 and tachometer
drive connections. If control signal is
present there, the problem is within the
ASU.
4. Internal ASU connections 4. Check for the presence of 0 to 10 VDC
control signal at X3 of Motor Control
or Motor Control Interface
Interface PCB. Check ASU connections
PCB inoperative.
(S1 & 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 Motor Control Interface Board.
5. Low temp alarm.
5. Verify that ASU is warmed up and that
hopper temperature is above the factoryset pump enable temperature.
Pump runs but there is
no adhesive output.
1. ASU is out of adhesive.
1. Add adhesive to hopper.
2. If pump has been serviced
and leads reversed, pump
will run with no output.
2. Check pump wiring to schematic.
Low or inconsistent
adhesive output.
1. Filter(s) clogged.
1. Remove and inspect filter basket
and primary filter.
2. Adhesive used is too
viscous.
2. Verify that system components are
at appropriate temperatures and that
the selected adhesive is correct for
the application.
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. Inspect applicators for plugged
nozzles or filters. Clean or repair
applicators as necessary.
Filter Basket
Primary Filter
Page 7-34
Revised 8/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Problem
Pressure
relief valve
Adhesive leak at pump
shaft seal.
Seal assembly
Possible Cause
Solution
5. The fixed pressure relief
valve is opening.
5. When fully closed (clockwise) and
all applicators are off, adhesive
pressure should be around 68 bar
(1000 psi). If it is significantly less,
the pressure relief valve should be
replaced.
1. Pump seal is incorrectly
positioned inside the seal
and bearing assembly.
1. Remove seal and bearing from pump.
Verify that all components are
correctly positioned.
2. Pump seal inoperative.
2. Remove seal from pump, inspect it
and replace it if worn or damaged.
Be sure there are no burrs or other
sharp edges on pump shaft or on
installation tools that could damage
a new seal.
Adhesive leak at pump- 1. O-ring in pump’s rear
to-hopper interface.
plate is inoperative.
Pump
Rear Plate O-ring
1.Remove seal from pump, inspect it
and replace it if worn or damaged. Be
sure there are no burrs or other sharp
edges on the rear plate o-ring groove
that could damage a new o-ring.
2. Pump assembly screws are 2. Verify that all four pump screws are
tightly assembled to the hopper.
missing or loose.
3. Helicoil insert pulled out
of hopper.
3. Remove pump and inspect hopper.
Repair or replace hopper as necessary.
Page 8-1
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Chapter 8
DISASSEMBLY & RE-ASSEMBLY PROCEDURES
Disassembly Procedures
Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All
disassembly procedures must be performed by qualified, trained technicians.
Note: Use the exploded-view drawings referenced with each procedure in conjunction with the
instructions outlined in this chapter. Read the “cautions” on page 8-4 before re-assembling the
ASU.
To Remove the Pump & Electronics Cover
Pump &
Electronics
Cover
1. Loosen the four captive screws (two on each side)
along the bottom of the pump and electronics cover.
2. Lift the cover straight up and off.
To Remove the Hopper Cover
heat shield
screw
1. Loosen the two captive screws along the bottom of
the hopper cover and the screw near the top corner of
the access cover.
2. Remove the screw that attaches to the heat shield.
3. Lift the hopper cover up and off.
To Remove the Hopper Lid
1. Remove the four flat head screws which are located one on each side of the lid base.
2. Pull the lid up to remove.
a. Lid Seal Replacement: In older units, a lid seal
(o-ring) is located inside the lid base. Remove the old
seal, which rests against the top of the hopper. Install
the new seal into the groove provided.
Primary
Filter
Overtemp
Thermostat
corner screw
Pump Enable Thermostat
Access Cover
Hi-Temperature (Overtemp) or Pump Enable Thermostat Replacement
Loosen two captive screws to remove the access
cover.
a. Hi-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:
Remove the two screws which hold the thermostat to
the hopper. De-solder to remove the two wires from
the old thermostat, then re-solder the wires to the new
thermostat.
Hopper
Cover
Hopper
Lid
Lid Seal
(obsolete - in
older units
only!)
Page 8-2
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
To Access the RTD Sensors
Remove the pump and electronics cover.
a. RTD for ASU: Each ASU has one RTD located
between the two cast-in heaters. This RTD slips into
its adapter and is easily plugged in electrically.
b. RTD for Drop-in Grid: If the optional drop-in grid
is installed, there is a second RTD located in the grid.
This RTD slips into its adapter and is easily plugged
in electrically.
Heater
Sensor
To Access the Electrical Components (See illustration
on page 10-3)
1. Verify again that the main power is OFF. Remove
the pump and electronics cover.
2. Remove the screw located on the top of the front
end cover which allows it to fully open on its hinge.
a. Main On/ Off Switch Replacement: Located on
the control panel. Open the two snaps on the circuit
breaker cover. The switch is freed via two screws
from the front, and is removed through the back.
b. Fuse Replacement: The Power PCB and (optional) Auxiliary PCBs contain 6.3 amp fuses which
can be accessed without removing the boards from
the ASU. These pcbs are mounted onto the base plate.
c. Relay Replacement: Located on panel divider on
ASUs with grids and/or auxiliary wattage, it is removed with two M4 screws.
d. Printed Circuit Board Replacement: Reference
the section entitled “Handling Printed Circuit Boards”
on page 7-3.
Remove the metal cover to access the Operator’s and
CPU Boards. The (optional) RTD Expansion PCB is
mounted onto the CPU Board. The (optional) Motor
Control Interface and Pressure PCBs are mounted
onto the the back of the metal cover. The Power PCB
and (optional) Auxiliary PCBs are mounted to the
ASU’s base plate. The Motor Speed Control and the
(optional) KBSI PCB are on the panel divider. The
diagram at right shows the Power Board’s harness
connects.
Notes: the fuses (on the Power and Auxiliary boards)
Motor
Control
Interface
PCB
Pressure PCB
metal cover
CPU PCB
Disconnect line-in
Disconnect
line-out
Operator
PCB
Remove screws
from front of
On/Off switch
Panel
Divider
Harness to:
KBSI PCB
Motor
Speed
Control
Hose 2
Hose 1
Hopper
Pump Relay
Fuses
Hopper
Hose 1
Hose 2
Pump
Power Board
Auxilary PCB (up to 3)
Page 8-3
Revised 4/08
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
are the only customer-replaceable parts on the PCBs. For replacement of the Scheduler’s Lithium
battery, return the CPU board to ITW Dynatec.
DANGER HOT SURFACE/ HIGH VOLTAGE
If the pump is not operable but the heating system will function, raise the
temperature of the application system to the operating temperature to aid in the
pump disassembly process. Otherwise, a 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.
To Access the Pump or Motor (See illustration on page
10-21)
Remove the pump and electronics cover. Remove the
access cover. Remove the screw located on the top of
the front end cover which allows it to fully open on its
hinge. Turn off the filter shutoff valve.
a. Piston Pump Removal:
1. Turn OFF air pressure, then disconnect the air line
from the solenoid valve mounted on the top of the
airmotor.
2. Disconnect the harness that runs from the solenoid
to the Power PCB. Disconnect the ground wire.
3. Remove the four 10mm nuts lockwashers and flat
washers that connect the pump to the hopper, using a
special thin wall deep socket.
4. Remove the pump/ airmotor assembly from the
end of the unit.
To re-assemble: tighten the pump assembly nuts into
the hopper. Torque should be approximately 40.7 Nm
(30 foot/lbs) at room temperature. With pump and
hopper at 177°C (350°F), the maximum allowable
torque on pump assembly nuts is 33.9 Nm (25 foot/lbs). A Piston Pump Rebuild Kit is available.
Air Fttings
Nuts
Piston Pump
Gear Motor
Bracket
Bolt to
Gear Motor
Clutch
Nuts
Gear Pump and Motor Removal:
1. Disconnect the motor electrically from the ASU by
disconnecting up to three wires (one wire per phase)
that connect to the Motor Speed Control PCB and one
ground wire. Remove the bolts and lockwashers
which connect the motor to the motor bracket.
2. Remove the four bolts and lockwashers which
connect the motor bracket to the base.
3. Remove the four 10mm nuts and lockwashers that
hold the pump to the hopper, using a special thin wall
deep socket.
4. Disconnect the coupling. Remove the pump
assembly from the end of the unit. To re-assemble: see
notes on allowable torques outlined in item “a” above.
Gear
Motor
Set
Screws
Pump
Power
PCB
Page 8-4
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
c. Pump Seal (O-ring) Replacement:
1. Remove the pump from the ASU (see instructions above,
“a” or “b”).
2. 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).
3. Reference the pump exploded-view illustration (in Chapter
10) for your specific pump.
4. Install the new seal. A Piston Pump Bearing and Shaft Seal
Kit, which contains the pump seal, bearing, lubricant, o-rings
and instructions, is available from ITW Dynatec.
Pump
Pump
Seal
Cast-in Heater
Note on the Cast-in Heaters
The two cast-in heaters installed in the base of the hopper are not replaceable and will last the life
of the ASU.
Re-Assembly Procedures
Unless noted, the S Series ASU’s re-assembly is simply the reverse sequence of the disassembly
procedures. However, the following “cautions” should be followed (whenever they apply) for
proper re-assembly:
CAUTION: In general, all O-RINGS AND SEALS should be replaced whenever
hot-melt equipment is re-assembled. All new o-rings should be lubricated with
o-ring lube (PN N07588).
CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the
pump air supply and on the outlet filter manifold. Apply thread sealant (PN
N02892) whenever tapered pipe threaded parts are re-assembled.
CAUTION: SOME FITTINGS used for adhesive on the ASU have straight threads
and o-ring seals. Use of thread sealant is not necessary with these parts, but the
o-ring seals should be clean and lubricated. Tighten straight-threaded parts and
fittings until their shoulders are firmly seated against the pump body (or other
surface). Excessive torque may damage straight-threaded parts and the use of
power wrenches is not recommended.
CAUTION: HOT-MELT RESIDUE should be cleaned from parts before they are
re-assembled, particularly from threaded parts. As a precaution against adhesive
residue preventing proper re-assembly, threaded parts should always be
re-tightened at operating temperature.
Page 9-1
Revised 6/09
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Chapter 9
AVAILABLE OPTIONS & ACCESSORIES
Pressure Gauge Kit: PN 101175
An optional analog pressure gauge can be mounted on the outlet filter manifold. Reading the
adhesive 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 (see illustration on page 3-6).
Though there is no “dedicated” port for the gauge, ports #2 or #4 are preferred. Fittings are included
in the kit.
Drop-in Grids: PN 106971 (DM S10G) or 106972 (DM S22G / DM S45G)
The drop-in grid is an extra heated grid which is installed near the bottom of the ASU’s hopper. The
additional grid allows faster melting of adhesive for applications requiring higher melt rates and
higher volumes of adhesive.
Filter Options:
100 Mesh Outlet Filter: PN 101247
Some situations call for a finer mesh outlet filter. A “dirty” adhesive or one with a short pot life are
examples. Systems utilizing very high temperatures or systems running in a dusty environment also
benefit from a 100 mesh filter. Standard equipment on Dynamelt is a 40 mesh filter (PN 101246).
Filter Kit PN 114290
To simplify ordering, a Filter Kit is available for the 100-mesh filter which contains a #028 o-ring, a
PN 006C024 filter nut and a PN 101247 100-mesh filter basket.
Pump Options and Accessories:
Piston Pump & Air Motor Assembly, Hot Melt Application: PN 106806
The Dynamelt S ASU is available with a constant-pressure, air-operated piston pump. It provides
smooth output pressure and insures a high pressure adhesive output from a low pressure, compressed air input. A piston pump is superior for intermittent applications which require no volumetric control.
Note: The following piston pump kits may be used with either the PN 106806 or 107880 piston pumps.
Piston Pump Repair Kit: PN 105328
The Piston Pump Repair Kit contains the following items needed to rebuild the 12:1 piston pump:
PN
Description
Qty.
PN
Description
Qty.
L16569
108772
108700
N01703
N01618
N07121
Bearing & Shaft Seal Kit
Adapter Plate O-ring
Lube, Seal, 1/4 oz.
Fitting
Fitting
Ring, Seal, 111
1
1
1
3
1
1
N00183
N01614
N00190
N01702
N00187
069X270
O-ring, 016
O-ring, 910
O-ring, 024
O-ring, 904
O-ring, 020
O-ring, 025
1
1
1
3
1
1
Piston Pump Airmotor Seals Kit: PN 109968
This is a seals and gaskets kit for the piston pump’s airmotor (airmotor PN 109970 or 115038).
Page 9-2
Revised 5/04
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Piston Pump Rebuild Kit: PN 109969
This kit contains a PN 105328 Piston Pump Seals Kit (includes o-rings, piston seals, gaskets, lube and
wear strips), a 109968 Piston Pump Airmotor Seals Kit, a L21189 Inlet Check Valve Assembly and a
L21188 Outlet Check Valve Assembly. Used on airmotor PN 109970 or 105070.
Piston Pump Bearing and Shaft Seal Kit: PN L16569
This kit contains all items needed to replace the piston pump’s shaft seal and bearing, including seals,
o-ring, pump shaft bearing and retaining ring. A seal pedestal and o-ring lubricant are also included.
Gear Pumps
For higher tolerances and precision, several gear pumps are available for the Dynamelt. Gear pumps
give better service for continuous applications or applications which require more control over the volume of adhesive pumped. Gear pumps available are:
Single Pumps:
PN 111253: 0.15 cc/rev single, standard accuracy, cast iron Gear Pump
PN 109908: 0.55 cc/rev single, standard accuracy, cast iron Gear Pump
PN 100860: 1.54 cc/rev single, standard accuracy Gear Pump
PN 100861: 3.18 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 109694: 20 cc/rev single, standard accuracy Gear Pump
PN 108875: 8.5 cc/rev single, high accuracy Gear Pump
PN 084E374: 0.584 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 111254: 0.15 cc/rev dual, standard accuracy, cast iron Gear Pump
PN 109909: 0.55 cc/rev dual, standard accuracy, cast iron Gear Pump
PN 100863: 1.54 cc/rev dual, standard accuracy Gear Pump
PN 100864: 3.18 cc/rev dual, standard accuracy Gear Pump
PN 084E389: 0.584 cc/rev dual, high accuracy Gear Pump
PN 084E432: 1.168 cc/rev dual, high accuracy Gear Pump
PN 108874: 2.920 cc/rev dual, high accuracy Gear Pump
Two Output, Two Filter Manifold: PN 102049
The two 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.
Gear Pump Repair Kit: PN 103151
Contains the following items needed to repair the PNs 100860 thru 100864 and 109908-109909 gear
pumps.
PN
Description
Qty.
PN
Description
Qty.
N00198
018X031
069X061
O-ring
Ball Bearing
Seal
2
5
1
069X064
078F017
078I001
O-ring
Ring, Clip
Key, Woodruff
3
4
1
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 9-3
Revised 5/06
Filter Manifold Assembly w. Dump Valve: PN 112567
A valve allows regulation of adhesive flow for more consistent, instantaneous lay down of glue.
The option includes an outlet filter manifold, filter basket, cover, valve, cover and hardware.
Available for piston pump models or for single-output gearpump models.
Pressure Transducer Assembly: PN 107253
A pressure transducer is an electronic probe that allows the melted adhesive’s pressure to be
processed by the ASU’s control system. They are used to monitor system operating pressures and
their limits. They troubleshoot clogged nozzles and filters.
Level Control Assembly: PN 107193
This device informs the operator, via a message on the DynaControl’s readout and an audible signal,
that the hopper’s adhesive level is low. It may also be wired to stop production, turn on an alarm
light or signal a PLC at a low adhesive level.
Flow Control: PN 104890
Used primarily on piston pump models, this valve (installed between the outlet filter manifold and
the hose) adjusts adhesive output, resulting in a more even flow.
High Temperature Operating Kit: PN 107162
To allow operation with temperature setpoints up to 232°C/ 450°F. Included are high temperature
o-rings, pressure valve, overtemp switch and a vented cover kit containing two fans.
