dynamelt m series adhesive supply unit operations and service

dynamelt   m series adhesive supply unit operations and service

ITW Dynatec

An Illinois Tool Works Company

31 Volunteer Drive

Hendersonville, TN 37075 USA

Telephone 615.824.3634

FAX 615.264.5222

ITW Dynatec GmbH

Industiestrasse 28

D-40822 Mettmann, Germany

Telephone 49.2104.915.0

FAX 49.210.2104.915.111

ITW Dynatec K.K.

Daiwashinagawa Bldg., 7-15 Konan, 3-Chome

Minata-Ku, Tokoyo 108 Japan

Telephone 81.3.3450.5901

FAX 81.3.3450.8405

Adhesive Application Solutions • ISO 9001 Certified

OPERATIONS & SERVICE MANUAL

Manual 20-37

Revised 5/18/04

DYNAMELT

M SERIES ADHESIVE SUPPLY UNIT

OPERATIONS AND SERVICE MANUAL

Model DM M70/ 140 DCL

Software V5.11M and up with Expanded DynaControl

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 2/01 c. 2001

DYNAMELT M70/140 DCL ASU Manual 20-37

This Service Manual is available in the following versions:

Language

English

German

French

Italian

Swedish

Spanish

Dutch

Japanese

Portugese

Finnish

Chinese

Manual #

20-37-L21

20-37-L22

20-37-L23

20-37-L24

20-37-L25

20-37-L26

20-37-L27

20-37-L28

20-37-L29

20-37-L30

20-37-L31

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2001

DYNAMELT M ASU Manual #20-37

Table of Contents Page iii

Revised 11/01

TABLE OF CONTENTS

Chapter 1 Safety Precautions

Chapter - Page #

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Temperatures

High Pressure

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Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Eye Protection & Protective Clothing

Safe Installation and Operation

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Treatment for Burns From Hot Melt Adhesives

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explosion/ Fire Hazard

Lockout/ Tagout

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1-2

1-2

1-2

1-3

1-1

1-1

1-1

1-1

1-3

1-3

Chapter 2 Description & Specifications

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Dimensions

Total System Wattage Capacity

Main Circuit Breaker Detrmination

Definition of ASU Code

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2-1

2-2

2-4

2-6

2-6

2-7

Chapter 3 Installation & Start Up

Placing the DYNAMELT ASU

To Open/ Close Panel Box Door

Installation

User Connections

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Printed Circuit Board Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose/ Head Electrical & Adhesive Connections (illustration)

3-1

3-2

3-2

3-3

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3-4

3-6

Electrical Connections & Filter Manifold Arrangement, Maximum Hose/ Head Configuration (illus.) 3-6

Adding Adhesive

Changing the Adhesive Formula

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Installation of Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Adjusting the Pressure Relief Valve

Pump Enable (Ready) Thermostat Calibration

Calibration of the Optional Voltage Tachometer

Level Controls

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Installation of the Optional Tach Generator or DC Tracking Signal

Calibration of the Optional Tach Generator or DC Tracking Signal

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Field Installation of the Optional Memory Card Reader

Typical Start Up and Shut Down Procedures

Storage and Disposal of the Application System

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3-8

3-8

3-8

3-9

3-11

3-12

3-13

3-14

3-15

3-16

3-18

3-19

Chapter 4 DynaControl Controller Set-Up

Temperature Control Functions in General

Defining DynaControl Temperature Control Terms

Error Indication and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional System Status Lights

Settings for a Typical Operation

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System Values that are Factory Programmed (not customer accessible)

Customer Programmable Values Preset at the Factory

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4-1

4-1

4-4

4-6

4-6

4-7

4-7

Page iv Table of Contents

Revised 11/01 c. 2001

DYNAMELT M ASU Manual 20-37

Default Settings of the DynaControl Controller

Helpful Tips for the User

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Serial Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8

4-9

4-10

Chapter 5 Programming of DynaControl Controller

Controller Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display & Keypad Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Programming Sequence: Quick Reference

Controller Setup

Turning the Controller On

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Language Selection

Temperature Scale Selection

Actual Temperatures Screen

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Use of the Actual Temperatures Screen

Programming Sequence

Monitoring

Setpoints Programming Screen

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Use of the Setpoints Programming Screen

Programming

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Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Programming Screen

Use of the Motor Programming Screen

Programming

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Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Clutch Programming Screen

Use of the Optional Clutch Programming Screen

Programming

Monitoring

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Optional Pressure (PSI/BAR) Programming Screen

Programming

Monitoring

Service Functions Screens

Service Page 1

High/ Low Temperature Deviation

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Use of the Optional Pressure (PSI/BAR) Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5-13

5-15

5-15

5-15

5-16

5-16

5-17

Standby Temperature

Standby /SleepSetup 5-17

Setpoint Limitation

Sequential Heating

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5-17

5-17

Temperature Offset 5-18

5-18

5-9

5-9

5-9

5-10

5-11

5-11

5-5

5-5

5-6

5-6

5-7

5-7

5-8

5-11

5-12

5-13

5-13

5-13

Temperature Scale

Change Security Lock

Service Page 2

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Customer Zone Names

Power On Configuration

Factory Defaults

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Keypad Locking

PC Link

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Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LCD Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-1

5-2

5-4

5-5

5-5

5-20

5-20

5-20

5-20

5-20

5-20

5-18

5-18

5-19

5-19

5-19

5-20

c. 2001

DYNAMELT M ASU Manual #20-37

Table of Contents Page v

Revised 11/01

Service Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming at Main Scheduler Screen

Use of the Main Scheduler Screen

Programming of 7-Day Scheduler

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Use of the 7-Day Scheduler Screen

Programming

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Programming of the Optional Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up/ Downloading Instructions: Controller to Remote PC (PC Link) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Dual (Split) Hopper Display & Keypad Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-21

5-22

5-23

5-24

5-25

5-25

5-26

5-27

5-31

Chapter 6 Preventive Maintenence

General Cleaning

Preventive Maintenance Schedule

Outlet Filter

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Outlet Filter Manifold (illustration)

Hose Fittings

Fasteners

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Optional High Flow Outlet Filter Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Shutoff Cleaning or Replacement

Pump Shaft Leak

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Preventive Manintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

6-5

6-5

6-5

6-1

6-1

6-1

6-2

6-3

6-4

6-4

Chapter 7 Troubleshooting

General Troubleshooting Notes

Preliminary Checks

Error Messages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose/ Applicator Troubleshooting Tip

Motor Speed Control PC Board Re-set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Temperature Redundant Overtemp Thermostat

Pump Enable Thermostat

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lithium Battery on PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CPU Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display CPU Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Control Interface Printed Circuit Board & Layout Illustration

Motor Speed Control Printed Circuit Board & Layout Illustration

48-Zone Power Printed Circuit Board & Layout Illustration

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Clutch Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional RS232/485 Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Pressure (PSI) Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater and Sensor Resistance Values

Resistance Tables

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Indication Alarm Troubleshooting Guide

Adjustable Adhesive Pressure Relief Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of the ASU’s Gear Pump

Troubleshooting the ASU Pump

Gear Pump Troubleshooting Guide

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10

7-10

7-11

7-12

7-13

7-14

7-22

7-23

7-24

7-25

7-2

7-3

7-4

7-5

7-6

7-7

7-9

7-1

7-1

7-1

7-1

7-1

7-2

7-2

Page vi Table of Contents

Revised 8/02 c. 2001

DYNAMELT M ASU Manual 20-37

Chapter 8 Disassembly & Re-assembly Procedures

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Access Doors

To Open the Junction Box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor or Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Manifold Cover

Heater Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Access the RTD Sensor in the Optional Drop-in Grid

To Access the Electrical Components Inside the Panel Box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Memory Card Reader Battery Replacement

To Access the Pump or Motor

Motor Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional DC Motor Brush Replacement

Pump Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Seal (O-ring) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Re-assembly Procedures & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8-3

8-3

8-3

8-3

8-1

8-1

8-1

8-2

8-2

8-2

8-3

8-4

8-4

8-4

8-5

8-5

8-5

Chapter 9 Available Options & Accessories

Pressure Gauge Kit

Pre-PSI and Post-PSI Transducers

Drop-in Grids

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Temperature Heater Groups

Filter Options & Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Options & Accessories

Gear Motor Options

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return (Re-circulating) Hoses

Pneumatic Clutch

Dual Hopper

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Flow ASUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DynaControl Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

9-2

9-2

9-3

9-3

9-3

9-1

9-1

9-1

9-1

9-1

9-3

9-3

9-5

Chapter 10 Component Illustrations & Bills of Material

Chapter Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief & High Temperature Filter Block Assemblies

Typical Electrical Panel Box Assembly

Cabinet Assemblies

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melt & Grid Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Adapter Assemblies

Pressure Gauge Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1

10-2

10-6

10-10

10-14

10-16

10-18

10-26

10-28

In addition to the assemblies listed above, this chapter may also contain illustrations for other optional assemblies ordered with your ASU.

c. 2001

DYNAMELT M ASU Manual #20-37

Table of Contents Page vii

Revised 12/02

Chapter 11 System Schematics & Engineering Drawings

Hose Schematic: all models

Head Schematic: all models

Optional System Status Lights

Optional Level Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flow Diagram, Outlet Filter Manifold/ Cross Channel

Typical Hydraulic Schematic

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Clutch Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instruction Sheet for Pump & Zone Configuration

Dynamelt M ASU Schematics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2

11-3

11-4

11-5

11-5

11-6

11-7

11-8

11-9 end of chapter

Appendix

Optional Dynatec/ Zenith Standard Accuracy Gear Pumps

Optional Dynatec/ Zenith High Accuracy Gear Pumps

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Zenith Melt Spinning Pumps

High Accuracy Pump Performance Chart

Pressure Transducer

Pneumatic Clutch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Memory Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix 1

Appendix 15

Appendix 29

Appendix 34

Appendix 35

Appendix 37

Appendix 47

Page viii Table of Contents

Revised 11/01 c. 2001

DYNAMELT M ASU Manual 20-37

ITW Dynatec

An Illinois Tool Works Company

ITW Dynatec c. 2001

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Chapter 1

SAFETY PRECAUTIONS

Page 1-1

Revised 9/98

All maintenance and service on this equipment must be performed by trained technicians.

All operators and service personnel must read and understand this manual before operating or servicing equipment.

Electrical

DANGER

HIGH VOLTAGE

Dangerous voltages exist at several points in this equipment. To avoid personal injury, do not touch exposed connections and components while input

High Temperatures

WARNING

HOT

SURFACE

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.

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

Protective Covers

WARNING

DO NOT OPERATE

WITHOUT GUARDS

IN PLACE

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.

Keep all guards in place!

To avoid personal injury, do not operate the application system without all covers, panels and safety guards properly installed.

Page 1-2

Revised 3/97

ITW Dynatec c. 2001

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Eye Protection & Protective Clothing

WARNING

EYE PROTECTION

REQUIRED

PROTECTIVE

CLOTHING

REQUIRED

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.

It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment!

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.

Always have first-aid information and supplies available.

Call a physician and/or an emergency medical technician immediately.

ITW Dynatec c. 2001

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Service

Refer all servicing to qualified personnel only.

Page 1-3

Revised 9/98

Explosion/ Fire Hazard

Never operate this unit in an explosive environment.

Use cleaning compounds recommended by ITW

Dynatec or your adhesive supplier only. Flash points

In This Manual

WARNINGS and CAUTIONS are found throughout this manual.

WARNINGS mean that failure to observe the specific 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.

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 c. 2001

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2001

DYNAMELT M ASU Manual #20-37

Description & Specifications Page 2-1

Revised 6/01

Chapter 2

DESCRIPTION AND SPECIFICATIONS

Description

The DYNAMELT

Ò

M Series adhesive supply units (ASU) are computer-controlled hot-melt supply units designed on metric standards. Utilizing ITW Dynatec’s DynaControl temperature controller, their control panels, with choice of display languages, provide comparative data of all setpoints, motors, etc. on a few convenient, comprehensive display screens.