UFD Kit: PN 107356
The installation of this kit converts the standard ASU into an “auxiliary wattage” model in order to
accomodate ITW Dynatec’s adhesive fiberizing technology. This technology results in higher
performance with up to 40% adhesive savings.
APS (Automatic Purge System) Model
A Dynamelt S APS model is available in 10kg and 22kg hopper sizes. The APS model is equipped
with all the pneumatic and controller safety devices necessary to melt polyurethane adhesives. PUR
adhesives produce extremely strong bonds and are environmentally desirable, however they require
the elimination of moisture in the ASU.
Motor Enable Relay Kit: PN 109437 (gearpump models only)
Allows use of hand-held applicators.
Piston Pump Line Speed Tracking:
Line Speed Tracking Assembly: PN 112769
For customers who desire line speed tracking capability on their piston pump units. The assembly
controls line speed changes and adjusts adhesive volume output proportionately. Components are
mounted externally within a box on the ASU and are controlled through the Dynacontrol controller.
Line Speed Tracking Kit: PN 113376
For customers who desire line speed tracking capability on their piston pump units. The assembly
controls line speed and adjusts adhesive output using a signal isolator and an I/P transducer. Components are mounted internally and are typically controlled through a parent machine.
Page 9-4
Revised 10/13
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Pneumatic Pressure Relief Valve Retrofit Kits:
PN 116620 Retrofit Kit for Piston Pump ASUs
PN 116621 Retrofit Kit for Gear Pump ASUs
PN 116707 Retrofit Kit for Gear Pump ASUs with Dual Filter Manifold
ITW Dynatec’s PN 115540 Pneumatic Pressure Relief Valve Assembly (contained in the above
kits) automatically relieves adhesive pressure whenever the unit is turned off or when pneumatic
air is disconnected. The retrofit kits are detailed in Chapter 10.
Pressure Relief Valve Repair Kit: PN 109982
Contains the following three items needed to repair the PN 101840 or PN 115540 Pressure Relief
Valve: a PN N00179 O-ring 012, a N01601 O-ring 908 and a N05733 Backup Ring, 012.
DynaControl Options:
Pendant Control & Holder: PN 108121
Pendant Control Panel Kit: PN 106961
The Pendant Control option gives the DynaControl keypad mobility via an up to 30 meter (100 ft)
cable. The Pendant Control Panel Kit replaces the standard built-in keypad. An optional standby
re-set switch and on/off light can be mounted on the front panel.
Remote Multi-line Pendant Assembly PN 109695
The Remote Pendant Assembly allows the operator to view multiple lines of data (temperature
setpoints, motor information and other parameters) on the controller readout. The assembly is
supplied with a twenty-foot cable.
Seven-Day Scheduler: PN 107182
This option enables the DynaControl to provide scheduling of ON and OFF times for
the Dynamelt ASU system at the keypad (see pushbutton icon at right). Up to ten
events may be scheduled. It therefore allows the operator to program ON and OFF heating cycles
which coincide with his production schedule throughout the work week. The scheduler helps conserve electricity usage and functions also as an additional safety feature.
Digital RPM Readout: PN 106390
This option provides a DynaControl display of actual pump revolutions per minute. No programming is necessary.
PN 107077 Encoder Assembly: a device which measures and displays (on the DynaControl) the
pump speed.
Line Speed Tracking for Gear Pump Models
This option allows the speed of the motor and ASU to follow the speed of a production line via a
reference voltage input. One of the following devices must be installed:
PN 015D050 Tach Generator: a mechanically operated device which produces a reference
voltage that allows the ASU’s gear pump to track a parent machine’s production line speed.
PN N06642 Signal Isolator: a device which conditions a parent machine’s production line’s DC
speed voltage or 4-20 mA current reference to allow the ASU’s gear pump to track line speed.
See Appendix for details.
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Page 9-5
Revised 9/13
Pressure Display: PN 106964 and one PN 104876 for each zone desired (Dual Gear Pump Models)
The pressure board option enables the controller (keypad icon illustrated at right) 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 an electronic pressure-reading
device (for ex.: a transducer) connected to the filter manifold.
System Status Lights:
PN 104280 Three-Tier Light
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 controller, the
lights illuminate to indicate “Power On”, “Ready” and “Alarm”. An audible signal accompanies the
“Alarm” light. The alarm may be wired to indicate low adhesive level.
PN 111608 Five-Tier Light
Similar in function to the three-tier status light, the five-tier light gives additional monitoring capability for “Standby” and “Low Adhesive Level”.
DynaControl Calibration Verification Kit: PN 110139
The calibration kit enables the user to verify the temperature accuracy of the controller. It contains all
adapters, cables, leads, resistors and clips needed, as well as instructions.
EtherNet/ IP Adapter Kit: PN 110772
This kit connects the DMS ASU to an EtherNet network so that all system parameters can be transmitted and received, allowing full remote operation of the ASU.
ASU Stand: PN 110334
A sturdy stainless steel, approx. 34”l x 20”w x 36”h, stand of welded construction is available for the
Dynamelt S. The ASU is mounted to the stand and the stand may be bolted to the floor. The stand’s
open construction, with shelves (for pattern controllers, etc.) allows access underneath the unit.
ASU Roll Cart: PN 108838
A gray enamel, flush top cart, of welded steel construction (24” x 30”, 1800 lb. capacity). Includes
two rigid and two locking 5” casters.
Water-Resistant ASU Assembly: PN 111301
Upgrade Kit only: PN 111302
In order to be water and dust resistant, the Dynamelt S Water-Resistant ASU may be ordered. Existing
ASU’s may be retrofitted with the installation of a water-resistant upgrade kit which uses seals and
stainless steel fasteners.
Page 9-6
Revised 11/13
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Recommended Service Parts List
Category Part No.
108689
N02937
L15653
L16569
103151
109982
100746
100747
100748
048H384
108566
104117
102762
107183
104166
036B015
807729
069X064
N00196
069X058
N00181
N00192
N06006
069X058
N00179
N00190
N00188
069X240
115283
Description
Qty.
Silicone Lubricant, O-ring, Dow 112, 0.25 oz
Thread Sealant.
Kit, Flushing Fluid, 1 gallon
Piston Pump Bearing & Shaft Seal Kit
Gear Pump Repair Kit
Pressure Relief Valve Repair Kit
Main Power Switch, 120v/240v, 1 Ph, 30 amp
Main Power Switch, 380v, 3 Ph, 30 amp
Main Power Switch, 240v, 1 Ph, 50 amp
Solid State Relay
Fuse, T6.3AF 5x20, fast (PC Boards)
Fuse, 6.3A, MET, 5mmx20mm (Power PCB)
1 amp Fuse (Motor Control Interface PCB) (gear pump models)
RTD Sensor, Hopper
Over-Temp Thermostat & Insulator
Pump Enable Thermostat
Pump Shaft Seal (Zenith/ TSHA pumps)
O-ring 041, Pump to Hopper (pump seal, Dynatec pumps)
O-ring 111
O-ring 028 (filter plug)
O-ring 014 (outlet filter/ manifold)
O-ring 032 (outlet filter/ manifold)
O-ring 224 (Digital RPM Readout option)
O-ring 028 (Zenith Pump adapter)
O-ring 012 (Zenith Pump adapter)
O-ring 024 (Zenith Pump adapter)
O-ring 022 (Zenith Pump adapter)
O-ring 036 (Zenith Pump adapter)
Motor Speed Control Kit, Y
2
1
1
1
1
1
1
1
1
1
5
1
1
1
1
1
2
2
2 to 6
1 or 2
2 or 4
2
1
1
2
1
1
1
1
CPU PCB
Power (I/O) PCB, 240v Replacement Kit
Power (I/O) PCB, 120v
Auxiliary Power PCB
Motor Control Interface PCB, 240v (gear pump models)
Motor Control Interface PCB, 120v (gear pump models)
Operator Panel PCB
PSI PCB (option)
1
1
1
1
1
1
1
1
Filter Basket, 40 mesh/420 micron
Filter Basket, 100 mesh/149 micron (optional)
Primary Filter Assembly (for DM S05 & S10)
Primary Filter Assembly (for DM S22 & S45)
2 or 4
2
1
1
Printed Circuit Boards:
113006
115578
109861
106095
110090
109862
107032
106147
Filter Replacements:
101246
101247
102751
102752
Page 10-1
Revised 3/05
ITW Dynatec c. 1999
DYNAMELT S ASU Manual #20-31
Chapter 10
COMPONENT ILLUSTRATIONS & BILLS OF MATERIAL
WARNING
All parts must be periodically inspected and replaced if worn or broken. Failure
to do this can affect equipment’s operation and can result in personal injury.
Chapter Format
This chapter contains the component illustrations (exploded-view drawings) for each assembly of
the DYNAMELT S SERIES ASU. These drawings are useful for finding part numbers as well as
for use when maintaining or repairing the unit.
Note: most common nuts, bolts and fasteners can be obtained locally at your hardware store. Specialty fasteners are available by contacting Dynatec’s Customer Service.
Page 10-2 Component Illustrations & BOM’s
Revised 1/11
c. 1999
DYNAMELT S ASU Manual #20-31
21
5
25
28
21
24
17
27
24
16
10
3
15
13
10
12
3
32
8
22
14
To air
filter
kit
28
9
23
20
21
4
7
6
1
11
5
18
19
3
26
2
27
28A 14
Piston Pump
Assembly
Piston Pump & Air Motor Assemblies #106806 and #115040
Item
Item Number
Description
Qty
1
109970
Air Motor Assembly (replaces 105070)
1
115038
Air Motor Assembly (low pressure)
1
2
NPN
2” Pump Piston
1
3*+
NPN
2” Piston Seal 60030-4238
1
4*+
NPN
2” Wear Strip 60624
1
5*+
108379
Valve Gasket
1
6
NPN
2” Strke Pump Tube
1
7*+
NPN
Pump Gasket A01046-02 (old-style pump only)
1
8
NPN
Mounting Flange A01046-11
1
9
105726
Mounting Flange with Float Seal
1
10*+
NPN
O--ring, -224
1
11
104437
Valve (with gasket 113007)
1
115037
Valve, Low Pressure
1
12
106931
Valve Manifold
1
13
109953
Pump Shaft (for old 105070 assembly)
1
14*+
NPN
Gasket Air Motor Cap
1
15
L16534
Piston, Pump Shaft
1
16*
N06918
Bellevue Washer, 1/4
1
17*
N01739
1/4-20 x .62 HHC Screw
1
18
072X254
Solenoid Nipple
1
19
030B108
Breathing Vent
1
20
111225
Solenoid Assembly, 240v
1
21
O-ring, -011
4
22
106613
4 Pole Connector
1
23
106933
Ground Wire (included with item 20)
1
24
N06913
O-ring, -118
1
25*+
NPN*
Seal, Rod Wiper, 625 Viton
1
26
115497
Street Elbow, 1/8 NPT
1
27
N06436
Elbow, 1/4 tube, Push-in x 1/8
2
28*
L16569
Seal And Bearing Assembly
1
28A
N06506
Airline Plug (used only on ASUs equipped with a mechanical pressure relief valve)
1
Note: *These items are included in Piston Pump Rebuild Kit PN 109969 (replaces 105330**).
cont.
Note: +These items are included in Air Motor Rebuild Kit 109968
c. 1999
DYNAMELT S ASU Manual #20-31
32
Component Illustrations & BOM’s Page 10-3
Revised 1/11
29
40
39
33
34
30
31
35
30
37
31
38
36
43
41
32
42
30
45
44
46
31
44
46
48
47
45
43
Piston Pump
Assembly
Piston Pump & Air Motor Assemblies #106806 and #115040 (continued)
Item
Part Number
Description
29
100750
Adapter Plate
30 *
N01703
Plug Fitting
31 *
N01702
O-ring , -904
32
101156
M6 x 20 SHC Screw (Note: torque to 90 in/lbs (10nm))
33 *
108772
Pump Seal
34
100344
Piston Pump Body
35 *
N01614
O-ring, -910
36 *
N00190
O-ring, #-024
37 *
N01618
Plug Fitting
38*
N00183
O-ring, -016
39 *
107011
Outlet Check Valve, Service Assembly (available as an assembly only)
40
N07121
Square Seal, -111
Qty.
1
3
3
8
1
1
1
1
1
1
1
1
41 *
42
107010
N00187
Inlet Check Valve Assembly (available as an assembly only)
O-ring, -020
1
1
43
44
45
46
47
48
N07677
100380
N06430
N01067
101888
105113
Fittings For Coalesing Air Filter
TFE Tubing, .250 Diameter
Filter Assembly
Brass Male Connect Fitting
Brass Nipple
Air Block
M4 X 8 SHC Screw
2.5’
1
1
2
1
2
Note:
*These items are included in Piston Pump Rebuild Kit 109969 (replaces 105330).
c. 1999
DYNAMELT S ASU Manual #20-31
Page 10-4 Component Illustrations & BOM’s
Revised 1/09
Bill of Materials for Dynamelt S Cabinet Assembly
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part Number
100616
100617
110333
100889
100890
100891
101889
106375
102079
106090
106089
111268
100887
100888
115051
107389
100749
107389
102058
109796
103289
103290
Description
Front Cover End
Rear Cover End
Rear Cover End (for use with Nordson connectors)
Hopper Cover, DMS05
Hopper Cover, DMS10
Hopper Cover, DMS22
Hopper Cover, DMS45
Heat Shield
Key Pad Label
Base, Model 22 & 45
Base, Model 05 & 10
Pump and Electrical Cover
Access Cover, DMS10
Access Cover, DMS22/DMS45
M4 x 6mm Screw
M4 x 8mm Screw
Hinge
M4 x 8mm Screw
Hopper Collar Gasket, DMS05/10 (included in Lid Assembly)
Hopper Collar Gasket, DMS22/45 (included in Lid Assembly)
Cover, Hose, Dual Filter (option)
Cover, Hose, Single Filter
Lid Assembly (available as an assembly only) DMS05/DMS10
Lid Assembly (available as an assembly only) DMS22/DMS45
Qty.
1
1
1
1
1
1
1
1
1
1
1
4
4
2
1
1
1
1
1
1
1
c. 1999
DYNAMELT S ASU Manual #20-31
Component Illustrations & BOM’s Page 10-5
Revised 10/08
5
4
13
1
8
10
6
18
7
16
12
13
14
3
9
15
2
11
17
Component Illustration: Dynamelt S Cabinet Assembly
c. 1999
DYNAMELT S ASU Manual #20-31
Page 10-6 Component Illustrations & BOM’s
Revised 1/12
Bill of Materials for DMS Drive Section
Item No.
Part Number
Description
Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
107084
109889
101156
104662
105865
107671
N00697
106935
106936
107254
105818
102172
105134
L00475
N00688
105061
105126
107352
Drive Section, 240v/380v or
Drive Section, 120v
M6 x 20 SHC Screw
M6 x 16 SHC Screw
M6 Hex Nut
5/16 Flat Washer
1/4 Lock Washer
Motor Mount Plate
M6-1.0 x 45mm HHC Screw
Gear Motor, 240V, 3PH, 0.25 HP
Motor Mount Bracket
Coupling
Spacer
Insulator Washer
Washer
Stud
M8 Nut
Insulation Barrier, Piston Pump
4
5
16
12
12
1
4
1
1
1
4
4
4
4
4
1
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
106390
104648
105101
N00688
N00697
107077
104647
N00853
N00692
104649
N06006
103470
106111
103121
104651
104653
Digital RPM Readout Kit (Option)
Encoder Bracket
M6--1.0 x 16mm HH Screw
1/4 Flat Washer
1/4 Spring Lock Washer
Encoder Assembly, DMS
Encoder Mount Arm
4-40 x .375 Fil Head Screw
#04 Spring Lock Washer
Encoder Drive Wheel
O-ring, -224
M3-0.5 x 5mm Flat Point Set Screw
M4-0.7 x 12mm Button Head Screw
M4-0.7 Hex Nut
Torsion Spring, .56 OD x .063d
M5 Shoulder Screw, 6 x 30mm
1
2
3
2
1
1
4
4
1
1
1
1
2
1
1
106806
107889
N00188
Piston Pump
Piston Pump (Option, Lotion)
O-ring, -022
Base (shown for reference)
1
1
1
1
32
33
34
c. 1999
DYNAMELT S ASU Manual #20-31
Component Illustrations & BOM’s Page 10-7
Revised 1/12
31
17
30
22 21
3
1
4
19
20
18
26
3
28
27 25
29
23 24
Digital RPM Readout Option
2
4
5
9
To
Panel Divider
3
16
5
6
2
4
5
Gear Pump
Option
32
10
Piston Pump Option
8
7
5
4
33
34
12
13
14
11
Component Illustration: DM S Drive Section
15
c. 1999
DYNAMELT S ASU Manual #20-31
Page 10-8 Component Illustrations & BOM’s
Revised 9/10
Bill of Materials for Typical Front Panel Assembly
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Part Number
Description
Qty.
107032
Operator Panel Board
1
104119
104133
105051
106003
106092
113006
110090
109862
106147
102762
105163
Insulation Cover
#4 x 5/8 type 25 Screw
#4 x 1/4 type 25 Screw
Key Pad Cover
Key Pad Insulation
Control Processor Board (CPU)
Motor Control Interface Board, 240v/380v (option) or
Motor Control Interface Board, 120v (option)
Pressure (PSI) Board (option)
1 Amp. Fuse
M3 x 8mm Flat Head Screw
1
4
10
1
1
1
1
1
1
1
2
111116
111117
110772
111497
105605
105606
108121
103340
102757
107176
103244
105056
100616
104100
100746
100747
100748
108116
108115
108048
105327
078A399
N00702
101627
109695
109647
Front Cover Replacement Kit, Standard
Front Cover Replacement Kit with Pendant (without light)
Front Cover Ethernet/ IP (not shown)
Front Cover Ethernet/ IP with Pendant Kit (not shown)
Pendant Power On Light (option)
Pendant Standby Reset Switch (option)
Pendant Control (option)
Pendant Control Bracket (option)
Cable 3m 3m (10’)
Cable 3m 6m (20’)
Cable 3m 12m (40’)
Cable 3m 30m (100’)
Front Panel (part of one of the front panel kits)
Main Power Switch, 240v, 3 Phase, 20amp
Main Power Switch, 120v/240v, Single Phase, 30amp
Main Power Switch, 380v-400v, 3 Phase, 30amp
Main Power Switch, 240v, Single Phase, 50amp
PCB Filter Kit
Mounting Bracket
PCB AS, Filter
M3 Int. Tooth Lock Washer
6-32 x 1/4 Button Head Screw
#6 Int. Tooth Lock Washer
M3-0,5 x 4mm Phil. Head Screw
Pendant Control, Multi-line, Assembly (option)
Ribbon Cable Assembly, 20 ft. (not shown)
1
1
104123
112380
112381
112382
110237
106424
M4 Male/ Female Standoff
8-32 x 1/2 HH Nylon Screw
Standoff, Hex, 8--32 x 1.75, Nylon
Standoff, Hex, 8--32 x .88, Nylon
Standoff, Hex, M4 x 28
M4 x 8 Button Head Screw
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
4
3
2
1
4
4
c. 1999
DYNAMELT S ASU Manual #20-31
Component Illustrations & BOM’s Page 10-9
Revised 12/06
11
12
16
10
41
7
Front View of
Control Panel
17
9
20 21
18
19
22
37
Optional Pendant Control
8
38
or
Optional Multi-line Pendant
Control
39
37
2
32
6
40
36
4
24
31
27
28
25
29
30
5
23
26
13
Component Illustration: Typical Front Panel Assembly
c. 1999
DYNAMELT S ASU Manual #20-31
Page 10-10 Component Illustrations & BOM’s
Revised 7/10
Bill of Materials for Internal Electrical Components
Item No.
1
2
3
4*
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Part Number
048H384
101304
106387
109888
110331
108566
104117
107193
110954
108500
105199
106090
106089
106094
106095
106375
106376
106435
106436
106528
106529
106960
N06642
106615
102446
106977
106976
100617
107466
106978
106111
107389
115138
not used
115153
106148
109862
109344
109345
106111
105164
107531
106157
105562
107208
109813
107391
103404
106812
Description
Qty.
Solid State Relay, DUAL 40A240VAC 80AMA
1
Receptical Hole Cover
(qty. option)
Harness Assembly, Hose
Harness Assembly, Hose 120v
Harness, (Nord. Cont.)
Fuse, 6.3A, MET, 5mm x 20mm (Fast Blow)
Fuse, 6.3A, MET, 5mm x 20mm (Slow Blow) (use in F1 pos. only)
Level Control (option)
M6 x 3/8, PHC Screw
(qty. = qty. of recepticals)
M3 Kep Nut
(qty. = qty. of receptical covers)
3/4 NPT Clamp Type Connector
1
Base Plate,DMS 22/45 or
1
Base Plate, DMS 05/10
Dynamelt Power PC Board (available as kit only, PN 115578)
1
Auxiliary Power PC Board (option)
Heat Shield Panel
1
Pump And Electrical Divider Panel
1
Heat Sink, (part of Power Board)
1
Heat Sink (part of Auxiliary Power Board)
Thermal Pad, Power PCB
1
Thermal Pad, Auxiliary PCB (option)
Front Cover Kit Standard
1
Signal Isolator PC Board, #KBSI--240D (option)
1
Velcro Tabs
4
Screws M4--0.70 x 10mm for velcro tabs (105164 flat washer)
4
Trigger Park PC Board
1
Trigger Relay PC Board, 1 Hose, 240v (option)
Back Cover End
1
Ground Terminals
Fuse, 2.5amp, GMC, Metric
1
Filter, RFI (EMI) Line, 240v
1
M4 x 0.7 x 12 Button Head Screw
4
Screw M4 x 8 w/ Lockwasher
2
Motor Speed Control, AC, 240v/380v
1
Mounting Plate, Yaskawa Speed Control
Motor Interface PC Board, 240v/380v (see Electrical Assembly) or
Motor Interface PC Board, 120v (see Electrical Assembly)
Motor Speed Control Mount Bracket
Nut Plate
BHSC Screw, M4 x 12mm, Black Oxide
#8 Flat Washer
M4--0.7 x 20mm, Black SHC Screw
M4 Lock Washer, Int. Tooth
Ground Lug 8-4 GA
M5X0.8 x 8mm, Zinc, Philps Pan Head Screw
M4 x 0.7 x 12mm Flat Head Screw
Nut, Keps, M4
M3 x 10mm SHC Screw
Terminal, Faston Tab, .25”
1
1
1
1
1
4
2
2
2
1
1
4
2
4
4
* The 108566 fuses should be used in the heater circuits. The 104117 fuse should be used in the F1 position on the power board.
c. 1999
DYNAMELT S ASU Manual #20-31
Component Illustrations & BOM’s Page 10-11
Revised 4/09
29
30
5
42
34
13
32
28
27
22
26
23
43
19
36
35
1
39 38 37 25
4
20
14
10
16
21
4
15
12
11
17
44 45
24
18
40
41
9
8
2
7
3
Component Illustration: Internal Electrical Components
6
Page 10-12 Component Illustrations & BOM’s
Revised 7/09
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for DM S5 & S10 Filter And Melt Section
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Part Number
100436
100435
N00094
104166
036B015
107183
not replaceable
101175
101174
104325
not used
103330
101624
N07830
102987
106971
036H003
107183
036E043
N00192
105149
108297
105100
N00704
N00181
N00210
107525
102751
104890
105603
105614
103283
105602
100896
102049
101840
006C024
069X058
101246
101247
101625
101624
104852
N00192
101833
N00754
105110
106182
N00181
N08024
N00196
107193
108635
108636
102411
105097
Description
Hopper, DM S10
Hopper, DM S05
Plug, Fitting, st thd, skt, #12
Mechanical O/T Thermostat Assembly
Pump Enable Thermostat
Temperature Sensor, RTD, PT 100
Cast-In Heater
Pressure Gauge Assembly (Option)
Pressure Gauge (option)
Fitting Adapter, #6 x 1/4 NPT (option)
Fitting, Adapter,1/4 BSPP x 1/4 NPT
Fitting, #6 JIC x 1/4 BSPP (includes N00196 O-ring)
Fitting, 90 deg., #6 JIC Male x #6 JIC Female
Insulator Cuff
Grid Group (Option For DMS10 only)
Drop-In Grid
Temperature Sensor, RTD, PT 100
Sensor Adapter
O-ring, #-032
Block-off Plate (used in place of grid)
M8--1.25X20 HH Screw
4-40 x 1/2 Phillips Head Screw
Lock Washer, #10
O-ring, #014
O-ring, -912 (included with filter shut-off)
Stand-off Support, 2.75”
Filter Shutoff Assembly (available as an assembly only)
Flow Control Assembly (option)
1-2 Hose, Single Pump, Filter Manifold Assembly (Standard)
4--6 Hose, Single Pump, Filter Manifold Assembly (Optional)
4--6 Hose, Dual Pump, Filter Manifold Assembly (Optional)
Filter Manifold (for assembly 105603)
Filter Manifold (for assembly 105614)
Filter Manifold (for assembly 103283)
Pressure Relief Valve
(Qty 2 for 103283)
Filter Nut
(Qty 2 for 103283)
O-ring, -028
(Qty 2 for 103283)
Filter Basket, 40 mesh/420 micron
(Qty 2 for 103283)
Filter Basket, 100 mesh/149 micron (option)
1/4-18 BSPP Plug
(105614 Qty 2/ 103283 Qty 4)
BSPP Hose Fitting
(105614 Qty 4/ 103283 Qty 2)
Drain Plug
O-ring, #-032
10-32 x 1/2 Tamper Proof Screw
1/4 Level Seal Plug
M8 x 55mm SHC Screw (used with 105603/ 105614 single)
M8 x 90mm SHC Screw (used with 103283 dual)
O-ring, -014
Cap Nut
O-ring, -111
Level Control (option)
Bracket , Sensor Guard
Screw, Shoulder, M6 x 6 x 25
Cap, Hi-temp.
SH Set Screw M6 x 30mm
Qty.
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
2
41
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
3
3
2
2--4
2--4
1
1
3
4
1
Component Illustrations & BOM’s Page 10-13
Revised 7/09
c. 1999
DYNAMELT S ASU Manual #20-31
Optional
Drop-In Grid
The DMS 05
hopper is shorter
14
18
15
22
16
20
21
17
or
17
24
7
Optional Pressure
Gauge Assembly
1
8
8
10
19
11
49
50
12
2
23
48
11
13
34
35
47
36
5
44
33
44
6
25
or
42
27
42
30
37
23
43
51
42
40
28
31
3
4
26
39
or
29
32
37
38
45
46
Component Illustration: DMS05 & S10 Filter & Melt Section
41
Page 10-14 Component Illustrations & BOM’s
Revised 7/09
c. 1996
DYNAMELT S ASU Manual #20-31
Bill of Materials for DM S22 & DM S45 Grid, Melt, Filter and Pressure Relief Section
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Part Number
100437
101891
109887
104166
036B015
not replaceable
107183
N00094
106972
104802
N00192
106174
108297
105149
N07402
107183
N00181
N00210
107526
101175
101174
104325
not used
103330
101624
N07830
102987
102752
104890
105603
105614
103283
105602
100896
102049
101840
006C024
069X058
101246
101247
101625
101624
104852
N00192
072X053
101833
105110
106182
N00181
N08024
N00196
107193
108635
108636
102411
Description
Hopper, DM S22, 240v/380v or
Hopper, DM S45, 240v/380v (note: this hopper is not shown) or
Hopper, DM S22, 120v
Mechanical Overtemp Thermostat Assembly
Pump Enable Thermostat
Cast In Heater
Temperature Sensor, RTD, PT 100 (option)
Fitting, Plug, #12
Drop-In Grid (option)
Drop-In Grid (option)
O-ring, -032 (option)
Sensor Adapter (option)
M8--1.25X20 HH Screw
Block-off Plate (used in place of grid)
5/16-18 x 3/4 Button Head Screw (used with block-off plate)
Temperature Sensor
O-ring, #-014
O-ring, -912 (included with Filter shut-off)
Stand-off Support, 3”
Pressure Gauge Assembly (option)
Pressure Gauge (option)
Fitting Adapter, #6 x 1/4 NPT (option)
Qty.
1
1
1
1
1
4
1
1
1
1
1
4
1
4
2
4
1
1
1
1
Fitting, Adapter,1/4 BSPP x 1/4 NPT
1
Fitting, #6 JIC x 1/4 BSPP (includes N00196 O-ring)
1
Fitting, 90 deg., #6 JIC Male x #6 JIC Female
1
Insulator Cuff
1
Filter ShutOff Assembly
1
Flow Control Assembly (option)
1
1-2 Hose, Single Pump, Filter Manifold Assembly (standard)
1
4--6 Hose, Single Pump, Filter Manifold Assembly (option)
1
4--6 Hose, Dual Pump, Filter Manifold Assembly (option)
1
Filter Manifold (for assembly 105603)
1
Filter Manifold (for assembly 105614)
1
Filter Manifold (for assembly 103283)
1
Pressure Relief Valve
(Qty 2 for 103283) 1
Filter Nut
(Qty 2 for 103283) 1
O-ring, -028
(Qty 2 for 103283) 1
Filter Basket, 40 mesh/420 micron
(Qty 2 for 103283) 1
Filter Basket, 100 mesh/149 micron (option)
1/4-18 BSB Plug
(105614 Qty 2/ 103283 Qty 4) 2
BSB Hose Fitting
(105614 Qty 4/ 103283 Qty 2) 1
Drain Plug
1
O-ring, #-032
1
1/4 Level Seal Plug
4
10-32 x 1/2 Tamper Proof Screw
1
8 x 55mm SHC Screw (filter block to hopper)
3
M8 x 90mm SHC Screw (used with 103283 dual)
3
O-ring, -014
2
Cap Nut
4-6
O-ring, -111
4--6
Level Control (option)
1
Bracket , Sensor Guard
1
Screw, Shoulder, M6 x 6 x 25
3
Cap, Hi-temp.
4
Component Illustrations & BOM’s Page 10-15
Revised 7/09
c. 1996
DYNAMELT S ASU Manual #20-31
9
13
Optional Drop-In Grid
11
12
5
or
8
7
16
14
8
Pressure Gauge
Assembly Option
17
18
1
18
15
20
6
21
21
22
23
33
10
48
49
34
35
47
46
43 43
5
32
4
40
29
26
40
15
42
50
2
40
24
3
39
27
30
38
28
41
or
25
31
36 37
44
45
Component Illustration: DM S22 Melt, Grid, Filter and Pressure Relief Section
(Note: The DM S45 is not shown in this illustration)
Page 10-16 Component Illustrations & BOM’s
Revised 3/05
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for Optional Bypass Filter Manifold Assembly 109779
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part Number
Description
109780
Manifold Filter Block
N01124
1/16-27 NPT Level Seal Plug
N00754
1/4-18 NPT Level Seal Plug
N00181
O-ring, -014, 75 Duro Viton
N00192
O-ring, -032, 75 Duro Viton
104852
M10 x 1.5 Filter Drain Plug
101833
10-32 x 1/2 Tamper Proof Screw
101625
1/4 BSPP Hex Socket Head Plug Fitting (all are not shown)
101624
#06 37° SAE x 1/4 BSPP Straight Fitting
N00196
O-ring, -111, 75 Duro Viton
N08024
#06 37° SAE Fitting Cap
101247
Filter Basket, 100 Mesh
101246
Filter Basket, 40 mesh (option)
006C024
Filter Nut
069X058
O-ring, -028, 75 Duro Viton
101840
Pressure Relief Valve
109781
Manifold Bypass Assembly
111821
Bypass valve Body
111822
Bypass Valve Stem
N00177
O-ring, -010
N00360
O-ring, -906
111823
M8 x 1.25 Hex Nut
001U002
Lube Silicone (Not Shown)
109791
Manifold Dump Valve Plug Assembly
109792
Dump Valve Plug
N00183
O-ring,-016, 75 Duro Viton
N00179
O-ring, -012, 75 Duro Viton
001U002
Lube, Silicone, Dow 112 (Not Shown)
106328
M4 x 0.7 x 16mm SHC Screw
001U002
Lube, Silicone, Dow 112 (Not Shown)
107324
Anti-Seize Compound (Not Shown)
N02937
Thread Sealant, w/TFE, Jet-Lube (Not Shown)
109793
M8 x 1.25 x 65mm SHC Screw, Black Oxide
109796
Cover, Output Manifold
Qty.