The Dynamelt M Series ASUs are available in three cabinet sizes and offer four hopper sizes. The

Dynamelt 70 & 140 models use microprocessor temperature controls to closely control the temperature of hot-melt adhesive for up to 8 hoses and 8 heads. Temperature setpoints are operator-selected for up to 32 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions.

The Dynamelt/ DynaControl 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. The seven-day scheduler allows programmable automatic startup and shutdown of the ASU throughout the workweek.

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 printed circuit 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. 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 M ASU uses an extremely dependable gear pump(s) to assure a smoother and higher precision flow. The single or dual pumps are driven by individual drives.

The Dynamelt’s teflon-coated hopper accepts adhesive in all popular forms, including pellets, slugs and blocks. The ASU can accomodate air-actuated automatic applicators (heads), electric applicators, hand-held applicators and/or special applicators. Options available include pressure gauge, two drop-in grids, dual hopper, pneumatic clutches, digital pressure readout and adhesive level control.

The DM70/140s are also available in high flow models.

Page 2-2 Description & Specifications

Revised 6/03 c. 2001

DYNAMELT M ASU Manual #20-37

Specifications

Environmental:

Storage/ shipping temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient service temperature

Noise emission

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-40 ° C to 70°C (-40° F to 158°F)

-7

° C to 50°C (20° F to 122°F)

< 60 dbA at 1 meter (39 inches)

Physical:

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of heads/ hoses see dimensional layouts on following pages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 to 8

Number of return hoses or auxillary zones

Number of hopper temperature zones

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 to 8

1 to 2

Number of pump/ motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of (optional) drop-in grids

1 to 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Number of standard grids

Gear pumps

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2.92 cc/rev standard

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .

styled, durable metal, dust and splatter resistant universal 15-pin Amphenol connectors at asu,

Hopper (tank) capacity

Hopper construction wrench-secured fluid fittings (#6 JIC)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DM M70 = 70 kg/ 154 lb

. . . . . . . . . . . . . . . . . . . . . . . .

DM M140 = 140 kg/ 308 lb machined welded aluminum, Teflon impregnated

Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight, empty hopper bottom screen, large pleated pump outlet filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TBD

Adhesive form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

accepts most forms

Electrical:

Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum supply amperes

200-240 VAC/ 3p/ 50-60 Hz

380 VAC/ 3p (“Wye”, “Y” or 5-wire connection)/ 50-60 Hz

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see circuit breaker size

Power consumption, hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power consumption, 2 drop-in grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10,000 watts

5,000 watts

Hopper heater type

Temperature control

Temperature sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

cast in microprocessor-based proportional integral derivitive (PID)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Ohm Platinum RTD standard

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 Ohm Nickel RTD optional durable, latching connectors

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1/2 hp, alternating current motor, TEFC*, direct drive, vertical orientation, right angle gearbox

Maximum current available for each hose or head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ampere

* totally enclosed, fan cooled

c. 2001

DYNAMELT M ASU Manual #20-37

Description & Specifications Page 2-3

Revised 6/01

Performance:

Adhesive temperature control range 40

Standby adhesive temperature range

Hopper ready adhesive temperature deviation

(factory set/ field adjustable)

± 20°C (36°F) from setpoint

Over-temperature cutoff for hopper 232 °C (450°F)

Adhesive viscosity

. . . . . . . . . . . . . . . . . . .

up to 80

°C to 232°C (100°F to 450°F)

°C (150°F) lower than setpoint

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm-up time, full hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 to 50,000 centipoise approximately 0.5 hour

Typical adhesive melt rate (depends on adhesive used)

Adhesive pressure

. . . . .

DM M70 = 27-95 kg/hr (59-209 lb/hr)

DM M140 = 34-115 kg/hr (75-253 lb/hr)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

up to 68 bar (1000 psi) maximum

DynaControl Temperature Control:

Controller power board . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 zones per board, modular construction

Display type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature control zones (DM70/140) . . . . . . . . . . . . . . . . . .

graphic, liquid crystal

32 maximum with solid state relays

Power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hopper: 10,000 watt hose: 1200 watt applicator head: 1200 watt auxiliary: 2000 watt

Solid state relay

Line speed inputs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15 VDC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 to 4

Other:

Display languages

Operator interface

. . . . . . . . . . . . . .

English, French, German, Spanish, Swedish, Italian, Japanese,

Portugese and Dutch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

multi-zone, liquid crystal display with alpha/numeric keyboard and function keys

Temperature standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High and low temp alarms

Ready interlock

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes yes

Password protection

Sequential heating

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes (hopper, hose, head staged heating)

Sensor open alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RS232 and RS485 communications capable

Seven-day scheduler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes yes

High temp capable

Line speed tracking

CE approval

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes yes

Page 2-4 Description & Specifications

Revised 2/04 c. 2001

DYNAMELT M ASU Manual #20-37

C

F

G

H

B

D

A

D

C

I

G

B

DIMENSION

mm inches

DYNAMELT M70 DCL Installation Dimensions

A B C D F G H I

1002.4 850 1301.6 342.9 838.2 320.68 1,377.7

39.46

33.46

51.24

13.5

33 12.625

54.24

c. 2001

DYNAMELT M ASU Manual #20-37

Description & Specifications Page 2-5

Revised 2/04

F

H

B

F

D

A

C

I

G

B

DIMENSION

mm inches

DYNAMELT M140 Installation Dimensions

A B C D E F G H I

1506.4 850 1301.6 1622.3 177.8 342.9 838.2 320.68 1377.7

59.31

33.46

51.24

63.87

7.00

13.5

33 12.625

54.24

E

Page 2-6 Description & Specifications

Revised 2/01

Total System Wattage Capacity

Maximum Wattage

Hopper + High Temp Heater

PreMelt

Optional Drop-in Grid

Up to 8 Hose Zones

(1200 w each)

Up to 8 Applicator Zones

(1200 w each)

Up to 8 AUX Zones

(2000 w each)

DYNAMELT MODELS

M70 M140

12,000 w

5000 w

-- --

9600 w

12,000w

5000 w

5000 w

9600 w

9600 w

16,000 w

9600 w

16,000 w

Maximum System Wattage: 52,200 w 57,200 w

c. 2001

DYNAMELT M ASU Manual #20-37

Main Circuit Breaker Determination

Main circuit breakers vary depending on each unit’s system configuration. ITW Dynatec typically determines the main circuit breaker by the mains load for a system, which, by codes, should be

125% to 150% of the maximum load. If a customer later modifies his system (by adding heads, hoses, auxiliary outputs, etc.), the main breaker may need to be upgraded to reflect the increase in load.

To determine your existing main circuit breaker, first determine if the ASU has been modified and the breaker upgraded accordingly. If not, and the breaker is original to the ASU, you will find the main circuit breaker listed in the Panel Box Assembly (PBA) section of the indented bill of materials inserted at the back of this manual. The main circuit breaker is the largest amperage circuit breaker listed in that bill of materials.

c. 2001

DYNAMELT M ASU Manual #20-37

Description & Specifications Page 2-7

Revised 6/03

Definition of Code: DYNAMELT DM 70 & 140 ASUs w. DynaControl

ASU Code: M X X D X # X X X / # X X X X D # P X -- XX, X, X . . .

M 1 4

D N 1 G A S

/

2 Z L S 2

D 2

P 2

-F1 G C

Code PN Base Unit

70 106051 70kg (154 lb) Hopper

14 106053 140kg (308 lb) Hopper

7D 106050 70kg (154 lb) Dual Hopper

1D 106052 140kg (308 lb) Dual Hopper

1H 106696 140kg (308 lb) Hopper, HiFlo

D DynaControl Controller

Code PN Grids

N n/a Standard

G 804634 Add Drop-in Grids

O n/a Omit Drop-in Grids

Qty.

Code PN Pump(s)

# = Quantity of each Type of Pump

GAS 100860 Dynatec 1.54cc single

GBS 100861 Dynatec 3.18cc single

GCS 100862 Dynatec 4.5cc single

GAD 100863 Dynatec 1.54cc dual

GBD 100864 Dynatec 3.18cc dual

ZLS 084E372 Zenith 0.160cc single

ZDS 084E428 Zenith 0.297cc single

ZES 084E374 Zenith 0.584cc single

ZFS 084E430 Zenith 1.168 single

ZGS 084E434 Zenith 2.92cc single

SHS 108875 S&P 8.5cc single

ZLD 084E387 Zenith 0.160cc dual

ZDD 084E388 Zenith 0.297cc dual

ZED 084E 389 Zenith 0.584cc dual

ZFD 084E432 Zenith 1.168cc dual

SGD 108874 S&P 2.92cc dual

ZIS 084E411 Zenith 20cc single, Large, HiFlo

ZJS 084E412 Zenith 30cc single, Large, HiFlo

ZKS 084E413 Zenith 45cc single, Large, HiFlo

SPC Special Pump (see sales order)

Code Power

2 240V/ 3P Delta/ no neutral

3 380V/ 3P Star/ neutral only

Motor/ Drive Groups (1/ pump)

# =Total number of drives

Drive Setup

# Drives # Front # Rear

1 drive

2 “

3 “

4 “

2

2

1

1

1

2

0

1

Code PN Panel Box Assembly

PE 806460 1 drive, 2 hose/ 2 head/ 2 auxilliary, 240v

PF 806462 2 drive, 4 hose/ 4 head/ 4 auxilliary, 240v

PG 806464 3 or 4 drive, 4 hose/ 4 head/ 4 auxilliary, 240v

PH 806466 4 drive, 8 hose/ 8 head/ 8 auxilliary, 240v

PI 806461 1 drive, 2 hose/ 2 head/ 2 auxilliary, 380v

PJ 806463 2 drive, 4 hose/ 4 head/ 4 auxilliary, 380v

PK 806465 3 or 4 drive, 4 hose/ 4 head/ 4 auxilliary, 380v

PL 806467 3 or 4 drive, 8 hose/ 8 head/ 8 auxilliary, 380v

PM “Custom Designed” Panel Box Assembly

Code PN Options

C 107793 Memory Card Reader Kit

M 101563 Additional Memory Card

D Digital Pressure Readout

Fx Filter Selection

F1 101246 40 mesh outlet filter

F2 101247 100 mesh outlet filter (Standard)

F3 106273 150 mesh outlet filter

G 805641 Analog Pressure Gauge Kit (1 per pump outlet)

K N06642 Signal Isolator

L 802886 One-Point Level Control Assy

N 806573 Three-Point Level Control Assy

P 107643 Remote Display Kit

Q 108475 RS232/485 Communication

R 108313 Digital RPM Readout

U 108445 Pneumatic Clutch Kit

Y 108425 Handgun Trigger Kit

Z 106103 Drain Valve

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-1

Revised 6/01

Chapter 3

INSTALLATION

Placing the DYNAMELT M ASU

The DYNAMELT

Ò

M SERIES ASU can stand alone on flat surfaces. The main electrical power and the serial communication connections come in from below the unit and connect under the DynaControl keypad, so access is needed there.

For installation dimensions, see illustration on page 2-4.

Hopper Lid

Hose/ Head

Electrical

Connections

Manifold

Cover

Controller Keypad

Main Disconnect

Switch

Panel Box

Keylock

Panel Box

Keylock

Access

Door

Keylock

Panel Box

The DYNAMELT M70/140 DCL ASU

Page 3-2 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

Re-read Chapter 1 “Safety Precautions” before performing any installation procedures. All installation procedures must be performed by qualified, trained technicians.

To Open/ Close Panel Box Door

“ON”

Position

1. With the key supplied, unlock the panel box door.

“Reset”

Position

2. Turn the main disconnect switch counterclockwise to “Reset” while pushing the tab clockwise with your thumb.

3. Pull door open.

4. To close: Turn switch to “ON”. Hold door closed while turning swith to “Reset” and then back to “ON”.

5. Lock the panel box door with the key.

Lockout Safety Tab

Installation

After the DYNAMELT M SERIES ASU has been properly positioned, the following general sequence should be followed for installation:

1. Make sure that incoming line power to the ASU and that the unit’s main disconnect switch are turned OFF.

F

R

F

O

E

S

E

T

T

RI

P

ON

Main Disconnect Switch

DANGER HIGH VOLTAGE

Disconnect and lock out input power to the application system, using the lockout safety illustrated above, before starting any installation procedures.