1
4
4
2
1
1
1
5
6
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
3
1
Component Illustrations & BOM’s Page 10-17
Revised 3/05
c. 1999
DYNAMELT S ASU Manual #20-31
13
14
12
24
21
17
23
20
28
15
18
25
19
5
26
4
2
4
3
2
1
3
2
2
32
3
9
7
6
10
3
11
8
Optional Bypass Filter Manifold Assembly 109779
33
Not to scale
16
Page 10-18 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for 1.54cc/ Rev. , Single Gear Pump Assembly PN 100860
Bill of Materials for 3.2cc/ Rev. , Single Gear Pump Assembly PN 100861
Part Number
#100860 / #100861
Description
Qty.
1
012D079 / 012D077
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & 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
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
104158
M10 Flange Nut
4
17
104072
M10-1.5 x 100 All Thread
4
18
107538
Lockwasher, Hi-clr, M10, Stl
4
Item No.
Component Illustrations & BOM’s Page 10-19
Rev. C Eng: JW Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
Pump # 100860 has one bearing in this shaft
Pump # 100861 has two bearing in this shaft
9
2
1
7
3
6
4
8
12
10
13
5
11
14
16
18
9
10
11
Pump # 100861 has two bearings in this shaft
Pump # 100860 has one bearings in this shaft
15
17
Component Illustration: 1.54cc/ Rev., Single Gear Pump Assembly PN 100860
Page 10-20 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for 4.50cc/ Rev. , Single Gear Pump Assembly PN 100862
Part Number
Description
1
012D072
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100868
Front Plate Assembly
1
8
012D073
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Diameter
4
10
012C018
Drive Gear, 4.5cc/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
104158
M10 Flange Nut
4
17
104073
M10-1.5 x 105 All Thread
4
18
107538
Lockwasher, Hi-clr, M10, Stl
4
Item No.
Qty.
c. 1999
DYNAMELT S ASU Manual #20-31
2
Component Illustrations & BOM’s Page 10-21
Revised 11/12
9
1
7
3
6
12
8
10
4
5
13
11
14
16
18
9
10
11
15
17
Component Illustration: 4.50cc/ Rev., Single Gear Pump Assembly PN 100862
Page 10-22 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for 1.54cc/ Rev. , Dual Gear Pump Assembly PN 100863
Part Number
Description
Qty.
1
012D083
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100866
Front Plate Assembly
1
8
012D082
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Dia.
3
10
012C020
Pump Gear, 1.5cc/rev.
4
11
069X064
O-ring, -041
3
12
078F017
Shaft Retaining Ring
4
13
018X041
Bearing Sleeve, Rear Plate
2
14
100865
Rear Plate Assembly
1
15
101692
M4 x 35 SHC Screw
2
16
104158
M10-1.5 x 100 Flange Nut
4
17
100869
Middle Plate
1
18
N00198
O-ring, -113
2
19
104073
M10-1.5 x 105 All Thread
4
20
107538
Lockwasher, Hi-clr, M10, Stl
4
Item No.
Component Illustrations & BOM’s Page 10-23
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
9
2
1
7
12
3
6
8
11
10
4
17
5
16
18 10
20
13
11
14
9
10
10
11
15
19
Component Illustration: 1.54cc/ Rev., Dual Gear Pump Assembly PN 100863
Page 10-24 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for 3.2cc/ Rev. , Dual Gear Pump Assembly PN 100864
Part Number
Description
Qty.
1
012D088
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100867
Front Plate Assembly
1
8
012D087
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Dia.
5
10
012C019
Drive Gear
4
11
069X064
O-ring, -041
3
12
078F017
Shaft Retaining Ring
4
13
018X041
Bearing Sleeve, Rear Plate
2
14
100865
Rear Plate Assembly
1
15
101691
M4 x 40 SHC Screw
2
16
104158
M10 Flange Nut
4
17
100870
Middle Plate
1
18
N00198
O-ring, -113
2
19
114890
M10-1.5 x 110 Stud
4
20
107538
Lockwasher, Hi-clr, M10, Stl
4
Item No.
Component Illustrations & BOM’s Page 10-25
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
9
2
1
7
3
6
12
8
11
10
4
17
5
18
16
20
10
13
11
14
9
10
10
11
15
19
Component Illustration: 3.2cc/ Rev., Dual Gear Pump Assembly PN 100864
Page 10-26 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
10
2
5
1
11
4
6
12
9
3
5
13
8
7
Bill of Materials for 10cc Single Gear Pump Assembly PN 109690
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part Number
Description
018X031
078F017
078I001
069X061
069X064
108588
101626
109685
109686
109689
109687
109688
069X160
001U002
107538
114890
104158
Ball Bearing, 1/8 Dia.
Snap Ring, 1/2”
Key, Woodruff, #404
Shaft Seal
O-ring, -041
M4x25mm, Blk, SHC Screw
M5-0.8 x 12mm SHC Screw
Pump Body 10cc/rev
Rear Bearing Plate 10cc/rev
Gear 10cc/rev
Drive Shaft 10cc/ 20cc
Driven shaft, 10cc/ 20cc
Shaft Seal Retainer
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 110 All Thread (not shown)
M10 Flange Nut (not shown)
Qty.
6
4
1
1
2
2
4
1
1
2
1
1
1
4
4
4
Component Illustrations & BOM’s Page 10-27
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
12
7
3
6
5
11
9
14
4
2
8
13
10
1
Bill of Materials for 20cc Single Gear Pump Assembly PN 109694
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part Number
109691
109692
109693
109688
109687
018X031
078F017
078I001
069X061
069X160
069X225
069X064
101626
102447
001U002
107538
114890
104158
Description
Pump Body, 20cc?rev
Rear Bearing Plate, 20cc/rev
Gear, 20cc/rev
Driven Shaft 10cc/20cc
Drive Shaft, 10cc/20cc
Ball Bearing, 1/8 Dia.
Snap Ring, External, 1/2”
Key Woodruff, #404
Seal Shaft
Shaft Seal Retainer
O-ring, -042
O-ring, -041
M5 x 12mm SHC Screw
M5 x 25mm SHC Screw
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 110 All Thread (not shown)
M10 Flange Nut (not shown)
Qty.
1
1
2
1
1
6
4
1
1
1
1
1
4
3
4
4
4
Page 10-28 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
10
2
5
1
11
4
12
6
3
9
5
13
8
7
Bill of Materials for 0.55 cc Rev. Single Gear Pump Assembly PN 109908
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part Number
Description
Qty.
018X031
078F017
078I001
069X061
069X064
100908
101626
109906
100865
109907
012D079
012D080
069X160
001U002
107538
104073
104158
Ball Bearing, 1/8 Dia.
Snap Ring, 1/2”
Key Woodruf, #404
Shaft Seal
O-ring, -041
M4-0.7 x 25mm SHC Screw
M5-0.8 x 12mm SHC Screw
Plate Front, .55cc/rev
Rear Bearing Plate .55cc/rev
Gear .55cc/rev
Drive Shaft 1.5cc Dual
Driven shaft, 1.5 cc Dual
Shaft Seal Retainer
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 105 All Thread (not shown)
M10 Flange Nut (not shown)
6
4
1
1
2
2
4
1
1
2
1
1
1
4
4
4
Component Illustrations & BOM’s Page 10-29
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
5
2
12
11
12
1
13
4
6
5
14
5
3
9
10
8
15
7
Bill of Materials for .55cc/ Rev. Dual Gear Pump Assembly PN 109909
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part Number
Description
Qty.
018X031
078F017
078I001
069X061
069X064
101692
101626
109906
100865
109905
N00198
109907
012D083
012D082
069X160
001U002
107538
104073
104158
Ball Bearing, 1/8 Dia.
Snap Ring, 1/2”
Key Woodruf, #404
Shaft Seal
O-ring, -041
M4-0.7 x 35mm SHC Screw
M5-0.8 x 12mm SHC Screw
Plate Front, .55cc/ rev
Rear Bearing Plate .55cc/rev
Plate, Middle Gear, 0.55cc/rev
O-ring, -113
Gear .55cc/rev
Drive Shaft 1.5cc Dual
Driven Shaft, 1.5cc Dual
Shaft Seal Retainer
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 105 All Thread (not shown)
M10 Flange Nut (not shown)
6
4
1
1
2
2
4
1
1
1
2
4
1
1
1
4
4
4
Page 10-30 Component Illustrations & BOM’s
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
10
2
5
1
11
4
12
6
3
9
5
13
8
7
Bill of Materials for 0.15 cc Rev. Single Gear Pump Assembly PN 111253
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part Number
Description
Qty.
018X031
078F017
078I001
069X061
069X064
100908
101626
111251
100865
111252
012D079
012D080
069X160
001U002
107538
104073
104158
Ball Bearing, 1/8 Dia.
Snap Ring, 1/2”
Key Woodruf, #404
Shaft Seal
O-ring, -041
M4-0.7 x 25mm SHC Screw
M5-0.8 x 12mm SHC Screw
Plate Front, .15cc/rev
Rear Bearing Plate .55cc/rev
Gear .15cc/rev
Drive Shaft 1.5cc Dual
Driven Shaft, 1.5cc Dual
Shaft Seal Retainer
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 105 All Thread (not shown)
M10 Flange Nut (not shown)
6
4
1
1
2
2
4
1
1
2
1
1
1
4
4
4
Component Illustrations & BOM’s Page 10-31
Revised 11/12
c. 1999
DYNAMELT S ASU Manual #20-31
16
2
12
11
5
12
1
13
4
6
5
14
5
3
9
10
8
15
7
Bill of Materials for .15cc/ Rev. Dual Gear Pump Assembly PN 111254
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part Number
Description
Qty.
018X031
078F017
078I001
069X061
069X064
101692
101626
111251
100865
111252
N00198
109907
012D083
012D082
069X160
N00198
001U002
107538
104073
104158
Ball Bearing, 1/8 Dia.
Snap Ring, 1/2”
Key Woodruf, #404
Shaft Seal
O-ring, -041
M4-0.7 x 35mm SHC Screw
M5-0.8 x 12mm SHC Screw
Plate Front, .55cc/rev
Rear Bearing Plate .55cc/rev
Plate, Middle Gear, 0.55/rev
O-ring, -113
Gear .55cc/rev
Drive Shaft 1.5 cc Dual
Driven Shaft, 1.5 cc Dual
Shaft Seal Retainer
O-ring, 2-113
Dow Corning 112 Lubricant (not shown)
Lockwasher, Hi-clr, M10, Stl (not shown)
M10-1.5 x 105 All Thread (not shown)
M10 Flange Nut (not shown)
6
4
1
1
2
2
4
1
1
1
2
4
1
1
1
2
4
4
4
Page 10-32 Component Illustrations & BOM’s
Revised 2/13
c. 1999
DYNAMELT S ASU Manual #20-31
TSHA Pump Adapter Assembly PN 084E405
5
to ASU
Hopper
3
8
6
10
9
7
11
4
1
2
12
Item No.
Part Number
Description
Qty.
084E405
Pump Adapter Assembly
1
1
012G023
Pump Adapter
1
2
069X058
O- ring #28
1
3
N00179
O- ring #12
2
4
N00190
O- ring #24
1
5
069X240
O-ring #36
1
6
N00188
O-ring #022
1
7
811305
Pump Adapter Gasket, TFE
1
8
104073
M10 x 105 All Thread (shown for reference only)
4
9
104158
M10 Flange Nut (shown for reference only)
4
10
106322
Flat Washers, M10, small OD (shown for reference only)
4
11
107538
Lock Washers, Hi-clr, M10, ST (shown for reference only)
4
12
(see order for PN)
TSHA Pump (shown for reference only):
084E428
TSHA .297cc Single Outlet
084E374
TSHA .584cc Single Outlet
084E430
TSHA 1.168cc Single Outlet
084E434
TSHA 2.292cc Single Outlet
108875
TSHA 8.5cc Single Outlet
084E389
TSHA .584cc Dual Outlet
084E432
TSHA 1.168cc Dual Outlet
108874
TSHA 2.292cc Dual Outlet
Component Illustrations & BOM’s Page 10-33
Revised 2/11
c. 1999
DYNAMELT S ASU Manual #20-31
Single Swirl Kit Assembly
PN 107113, 240V
Dual Swirl Kit Assembly
PN 107114, 240V
Bill of Materials for PN 107113 Single Swirl Kit & PN 107114 Dual Swirl Kit
Item No.
Part Number
Description
Qty.
107113
Qty.
107114
Page 10-34 Component Illustrations & BOM’s
Revised 2/07
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials Optional Filter Manifold with Dump Valve Assembly-112567
Item No.
Part Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
112610
N01124
N00754
N00181
N00192
104852
101833
101625
101624
N00196
N08024
101246
006C024
069X058
101840
16
34
35
36
37
38
39
40
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Description
Manifold Filter Block
1/16-27 NPT Level Seal Plug
1/4-18 NPT Level Seal Plug
O-ring, -014, 75 Duro Viton
O-ring, -032, 75 Duro Viton
M10 x 1.5 Filter Drain Plug
10-32 x 1/2 Tamper Proof Screw
1/4 BSPP Hex Socket Head Plug Fitting (all are not shown)
#06 37° SAE x 1/4 BSPP Straight Fitting
O-ring, -111, 75 Duro Viton
#06 37° SAE Fitting Cap
Filter Basket, 40 mesh
Filter Nut
O-ring, -028, 75 Duro Viton
Pressure Relief Valve
109784
Manifold Dump Valve Assembly
109785
Dump Valve Base
109786
Dump Valve Stem
N00179
O-ring, -009, 75 Duro Viton
109787
Compression Spring, .845 OD x .085 WD x 1.00 LG,
109788
Dump Valve Piston
N00175
O-ring, -008, 75 Duro Viton
108712
Belleville Washer, .343 x .164 x .019, SST
108352
M4 x 0.7 Hex Nut
N03894
O-ring, -218, 75 Duro Viton
109789
Dump Valve Seat
N00183
O-ring, -016, 75 Duro Viton
N00179
O-ring, -012, 75 Duro Viton
109790
Dump Valve Cylinder
N00099
1/8 NPT x .25 Tube Male Elbow Fitting
001U002
Lube, Silicone, Dow 112
N02937
Thread Sealant
107531
M4 x .07 x 20mm SHC Screw
001U002
Lube, Silicone, Dow 112 (Not Shown)
107324
Anti-Seize Compound (Not Shown)
N02937
Thread Sealant, w/TFE, Jet-Lube (Not Shown)
109793
M8 x 1.25 x 65mm SHC Screw, Black Oxide
109796
Cover, Output Manifold
109794
Fitting,M run T .25 x 1/4 NPT
109795
Tube, Air
Qty.
1
4
4
2
1
1
1
5
6
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
3
1
1
1
Component Illustrations & BOM’s Page 10-35
Revised 2/07
c. 1999
DYNAMELT S ASU Manual #20-31
39
40
30
33
29
13
24
16
14
23
21
12
24
25
22
20
18
15
19
17
27
28
4
26
2
2
5
4
3
38
1
3
2
Not to scale
2
37
3
9
7
6
11
10
3
8
Component Illustration: Optional Filter Manifold with Dump Valve Assembly-112567
Page 10-36 Component Illustrations & BOM’s
Revised 6/11
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for Optional Pneumatic Pressure Relief Valve Assemblies
Item No.
Part Number
Description
*
* See detailed drawing on following pages.
Qty.
Component Illustrations & BOM’s Page 10-37
Revised 6/11
c. 1999
DYNAMELT S ASU Manual #20-31
PN 117048 Assy.
PN 116709 or
PN 116711 Assy.
PN 116712 Assy.
PN 116708 or
PN 116710 Assy.
Component Illustration: Optional Pneumatic Pressure Relief Valve Assemblies
Page 10-38 Component Illustrations & BOM’s
Revised 10/13
c. 1999
DYNAMELT S ASU Manual #20-31
Bill of Materials for PN 115540 Pneumatic Pressure Relief Valve Assembly
Item No. Part Number
Qty.
Description
c. 1999
DYNAMELT S ASU Manual #20-31
Component Illustrations & BOM’s Page 10-39
Revised 1/11
Component Illustration: PN 115540 Pneumatic Pressure Relief Valve
Page 10-40 Component Illustrations & BOM’s
Revised 9/11
c. 1999
DYNAMELT S ASU Manual #20-31
PN 116620 Pneumatic Pressure Relief Valve Retrofit Kit for Piston Pump Models and
Installation
Bill of Materials for PN 116620 PRV/ PP Retrofit Kit
Item No. Part Number
Installation Procedure
Description
Qty.
Component Illustrations & BOM’s Page 10-41
Revised 9/11
c. 1999
DYNAMELT S ASU Manual #20-31
PN 116621 Pneumatic Pressure Relief Valve Retrofit Kit for Gear Pump Models and
Installation
Bill of Materials for PN 116621 PRV/ GP Retrofit Kit
Item No. Part Number
Installation Procedure
Description
Qty.
Page 10-42 Component Illustrations & BOM’s
Revised 9/11
c. 1999
DYNAMELT S ASU Manual #20-31
PN 116707 Pneumatic Pressure Relief Valve Retrofit Kit for Gear Pump Models with
Dual Filter Manifold and Installation
Bill of Materials for PN 116707 PRV/ GP/ Dual Filter Manifold Retrofit Kit
Item No. Part Number
Installation Procedure
Description
Qty.
Page 11-1
Revised 10/99
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Chapter 11
SYSTEM SCHEMATICS
& ENGINEERING DRAWINGS
Page 11-2
Revised 3/03
HOSE SCHEMATIC PN 101082 REV. E
ASU to Applicator, DynaControl
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
Page 11-3
Revised 1/01
HEAD SCHEMATIC PN 103117 REV. B
Page 11-4
Revised 4/03
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
OPTIONAL CLUTCH KIT PN 107094
INSTALLATION, BOM & SCHEMATIC
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
OPTIONAL 110/120V GFI KIT PN 808633 CUSTOMER INSTALLATION & SCHEMATIC
Page 11-5
Revised 3/03
Page 11-6
Revised 4/03
ITW Dynatec c. 1999
DYNAMELT S ASU Manual 20-31
12-POSITION NORD
RECEPTACLE
PN 110331 PIN CONNECTOR AND WIRING DIAGRAM FOR OPTIONAL DMS w. NORD CONNECTORS
HOSE HARNESS ASSEMBLY
c. 1999
DYNAMELT S ASU Manual 20-31
Notes:
Appendix 1
Revised 4/04
Appendix 2
Revised 3/05
Notes:
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 3
Revised 6/03
c. 1999
DYNAMELT S ASU Manual 20-31
DYNATEC/ ZENITH STANDARD ACCURACY GEAR PUMPS
INSTALLATION, CARE & MAINTENANCE MANUAL
PN 084E427, 084E429, 084E431, 084E433, 084E435
Part Number
Material
Type/Accuracy
Output/Rev
Shaft Seal PN
084E427
Nodular Iron
Single/ Standard
0.29cc
807729
084E429
Nodular Iron
Single/ Standard
1.17cc
807729
084E431
Nodular Iron
Dual/ Standard
1.17cc
807729
084E433
Nodular Iron
Single/ Standard
2.92cc
807729
084E435
Nodular Iron
Dual/ Standard
2.92cc
807729
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. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.
Manual revised 8/94
Appendix 4
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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 inaccuracies, 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 precision and simplicity. Manufacturing techniques were developed to hold tolerances to
.00005”, and an internal pressure relief mechanism assured reliable precision metering. The
pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.
For years since, chemical engineers have relied on Zenith to provide precision fluid handling 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 Capability
Operating temperatures to 450 degrees F (232 degrees C).
Maximum Life
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
Maximum 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.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 5
Revised 10/99
SPECIFICATIONS
Pump Type: Rotary external spur gear, single stream.
Rotation: Clockwise
Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.
Temperature: To 450 degrees F (232 degrees C)
OPERATION
All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a
port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed gear tooth volumes and is transported around the outer diameter of the gear pocket.
As the gears mesh together, the fluid is displaced in a very precise amount out through the
discharge port that is drilled alongside the inlet port in the rear plate.
Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pressure 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.
Dynatec/ 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. Because 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-pressure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential
pressure and pump clearances. Under reasonably stable operating conditions, slippage is repeatable and predictable and pump operation can be adjusted to compensate.
The Standard Accuracy Pumps are designed for high-temperature and high-pressure operation. As such, operating temperatures to 450 degrees F can be achieved.
INSTALLATION
Pumps should be carefully unpacked to make sure that the shipment is complete. If any
items are missing or damaged, the freight carrier and Dynatec should be notified immediately.
While the pump is composed of steel, it is a precision instrument. Dropping the pump or hitting with a non-yielding material can cause serious damage to the components. All materials
are through-hardened to maximum hardness resulting in brittle material. Treat
cont.
Appendix 6
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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.
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 prevent leakage between the pump and block. Mounting bolts should be a Grade
8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize compound such as DAG Dispersion #154. Bolts should be alternatively torqued in even increments 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” installation procedure. For any special applications, considerations or simply to ask our advice, please contact Dynatec.
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 running clearances.
3. Turn pumps by hand before running. Pumps should turn freely.
4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the
coupling* and that it is aligned within one degree angular and .005” parallel with the true
pump drive axis. (*Note: the coupling is the rotating 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 Dynatec 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
REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop 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 machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths
of an inch (.0001”/ .0002”). Because of these close running clearances,
cont.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 7
Revised 10/99
these pumps require careful maintenence and handling, especially of component parts. The
slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These
pumps are precision instruments; you can’t keep 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 Metering Pumps, place them in a suitable furnace and gradually heat
in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to 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.
Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.
The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization 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. 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 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. 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 performance of a pump immediately before removing it from service and correlating the performance 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 Dynatec for complete 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 Dynatec (at 1-800-538-9540) for further information on these items.
Appendix 8
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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 recommended for disassembly.
NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.
Refer to assembly drawing (located in the back of this manual) for your correct pump type.
1. Remove the seal arrangement.
2. Remove all binder screws.
3. Remove pins (10) and arbor (5) with an arbor press in the direction which
disengages the press fit in the shortest distance.
NOTE: Dowels and arbors for the standard accuracy pumps are press fit in the gear/ rear
plate.
4. Separate the plates by pry slots that are available in the pump. Great care should be
taken not to scratch or damage the internal pump surface when prying the plates apart.
5. After disassembly, clean all components in a non-destructive solvent.
6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang
parts together.
7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and
faces of the gears may be hand blocked on 600 grit paper and any nicks, burrs or sharp edges
can be lightly removed with a honing stone. Be careful not to round off the edges of the gear
teeth while lapping.
CAUTION: Since the 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 circumstances.
Place a layer of 600 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 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. Use
chemical brushes to clean between gear teeth, bores and reliefs.
8. Replace sleeve bearings as necessary and hone in the plate to the original new part
specifications.
9. After each resurfacing, carefully gauge the area between the inlet and discharge ports
at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical
part of the plate. Scoring or wear marks here will allow increased slippage from the
cont.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 9
Revised 10/99
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.
Figure 1
STANDARD ACCURACY PUMP RE-ASSEMBLY
NOTE: During and between each re-assembly step, manually turn the metering gears to ensure that they are free turning. If binding occurs at any time, determine the cause and correct
it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump
component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned,
the pieces will fit easily into place and the pump will turn freely. 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.
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. Place the 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 resistant lubricant and install. Torque the screws in even increments to the manufacturer’s recommended 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. When a carbon seal plate is used, always use a new
carbon seal that has been lightly polished on 600 grit paper. When 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.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 10
Revised 10/99
from the packing housing.
12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or
worn. Worn shafts will result in premature seal leakage and should be replaced.
13. Inspect lip seals for wear, cracks and abrasions. Replace if needed.
14. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-OLubricate 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 lbs./in. Check for free rotation.
SCREW TORQUE VALUES (Standard Alloy Steel)*
Screw Size & Thread
(UNC Alloy Steel)
#10-24 (w/ carbon seal gasket)
#10-24 (w/o carbon seal gasket)
#12-24
1/4-20
5/16-18
3/8-16
into aluminum
block (hopper)
7/16-14
Torque (Lubricated Threads)
Lbs.-in.
Nxm
Lbs.-ft.
[50]
[64]
[120]
[150]
[305]
[360]
[480]
[4.2]
[5.3]
[10]
[12.5]
[25]
[30]
[40]
5.7
7.2
13.6
16.9
33.9
40.6
54.2
Table 1
*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 constructed of type H-11 high-temperature alloy steel provide extremely high creep
resistance.
Appendix 11
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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 temperature, pressures, viscosities
and materials.
4. Entrained particle.
Return pump to ITW Dynatec
for repair.
5. Possible internal damages.
Return pump to ITW Dynatec
for repair.
1. Worn seal plate.
Return pump to ITW Dynatec
for repair.
2. Insufficient inlet pressure.
Increase inlet pressure.
3. Worn lip seal.*
Replace lip seal.
1. Worn gear(s).
Return pump to ITW Dynatec.
for repair.
2. Worn bearings.
Return pump to ITW Dynatec.
for repair.
3. Process conditions changed.
Consult factory for
clearance recommended
on new process conditions.
Excessive seal
assembly leakage
Reduced pump efficiency
* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.
Appendix 12
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 13
Revised 10/99
Appendix 14
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 15
Revised 10/99
Appendix 16
Revised 10/99
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 17
Revised 6/03
c. 1999
DYNAMELT S ASU Manual 20-31
DYNATEC/ ZENITH HIGH ACCURACY GEAR PUMPS
INSTALLATION, CARE & MAINTENANCE MANUAL
PN 084E428, 084E430, 084E432, 084E434
Part Number
Material
Type/Accuracy
Output/Rev
Shaft Seal PN
084E428
Tool Steel
Single/ High
0.297cc
807729
084E430
Tool Steel
Single/ High
1.168cc
807729
084E432
Tool Steel
Dual/ High
1.168cc
807729
084E434
Tool Steel
Single/ High
2.920cc
807729
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. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.
Manual revised 8/94
Appendix 18
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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 inaccuracies, 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 precision and simplicity. Manufacturing techniques were developed to hold tolerances to
.00005”, and an internal pressure relief mechanism assured reliable precision metering. The
pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.
For years since, chemical engineers have relied on Zenith to provide precision fluid handling 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 Capability
Operating temperatures to 550 degrees F (288 degrees C).
Maximum Life
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
Maximum 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.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 19
Revised 10/99
SPECIFICATIONS
Pump Type: Rotary external spur gear, single stream.
Rotation: Clockwise
Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.
Temperature: To 550 degrees F (288 degrees C)
DESIGN
Dynatec/ Zenith High Accuracy Metering Pumps consist of two gears rotating in mesh within a closely fitted housing that is comprised of three plates. The center gear plate fits closely
around the outside diameter of the metering gears. The front and rear plates sandwich the
center plate and restrict axial movement of the gears. Power is transmitted to the gears by
the drive shaft which is a through shaft. Shaft sealing is accomplished with a high temperature cup seal.
High-accuracy pumps are precision instruments requiring skilled and careful maintenence.
Constructed of high-quality tool and die steels such as AISI D2, M2, M4 and CPM-M4, or
other high-performance alloys, they are tempered after heat treatment to hardnesses ranging
from HRc 58 to HRc 64. Since the 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.
The Type D2 tool steel is often selected for the side and center plates as it offers good abrasion 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 M2 or M4.
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 resistant Type M4 tool steel. Types M2 and CPM-M4 steels are commonly used for the metering
gears, drive shaft and universal seal coupling, due to their superior torsional strength and
abrasion resistance for these items that are the most critical to proper metering performance.
OPERATION
All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a
port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed 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 20
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pressure 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.
Dynatec/ 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. Because 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-pressure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential
pressure and pump clearances. Under reasonably stable operating conditions, slippage is repeatable 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 hitting with a non-yielding material can cause serious damage to the components. All 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.
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 prevent leakage between the pump and block. Mounting bolts should be a Grade
8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize compound such as DAG Dispersion #154. Bolts should be alternatively torqued in even increments up to Dynatec’s recommended limit for the bolt size used. See Table 1 on page 25 for
torque values.
The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact Dynatec.
cont.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 21
Revised 10/99
TO PREPARE THE PUMP FOR USE:
1. Always flush out the plumbing system before connecting the pump.
2. Filters should be installed prior to the pump inlet that filter ideally to half the pump running clearances.
3. Turn pumps by hand before running. Pumps should turn freely.
4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the
coupling* and that it is aligned within one degree angular and .005” parallel with the true
pump drive axis. (*Note: the coupling is the rotating 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 Dynatec 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
REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop 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 machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths
of an inch (.0001”/ .0002”). Because of these close running clearances, these pumps require
careful maintenence and handling, especially of component parts. The slightest burr, nick or
particle of foreign matter can cause scoring or even seizure. These pumps are precision instruments; you can’t keep 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 Metering Pumps, place them in a suitable furnace and gradually heat
in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to 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.
Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.
The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization process usually takes between 3 and 12 hours, depending on the polymer type,
temperature, pump size and furnace load.
cont.
Appendix 22
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
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. 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 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. 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 performance of a pump immediately before removing it from service and correlating the performance 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 Dynatec for complete 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 Dynatec (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 recommended for disassembly.
NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.
Refer to assembly drawing (located in the back of this manual) for your correct pump type.
1. Remove the seal arrangement.
2. Remove all binder screws.
3. Remove dowels (10) and arbor (5) with an arbor press in the direction which
disengages the press fit in the shortest distance.
NOTE: Dowels and arbors for the high accuracy pumps are press fit in the rear front plate (1)
and slip fit in the center (2) and side plates (3).
cont.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 23
Revised 10/99
4. Separate the plates by pry slots. Great care should be taken not to scratch or damage
the internal pump surface when prying the plates apart.
5. After disassembly, clean all components in a glass bead blast cabinet to remove any
debris remaining after heat cleaning. Alternative, non-destructive cleaning methods such as
water jet or solvents are also acceptable.
6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang
parts together.
7. Inspect all parts for nicks, 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: Since the 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, lapping these components is not necessary and should not be done under any circumstances.
Place a layer of 400 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 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. Use
chemical brushes to clean between gear teeth, bores and reliefs.
8. Replace sleeve bearings as necessary and hone in the plate to the original new part
specifications.
9. After each resurfacing, carefully gauge the area between the inlet and discharge ports
at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical
part of the plate. Scoring or wear marks here will allow increased slippage from the highpressure 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.
Figure 1
Appendix 24
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
HIGH ACCURACY PUMP RE-ASSEMBLY
NOTE: During and between each re-assembly step, manually turn the metering gears to ensure that they are free turning. If binding occurs at any time, determine the cause and correct
it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump
component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned,
the pieces will fit easily into place and the pump will turn freely. 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 fixture.
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. Place the driven metering gear on its arbor and carefully mesh with the drive metering
gear.
6. Carefully lower the center plate (2) over the gears.
NOTE: Repeat steps 5 and 6 for four-gear pumps, placing the middle plate between gear
plates.
7. Position the front side plate (1).
8. Rotate the gears to ensure free rotation.
9. Press the dowels (10) into place moving in the direction of the shortest press distance.
(Usually from the rear side of the pump.)