Make sure there is no electrical power on the leads you will be connecting.

2. Within the panel box assembly: Connect 3 electrical leads with the appropriate voltage to the main circuit breaker and connect one electrical lead to the ground (PE) terminal (see diagram following).

380v ASUs only: In addition to above, connect one lead to the neutral terminal.

CAUTION: Grounding conductors never carry electrical current. The use of a neutral conducting wire as earth ground is incorrect and may cause damage to the controller.

cont.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-3

Revised 11/01

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 240 vac ASU:

PE

Input Power from Main Power 240vac

Ground

Main Power Switch/L1, L2, L3

Terminal rail

Required connections for 380 vac ASU:

N, PE

Input Power, from Main Power, 380 vac

Neutral, Ground

Main Power Switch/L1, L2, L3

Terminal rail

Non-essential connections; connect if feature is desired:

R1, R2

A1, A2

E1, E2

P1, P2

P3, P4

Normally Open Ready

(parent machine interlock)

External Standby

(controller standby mode)

Power PCB/ JS4/ pins 1 & 2 and

Power PCB/ JS2/ pins 1 & 2

Normally Closed Alarm

(controller display alarms)

CPU PCB/ X1/ pins 1 & 2

CPU/ X4/ connect 5 and 9 or 10

Program Select 1&2

(controller program selection)

CPU/ X4/ connect 1 to 9 or 10**

Program Select 3&4

Power On Output

” ” ” CPU/ X4/ connect 7 to 9 or 10**

Power PCB/ JS1/ pins 1 & 2

Options: Make connections for the following if installed on your ASU:

S1, S2

H1, H2

Ribboncable

Tachometer

(line speed tracking)

Hand-Held Applicator, Footswitch

Low Adhesive Level

(output alarm)

CPU PCB/ X1/ pins 3 & 4

Dual Hopper: Low Adhesive Level

(output alarm) as above. CPU1 = Hopper 1 and

Pressure Transducer(s)

Pressure Transducer(s) (

(1 to 4 transducers)

Clutch Customer Enable

Clutch Customer Enable high & low psi alarms)

(for motor 1)

(for motor 2)

RS232/485 Communication

MCI*/ X3/ 0 (ground) & 10 (+)

MCI*/ X3/ TR

CPU2 = Hopper 2

PSI PCB/ X1, X2, X3, X4

PSI PCB/ X6

Clutch PCB/ JS1/ pins 1 & 2

Clutch PCB/ JS1/ pins 3 & 4

Display CPU PCB

* MCI = Motor Control Interface PC Board

User Connections

** Program Selection Table

P1/P2

Pin 1

P3/P4

Pin 7

Program #

open open closed open

= Program 1

= Program 2 open closed = Program 3 closed closed = Program 4

Page 3-4 Installation

Revised 2/03 c. 2001

DYNAMELT M ASU Manual #20-37

Printed Circuit Board Location Diagram

The printed circuit boards (PCBs) are located within the main panel box assembly.

Note: When multiple PCBs are installed to accomodate multiple components (ie, four motor speed control PCBs and four motor control interface PCBs to accomodate four motors, as illustrated below), make connections to all PCBs.

Note: On Split Hopper Models (DM140 only) CPU PCB #1 controls Hopper #1 and CPU PCB #2 controls Hopper #2.

CPU Boards

(2 shown)

Motor Control interface Board

(4 shown)

Pressure Boards

(3 shown)

Motor Speed Control

Drive Board

(4 shown)

Main Circuit

Breaker

Main Ground

Lug (PE)Terminal

Side Panel

L1 L2 L3

X 1

CPU #1

X3

X 4

CPU #2

X1

X2

X3

X4

X6

Contactor

Neutral (380v only)

RS232/485

Communication

Board

JS1

JS1

JS4

JS2

Power Board

Circuit

Breakers

Circuit

Breaker

Neutral

(380v only)

Circuit

Breakers

Level

Control

Clutch

Board

Clutch

Board

Signal Isolator

Board

Typical Panel Box Layout

(DM140 shown)

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-5

Revised 6/01

4. The adhesive hoses are connected at the rear cover (see illustration on page 3-6). Each hose is connected at both an adhesive port and an electrical connect. Make your electrical hose connections at the numbered connects above the filter manifolds. Route hoses so that there is at least an eight-inch radius at any bend. Do not hang hoses without proper support. Do not crimp, clamp, squeeze or tie hoses.

Two feed hose adhesive ports are located at the bottom of each filter manifold. When making hose connections, use the numbered guides shown on the illustration to coordinate; ie. when using one hose make your hookup to electrical connection #1 and adhesive port #1. When using two heads/ hoses, hookup hose/ head #1 to electrical connection #1 and adhesive port #1, then hookup hose/ head #2 to electrical connection #2 and adhesive port #2, etc.

Two return hose adhesive ports are located at the top of each filter manifold. Use the illustration to coordinate adhesive port and electrical connections as above. Return hoses are designated as

“auxiliary” ports.

5. Connect (optional) PSI transducers at the PSI ports labeled on the filter manifold. Position them from left to right across the manifolds as shown in the lower illustration on page 3-6.

Transducers measuring adhesive pressure before it enters the filter use the ports stamped “Pre

PSI” and transducers measuring pressure after the filter use the ports stamped “Post PSI”.

Transducers must be wired into the pressure printed circuit board.

Units not using transducers may use either a PSI port or a feed hose port to mount a (optional) pressure gauge. If all ports are in use, the pressure gauge may be installed in line with a hose.

Refer to the hose and applicator manuals for further details on these items.

Page 3-6 Installation

Revised 6/01

Electrical

Connections

F1

#1

A1

Auxiliary

#1

Filter Nut

c. 2001

DYNAMELT M ASU Manual #20-37

Closeable Cross

Channel

Head/ Hose

Electrical

Connects

Auxiliary

(Return Hose)

Electrical

Connects

Tamper Proof Screw

Bleed Valve Port

Retainer Plate

Heater Channel

RTD Sensor Channel

Purge Drain

Hose/ Head Electrical and Adhesive Connections

F1 F2

A1

A2

A 1 A 2

PSI 1 PSI 2

F 1 F 2

F3 F4

A3

A4

A 3 A 4

PSI 3 PSI 4

F 3 F 4

F5

F6

A5 A6

A 5 A 6

PSI 5 PSI 6

F 5 F 6

F7

F8

A7

A8

A 7 A 8

PSI 7 PSI 8

F 7 F 8

Adhesive supplied by motor/pump #1

Adhesive supplied by motor/pump #2

Adhesive supplied by motor/pump #3

Adhesive supplied by motor/pump #4

Up to Four Filter Blocks with up to 16 Adhesive Ports

Note:

Always connect Auxiliary (Return) Hose #1 (A1) to Auxiliary Electrical Connect #1 (A1), Feed Hose #1 (F1) to

Feed Electrical Connect #1 (F1), etc. as described on page 3-3.

Dynamelt M70 & M140: Electrical Connection and Filter Manifold Arrangement for

Maximum Head/ Hose Configuration

c. 2001

DYNAMELT M ASU Manual #20-37

This page is intensionally blank.

Installation Page 3-7

Revised 11/01

Page 3-8 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

Adding Adhesive

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.

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.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-9

Revised 6/01

Adjusting the Pressure Relief Valve

The function of the pressure relief valve is to protect the gear pump(s) and the pump drive components from overload and to protect other components from potentially damaging pressure levels.

The system will allow pressures up to 1000 PSI, however, typical factory settings are 500 PSI.

WARNING HIGH PRESSURE

NOTE: The following procedure will require the hot melt adhesive to be at a high temperature and the application system to have substantial pressure. Safety glasses, insulated gloves and longsleeved protective clothing must be worn to prevent the possibility of serious injury from the molten adhesive. Refer to

Chapter 1 and the section entitled

“SAFETY PRECAUTIONS” for further details and First Aid information.

To Adjust Pressure Relief:

Note: This adjustment should be done with a melt pressure gauge or a pressure transducer installed. Failure to use proper equipment can result in excessive pressure levels.

1. Turn the application system ON and raise the temperatures of all components to normal operating temperatures.

Note: Position a bucket or other waste receptacle under the applicator(s) so that adhesive will be collected during the adjustment procedure.

2. At the controller, set the motor speed to “0” so that the gearmotor is not turning.

3. Locate the pressure relief assembly on the filter manifold (where the hoses attach to the ASU) and remove the access cover.

4. Position a heat-resistant container below the manifold. With a hex key screwdriver (allen wrench), slowly loosen the manifold’s two purge set screws (do not attempt to remove them).

Allow adhesive and pressure to escape out of the manifold. Adhesive will drain into the container.

5. Remove the adjustment screw cap (see diagrams below) and loosen the jam nut. Turn the adjustment screw counter-clockwise until it is two turns from being completely out of the filter plug.

Note: if the adjustment screw comes out of the filter plug, be prepared for some adhesive to flow out of the screw hole.

cont.

Screw cap

Turning the adjustment screw

counterclockwise opens the outlet and decreases the pressure to the hose.

Jam nut

Adjustment screw

Turning the adjustment screw

clockwise closes the outlet and increases the pressure to the hose.

Page 3-10 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

6. At the controller, turn the motor ON to its maximum operating speed.

7. Actuate (open) the valves on the applicator(s) in order to fill them with adhesive and purge air from the system.

8. Close the valves (those openend in the last step) to stop the flow of adhesive.

9. Using a wrench, turn the adjustment screw clockwise to increase the pressure to the applicator(s).

CAUTION: Approach desired pressure with caution. DO NOT TURN THE ADJUSTMENT

SCREW COMPLETELY CLOCKWISE (BOTTOMING IT INTO THE PLUG), since this would shut off the pressure relief channel and could cause extensive damage to the pump, motor and seals. Be aware that the higher the adjusted pressure, the more sensitive the adjustment is (i.e., at higher pressures, smaller adjustments to the screw will make larger changes to actual pressure).

10. After desired pressure is achieved, tighten the jam nut down onto the adjustment screw and lock it in place.

11. Replace and tighten the adjustment screw cap.

12. While the motor is operating at maximum speed, observe the adhesive flow from the applicator(s).

13. Reduce the motor speed, in increments of about 10%, until the adhesive flow begins to decrease.

Note: Though the speed of the motor is reduced, there will be no change in the amount of adhesive flow coming out of the applicator. This is because the pressure relief is designed to allow only a maximum adhesive pressure regardless of the motor speed past a certain point.

Then, increase motor speed in smaller increments (1 to 5%) until adhesive flow returns to the desired amount.

Note: This is the optimum point of operation for the motor, pump and pressure relief. It will also facilitate the best system performance and reduce wear on these components.

The application system is now adjusted for normal operation.

14. Re-tighten the two purge screws and re-install the access cover.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-11

Revised 6/01

Pump Enable (Ready) Thermostat Calibration

The Pump Enable (Ready) Thermostat is preset to 132

°C (270°F), unless the customer has specified a different preset temperature on his original ASU order. Generally, the pump enable thermostat is set approximately 30

°C (50°F) lower than the application setpoint. If a different temperature is desired, use the following procedure to re-calibrate the thermostat.

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 setpoint to the temperature at which you want the pump to start, i.e. 107 °C (225°F).

Hopper

2. Use the key to unlock the side door, then remove it, being carefull not to pull out the ground wire attached.

3. Wait for the hopper temperature to stabilize at 107

°C (225°F), then: a. For thermostats with purple & black wire leads or tan leads: turn the thermostat’s adjustment screw counter-clockwise to increase

the pump’s

Pump EnableThermostat motor begins turning. Adjust no further.

b. For thermostats with tan (with tracer) wire leads: turn the thermostat’s adjustment screw clockwise to increase the temperature (or counter-clockwise to decrease it) until

4. Replace the side door.

5. At the keypad, re-set the hopper temperature setpoint to its correct “run” temperature.

Page 3-12 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

Calibration of the Optional Voltage Tachometer

A voltage tachometer allows the system operator to monitor gear pump motor speed from the controller. This information is useful since the amount of glue dispensed per product can be varied by adjusting the motor rpm (an increase in rpm = an increase in glue dispensed).