10. Lubricate the binder screws (47, 48) with DAG dispersion #154 or a similar heat resistant lubricant and install. Torque the screws in even increments to the manufacturer’s recommended 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. 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 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 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-OLubricate or an equivalent silicone-based oil.
14. Install lip seals into seal housing (22) as shown.
15. Tighten seal housing screws to 60 lbs./in. Check for rotation.
Appendix 25
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
SCREW TORQUE VALUES (Standard Alloy Steel)*
Screw Size & Thread
(UNC Alloy Steel)
#10-24 (w/ carbon seal gasket)
#10-24 (w/o carbon seal gasket)
#12-24
1/4-20
5/16-18
3/8-16
into aluminum
block (hopper)
7/16-14
Torque (Lubricated Threads)
Lbs.-in.
Nxm
Lbs.-ft.
[50]
[64]
[120]
[150]
[305]
[360]
[480]
[4.2]
[5.3]
[10]
[12.5]
[25]
[30]
[40]
5.7
7.2
13.6
16.9
33.9
40.6
54.2
Table 1
*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 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 temperature, pressures, viscosities
and materials.
4. Entrained particle.
Return pump to ITW
Dynatec for repair.
cont.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 26
Revised 10/99
TROUBLESHOOTING GUIDE, continued
Trouble
Excessive seal
assembly leakage
Reduced pump efficiency
Probable Cause
Remedy
5. Possible internal damages.
Return pump to ITW Dynatec
for repair.
1. Worn seal plate.
Return pump to ITW Dynatec
for repair.
2. Insufficient inlet pressure.
Increase inlet pressure.
3. Worn lip seal.*
Replace lip seal.
1. Worn gear(s).
Return pump to ITW Dynatec
for repair.
2. Worn bearings.
Return pump to ITW Dynatec
for repair.
3. Process conditions changed.
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.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 27
Revised 10/99
Appendix 28
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 29
Revised 10/99
Appendix 30
Revised 10/99
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 31
Revised 10/99
Appendix 32
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 33
Revised 10/99
Appendix 34
Revised 10/99
c. 1999
DYNAMELT S ASU Manual 20-31
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 35
Revised 10/99
Appendix 36
Revised 10/99
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
c. 1999
DYNAMELT S ASU Manual 20-31
VOLUMETRIC EFFICIENCY %
10
20
30
40
50
60
70
80
90
100
.02
VOLUMETRIC EFFICIENCY FACTOR
.01
.05
DP
mN
.10
N = RPM
.2
084E388
084E428
.297 cc/rev
.5
084E374
084E389
.584 cc/rev
D P = DIFFERENTIAL PRESSURE (PSI)
m = APPARENT VISCOSITY (CENTIPOISES)
084E387
.160 cc/rev
HIGH ACCURANCY PUMP PERFORMANCE
1.0
084E430
084E432
1.168 cc/
rev
084E376
1.752 cc/rev
084E434
084E436
2.92 cc/rev
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 37
Revised 10/99
Appendix 38
Revised 10/99
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 47
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
OIL- FILLED
MELT PRESSURE TRANSDUCERS
W3 SERIES
mV/V output
PN 800225 Pressure Transducer
MV, 1.5/30NHG
The W3 series of Gefran, are pressure transducers for
using in High temperature environment.
The main characteristic of this series is the capability to
read temperature of the media up to 315C.
The constructive principle is based on the hydraulic trasmission of the pressure.
The fluid- filled system assures the temperature stability.
The phisical measure is transformed in a electrical measure by means the strain- gauge technology.
FEATURES
 Pressure ranges from:
0- 35 to 0- 1000 bar / 0- 500 to 0- 15000 psi
 Accuracy: <0.25% FSO (H); <0.5% FSO (M)
 Fluid- filled system for temperature stability
 Oil filling meets FDA requirements CFR 178.3620 and
CFR 172.878
 Oil filling volume:
W30 (30mm 3); W31- W32- W33 (40mm3)
 1/2- 20UNF, M18x1.5, standard threads; other types available on request
 Standard diaphragm is a 17- 7 PH stainless steel GTP
coating corrugated diaphragm
GTP (advanced protection)
Coating with high resistance against corrosion, abrasion
and high temperature
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 48
Revised 1/13
15 [0.59I]
15 [0.59I]
W30
ø26.5 [1.04I]
D5
D4
45
A
B
A
C
D1
B
D2
D3
C
15 [0.59I]
W31
ø26.5 [1.04I]
Ch
[Hex]
ø10.67
[ ø0.42 ]
26 [1.02I]
100 [3.94I]
ø28 [1.10I]
ø12.7
[ ø0.5 ]
Ch.
5.56 - 0.26
D5
[ 0.22” - 0.01 ]
11.2
[ 0.44 ]
D4
15.74
[ 0.62 ]
45
D1
C
152.4 [6I]
D4
12.7 [0.5I]
D5
457 [18I]
ø10.5 - 0.025
[ ø0.41” - 0.001 ]
16
B
A
D3
ø7.8 - 0.05
[ ø0.31” - 0.002 ]
771.1 [30.4I]
12.7 [0.5I]
[ 5/8 ]
D2
D3
D5
A
Ch.
D5
152.4 [6I]
45
D1
B
A
C
C
Ch
[Hex]
D4
D2
D3
12.7 [0.5I]
B
15 [0.59I]
76.5
ø16 - 0.4
[ ø0.63” - 0.016 ]
ø18
[ ø0.71 ]
6 - 0.26
[ 0.24” - 0.01 ]
14.8 - 0.4
[ 0.58” - 0.016 ]
26 [1.02I]
25.5 [1I]
457 [18I]
ø7.5 [0.30I]
ø16 - 0.08
[ ø0.63” - 0.003 ]
19
ø7.5 [0.30I]
440 [17.32I]
D4
ø26.5 [1.04I]
[ 0.75 ]
ø9 [0.35I]
19
[ 3/4 ]
NOTE : dimensions refer to rigid stem
length option “4” (153 mm – 6”)
WARNING : For installation use a
maximum tightening torque of
56 Nm(500 in- lb)
ø1.6 [0.063I]
15 [0.59I]
D3
ø10 - 0.05
[ ø0.394 - 0.002 ]
C
26 [1.02I]
76.5
D2
M18x1.5
255 [10I]
D1
Ch.
D1
45
B
A
259.6 [10.22I]
Ch.
1/2 - 20UNF
45.2 [1.78I]
D1
ø7.5 [0.30I]
152.4 [6I]
15.7 [0.62I]
76.5
76.5
ø26.5 [1.04I]
D2
752.4 [29.62I]
W32
D2
D3
W33
Appendix 49
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
ELECTRICAL CONNECTIONS
mV/V OUTPUT
6 pin connector
VPT07RA10- 6PT2
(PT02A- 10- 6P)
8- pin
Supply Voltage
+
C
A
Supply Voltage
-
D
C
Signal
-
B
D
Signal
+
A
B
E- F
E- F
Calibration shunt
R- Cal
6- pin
G- H
n.c.
Connect the cable sheathing
to the side of the instrument.
8 pin connector
PC02E- 12- 8P Bendix
ACCESSORIES
Connectors
6- pin mating connector (IP65 protection degree)
8- pin mating connector
CON300
CON307
Extension cables
6- pin connector with 8m (25ft) cable
C08W
6- pin connector with 15m (50ft) cable
C15W
6- pin connector with 25m (75ft) cable
C25W
6- pin connector with 30m (100ft) cable
C30W
Other lengths
consult factory
Accessories
Mounting bracket
SF18
Dummy plug for 1/2- 20UNF
SC12
Dummy plug for M18x1.5
SC18
Drill kit for 1/2- 20UNF
KF12
Drill kit for M18x1.5
KF18
Cleaning kit for 1/2- 20UNF
CT12
Cleaning kit for M18x1.5
CT18
Thermocouple for W32 model
Type “J” (153mm - 6” stem)
TTER601
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 50
Revised 1/13
W
ORDER CODE
OUTPUT SIGNAL
2
2.5 mV/V
3
3.33 mV/V
VERSION
Rigid stem
0
1
Rigid stem + flexible
2
With thermocouple
3
Exposed capillary
CONNECTOR
Standard
6 pin
8 pin
6
8
ACCURACY CLASS
0.25% FSO
H
(ranges ≥ 100 bar/1500 psi)
0.5% FSO
bar
35
50
70
100
200
350
500
700
1000
M
RANGE
psi
500
B35U
B05D
750
B07D 1000
B01C 1500
B02C 3000
B35D 5000
B05C 7500
P05C
P75D
P01M
P15C
P03M
P05M
P75C
B07C
10000
P10M
B01M
15000
P15M
000
000 = Standard version
Special or customized versions
available on request
FLEXIBLE LENGTH (*)
(mm / inches)
Standard (W30)
0
none
Standard (W31, W32)
18”
D
457mm
24”
E
610mm
30
F
760mm
Standard (W33)
28
L
711mm
Available on request
A
3”
76mm
6”
B
152mm
12
C
300mm
RIGID STEM LENGTH (*)
(mm / inches)
Standard (W30, W31, W32)
4
153mm
6”
5
318mm
12.5”
Standard (W33)
0
none
Available on request
1
1.5”
38mm
2”
2
50mm
3
3”
76mm
14”
6
350mm
16”
400mm
7
18”
8
456mm
(*) Note : maximum combined
stem/flex length is
914mm - 36
THREAD
Standard
1
1/2 - 20 UNF
4
M18 x 1.5
Examples
W32- 6- M- B07C- 1- 4- D- 000
Melt pressure transducer with type “J” thermocouple, 3.33 mV/V output, 6- pin connector, 1/2- 20UNF thread, 700bar full scale,
0.5 % accuracy class, 153 mm (6”) rigid stem, 457mm (18”) flexible capillary.
W20- 8- M- P03M- 1- 4- 0- 000
Melt pressure transducer, rigid stem, 2.5 mV/V output, 8- pin connector, 1/2- 20UNF thread, 3000psi full scale, 0.5 % accuracy
class, 153 mm (6”) rigid stem
GEFRAN reserves the right to make any kind of design or functional modification at any moment without prior notice.
GEFRAN spa
via Sebina, 74
25050 PROVAGLIO D’ISEO (BS) - ITALIA
tel. 0309888.1 - fax. 0309839063
Internet: http://www.gefran.com
DTS_W3_09- 2010_ENG
Appendix 51
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
TOOL-STEEL HIGH ACCURACY GEAR PUMPS
USER’S GUIDE
Pump #
Identifier
Displacement
Type
108863
108864
108865
108866
108867
108868
108869
108870
108871
108872
108873
108874
108875
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
TSHA*
0.160 cc rev.
0.160 cc rev.
0.297 cc rev.
0.297 cc rev.
0.584 cc rev.
0.584 cc rev.
1.168 cc rev.
1.168 cc rev.
1.752 cc rev.
2.920 cc rev.
4.500 cc rev.
2.920 cc rev.
8.500 cc rev.
single
dual
single
dual
single
dual
single
dual
single
single
dual
dual
single
# Gears
2
4
2
4
2
4
2
4
2
2
4
4
2
# Plates
3
5
3
5
3
5
3
5
3
3
5
5
3
Shaft Seal #
807729
807729
807729
807729
807729
807729
807729
807729
807729
807729
807729
807729
807729
* Tool Steel, High Accuracy
Customer should read and thoroughly understand this
manual before installation and operation of pump.
If necessary, any Dynatec pump requiring maintenance can be returned
to the factory for complete repair and overhaul. Please contact our Rebuild
Department for further details.
Appendix 52
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
Description
ITW Dynatec’s metering gearpumps are manufactured to precise tolerances. To retain their high
performance, these pumps must be carefully installed and maintained. These pumps are CE (Declaration of Conformity) rated.
Health & Safety
Dismantling
Internal components are precisely machined and have sharp edges and corners. These features are
essential to the accurate metering performance. Particular care must be exercised when handling
these components.
Cleaning
Cleaning fluids and methods are subject to strict Health and Safety regulations. Avoid contact
with skin, do not inhale fumes and protect eyes.
Operation
Pump outlet pressure and speed limits are dependant on fluid viscosity and throughput. Pump inlet pressure is an important feature for lubrication and fluid homogeneity. Materials for pump
construction are important for corrosion and wear resistance. Consult ITW Dynatec for detailed
applications. Normally the pumps are single or dual output. Typical speed ranges are 10-90 rev/
min.
Flushing
To avoid contamination of process fluid, the pump should be flushed out to remove test oil. Precaution must also be taken to flush out pumps at plant shutdown, since congealed fluid can cause
seizure.
Filtration
Unless fluid purity can be guaranteed (especially from metal fragments), filtration must be
installed before pump inlet, to avoid damage to pump internals.
Note: The following guide is for general purposes only. Due allowance must be made for any special features.
Installation
Ensure pump is free from protective packing materials and rotates freely.
Pump Drive
Drive alignment is very important. Ensure backlash is 0.1mm (0.004”) to avoid shock or radial
load. In the event of driveshaft connection, two flexible components must be incorporated into
each driveshaft to allow for misalignment. These flexible components must have the capacity to
distort over the misalignment range while ensuring that any radial load is minimal. Do not allow
Appendix 53
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
shaft to put end thrust on the pump.
Rotation
Ensure drive rotates in correct direction (generally counter-clockwise at the pump drive spindle).
The pump must be checked for smooth operation by hand.
Fixing and Lubrication
The pump must be fixed securely to maintain position and alignment. When secured by lubricated
bolts, torque them evenly to the suggested torque (see Maintenance).
Start drive and bring up to speed slowly. Flush with process fluid.
Note: motor baseplate assemblies should be pre-checked in case the drive alignment has been disturbed.
Gland Leakage
If oil seal is fitted, there should not be any fluid leakage.
Problem-finding Chart
Problem
Remedy
LEAKAGE
Screws not tight
Re-torque
Seal scratched or worn
Replace seal
FLOW RATE ERROR
Gear worn on diameter
or width
Return to ITW Dynatec
Gear teeth damage
Return to ITW Dynatec
Plates worn, scratched or not
flat
Return to ITW Dynatec
Low inlet pressure (cavitation)
Check process
High outlet pressure (slippage)
Check process
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 54
Revised 1/13
Cleaning
Before removal from machine, the pump should be rotated for a short period (with inlet supply
shut off) to discharge process fluid. Care should be taken, when removing and stripping the pump,
to allow for any residual fluid. Pump components can be solvent or ultrasonically cleaned by immersion, using a compartmentalized wire baset. Dry in air. Stubborn residues may be removed
with a brass wire brush. Avoid burnishing the sharp edges of gear and gear races.
Fluid immersion in rust inhibitor is advised. If components are to be stored for some time, they
should be lightly smeared with oil.
Maintenance
Tightening Torque
for High Tensile ISO 12.9 Lubricated Bolts (300C max)
Bolt Size & Qty.
M5
(4)
M10 (4)
M10 (4)
Bolt Location
Torque Nm/ Ft.lbs.
retainer cap
7.1/ 5.2
mounting bolts
mounting bolts
41/ 30 at ambient temperature
24/ 18 at production temperature
Notes: If mounting bolts are torqued at production temperature, they should be re-torqued (to 41
Nm/30 Ft lb.) when machine is at ambient temperature.
1 Nm = 8.85 in/lbs. Torques given above are for Metric and UNF threads. Multiply by 0.8 for
UNC and BSF threads.Multiply by 0.8 for BSVV threads (multiply by 0.67 for stainless steel)
ITW Dynatec frequently provides special features at their customer’s request. Please consult with
ITW Dynatec, quoting job and pump references, if questions arise.
Appendix 55
Revised 1/13
c. 1999
DYNAMELT S ASU Manual 20-31
Reconditioning
Should reconditioning (overhauling) become necessary, return the pump to ITW Dynatec.
Pump Shaft Seal Replacement
The ITW Part Number for all Standard Tool Steel High Accuracy Pump Shaft Seals (8.5cc and
smaller) is PN 807729.
DANGER HOT SURFACE & HIGH VOLTAGE
If the pump is not operable but the heating system will function, raise the
temperature of the application system to the operating temperature to aid in the
pump disassembly process. Otherwise, a heat gun or other controlled heating
method is recommended to melt hardened hot melt material. Never use a torch
or an open flame on any of the components of the application system. Once the
system is up to temperature, disconnect all incoming power before proceeding.
Pump Shaft Seal (O-ring) Replacement:
In most cases, the pump does not have to be
removed from the ASU in order to replace the
shaft seal.
Pump
1. Disconnect the drive coupling so that the
pump may be accessed.
Cap
2. Remove the four screws in the pump “cap”
and remove the cap.
3. Within the cap is the pump shaft seal. Remove the old seal.
Shaft
4. Clean all pump parts, paying particular
attention to the pump shaft seal groove.
5. Lightly lubricate the shaft seal before inserting it in the shaft seal groove.
6. Before re-assembling, wrap a small piece of paper around the shaft so that the shaft’s
woodruff key seat does not damage the new seal.
7. Re-assemble. Remove paper.
8. Re-tighten four screws.
9. Re-connect drive coupling.
10. Return ASU to operation and check pump for leaks.
c. 1999
DYNAMELT S ASU Manual 20-31
Appendix 56
Revised 1/13
Rebuild Kit for 8.5cc TSHA Pump, PN 111939
The rebuild kit for the PN 108875 8.5cc TSHA pump consists of the following parts:
PN
Description
Qty.
PN
Description
Qty.
111699
111699
111701
111702
111704
Drive Shaft
Idler Shaft
Bushing, Front Plate
Bushing, Back Plate
Dowel
1
1
1
1
2
111707
111709
807729
111705
078I001
Retaining Ring
Screw, 10-24
Pump Shaft Seal
Key
Key, Woodruff
1
4
1
1
1
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Page 1
Revised 4/11
PN 110772 DMS/ PN 112530 DDS/ PN 680079 D25/45 DynaControl EtherNet/IP
Adapter Option, V1.10
General
This optional adapter provides an EtherNet/IP connection for either the Dynamelt S, the DDS or
the D24/45 hot melt ASUs. With this connection it is possible to monitor and control the basic
functions of the hot melt unit from a remote PLC or PC. Instructions for Dynamelt S, DDS and
D25/45 ASUs are identical.
This adapter uses an ODVA approved module. In order to fully operate, the ASU must be
equipped with firmware rev. V5.11S or later.
Basic Features:
-
10/100 Mbit/s
DHCP/BootP
Access to basic process parameters
Local and remote access
Watchdog signal
Page 2
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Installing the EtherNet/IP-Adapter Hardware
(See the following page for Figure A and B illustrations.)
Installation Procedure
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Dynamelt S ASU Installation Diagram PN 112929
(see page 15 for Installation Diagram for D25/45 ASU)
Page 3
Revised 4/11
Page 4
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Installing the EtherNet/IP-Adapter Software in a ControlLogix5000 System
These installation steps assume that RSLogix5000 and ControlLogix5000 with an EtherNet/IP
module/bridge (1756 ENBT or similar) are set up and working properly.
1. Connect the Dynatec Hot melt unit (ASU) to the Ethernet network using a standard RJ45cable.
2. Start RsLogix5000 with a new or existing project. Set to “Offline” mode.
3. Add the EtherNet/IP-Adapter to the PLC Configuration:
- Start by right clicking the EtherNet/IP module/bridge in the configuration
- Select “New Module”
- Select “Generic Ethernet Module”
- Press OK
4. Configure the EtherNet/IP-Adapter:
- Enter the name of the module. (for example “Dynatec Melter”. If you desire to import the
controller tags provided on the CD-ROM, the module name must be exactly “Dynatec
Melter”. See step #6 following).
- Set Comm Format to “Data-INT”, since all data are 16-bit words
- Set Connection Parameter Assembly Instance to 100 for Input and 150 for Output
- Set Size for both to 64 (16-bit)
- Set the Configuration Instance to 1 but the size to 0 since this instance is not supported
- Set the IP-Address to 192.168.23.180. For more details about IP-Address see the following
section, “Changing the IP-Address”
- Press Next >
- On next dialog, select Requested Packet Interval: 100ms
- Do not Inhibit Module
- Press Finish >>. On the main screen you should see the ETHERNET-MODULE under
the I/O Configuration
- Select “ Go Online” from the “Communications” menu
- Select “ Download” in the next window
- Confirm the Download
5. Checking the I/O Tags
After successful configuration of the EtherNet/IP-Adapter, it is possible to access the
input/output data. There are three Controller Tags: “Dynatec Melter: C”, “Dynatec Melter: I”
and “Dynatec Melter: O”. The input/output tags consist of 64 words each.
“Dynatec Melter: C” is the configuration tag (not used).
“Dynatec Melter: I”
is the data coming from the Dynatec hot melt unit
“Dynatec Melter: O” holds the data going to the hot melt unit.
The definitions of the data tags are explained in the last two pages of this section.
6. Importing Controller Tags
The CD-ROM that is provided with the EtherNet/IP option contains a pre-defined controller tag
table. In order to save time, this table may be imported.
- In the RSLogix5000 go offline
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
-
Page 5
Revised 4/11
Select Tools -> Import Tags
Select the “Dynatec-Controller-Tags. CSV” from the CD-ROM
Click Import
If the import was successful, the Report Window in the lower part of the screen should
indicate 81 imported tags.
Go back to the controller tag screen and verify the tags.
Details on the Communication
Local Access
As soon as a valid communication is established, the PLC gains control over the hot melt unit.
The PLC has priority over the local keypad on the hot melt unit. Nevertheless, it is possible to
enter the new setpoints locally. In order to coordinate this, the OUT-word 22 and 23 are used.
The access control is separate for temperature and motor setting.
-
Setting LocalAccessTemps to 1 allows the user to make changes to the temperature
setpoints on the hotmelt unit. The PLC can read the changes from the corresponding INwords but the temperatures in the OUT area will not be effective on the hot melt unit.
-
Setting LocalAccessTemps to 0 switches the control back to PLC control. All
temperature OUT-words will be transferred to the hot melt unit. A local change of
temperature setpoints is not possible since the PLC will instantly overwrite the entry.
-
LocalAccessMotors controls the access to pump settings analog to the description above.
-
After a local change of setpoints, the PLC first must read the new setpoints before
switching back to PLC control.
-
It is not possible to deactivate a temperature zone locally on the hot melt unit since the
PLC always sends the ZoneEnable/Disable information.
Zones Enabling/Disabling
Temperature zones that are temporarily not used can be remotely deactivated by setting a
corresponding value to OUT-word 24. Each bit of this word represents one temperature zone.
Bit0 = zone1, Bit1 = zone2 etc. Setting the bit will activate the zone. Resetting will deactivate
the zone.
Motor Controller
It is possible to change the mode and the manual speed of the pump(s) of Dynamelt S units
equipped with gear pumps. When the PLC must control the pump speed, Local Access Motors
must be set to 0.
The pump mode (Word 18 & 19) must be set to the ASCII equivalent value for ‘M’ –Manual
(PLC control), ‘A’-Automatic (line following, 0 to 10V), or ‘S’-Stop.
If set to manual, the manual speed (Word 20 & 21) will be active. This speed setting must be
transmitted in increments of 0.1% (0 to 1000 = 0.0 to 100.0%).
Page 6
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
If the hot melt machine is equipped with a pump rpm readout, the actual pump speed can be read
in word 48 (word 49 for pump #2). This value represents the actual pump speed X 10 (0.0 to
100.0 rpm).
If the pump is running in automatic mode, the pump speed setpoint, which follows the line speed
using the 0-10V input, can be read in word 50 (word 51 for pump #2). This value shows 0.1%
resolution (0 to 1000).
Note: If the hotmelt machine has a minimum pump speed programmed, this speed will be active
and indicated here in case the parent machine is in standby.
Adhesive Level Indication
Word 54 shows the state of the optional adhesive level control. A 0 indicates the level is O.K.
and a 1 indicates a low-level situation. This signal is an instantaneous non-latched indication.
In order to avoid local low-level indications, which have to be reset on the keypad, the low-level
detection should be disabled in the customer set-up menu of the Dynamelt S hot melt unit.
Zone Status Indication
IN-words 56 to 60 indicate the status of all zones. This information is bit-wise coded.
Example:
Dec.
Hex.
Binary 15~0
= Zone 16 to 1
.
007Fh 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1
IN-word 56:
127
IN-word 57:
96
0060h
0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0
IN-word 58:
21
0015h
0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1
IN-word 59:
10
000Ah 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0
IN-word 60:
0
0000h
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 W W H R H R H
Hopper is heating
…
Hose 1&2 are ready
Head 1 & 2 are heating
Hose/Head 3 are waiting
Note: If IN-word 60 is not 0, at least one temperature zone is in Alarm mode.
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Page 7
Revised 4/11
Temperature Unit
The temperature units used for the communication can be changed between Fahrenheit and
Celsius. The OUT-word 26 decides between the units. A value of “0” selects °F, a value of “1”
selects °C.
Identification Word
OUT-word 63 is used as an identification word. This word must be set to a certain value to
validate the communication. If this word is set differently, the hot melt unit will not accept the
OUT area although the IN-area will show proper values. Dynamelt S hot melt units require IDword set to 34 for unmonitored communication or a toggling word of 0/1 for monitored
communication. If toggle mode is used, the word should toggle once per second to validate
communication. Once toggle mode is used, the unmonitored communication can’t be used again.
In monitored communication, the Dynamelt unit switches off pumps after 4 seconds if
communication seems to be broken. Dynatec recommends use of the monitored communication
for security reasons.
Examples for a typical communication
Initializing:
Set OUT 52 to 1:
Switches the controller on
Set OUT 63 to 34:
Identifies the communication
Set OUT 22 to 1:
User can change setpoints locally
Set OUT 26 to 0:
Set temperature units to Fahrenheit (or use 1 for Celsius)
Set OUT 23 to 0:
PLC controls pump speed, no local access
Set OUT 18 to 77:
Motor mode must be in Manual to allow PLC control
3-Hose Operation:
Set OUT 24 to 127:
Zones 1 to 7 are enabled
2-Hose Operation:
Set OUT 24 to 31:
Zones 1 to 5 are enabled
Ready Condition:
Compare OUT 56 with OUT 59:
If both words are equal, then the
system is ready
Page 8
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Changing the IP-Address
The EtherNet/IP-Adapter will be factory set to 192.168.23.180 but the DHCP/BOOTP function is
enabled. That means the module will request a new IP-address after power up. If this request is not
serviced, the old IP-address will be valid.
There are several ways to change the IP-address. In any case, a PC must be connected to the
module, either directly via crossover cable or via hub/switch to the network with the module.
Using the Ethernet IP Changing Utility (recommended)
Provided with the module a Microsoft Windows® application called IPConfig is included. The
program checks the network and shows all found Dynatec units equipped with Ethernet/IP.
You can double-click onto the unit to see an additional menu that allows you to change the
network settings.
Double-click onto the found Dynamelt unit.
You can now enter a new IP address and the other necessary parameters for your network
configuration. Press “Set” to confirm your changes.
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Page 9
Revised 4/11
Using the ARP Command
The MS-DOS™ command ARP can be used to change the IP-address. Please consult your
network administrator if you are not familiar with this matter.
In order to process this command, you need the MAC address of the module. This can be found
on the holding bracket.
- Connect the EtherNet-cable to a PC network
- Open a MS-DOS™ window
- Type: arp –s <IP-address> <MAC-address>
- Type: ping <IP address>
- Type: arp –d <IP-address>
Notes: The first three bytes of the IP-address must be the same as the PC executing the arp
command. It is normal that after changing the IP-address via arp command, the first ping
command shows one lost data package.
Using the Configuration File
The file ethcfg.cfg can be used to change the IP-address. This method is possible only if the
actual IP-address is known (e.g. the factory set 192.168.23.180), See also section “Configuration
File”.
- Open a FTP connection to the module (e.g. Windows Explorer™ FTP://192.168.23.180)
- Locate the ethcfg.cfg
- Copy this file to a folder on your PC
- Open the file with any text editor
- Change the IP-address
- Save the file using the same name
- Copy the file back to the module
- Re-cycle power on the module (hot melt unit)
Note: If the configuration file ethcfg.cfg is not found, the module will automatically activate a
DHCP/BOOTP request.
Using the BootP-Server Function
The BOOTP-Server comes with the RSLinx Tools of the Rockwell Automation™ Software or
can be downloaded as a stand-alone application. Version V2.3.2 or newer allows to change the
IP-address of the EtherNet/IP module.
Note: The EtherNet/IP module only requests an IP-address assignment for approx. 30 sec.
If this request is not serviced within this time (by entering the desired IP-address in the relation
list) the module’s power (hot melt machine) must be re-cycled.
Page 10
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Diagnostic LED’s
1. Net Stat. = Network Status
State
Summary
Description
Steady Off
No power or no IP
address
The module has no power or no IP address has
been assigned.
Steady Green
Connected
The module has at least one established
EtherNet/IP connection.
Flashing Green
No connections
There are no EtherNet/IP connections established to
the module.
Flashing Red
Connection Timeout
One or more of the connections in which this module
is the target has timed out. This state is only left if all
timed out connections are re-established or if the
module is reset.
Steady Red
Duplicate IP Address
The module has detected that its IP address is
already in use
Flashing
Green/Red
Self-Test
The module is performing a power on self test
2. Active = This led flashes green each time a packet is received or transmitted.
3. Mod. Stat. = Module Status
State
Summary
Description
Steady Off
No power
The module has no power.
Steady Green
Device operational
The module is operating correctly.
Flashing Green
Standby
The module has not been configured.
Flashing Red
Minor Fault
A minor recoverable fault has been detected
Steady Red
Major Fault
A major internal fault has been detected
Flashing
Green/Red
Self-Test
The module is performing a power on self test
4. Link = Link Activity
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Color
State
Green
On
Page 11
Revised 4/11
Description
The module has a link
Off
The module does not sense a link
Configuration File
The EtherNet/IP module contains a file (ethcfg.cfg) that is read by the module at start up. This
file defines the network properties of the module. Any text editor can be used to edit the
parameters.
Note: It is very important to follow the exact syntax specification, otherwise the module might
have problems interpreting it, which can result in a faulty or non-expected behavior.
The file can be uploaded and after modification, downloaded using the FTP function.
(e.g. open a Windows Explorer window. Type ‘FTP://192.168.23.200’)
The format of the file is shown as follows:
FORMAT
EXPLANATION
[IP address]
192.168.23.180
IP Address
[Subnet mask]
255.255.255.0
Subnet mask
[Gateway address]
0.0.0.
Gateway address
[DHCP/BOOTP]
DHCP/BootP
ON
ON - Enabled
OFF – Disabled
[SPEED]
Speed
Auto
Auto – Default. Auto Negotiation will be used.
100 – Forces the module to operate at 100Mbit/s only
10 – Forces the module to operate at 10Mbit/s only
Page 12
Revised 4/11
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
FORMAT
EXPLANATION
[Duplex]
Duplex
Auto
Auto – Default. Auto negotiation will be used.