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. Be sure to read and follow the safety procedures in Chapter 1 of this manual. Only qualified persons accustomed to working with live electrical circuits should per-

form this procedure on the Dynamelt system.

Calibration Procedure

1. Turn the application system ON and raise the temperatures of all components to normal operating temperatures.

2. Turn main power OFF and open the panel box door. Restore power to the ASU.

3. At the controller keypad, verify normal operation in AUTO, STOP and MANUAL modes

(refer to “Motor Control Programming” in Chapter 5 if needed).

4. At the controller keypad, set motor speed to MANUAL mode and to 100% full speed.

5. With an external tachometer, measure the motor RPM.

6. On the Motor Control Interface PCB, turn the MAX ADJUST potentiometer until the RPM of the external tachometer reads 1800 rpm.

7. Calibration of this motor is complete. If additional motors are used on your application system, repeat the above procedure for each motor.

8. Close the panel box door and restore application system to normal operation.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-13

Revised 6/01

Installation of the Optional Tach Generator or a DC Tracking Signal

The installation of a tach generator or a similar DC tracking signal allows speed tracking of the gear pump through voltage following. Multiple motor boards may be wired in parallel to the tach generator. On the 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. Open the panel box and locate the Motor Control Interface Board (see layout illustrtion in

Chapter 7). The device will be connected to the “0” and “10” terminals on X3.

3. A. To install a tach generator: i. If, when facing the shaft on the tach generator, the rotation of the shaft is clockwise, connect the black lead wire to the “0” terminal and connect the white lead wire to “10”.

or

ii. If, when facing the shaft on the tach generator, the rotation of the shaft is counter-clockwise, connect the black lead wire 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. Close the ASU’s panel box door.

5. Re-connect input power and restore the application system to normal operation.

Procede to “Calibration of the Optional Tach Generator or DC Tracking Signal”.

Page 3-14 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

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 for each motor: a. Go to Motors screen.

b. Choose AUTO mode. Press Enter.

c. Scroll to Min % and enter a value of “0”. Press Enter.

d. Scroll to Max % and enter a value of “100”. Press Enter.

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.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-15

Revised 11/02

Optional Level Controls

Single Point Level Control

The level control device informs the ASU’s operator, via a “Level Low” message on the Dynacontrol controller’s System Status display, that the ASU’s hopper needs to be refilled or that it is overfull. It may also be wired to stop production. When the alarm activates, press “C” to reset it.

You then have five minutes to refill the hopper before the alarm reactivates and the ASU’s pumps stop.

The single point level control monitors a low adhesive level.

The capacitive sensor is mounted in the hopper. The sensor cable is plugged into an amplifier.

DO NOT CUT the sensor cable.

Adjustment of the Single Point Level Control:

To adjust the adhesive level control’s sensitivity, access the control’s amplifier, located inside the panel box assembly. On the amplifier (diagrammed below) is a sensitivity adjustment screw.

Turn the screw clockwise to increase sensitivity (or counter-clockwise to decrease). The yellow

LED lights to indicate the presence of adhesive. When the LED goes out, the alarm will activate.

Sensor

Connect

1 2 3 4 5 6 min max

S

7 8 9 10 11 12

Sensitivity Adjustment Screw

Yellow LED

Amplifier

Multi-Point Level Control

Refer to the level control manufacturer’s manual for complete instructions on its setup and operation.

The multi-point level control is used with customer-controlled devices (not the Dynacontrol controller). It has the capability for three separately calibrated outputs. However, for most applications, one output, calibrated with a high and a low level, is sufficient.

The two other outputs may be used as safeties (such as “critical high” and “critical low”) for multi-ASU systems with bulk feeders.

Page 3-16 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

Field Installation of the Optional Memory Card Reader

If ordered as an option with a new Dynamelt ASU, the Memory Card Reader will be factory installed. To add a Memory Card Reader to a unit in the field, follow these installation instructions:

IMPORTANT: A Dynatec factory-formatted Memory Card (PN 107994) is required for the controller to function properly. Do not attempt to use any other card.

DANGER HIGH VOLTAGE

Dynamelt systems use electrical power that can be life threatening. Disconnect and lock out input power to the application system before starting any installation procedures. In addition, disconnect ALL incoming power to the ASU.

POWER TO THE MAIN CIRCUIT BREAKER MUST BE DISCONNECTED.

1. Switch OFF the Main Disconnect (this is the circuit breaker lever located on the panel box) and open the panel box door.

2. Remove the DynaControl mounting bracket from the ASU via four screws accessed from inside the panel box assembly.

3. On the inside of the mounting bracket, remove the two nuts from the cover over the card reader slot. Place the Memory

Card Reader assembly into the cut out window with its ribbon cable connector facing inside. Use the two screws supplied to mount the assembly to the bracket.

Card Reader assembly

3. Install either end of the 40-pin ribbon cable (supplied) into the connection on the Display CPU board.

4. Connect the ribbon cable from the CPU board to the connection on the Memory Card Reader assembly.

cover

5. Re-install the mounting bracket onto the panel box with the four screws.

6. Close the panel box and re-connect input power to the application system and start up the ASU.

7. Insert the Memory Card into its slot on the control panel, with the terminal connection end of the card leading into the housing. The card will click into place when it is correctly inserted.

Main

Disconnect

Switch

Dynacontrol

Mounting

Bracket

Memory

Card

Reader connection

2

16

Display CPU Board

cont.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-17

Revised 11/01

8. On the controller’s keypad display, you will be asked to choose either:

“SAVE” (meaning that data will be transferred from the controller to the card), or

“LOAD” (meaning that data will be transferred from the card to the controller).

9. Press the F1 or F2 button to confirm your choice, or

Press the F4 button to cancel out.

10. Re-insert the card and watch the controller’s display to see if the card is being read by the controller.

Page 3-18 Installation

Revised 8/02 c. 2001

DYNAMELT M ASU Manual #20-37

Typical Start-Up and Shut Down of the DYNAMELT M Application System

The following simplified sequence assumes that the 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 Disconnect (the circuit breaker located on the panel box).

3. At the DynaControl keypad, press the controller’s F1 button, if prompted to do so.

4. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the temperatures of the temperature zones to stabilize. Monitor the System Status display to see when “Heat

Up” changes to “Ready”. Undertemp arrows will blink until the temperature zones are up to ready temperature.

5. When temperatures are ready, the pump and motor are enabled to pump adhesive.

At the pump screen:

Select Auto or Manual Mode. Select desired pump, press Enter.

a. If Pump is in Auto Mode: Adhesive will begin to pump when the production line begins to operate.

b. If Pump is in Manual Mode: i. Press Manual (F1). Press Enter.

ii. Enter desired speed value. Press Enter.

iii. Scroll to select next pump (if applicable). Repeat steps i thru iii until all pumps are programmed.

Adhesive will begin to pump once the pump enable thermostat closes and “Ready” condition is attained.

Shut Down Procedures

At the pump screen:

1. If Pump is in Auto Mode: a. Press STOP or STOP ALL (F3).

b. Turn OFF the Main Disconnect Switch.

2. If Pump is in Manual Mode: a. Press STOP or STOP ALL (F3).

b. Turn OFF the Main Disconnect Switch.

3. If 7-Day Scheduler is in use: Turn ON and OFF with the Controller On/Off pushbutton.

Note: Except in the case of the 7-Day Scheduler, use of the Main Power Switch to turn the unit

OFF will avoid unexpected ASU activation in the event of a power outtage.

c. 2001

DYNAMELT M ASU Manual #20-37

Installation Page 3-19

Revised 6/01

Storage and Disposal of the DYNAMELT M Application System

Temporary Storage of the Unit

1. Flush the adhesive application system with flushing fluid (PN L15653), following the instructions detailed in chapter 6 of this manual.

2. Clean or replace both the outlet filter and the primary filter, following instructions detailed in chapter 6.

3. Shut OFF all pressure and power sources.

4. Release residual air pressure (if applicable).

5. Remove all residual adhesive and wipe components clean.

6. Remove all air lines (if applicable) and all power supply cables.

7. Pack the unit in a corrosion-proof manner.

8. Store the unit in such a way that it is protected from damage.

Disposal of the Unit

1. Shut OFF all pressure and power sources.

2. Release residual air pressure (if applicable).

3. Remove all residual adhesive.

4. Remove all air and adhesive hoses and all power supply cables.

5. Dismantle all components and sort into mechanical and electrical components.

6. Arrange for all components to be recycled.

Page 3-20 Installation

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-1

Revised 10/00

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 DYNA-

MELT

Ò 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 de-

grees Celsius and Fahrenheit. Other parameters are independently selected values.

Defining DynaControl Temperature Control Terms

Adhesive Temperature Control Range

The temperature limits within which the ASU, hoses and applicators may be programmed and 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. The controller will revert to its defaults whenever it is reset. The DynaControl controller’s defaults are listed in this chapter.

Error Indication Alarms

Alarms which indicate that the programmed over-temperature values have been exceeded for one or more hopper, hose or head zones. Alarms may also indicate an open or short-circuited sensor.

Mechanical High-Temperature Protection

A mechanical, redundant thermostat located on the hopper which turns OFF the system at 232 °C

(450 °F).

Microprocessor-based Proportional Temperature Control

The built-in control system that controls, monitors and displays all system temperature values.

cont.

Page 4-2 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Over-Temperature Setpoint

The programmable temperatures that will cause alarms (blinking up and down display arrows) to occur when those temperatures are exceeded. Power is not disconnected, the READY contact opens and the alarm contact opens. If an external alarm has been connected, it will activate. The over-temp setpoint is the upper limit of the ready temperature range of each zone.

PC Link

Also referred to as remote I/O interface, this is a DynaControl controller option that allows monitoring and programming from a customer-provided PLC (programmable logic controller) or a PC (personal computer).

P-I Loop

A temperature control loop which bases heater output proportional (P) to the difference betweeen setpoint and actual temperature and combines it mathematically with a time (I = integral) factor.

Power I/O PCBs

The Power I/O printed circuit board (PCB) provides control signals to, and monitoring signals from, all the temperature zones in the ASU’s system. The ASU’s hopper, hoses and applicators are controlled by the Power I/O PCB.

Pump Enable Temperature

The pump enable temperature protects the pump, pump shaft, motor and motor control board from damage by not allowing the pump to activate until a low limit (the programmed pump enable temperature) is achieved.

RTD Sensors

The standard Dynamelt system uses 100-ohm platinum resistance temperature detector sensors for all temperature controls. As an option, the unit can be configured for 120-ohm nickel sensors.

Ready Temperature

The programmable temperature, on gear pump models, which allows the ASU pump to turn ON.

The default ready temperature range is a deviation of ± 20°C (± 36°F) from the setpoint. The setpoint minus the deviation is the low limit of the range, and the setpoint plus the deviation is the high limit of the range.

Recipe

A program recipe is a set of temperature setpoints and parameters which the user has programmed and wishes to store in the controller for future use. Up to four recipes may be stored in the Dyna-

Control controller.

Sequential Heating

The heating sequence which allows the slower-heating hopper to reach operating temperature 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 grids) 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

cont.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-3

Revised 5/01

sequence is bypassed and they will be turned ON. The heat up sequence is restored after Standby is turned from ON to OFF. Sequential heating is not needed for most applications and can delay total system warm-up time.

Standby Condition

The system condition where the 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.

Setpoint

A programmable temperature that has been selected for hopper, hoses, applicators or auxiliary zones.

Setpoint Limitation

This is a universal maximum temperature for all zones. The programmer cannot program a temperature setpoint higher than the setpoint limitation.

System Logbook

This is the controller’s record-keeping function. It contains the DynaControl’s list of the last

1,000 controller events

,

its Data Logger which records the last 1000 lines of selected actual temperatures and a counter which records the system’s elapsed hours.

Temperature Zone Enable

The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not ever appear on the controller’s display and heating is switched OFF.

Temperature Zone Offset

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.

Page 4-4 Controller Setup

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Error Indication & Alarms

Error Indication (Blinking Up and Down Arrows)

The following illustration shows the display screen when one or more error indication conditions occur. The conditions that will trigger an error indication are: a. When a hopper, hose, head or auxiliary zone has exceeded its selected overtemperature setpoint, which is the setpoint plus its high/low alarm setting, or when it is below its selected under-temperature setpoint, which is the setpoint minus its high/ low alarm setting. In these cases, heater power will not be switched off.

b. When a hopper, hose, head or auxiliary zone sensor has an open circuit. In this case, heater power will be switched off.

Blinking up arrow indicates overtemp.

Blinking down arrow indicates undertemp.

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

274

HOLD

Hose

Head

Aux Zone

Pump

%

SETPOINTS

MANU

HOLD

PUMP

2.

310

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

MANU

HOLD

STOP

HOLD

PRESSURE

?

?

STOP

HOLD

HELP

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

“?” indicates no sensor (open circuit).

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-5

Revised 11/02

Error Alarms (Message Window)

The display of a message window, as illustrated below, signifies an error alarm. The operator’s response to an error alarm is to press “F4” and to troubleshoot.

If a sensor error alarm or an overtemperature alarm occurs during operation, the controller will switch off internal power to the heaters and an appropriate error alarm display will appear.

Pressing the “F4” function key acknowledges the error. If several zones display alarms, each must be acknowledged by pressing “F4”. The alarm display is switched off and the controller then switches off the faulty zone until the ASU is ready for operation again.

When the actual temperature exceeds the setpoint limitation (plus a tolerance) the overtemperature alarm window is displayed and main power is switched off.

Examples of Error Alarms

The Overtemperature Alarm indicates that the named zone has exceeded its programmed setpoint limitation.

The controller will shut off power to the heaters. Press

F4 and troubleshoot the problem.

The Sensor Failure Alarm can indicate either a sensor open or a sensor short. Sensor open is accompanied by a blinking up arrow on the actual temperatures display screen. Sensor short is accompanied by a blinking down arrow. Press F4 to reset the error message and then either a. manually turn the zone OFF (via Setpoints F1/ indicated zone/ On/Off F3), or b. troubleshoot the problem.

The Hopper Overtemp Alarm indicates that adhesive temperatures in the ASU’s hopper have exceeded the setting of the mechanical (redundant) thermostat.

Press F4 and troubleshoot the problem.

The Communication Error Alarm indicates an internal failure, unrelated to zone temperatures. Call ITW

Dynatec for assistance.

Overtemperature

Zone Name ##

Sensor Failure

Zone Name ##

Hopper Overtemp

Communication error

Page 4-6 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Optional System Status Lights

This tri-color stack light eases remote monitoring of the system’s status.

The lower, white 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.

Red

Green

White

Audible

Alarm

Alarm

System

Ready

Power

“ON”

The status lights may be wired to indicate either high/low temperature, low adhesive level or open/short sensor. See Chapter 11 for wiring diagram.

Settings for a Typical Operation

Note: The values given here are approximate settings for a typical packaging operation. The values you choose will be based on the type of equipment and adhesive you are using and the nature of your particular operation.

If Application Temperature is 177°C (350°F):

Hose and head temperature: 177

°C (350°F).

Hopper setpoint temperature: 163

°C (325°F).

Hi/ Lo limit deviation: 12

°C (20°F).

ASU operating range: 149

°C to 177°C (300°F to 350°F).

Standby condition temperature (deviation): 30

°C (50°F).

Hopper over-temperature setpoint : 177

°C (350°F)

Mechanical thermostat (for the hopper) over-temperature: 219

°C (425°F)

For most operations, temperature fluctuations will be very small and of short duration. For these reasons, the settings above are recommended.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-7

Revised 10/00

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).

” ” ” for high temp mode enabled ASUs: 232

°C (450°F)

Maximum alarm deviation: 50 ° (C or F).

Minimum alarm deviation: 5 ° (C or F).

Maximum standby temperature: 150 ° (C or F) less than setpoint.

Minimum standby temperature: 30 ° (C or F) less than setpoint.

“Actual” temperature indication range: 0 °C to 260°C (32°F to 500°F).

Customer Programmable Values Preset At The Factory

ITW Dynatec can set the controller’s system values to customer’s specs, if provided.

If customer’s specs are not provided, the following values will be entered into the DynaControl 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: varies from 138 to 149 °C (280 to 300°F).

Hopper setpoint: 143 °C (290°F).

All zones are switched off, except for the hopper and the optional drop-in grid.

Motor rpm: 0 in the “OFF” mode.

Standby: 80 °C (140°F) under setpoint.

Hi and low alarms: ± 12°C (20°F) from setpoint.

Pump enable temperature: 132 °C (270°F).

Page 4-8 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Default Settings of the DynaControl Controller

Default settings are the manufacturer’s preset values to which the system 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.

Defaults

Language: English

Setting for Customer Access Code: “9999”.

Temperature setpoint for each zone: -- -- --

Hopper ready temperature: 135

°C (270°F).

Over-temperature limit: Your chosen setpoint limitation + 10 ° C or F.

For example: if your setpoint limitation is 218

°C (425°F), then your over-temp limit = 228°C (435°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: first hopper zones, then hose/ head zones and auxiliary zones.

Setpoint limitation: 218 °C (425°F).

Minimum pump speed: 0% of full speed.

Maximum pump speed: 100% of full speed.

Proportional Integral values (P-I values): for Premelt, Hopper and Filterblock temperature zones, P = 15 and I = 3. For all other zones, P = 12 and I = 2

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-9

Revised 11/01

Helpful Tips for the User

When the ASU is turned ON, all temperature setpoints and other operating parameters will be exactly where they were when the ASU was turned off.

When the ASU is turned ON, all system heaters go ON if the automatic heater startup is enabled and if setpoints are programmed unless sequential heatups have been set. However, if hopper temperature is above ready temperature when the ASU is turned ON, all hose and head sequential heatups will be bypassed and hoses and heads will be turned ON.

If the system is turned OFF and then ON again, the standby condition will be disabled.

Page 4-10 Controller Setup

Revised 9/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Serial Protocol for RS232 and RS485 Options, V5.00 d & up

Specifications

-- RS232C, no handshake

-- RS485, 4 wires

-- baud rate 1200 ¼57600 baud

-- character format 8 databits + 1 startbit + 1 stopbit

-- parity: no parity check

General information

-- DynaControl is always slave. The controller is only reacting when addressed by a master.

-- DynaControl is only responding when own slave address is received.

Slave address is programmable via front panel (PC--LINK Setup).

-- Multi--digit values are transferred most significant digit first, each digit is ASCII coded.

-- Used control characters:

STX 02 Start of Text

ETX 03 End of Text

EOT 04 End of Transmission

ENQ 05 Enquiry

ACK 06 Positive Acknowledge

NAK 15 Negative Acknowledge

Structure of commands

-- Master transmits to DynaControl:

EOT, addr, opcode, 0..n data bytes, ENQ

-- DynaControl responds:

STX, 1...n data bytes, ETX

Address Setting

Each telegram sent to the DynaControl contains the slave address.

DynaControl is only responding if the received address matches the programmable address.

Examples:

Controller address = 37

1.

Write temperature setpoints

Zone 3 = 250_F

Zone 4 = 280_F

Zone 5 = 300_F

Zone 6 = 350_F, but temporarily not in use

EOT , 3 , 7 , F , 0 , 3 , 0 , 2 , 5 , 0 , 0 , 2 , 8 , 0 , 0 , 3 , 0 , 0 , 1 , 3 , 5 , 0 , ENQ

| 37 | | 3 | 250 | 280 | 300 | 350 / Off | note: adding 1000 to the setpoint will deactivate this zone.

2.

Read actual temperatures

EOT , 3 , 7 , d , 0 , 0, ENQ

| 37 | | 00 | note: zone number 00 will request information of all available zones

ITW Dynatec c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Controller Setup Page 4-11

Revised 7/01

Return String:

STX , 0 , 2 , 3 , 5 , 0 , 2 , 4 , 4 , 1 , 9 , 9 , 9 0 , 2 , 3 , 5

¼¼¼.ETX

--> zone 1 is 235_F, zone 2 is 244_F , zone 3 has no sensor attached

¼.

Note: 1999 indicates open sensor,0999 indicates sensor short circuit

3.

Read actual pump speed

EOT , 3 , 7, e , 0 , 0 , ENQ request the speed of all pumps

Return String:

STX , 0 , 8, 5 , 0 , 0 , 6 , 6 , 4 , ETX

--> System has 2 pumps, pump1: 85.0Rpm, pump2: 66.4Rpm

4.

Read System Status

EOT, 3 , 7 , f , ENQ

Return String:

STX , F , ETX --> ‘F’ = 46hex

Bit wise: 0

7

Always

!

1

6

0

5

0

4

0

3

1

2

1

1

0

0

No setback, normal mode

Controller is on

Enable thermostat closed

Hopper not empty

No low temper.

No high temper.

= Ready

è

è

è

è

5.

Read status of all temperature zones

EOT , 3 , 7 , l , 0 , 0 , ENQ

Return String:

STX , 0 , 2 , 2 , 3 , 1 , 1 , 7, 7, ¼¼.ETX

è zone 1: is not used (0) zone 2&3: heating, but below setpoint window (2) zone 4:heating and ready (3) zone 5&6: waiting due to heat up sequence (1) zone 7&8: no sensor attached (7)

cont.

DynaControl Version V5M Serial Protocol

Opcode

Parameter

Syntax*

0x41 / 'A' zz.n*dddd

0x46 / 'F' zz.n*dddd

0x61 / 'a' zz

0x64 / 'd'

0x42 / 'B' zz zz.n*dd

0x62 / 'b' zz

0x43 / 'C' zz.n*dddd

0x63 / 'c'

0x65 / 'e'

0x6c / 'l'

0x67 / 'g' zz zz zz zz

0x50 / 'P' zz.n*dddd

0x70 / 'p' zz

0x4d / 'M'

0x6d / 'm' zz.n*d zz

0x66 / 'f'

0x6a / 'j'

0x69 / 'i'

0x48 / 'H' n.a.

n.a.

zz d

0x52 / 'R'

0x72 / 'r'

0x4c / 'L' d n.a.

n.a.

Return String

ACK / NAK

ACK / NAK dddd (n*dddd) dddd (n*dddd)

ACK / NAK dd (n*dd)

ACK / NAK dddd (n*dddd) dddd (n*dddd) dddd (n*dddd) dddd (n*dddd)

ACK / NAK dddd (n*dddd)

ACK / NAK n*d sys-data 1 sys-data 2 n*d

ACK

ACK / NAK d

ACK / NAK

Function

write temperature setpoints °C (10 to 232) , will switch to Celsius write temperature setpoints °F (50 to 450), will switch to Fahrenheit read temperature setpoints read actual temperature (1999 = open sensor, 0999 = shorted sensor) write temperature tolerance window (5 to 50 degree) read temperature tolerance window write pump speed setpoint (0.0 to 100.0%) read pump speed setpoint (0.0 to 100.0%) read actual pump speed (0.0 to 150.0 Rpm) read line speed input (0.0 to 100.0%) read pressure transducer (0.0 to 150.0BAR / 0 to 1500PSI, 2000= open transd.) write pressure alarm value (0.0 to 150.0BAR / 0 to 1500PSI read pressure alarm value (0.0 to 150.0BAR / 0 to 1500PSI) write pump mode ('S'=Stop, 'M'=Manual, 'A'=Automatic) read pump mode ('S'=Stop, 'M'=Manual, 'A'=Automatic) read system status 1 (see note 1) read system status 2 (see note 2) read status of temperature zone (see note 3) set system mode (see note 4) set active program number (1 to 4) read active program number (1 to 4) reset error message

Version: V5.00e

Date: 09.27.01

Option

1 zone / multiple zones

1 zone / multiple zones

1 zone / all zones

1 zone / all zones

1 zone / multiple zones

1 zone / all zones

1 pump / multiple pumps

1 pump / all pumps

1 pump / all pumps

1 pump / all pumps

1 transducer / all transd.