Full – Forces the module to operate at full duplex only
Half - Forces the module to operate at half duplex only
[SMTP address]
0.0.0.0
[SMTP username]
SMTP server/ login settings
SMTP server/ login settings
username
[SMTP password]
password
SMTP server/ login settings
[DNS1 address]
0.0.0.0
Primary and Secondary DNS
[DNS2 address]
0.0.0.0
Primary and Secondary DNS
[Domain name]
hms.se
Domain Name (Optional)
[Host name]
Host Name (Optional)
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Page 13
Revised 4/11
Page 14
Revised 4/11
Word
Address
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Function
Reserved
Reserved
Setpoint Zone 1
Setpoint Zone 2
Setpoint Zone 3
Setpoint Zone 4
Setpoint Zone 5
Setpoint Zone 6
Setpoint Zone 7
Setpoint Zone 8
Setpoint Zone 9
Setpoint Zone 10
Setpoint Zone 11
Setpoint Zone 12
Setpoint Zone 13
Setpoint Zone 14
Setpoint Zone 15
Setpoint Zone 16
Motor Mode Pump 1
Motor Mode Pump 2
Manual Speed Pump 1
Manual Speed Pump 2
Pressure Channel 1
Pressure Channel 2
Pressure Channel 3
Pressure Channel 4
Actual Temp. Zone 1
Actual Temp. Zone 2
Actual Temp. Zone 3
Actual Temp. Zone 4
Actual Temp. Zone 5
Actual Temp. Zone 6
Actual Temp. Zone 7
Actual Temp. Zone 8
Actual Temp. Zone 9
Actual Temp. Zone 10
Actual Temp. Zone 11
Actual Temp. Zone 12
Actual Temp. Zone 13
Actual Temp. Zone 14
Actual Temp. Zone 15
Actual Temp. Zone 16
Actual Speed Pump 1
Actual Speed Pump 2
Line Speed Pump 1
Line Speed Pump 2
Controller ON/OFF
Standby ON/OFF
Adhesive Level Status
Zone RTD Fault *3
Zone On/Off '0' *3
Zone Waiting 'W' *3
Zone Heating 'H' *3
Dynacontrol - EtherNet/IP
Data Table
Date: 01/21/11
Page 1 of 2
IN-Area (Dynacontrol to PLC)
Version: V1.10 (V5.36S)
Zone Name
Hopper
Hose 1
Head 1
Hose 2
Head 2
Hose 3
Head 3
Hose 4
Head 4
Hose 5
Head 5
Hose 6
Head 6
Premelt Zone
Pump
Pump
-
Hopper
Hose 1
Head 1
Hose 2
Head 2
Hose 3
Head 3
Hose 4
Head 4
Hose 5
Head 5
Hose 6
Head 6
Premelt Zone
Pump 1
Valid Range
'S' (83) = Stop / 'M' (77) = Manual / 'A' (65) = Auto
0 to 1000 = 0.0 to 100.0%
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
0 to 500°F
[500 = 50.0%]
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
(1999 = open sensor / 999 = shorted sensor)
0 to 1500 = 0.0 to 150.0 RPM
Pump 1
0 to 1000 = 0.0 to 100.0%
Each zone is
represented by
the corresponding
bit in these 16 bit
0 = controller is OFF / 1 = controller is ON
0 = Normal Mode / 1 = Standby is active
0 = Level is OK / 1 = Level is low
0 = RTD on this Zone is o.k. / 1 = RTD Fault on this Zone
0 = Zone deactivated / 1 = Zone activated
0 = Zone is not waiting / 1 = Zone is waiting
0 = Zone is not heating / 1 = Zone is heating
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
59
60
Zone Ready 'R' *3
Zone Alarm 'A' *3
61
System Status
62
63
Watchdog
words
Page 15
Revised 4/11
0 = Zone is not ready/ 1 = Zone is ready
0 = Zone has no alarm / 1 = Zone has alarm
Bit0: Motor in Run mode,
Bit2: Pump enable temp. reached,
Signal toggles every 0.5sec. (0/1)
Dynacontrol - EtherNet/IP
Data Table
Date: 01/21/11
OUT-Area (PLC to
DynaControl)
Word
Address
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Function
Reserved
Reserved
Setpoint Zone 1
Setpoint Zone 2
Setpoint Zone 3
Setpoint Zone 4
Setpoint Zone 5
Setpoint Zone 6
Setpoint Zone 7
Setpoint Zone 8
Setpoint Zone 9
Setpoint Zone 10
Setpoint Zone 11
Setpoint Zone 12
Setpoint Zone 13
Setpoint Zone 14
Setpoint Zone 15
Setpoint Zone 16
Motor Mode Pump 1
Motor Mode Pump 2
Manual Speed Pump 1
Manual Speed Pump 2
Local Access Temps.
Local Access Motors
Zones Enable
Error Reset
Temp. Unit Selection
Bit1: Temperatures ready,
Bit3: Low temp. thermostat closed
Page 2 of 2
Version: V1.10 (V5.36S)
Zone Name
Hopper
Hose 1
Head 1
Hose 2
Head 2
Hose 3
Head 3
Hose 4
Head 4
Hose 5
Head 5
Hose 6
Head 6
Premelt Zone
Pump
Pump
all Temps.
all Pumps
Zone 1 to 16
-
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
100°F - 425°F
/
/
/
/
/
/
/
/
/
/
/
/
/
/
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
50°C - 218°C
'S' (83) = Stop / 'M' (77) = Manual / 'A' (65) = Auto
0 to 1000 = 0.0 to 100.0% [500 = 50.0%]
1 = Local Access Enable
1 = Local Access Enable
each bit: 1 = zone enabled
0 to 1 transition will reset RTD fault
0 = Fahrenheit / 1 = Celsius
Page 16
Revised 4/11
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
ITW Dynatec c. 2003
DYNAMELT S ASU Manual 20-31, D25/45 ASU Manual 20-51
Controller ON/OFF
Standby ON/OFF
0 will switch off / 1 will switch on
0 selects normal / 1 activates Standby Mode
Identification Word
Set to 34 or toggle between 0/1 to validate
communication
ITW Dynatec c. 2007
PN 113376 Line Speed Tracking Kit
Page 1
Revised 11/13
Dynamelt S Adhesive Application System, V.5
INTERNALLY-MOUNTED LINE SPEED TRACKING KIT FOR
PISTON PUMP MODELS
Internally-Mounted Line Speed Tracking Kit for Piston Pump Models: PN 113376
This Dynamelt S option is designed for customers who desire line speed tracking capability on their
piston pump units. The line-speed tracking assembly controls line speed and adjusts adhesive output
using a signal isolator and an I/P transducer. Components are mounted internally and are typically
controlled through a parent machine.
Settings for Option
1. Factory Settings:
a. The CUR/VLT selector must be set “VLT” (Voltage Input).
b. Adjustment of the Minimum Potentiometer:
i. Connect a mA-meter between #9 Output on the Signal Isolator and I/P Transducer
white lead.
ii. Select DC Amps.
iii. Switch DynaControl Controller to Manual Mode 20% (20% = 4mA in a 4-20mA
range).
iv. Adjust Min Potentiometer of the Signal Isolator PCB so that meter shows 4mA.
c. Adjustment of the Maximum Potentiometer:
i. Switch DynaControl Controller to Manual Mode 100%.
ii. Adjust Max Potentiometer of the Signal Isolator PCB so meter shows 20mA.
Never exceed the 20mA as this can damage the I/P Transducer.
iii. Switch back to Auto Mode.
2. I/P Transducer:
The I/P Transducer does not require any adjustments since this can be done via the Signal
Isolator PCB or the DynaControl Controller keypad.
3. Field Adjustment:
Use only the Minimum and Maximum Pump Speed Adjustment of the DynaControl controller to
adjust the necessary pump pressure. See Ch. 5, pg. 5-26.
Note: The customer should make no adjustments to the transducer.
Further information
For programming instructions, see Manual #20-31 Dynamelt S ASU, Ch. 5.
For information about the line speed tracking printed circuit board, see Manual #20-31 Dynamelt S
ASU, Ch. 7.
For information about the signal isolator, see Manual #20-31 Dynamelt S ASU, Appendix.
Page 2
Revised 11/13
ITW Dynatec c. 2007
PN 113376 Line Speed Tracking Kit
PN 113376 Line Speed Tracking Kit Wiring & Air Line Diagrams, Rev. E
Page 3
Revised 11/13
ITW Dynatec c. 2007
PN 113376 Line Speed Tracking Kit
Bill of Materials: Line Speed Tracking Kit PN 113376
Item No.
Part No.
Qty.
Description
Page 4
Revised 11/13
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 2007
PN 113376 Line Speed Tracking Kit
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Page 1
Revised 1/23/04
Dynamelt S Adhesive Application System, V.5
HIGH TEMPERATURE OPTIONS
High Temperature Models
The DYNAMELTÒ S Series adhesive supply units (ASUs) are available in high-temperature (HT)
models. These ASUs operate at setpoints up to 232°C/450°F and are designed to operate in a high
ambient temperature (over 38°C/100°F) environment.
The high-temperature ASUs are equipped with a vented pump and electronics cover that contains
two fans which activate automatically with the ASU’s circuit breaker. The fans draw filtered air
through the electronics compartment to cool the printed circuit boards.
On the high operating temperatures ASUs, special high-temperature pressure relief valve, over-temp
switch assembly and high-temperature o-rings are installed. Special factory settings allow all controller features to function in the same manner as the standard Dynamelt S ASU, but with setpoints
up to 232°C/450°F. The HT models are available as single gearpump units only.
High Operating Temperatures PN 107162
A standard Dynamelt S single gearpump ASU may be modified to operate at temperature setpoints
up to 232°C/450°F by installing the kit listed above. Included are high temperature o-rings and
pressure relief valve, a vented cover kit containing two fans and a high temperature over-temperature switch assembly.
This Manual
This manual serves as an installation guide for the retrofit kits. It also contains a wiring diagram
and describes maintenance and spare parts unique to the Dynamelt S HT ASUs.
For all other information (ie, programming, operation, troubleshooting, system schematics, exploded-view diagrams of standard components, etc.) refer to your Dynamelt S ASU Manual
(#20-31).
Page 2
Revised 5/00
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Installation Instructions
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.
Remove the ASU’s old pump and electronics cover by loosening the four captive screws at the bottom of the cover, then lifting the cover up and off.
Install Over-Temp Switch Assembly (Thermostat)
The retrofit kit provides a high temperature over-temp switch assembly whch replaces the old one
installed on the ASU. The over-temp switch assembly (thermostat) is located in the base of the hopper.
Refer to page 8-1 of the Dynamelt S ASU Manual, “Hi-Temperature Thermostat Replacement”, for
procedure.
Wire Fan Cable to ASU
The fans located on the new pump and electronics cover must be wired to the Dynamelt S ASU by
means of a detachable fan cable.
The fan cable is connected to the ASU’s Power Printed Circuit Board (for a layout diagram of this
pcb, see page 7-6 in the ASU manual). Refer to page 5 of this manual for wiring diagrams and instructions.
cont.
Page 3
Revised 5/00
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Install O-ring Group
Each high-temperature o-ring listed in the chart below must be installed on the ASU. Refer to
pages 6 & 7 of this manual for illustration of o-ring locations. This group does not provide o-rings
for the pressure relief valve, additional hose ports, drop-in grids, pressure gauges or other accessories.
High Temp
Part Number
O-ring
Size
Qty
Location on ASU
Replaces
Part Number
N07081
- 014
2
1
5
Between Filter Manifold and Hopper
Inside Filter Shutoff Assembly (PN 102752)
On Hose Port Plugs (PN 101625)
N00181
N00181
069X024
N07088
- 912
1
1
On Filter Shutoff Assembly (PN 102752)
On Plug (PN N00094) in Hopper opposite the
Filter Shutoff
N00210
N00210
069X098
- 041
2
Gear Pump Face Seal
069X064
069X099
- 028
1
On Filter Nut (PN 006C024)
069X058
069X229
- 022
1
Between Pump Outlet and Hopper
N00188
069X285
- 032
1
Between Filter Manifold and Hopper
N00192
100097
- 111
2
On Hose Port Fitting (PN 101624)
N00196
Install Pressure Relief Valve
1. At the rear of the ASU, remove the hose cover (item #17 on ASU Manual page 10-4 & 10-5).
2. Unscrew and remove the old pressure relief valve (item #35 on ASU Manual page 10-12 &
10-13) located on the outlet filter manifold. Replace with the high temp pressure relief valve
provided.
Final Installation Sequence
1. Connect the fans electrically to the fan cable.
2. Install the new pump and electronics cover via four captive screws.
3. Re-connect input power to the application system and start up the ASU.
4. Re-program the temperature setpoints on the DynaControl controller as desired.
Page 4
Revised 5/00
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Maintenance
Fan Filter
The fan filter, located within the fan cover on the top of the pump and electronics cover, needs periodic cleaning (or replacement). After installation, inspect and clean the filter weekly. The time
between filter cleaning may be increased as experience dictates.
To clean filter:
1. Remove the four button head screws that attach the fan cover to the pump and electronics cover.
2. Remove the open cell, foam filter from inside the cover.
3. Rinse the filter in clean water. Use of detergent is o.k. if filter is rinsed thoroughly.
4. Re-install filter after it is completely dry.
CAUTION: DO NOT OIL the filter. The filter must be kept clean and dry.
Recommended Service Parts List for High-Temp Option
Part No.
Description
106422
N07091
106434
106519
Fan Inlet Filter
Hi-Temp O-ring, -908 (pressure relief valve)
Hi-Temp O-ring Group
Over-Temp Switch Assembly
Qty.
1
1
1
1
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Wiring Diagram
Fan Wiring Instructions: Drawing PN 107169
Page 5
Revised 5/00
Page 6
Revised 8/08
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Bill of Materials: PN 107162 Dynamelt S Assembly Kit for Conversion to Hi-temp
Item No.
Description
Part Number
112056 Fan And Cover Assembly
1
106419
2
Qty.
1
Fan Assembly
1
Fan Base
1
3
106421
M4 x 0.7 x 30mm SHC Screw
8
4
106422
Inlet Fan Filter
1
Fan Assembly Cover
1
M4 x 0.7 x 8mm Button head Screw
8
Pump and Electrical Cover
1
Cable Assembly, Fan
1
5
6
106424
7
8
9
10
106426
106519 Over-temp. Switch Assembly (OT Thermostat)
1
106432 Hi-temp. Seal And Valve Kit
1
106433
Pressure Relief Valve, 0-1000 PSI
1
106434
Hi-Temp O-ring Group
1
11
069X098
Hi-Temp O-ring, # -041
2
12
069X099
Hi-Temp O-ring, # -028
1
13
069X229
Hi-Temp O-ring, # -022
1
14
069X285
Hi-Temp O-ring, # -032
1
15
100097
Hi-Temp O-ring, # -111
2
16
N07081
Hi-Temp O-ring, # -014
8
17
N07088
Hi-Temp O-ring, # -912
2
Page 7
Revised 4/09
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
5
6
4
3
2
1
7
6
8
Pump
11
13
17
12
10
Filter
Manifold
17
16
16
16
9
Primary Filter
14
15
Component Illustration: Dynamelt S Assembly Kit For Conversion To Hi-temp
Page 8
Revised 8/03
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
8
1
2
3
4
7
6
9
or 10
11 14
5
5
12
13
or
15
16 17
Dynamelt S 22/45 High Temp Grid Group - 110459
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part Number
104802
N07081
069X285
106174
107204
107183
108297
N05889
107525
107526
048H384
106393
106379
107389
107179
106095
106529
Description
Knife Grid
O-ring, -014 Hi Temp
O-ring, -032, Hi Temp
Sensor adaptor
Wire Assembly, Jumper , Relay
Temperature Sensor
M8 x 20mm Hex Head Screw
Term, Fem, 16---14, Slip-on
Lower Gid Support
Upper Grid Support
Relay, SSR, Dual
Wire harness
Cable Assembly
M4 x 8mm Pan head
Cable Assembly
PCB Assembly, Aux Power
Thermal Pad, PCB
Qty.
Description
1
4
1
1
1
1
4
1
1
1
1
1
1
2
1
1
1
Page 9
Revised 8/03
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
Dynamelt S 22/45 High Temp Tee Block Assembly - 110460
Item No.
1
2
3
4
5
6
7
8
Part Number
103901
803638
103902
1039033
N07081
101625
100097
101624
Description
Tee Block
O-ring, -017, Hi Temp
Flow Nipple
Flow Nipple Nut
O-ring, -014, Hi Temp.
1/4 BSPP Plug
O-ring,-111, Hi Temp.
#6 JIC x 1/4 BSPP
Qty.
1
4
2
2
2
2
1
1
Page 10
Revised 8/03
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1999
DYNAMELT S HT ASU Manual #20-35
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