1 transd. / multiple transd.

1 transducer / all transd.

1 pump / multiple pumps

1 pump / all pumps

1 zone / all zones

*1: System status: Bit0=Setback active, Bit1=Controller on, Bit2= Enable thermostat active, Bit3= Low Level, Bit4= Low Temp.,Bit5=High,Temp., Bit6= always 1

*2: System status: Bit0= scheduler avtive, Bit6= always 1

*3: Zone status: 0=off, 1=wait, 2= heat up, 3= ready, 4= low temp., 5= high temp. , 6= sensor short circuit, 7= sensor open

*4: System mode: Bit0= SetbackOn/Off, Bit1= Heat up sequence yes/no, Bit2= Scheduler active yes/no, Bit3= controller On/Off

*: zz: zone number 01 to max. or 00 for all zones, dddd: four digit data, dd: two digit data, d: one digit data or character

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-1

Revised 5/01

Chapter 5

PROGRAMMING INSTRUCTIONS

FOR DynaControlä CONTROLLER WITH EXPANDED KEYPAD V.5.00c & UP

Controller Safety Consideration

DANGER HIGH VOLTAGE

Never open the control panel without switching off the main disconnect switch to ensure that it is disconnected from its power source.

The printed circuit boards should always be carefully removed. DO NOT handle the boards except by their edges. Read the section on PCBs in Chapter 7 of this manual for further cautions.

Software Version

You can determine the software version of your controller by noting it when it comes up on the

Help Screen or on the display at startup:

* * * ITW Dynatec * * *

M-Control V 5.00c

Current Software Version

Page 5-2 Programming

Revised 12/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #50-13, 20-36, 20-37, 20-38

Display & Keypad Reference

System Status:

Ready

Heat up

Alarm

Standby

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

Hose

Head

Aux Zone

274

HOLD

Pump

%

SETPOINTS

AUTO

HOLD

PUMP

Scheduler Active Indicator

Day of Week

Time of Day

Numeric Entry Keys

2.

310

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

PRESSURE

?

?

CLEAR

Scheduler Key:

Standby

Day/Date Clock

7-Day Scheduler

Program Recipes

Service Key

On/Off Key & LED

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Delete

Enter

Enter

“%” or

“RPM” if optional actual

RPM readout is installed

Display & Function Keypad

(Actual Temps Screen shown as example)

Arrow

Keys

Symbol = use to enter a space, colon, dash, dot, “Q” or “Z” into text

Continued

< >

Numeric

Keypad

Enter

0 = toggle from numeric

(1,2,3) to alphabetic

(A,B,C) entry

Program #:

P1, P2, P3 or P4 current software version

SYSTEM: Alarm

P#

Tue.

3:36 PM

*** M-Control *** V5.00c

C

1, 2, 3

Press Enter to activate or confirm

Enter a numeric value with 0 - 9 keys

A,B,C

Enter a letter on the alpha-numeric

< >

F

This item or this screen is locked

This item is factory setup* only

Press button C to see more zones

HELP Screen

(F4 on Actual Temperatures Screen)

Flashing “C” indicates optional serial communication (PC Link) is ON

* Factory Setup = can be modified by ITW Dynatec’s technicians only

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-3

Revised 5/01

Display Reference, cont.

Condition of Pump Enable Thermostat

Black box = item is selected for programming

System Status Line

Zone Names

Information lines

Function keys:

Scroll Up, Down or Right

“Return” to last screen

Go to “Pressure” screen

Go to “Pump” screen

Toggle “On/Off”

“All _ _ _” = all in category

“ABC/abc” = letter case

“Clear” an alarm or message

“Copy” = copy word(s) to a clipboard

“Paste” = paste copied words into text

“CLR Line” = clear entire line

SYSTEM: Alarm Lo

SETPOINTS °°°°F

Premelt

Progmelt

Filterblock

1

300

2

301

299--------------299

380

Numeric Entry

Keys

Tue. 3:36 PM

Next Page Press C

3 4 >

Hose

Head

Aux Zone

274

------

INFO: UPPER PREMELT GRID

Set: 300°F Act: 300°F Tol:±30°F

273

------

251

------

------

273

------

------

Zo: 1

1, 2, 3

RETURN

Setpoint Programming Screen

Screen continues, press “C” to view

Zone Status:

### = Temperature

HOLD = In priority queue, waiting for release

= Over temp

= Under temp

-- -- -- = Off

? = no sensor

Zo: # = this is the controller’s identification # for each zone

Programming entry:

1,2,3 = numeric only

A,B,C = alpha only

Function keys:

F1, 2, 3, 4

Dashed line (------) indicates Progmelts are linked (models M70/140/210 only)

For illustrations of the screens of the Dual Hopper ASUs, see pages 5-28 & 29.

User-chosen name

Function key:

“Manual”, “Automatic” or

“Stop” = pump modes

“Restart” pump

“All Stop” = stop all pumps

SYSTEM: Ready Tue. 3:36 PM

Press Enter and Select Mode

Set

Pump Mode %

Min

%

Max

%

Actual

RPM

1 MANU.

2 AUTO.

3 STOP

5.0

5.0

80.0

RUN

RUN

RUN

90.5

87

INFO: RIGHT PUMP

MANUAL AUTOMATIC STOP

Mtr 1

Enter

Arrow

Motor Programming Screen

Pump Programming Screen

Actual RPM = optional display

(tach generator required)

Lock = this screen is locked from further programming

Page 5-4 Programming

Revised 7/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Basic Programming Sequence: Quick Reference

Follow the screen-by-screen steps outlined in the remainder of this chapter for complete setup and programming instructions. Thereafter, use this page as a “quick reference”.

Press

Turn Controller On x2, 6

Language Selection

F4 x1, 8

Temperature Scale Selection

Actual Temperatures:

F1 To Program Setpoints

F2 To Program Pump/ Motor(s)

F2 To Program Optional Clutch(es)

F3 To Program Optional Pressure Transducers

ITW

x1 x2

Service Page 1:

1 = High Low Temperature Deviation

2 = Setback Temperature

3 = Setback/ Sleep Setup

4 = Setpoint Limitation

Service Page 2:

1 = Customer Zone Names

2 = Power On Configration

3 = Factory Defaults

4 = Keypad Locking

5 = PC Link

To Program Scheduler

1 = Manual Standby Activation

2 = Time & Date Clock

3 = Program 7-Day Scheduler

To Program Optional Memory Card

6 = Temperature Offset

7 = Sequential Heating

8 = Temperature Scale

9 = Change Security Lock or Access Code

6 = Language

7 = LCD Contrast

8 = System Logbook

9 = Change Security Lock

4 = Select Program Recipes

5 = Manual Scheduler Activation

End

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-5

Revised 5/01

Controller Setup

Below is the step-by-step process of setting up the controller.

Note: Whenever an Access Code is required, enter your individual code. The default code is 9999. If you have lost your code, call ITW Dynatec Customer Service: 1-800-538-9540 (in the USA) or con-

tact your local repsentative.

Turn the Controller ON

Turn the controller ON using the ASUs main On/ Off switch.

Language Selection

English is the default language. If you desire another language (choices are German, French, Italian, Spanish, Swedish, Portugese, Japanese and Dutch), make your selection:

Press the Service Key two times to advance to Service Page 2.

Press #6 on the numeric keypad, followed by Enter

.

Press the numeric key of your language choice, followed by Enter .

(OR Scroll to your choice, then press Enter .

Note: To quickly return to the English language, turn the controller OFF. Then press both Enter and “9” and hold while turning the controller ON.

Temperature Scale Selection

Press the Service Key twice to advance to Service Page 1.

Press #8 on the numeric keypad, followed by Enter

.

Toggle to make your choice between °C scale or °F scale. Press

Press Return (F4) to Go to the Actual Temperatures Screen

Enter.

Page 5-6 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Actual Temperatures Screen

The Actual Temperatures Screen serves as the controller’s main menu. From here you can go to any other screen. The Actual Temperatures Screen is also the most useful screen to display for monitoring purposes.

System Status 7-Day Scheduler Active

Scheduler Key

Service Key

Controller

On/Off Key

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

274

HOLD

Hose

Head

Aux Zone

Pump

%

SETPOINTS

AUTO

78.0

PUMP

2.

301

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

?

?

PRESSURE HELP

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Pump Info Lines

Use of the Actual Temperatures Screen

To: Press This

Function Key

On/Off

Setpoints (F1)

Pumps (F2)

Pressure (F3)

Help (F4)

Service

Scheduler

Toggle display, pumps and heaters power ON or OFF

Go to the setpoints programming screen

Go to the pumps programming screen

Go to the pressure screen

Go to the Help screen.

Go to the first of the three service screens

Go the the Main Scheduler screen

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-7

Revised 5/01

Use of the Actual Temperatures Screen, cont.

Programming Sequence

(details on following pages)

1. Press Setpoints. After programming all of your temperature setpoints, return to the Actual Temperatures Screen.

2. Press Pumps. After programming all pumps and optional clutch(es), return to the Actual Temperatures Screen.

3. Press Pressure if optional pressure transducers are installed on ASU. After setting limits for all pressure transducers, return to the Actual Temperatures Screen.

4. Press Scheduler Key to program the following functions: Standby, Time & Date Clock, 7-Day

Scheduler and/ or Program Recipes.

5. Press Help to view the Help screen (illustrated on page 5-2).

Monitoring

:

1. System Status display describes system status as one of the following: a. System Heat up: power is ON but zone temperatures have not risen to setpoint range.

b. System Ready: all zones have reached setpoint temperatures.

c. Alarm: a temperature zone is out of its setpoint tolerance range. An overtemp alarm is indicated by an upwards arrow next to a temperature. An undertemp alarm is indicated by a downwards arrow next to a temperature.

d. Alarm Lo: the pump enable thermostat (undertemp thermostat) is preventing operation due to a low temperature condition.

e. Standby: the system is in a programmed standby state.

2. Actual Temperatures or Zone Status of all zones is displayed: a. ###: a three-digit number indicates a zone’s actual temperature.

b. HOLD: zone is waiting for release. Temperatures have not risen to setpoint range.

c. Arrow up: zone is over temperature.

d. Arrow down: zone is under temperature.

e. ?: there is no sensor. Zone needs troubleshooting.

f. >: there are more temperature zones not seen on the current display. To view them, press C on the numeric keypad (bottom row, first key).

3. 7-Day Scheduler Active display shows that the 7-Day Scheduler is programmed and in use.

4. Pump Info Lines indicate pump mode (”Auto” on the illustration on page 5-6) and external reference percent or set speed percent.

5. If the optional Actual RPM display (shown on page 5-3) is installed, actual pump rpm may be monitored.

Page 5-8 Programming

Revised 5/01

Setpoints Programming Screen

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

SYSTEM: Alarm Lo

SETPOINTS °°°°F

Premelt

Progmelt

Filterblock

1.

300

350

380

1

2.

300

Hose

Head

Aux Zone

275

275

INFO: UPPER PREMELT GRID

Set: 300°F Act: 300°F Tol:±30°F

275

275

Tue. 3:36 PM

3 4

275

275

------

275

275

Zo: 1

RETURN

Delete

Enter

Controller identification number for zone

Zone Info Lines

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-9

Revised 5/01

Use of the Setpoints Programming Screen

Each of the temperature zones is programmed individually by using the function keys as follows:

Press This To:

Function Key

Scroll Up, Down or Right (F1, 2, 3) Select each zone’s setpoint

Return (F4) Return to the Actual Temperatures Screen

(Enter)

All -- -- -- (F1)

On/Off (F3)

Clear (F4)

Enter a numeric value

All zones in a category (ie, All Hoses, All Heads, etc.)

Toggle a zone on or off

Eliminate an error message or alarm

Programming

1. Scroll to the first temperature zone setpoint you desire to program.

2. On the numeric keypad, enter the desired setpoint value.

3. Press Enter .

4. Scroll to the next setpoint to be programmed and repeat steps 2 and 3.

Notes: a. To turn a zone OFF: scroll to zone, press Enter to select, press ON/OFF (F3).

b. When turning a switched-off zone back ON, it will retain its previous setpoint.

c. To change all zones in a category (ie, all hoses, or all aux zones, etc.): scroll to one item in that category, enter desired value, then press F1 (this does not apply to zones which are turned

OFF).

Monitoring

1. “Zo #”: the number which appears here is the controller’s identification number for this zone.

This number cannot be changed by user.

2. The Zone Info Lines indicate the user-defined zone name (programmed on Service Page 2, menu item 1), the zone’s setpoint, the zone’s actual temperature, the zone’s tolerance (programmed on Service Page 1, menu item 1) and the zone’s identification number.

Page 5-10 Programming

Revised 5/01

Pump Programming Screen

Optional

RPM

Display

SYSTEM: Ready

Arrow

Tue. 3:36 PM

Press Enter and Select Mode

Keys

Set Min Max Actual

Pump Mode % % % RPM

1 MANU.

2 AUTO.

3 STOP

78.0

5.0

5.0

80.0

RUN

RUN

HOLD

90.5

87

INFO: RIGHT PUMP

MANUAL AUTOMATIC STOP

Mtr 1

1, 2, 3

RETURN

Delete Enter

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Alternative programming function keys:

STOP ALL RETURN

CLUTCHES RE-START

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-11

Revised 5/01

Use of the Pump(s) Programming Screen

Each of the pump(s) is programmed individually by using the function keys as follows:

Press This

Function Key

To:

Scroll Up or Down (F1, 2) Select a pump.

Stop All (F3) To stop all pumps in system

Re-Start (F4)

Manual (F1)

To re-start all pimps

Choose Manual Mode for the selected pump

Automatic (F2)

Stop (F3)

Clutches (F2)

Return (F4)

(Enter)

Choose Automatic Mode for the selected pump

Choose Stop Mode for the selected pump

Go to the Clutch Programming Screen (if clutches are installed)

Return to the Actual Temperatures Screen

Enter a numeric value

Programming

1. Scroll to select a pump. Press Enter.

2. Press Manual, Automatic or Stop as desired pump mode. Press Enter.

3. If in Manual mode, enter pump speed ##.# in the Set % column: a. Use numeric keypad to enter desired rpm value.

b. Press Enter.

4. If in Automatic: a. Scroll to Min % to program minimum pump speed. Enter value as described above.

Note: typically, at 0 volts, this value will be between 0 and 10% (default = 0%).

b. Scroll to Max % to program maximum pump speed. Enter value as described above.

Note: typically, at 10 volts, this value will be between 0 and 100%, depending on motor installed on ASU (default = 100%).

5. Scroll to select next pump to be programmed. Repeat steps 2 thru 5 until all pumps are programmed.

6. If clutches are installed on ASU, Press Clutches (F2) to program (see next page).

Monitoring

1. RUN indicates the pump/ motor is enabled.

2. HOLD indicates that the controller is preventing the pump/ motor from running, due to a low temperature, a standby condition, etc.

2. The Info Line indicates the user-defined name for the selected pump (programmed on Service

Page 2, menu item 1).

3. If the optional Actual RPM display is installed, actual pump rpm may be monitored. With this option, the RUN/HOLD column is eliminated. The Actual RPM display is also seen on the Actual

Temperatures Screen.

Page 5-12 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Optional Clutch Programming Screen

The Clutch screen is active, as a subset of the Pump Programming Screen, only if clutches are installed on your ASU. It is reached by Pressing F2 “Clutches” on the Pump Screen (seen on previous pages).

The number of clutches on the ASU will equal the number of motors:

For DM 35: there is a maximum of two pumps/ clutches

For DM 70/ 140: there is a maximum of four pumps/ clutches

For DM 210: there is a maximum of six pumps/ clutches

SYSTEM : Ready

Arrow

Tue. 3:36 PM

Press Enter and Select Mode

Keys

Switch Clutches ON/OFF with button 1 . . 6

Pump - Clutch 1

Pump - Clutch 2

Pump - Clutch 3

Pump - Clutch 4

Pump - Clutch 4

Pump - Clutch 6

RE-START

ON

ON

OFF

OFF

OFF

OFF

STOP ALL

1, 2, 3

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Turn Clutch ON/OFF using numeric keys 1 thru 6

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Use of the Optional Clutch Programming Screen

To: Press This

Function Key

Re-start (F2)

Stop All

Return (F4)

Turn ON all clutches at once

Turn OFF all clutches

Return to the Pump Screen

Programming Page 5-13

Revised 5/01

Programming

1. To turn individual clutches On or Off, toggle individually on the numeric keypad.

Monitoring

1. On/ Off status of each clutch is indicated.

Optional Pressure (PSI/ BAR) Programming Screens

The two Pressure Programming screens are active only if pressure transducers (sensors) are installed on your ASU. They are reached by Pressing F3 “Pressure” on the Actual Temperatures

Screen.

The number of pressure transducers on the ASU will vary per ASU:

For DM 35: there is a maximum of four pressure transducers

For DM 70/ 140: there is a maximum of eight pressure transducers

For DM 210: there is a maximum of twelve pressure transducers

Pressure Screen #1

cont.

SYSTEM : Ready

Arrow

Keys

Pressure PSI (BAR)

Sensor Act.

3

4

1

2

100

100

?

100

Tue. 3:36 PM

Pre Filter Pump 1

Post Filter Pump 1

Pre Filter Pump 2

Post Filter Pump 2

PR.LIMITS

SETUP RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Page 5-14 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Optional Pressure (PSI/ BAR) Programming Screens, cont.

Pressing “Setup” (F3) on Screen 1 brings up a message screen:

Access Code: ________

Pressure Sensor Type: max.

Bar/PSI Calibrat.

System depressurized ?

PSI/BAR

RETURN

CONFIRM RETURN

Pressure Screen #2

SYSTEM : Ready

Arrow

Keys

Pressure PSI (BAR)

Sensor Act.

3

4

1

2

100

100

?

100

Tue. 3:36 PM

Alarm PSI (BAR)

Low High

10

10

10

110

HI <--> LO

500

90

500

500

1, 2, 3

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-15

Revised 5/01

Use of the Optional Pressure Programming Screens

Press This

Function Key

Pr. Limits (F2)

Setup (F3)

To:

Go to Pressure Screen #2 to set low and high alarms

Enter access code in order to advance to calibration

Return (F4) Return to the Actual Temperatures Screen

Scroll Up or Down (F1 or F2) Select each sensor (transducer)

Hi <--> Lo ((F3)

Bar/PSI (F1)

Calibrat. (F2)

Select the screen’s high or low column

Choose pressure scale

Calibrate all transducers

Programming

1. The names of the pressure transducers (shown on the preceeding page as “Pre Filter Pump 1”, etc.) are programmed at Service Page 2, Function #1 (see page 5-19).

2. On Pressure Screen #1, press Pr. Limits (F2) to advance to Pressure Screen #2. Use the Scroll keys to select a Low or High limit for the first pressure transducer (sensor) to be programmed. Use the numeric keypad to enter your desired value. Press Enter. Repeat until all desired pressure transducers are programmed with Low and High pressure limits. Use Hi<-->Lo (F3) to move between columns as necessary.

3. Press Return (F4) to return to Pressure Screen #1. Press Setup (F3). On the first message screen, enter your four-digit access code. On the second message screen, enter the maximum Bar/PSI value of the pressure transducer(s) installed on your ASU.

4. Press Bar/PSI (F1) to choose display in Bar or PSI.

5. Press Calibrat (F2) to calibrate all the pressure transducers installed. The controller will ask,

“System depressurized ?”, press Confirm (F3).

Note: Before confirming, verify that all transducers are at “0” pressure. Pumps must be turned

OFF and time allowed for system pressure to drop to “0”.

The controller will display “Waiting”. After a few seconds, the Pressure Screen will appear and, in its last column, will list if each pressure transducer has “Passed” or “Failed” the calibration.

(Note: “Failed” indicates a problem with the transducer or the Pressure PCB.)

6. Press Return (F4) to return to Pressure Screen.

7. Press Return (F4) again to return to Actual Temperatures Screen.

Monitoring

1. Actual pressure values may be monitored for each transducer on either screen.

2. Over pressure or Under pressure arrows indicate conditions.

3. A question mark ? indicates that no transducer is installed, or that installation is not complete for this transducer position.

Page 5-16 Programming

Revised 7/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Service Functions Screens

The three Service Function Screens are designated Service Page 1, Service Page 2 and Service

Page 3. They are accessed by pressing the Service Key 1, 2 or 3 times.

Functions coded ---- are active and require no code to program.

Functions coded with a key are locked and require entry of a code before programming.

For example, as seen on the diagrammed screen below, Setpoint Limitation is locked from further programming.

Functions coded

F are ITW Dynatec factory setups and are not user accessible.

Program the Service Functions as described on the following pages. Many functions are programmed simply by a toggle or by a single numeric entry.

Service Page 1

Service Key

SYSTEM : Ready

Service Page 1 Press

Keys

Hi/Lo Temperature

Standby Temperature

Standby/ Sleep Setup

Setpoint Limitation

N/A

Temperature Offset

Sequential Heating

°C / °F

Change Security Lock

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

CODE

----

----

----

----

----

----

----

9

1, 2, 3

RETURN

Delete Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Alpha/Numeric

Keypad

Enter

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-17

Revised 7/02

Service Functions Screens,

Page 1 cont.

Function #

Press #1 to program High/ Low Temperature Deviation. Enter a numeric value for the first zone selected. Press Enter to confirm. Scroll to next desired zone and repeat until all zones are programmed. Then Press Return (F4) to return to menu. Note: after entering one value in any category, you may press All xxx. (F1) to change all the items in that category.

The High/ Low Temperature Deviation is a range (

±) representing the high and low temperature

limits of each setpoint. During operation, these limits activate the error alarms which alert the op-

erator to over-temp and under-temp conditions in the temperature zones. The smallest deviation programmable is ±5° (C or F) and the largest is ± 50°.

Press #2 to program Standby Temperature. Enter a numeric value for each category. Press Enter.

Press Return (F4). Note: if the same Standby Temperature is desired for all zones: enter the value in the first row, then press Enter.

The Standby Temperature is a reduction in temperature by which all the temperature zones will be reduced in a standby condition. For example, if the hopper setpoint is 275

° and you program a 100

degree standby temperature, the controller will reduce the hopper temperature to 175

°. Numerically, the controller will accept any standby temperature within the range of -30

°C and -150°C (-30°F and -150

°F).

Press #3 to program Standby Time Delay and Sleep Mode. Enter a numeric value for the time delay. Press Enter. Toggle (press F1 or F2) to Sleep Mode. Enter a numeric value for Sleep Mode

Delay. Press Enter. Press Return (F4).

The Standby Time Delay allows programming of a delay from the time the “external standby” ter-

minals (for connection, see Chapter 3) are connected until the ASU enters its standby mode. The time delay selected must be in the range from 0:00 (which represents an immediate entry into standby, i.e. no delay) to 18.0 hours.

The Sleep Mode may be activated only during Standby. It becomes activated after a programmed length of time (0.1 to 18.0 hours). During Sleep Mode all heaters are turned OFF and the motors are stopped. The display reads “F1 to Start Heating” when in Sleep Mode. To disable the Sleep

Mode, press Disable (F3).

Standby and Sleep Mode work together. For example, if you program a Standby of 1 hour and a

Sleep Mode of 3 hours, the ASU enters Standby one hour after the external contact is closed. The

ASU enters Sleep Mode three hours after entering Standby.

Press #4 to program Setpoint Limitation. Enter a numeric value. Press Enter. Press Return (F4).

The Setpoint Limitation is a universal maximum temperature for all temperature zones (ie, the overtemperature limit). The controller will not allow the operator to program a higher setpoint

than the value of the setpoint limitation. The default setpoint limitation is 218

°C (425°F). The selectable range for the setpoint limitation is 40 °C - 232°C (100°F - 450°F).

Function #5 is not active in the present controller configuration. No programming is possible.

Page 5-18 Programming

Revised 7/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Service Functions Screens,

Page 1 cont.

Press #6 to program Temperature Offset. Enter a numeric value for the first zone selected.

Press Enter. Scroll to next desired zone and repeat until all zones are programmed. Press Return

(F4). Note: to enter a negative value, enter the value, then press Negative (F3).

The Temperature Zone Offset is a mathematical factor which compensates for differences in temperature between the placement of the system’s heaters and sensors. An offset is often used for large applicator heads, printrolls, printwheels or other custom devices. Usually no offset is re-

quired for standard heads. The offset may be programmed up to

± 50 degrees (C or F) of the zone’s temperature.

Press #7 to program Sequential Heating. Scroll to choose one of the three selections: No sequence,

First all hopper zones or Hold electric head. Press Confirm (F3).

Sequential heating allows you to choose the heating order of the temperature zones, so that zones requiring more time to heat up to temperature can be programmed to begin heating before others.

In the case of the “Hold Electric Head” selection, programming of a reduced temperature for ten minutes allows for the stabilization of the electric valves.

a. A “No sequence” designation means that all temperature zones will begin to heat immediately after the ASU is powered on.

b. “First all hopper zones” means that the hose/ head/ auxiliary zones do not begin heating until all hopper zones have reached the low limit of their setpoints. Zones which are switched OFF are not applicable.

c. “Hold Electric Heads at xxx F for 10 minutes” applies to systems utilizing electric applicators only. After choosing this selection and programming the temperature (to the softening point of your adhesive, see your adhesive manufacturer), the controller holds all electric heads at the operator-selected temperature for ten minutes before releasing them to operating setpoint.

The controller’s default heating sequence for the Dynamelt ASU is first all hopper zones. This allows the larger mass of adhesive in the hopper to begin heating immediately.

Press #8 to program Temperature Scale. Program directly on the menu screen by pressing #8 key to choose between Centigrade or Fahrenheit. Press Return (F4).

Press #9 to Change Security Lock for Service Page 1. Enter your access code. Press Enter. Scroll

F1 or F2 to select desired function. Press F3 to Lock or Unlock function from programming. Repeat for each desired function.

To Change Your Access Code: Scroll F1 or F2 to select “Change Access Code”. Enter your desired new access code. Press Enter to Confirm. Press Return (F4).

Press Service Key to advance to Service Page 2.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-19

Revised 11/01

Service Functions Screens, cont.

Service Page 2

Programming of the Service Functions on this screen is similar to the programming of Page 1.

SYSTEM : Ready

Service Page 2

Keys

Press

Customer Zone Names

PowerOn Configuration

Factory Defaults

Keypad Locking

PC Link

Language

LCD Contrast

System Logbook

Change Security Lock

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

CODE

----

----

----

----

----

----

----

----

9

1, 2, 3

RETURN

Function #

Press #1 to program Customer Zone Names. This function allows the programmer to enter his de-

sired name for each temperature zone, pump and (optional) pressure transducer. This upto-20-character name will be the name displayed in the controller’s Info Lines. Program following these rules: a. use the Alpha/Numeric keypad to enter letters and numbers. When entering letters, use one, two or three presses of a key to distinguish between the letters. Press Enter after each desired letter or number is in place.

b. press the 0 (zero) key to toggle from letters to numbers, c. press the SYM key to enter a space, colon, dash, dot, “Q”, “Z” or other special characters, d. press F1 to toggle from upper to lower case, e. you cannot back up. If an error is made, press Enter repeatidly to advance through the name loop until you reach the point for correction and re-write as desired, f. press CLR LINE to clear an entire line, g. you may COPY (F2), PASTE (F3) and then modify to save time when names are similar, h. press F4 to advance to the next motor or zone to be named.

To program Customer Zone Names: Press F1 to program Temperature zones, F2 to program

Pumps or F3 to program Pressure Transducers. Scroll to the first item to be named. Press Enter to allow naming. Using the Alpha/Numeric keypad and following the rules given above, spell out name as desired. Press F1, F2 or F3 to select another item to name. Repeat until all items are named as desired. Press F4 again to Return to Service Page 2 screen.

Press #2 to program Power On Configuration. This function gives the user the choice of having the

heaters and pumps come on (or remain off) whenever the ASU is powered on. USA default is both

On. European default is Heaters On, Pumps Off. Note: programming here overrides programming made at the next Service Function (Function #3 Factory Defaults).

Press 1 to toggle the heaters On or Off. Press 2 to toggle the pumps On or Off. Press 3 to toggle the external inputs On or Off. Note: if you select heaters Off, the controller will remind you, at power on, to press F1 to turn the heaters On.

Page 5-20 Programming

Revised 12/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #50-13, 20-36, 20-37, 20-38

Service Functions Screens,

Page 2 cont.

Press #3 to program Factory Defaults.

CAUTION: Factory Default programming is not essential. If done improperly, it can cause re-programming of setpoints to be necessary. If you are satisfied with your ASU’s setup, you may leave

Factory Defaults unprogrammed

.

Upon entering this screen, the “ASU Type” (model) of your melter will be displayed. Use this screen to program the quantity of hoses, quantity of premelt grids and quantity of pumps installed on your ASU, if desired. It is o.k. to leave these items unchanged or with “?” selected.

Scroll (F1) to the line you wish to amend (ie, hose, premelt, pump). Press Change (F2) repeatedly to view the list of possibilities for this line. Press Change until your desired quantity is displayed.

Repeat until all lines are programmed.

Then, Scroll (F1) to Configure EU/ US. Press Change (F2) to toggle between EU Setup or US

Setup for setpoints and parameters* if required.

Press Load (F3). Then press Confirm (F1). Press Return (F4) to return to menu.

*Choosing EU or US reloads all factory setpoints and parameters as follows:

EU (European) Setup = Temperature scale is Centigrade, pressure is measured in BAR, pumps are in STOP mode at startup and heaters are active at startup.

US (United States) Setup = Temperature scale is Fahrenheit, pressure is measured in PSI, pumps start in the mode they were left in at shutdown and heaters are active at startup.

Press #4 to program Keypad Locking. Scroll to either Temperature Settings or Pump Settings.

Press F3 to toggle Locked or Free. Scroll to other setting and press F3 to toggle Locked or Free.

Press F4 to Return to menu.

Selecting Locked prevents further programming to either temperature setpoints or pumps. Selecting Free allows further programming.

Press #5 to program optional PC Link (serial communication). Scroll to select either:

“Load: from Computer to this Controller” or

“Save: From this Controller to Computer.

Press F1 to Load. Press F2 to Save. Press F3 to Configure BAUD rate or FIFO. The message

“Waiting” indicates the controller/ computer is processing data. The message “Transmission

Done” indicates the computer/ controller has completed transmission. Press F4 to Return to menu.

The DynaControl is capable of bi-directional data transfer of all system parameters to a remote computer. If this option is installed on your ASU, program it at this step. To program your remote computer, see page 5-27. When PC Link is installed and the external serial communication is ON, a flashing “C” appears at the upper right of the HELP screen.

Press #6 to program Language. Scroll to desired language. Press F4 to Return to menu.

Press #7 to program LCD-Contrast. Press F1 (+) to increase contrast or F2 (--) to decrease contrast of display. Press F4 to Return to menu.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-21

Revised 5/01

Service Functions Screens,

Page 2 cont.

Press #8 to program System Logbook. The System Logbook has the following functions:

1. System Logbook: a list of the last 1,000 controller events. Use F1 and F2 to move forward or backward thru the logbook. Use F3 Configuration to choose to log “all system data” or “errors only”.

2. Data Logger: a list of the last 1,000 lines of actual temperatures for up to five selected zones.

The time interval at which these temperatures are recorded is programmable. The first screen of the

Data Logger is the actual data list. Move through the data by pushing F1 Forward or F2 Backward.

To program, press F3 Configure. The Data Logger programming screen is seen below. Use the arrows to select a desired function. Use the numeric keypad to enter zone numbers or the time interval

(in 1/10ths of a minute). Press Enter to confirm your choices. Toggle to select Mode.

SYSTEM : Ready

Arrow

Keys

Select Zones:

2

4

Enter Time Interval: 0.1 min.

Mode Run/Stop: RUN

.

Premelt 1

12

Tue. 3:36 PM

20 34 name of the selected zone (Zone #2)

RETURN

3. Elapsed Hours: the number of hours that the system has been running. Not resettable.

Press #9 to Change Security Lock for Service Page 2. Enter your 4-digit access code. Press Enter.

Press F1 or F2 to select desired function. Press F3 to Lock or Unlock function from programming.

Repeat for each desired function. Press Return (F4). Press Return (F4) again to go to Actual Temp

Screen.

Service Page 3

All of the functions on Service Page 3 are ITW Dynatec-accessible only. No operator programming is possible.

SYSTEM : Ready

Service Page 3 Press

Keys

Zone Arrangement

PI Loop Setup

Split Hopper Setup

Gear Ratio

RPM Display Yes/No

Pump/Clutch Yes/No

Level Control Yes/No

I/O Troubleshooting

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

F

F

F

F

F

Change Security Lock 9 1, 2, 3

RETURN

Page 5-22 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming at Main Scheduler Screen

The Main Scheduler Screen functions include Standby, Date & Time Clock, 7-Day Scheduler and

Program Recipes.

Press the Scheduler Key to advance to the Main Scheduler Screen.

Main Scheduler Screen

Scheduler Key

SYSTEM : Ready

Arrow

Keys

Activate/ Deactivate Standby 1

Change Time & Date

Program Scheduler

Select Recipes 4

Activate/ Deactivate Scheduler 5

2

3

.

Tue. 3:36 PM

1, 2, 3

RETURN

Delete Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-23

Revised 11/01

Use of the Main Scheduler Screen

Function #

Press #1 to manually activate or deactivate Standby. Press Press F4 to return to the Main Scheduler screen. Note: use of this key will override a programmed Standby.

Press #2 to program the time-of-day and date-of-year clock. Press F1 or F2 to change a selected item, press F3 to select another item. Press Press F4 to return to the Main Scheduler screen.

Press #3 to program the 7-Day Scheduler. See programming details and screen on following page.

Press #4 to select an active recipe (1-4). Use F1 or F2 to select recipe #1, 2, 3 or 4. Press F3 to Confirm. Press F4 to return to the Main Scheduler screen.

Up to four separate setpoint recipes (programs) can be programmed and stored in the controller, though only one recipe is active at any given time. Setpoints may differ from one recipe to another.

When switching between recipes, the new recipe’s setpoints take over, so there may be error alarms if the new recipe’s unused temperature zones are turned on.

The program recipes are referred to as: Recipe 1, Recipe 2, Recipe 3 and Recipe 4.

To create a Recipe: advance to the Main Scheduler Screen and press #4. Use F1 or F2 to choose a recipe number (for this example, say #2). Press F3 to confirm. Press F4, then press F4 again to go to the Actual Temperatures Screen. Program all controller setpoints and functions as outlined on page

5-4. When all programming is completed, Recipe #2 is created.

Press #5 to activate or deactivate the 7-Day Scheduler. Press F4 to return to the Main Scheduler screen.

Press F4 to return to the Actual Temperatures Screen.

Shortcuts

1. To activate or de-activate the Scheduler from the the Actual Temperatures Screen (Main Menu): toggle by pressing and holding the Service (wrench) Key for five seconds.

2. To activate or de-activate Standby from the the Actual Temperatures Screen (Main Menu): toggle by pressing and holding the Scheduler (clock) Key for five seconds.

Page 5-24 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming of 7-Day Scheduler

7-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.

It should not be turned off by the main power switch while the scheduler is active. To turn the

ASU OFF (temporarily overriding the scheduler), use the DynaControl On/ Off keypad icon.

In the event of a power outage, or a manually switched main power ON, an active scheduler overrides the “Power On Heater Start” parameter. That is, if the scheduler is in “Switch ON” at the time of a power ON, the heaters will be turned ON. Likewise, if the scheduler is in “Switch OFF” at the time of a power ON, the heaters will be turned OFF.

When the seven-day scheduler is programmed and active, the scheduler icon on the controller screen flashes continuously.

7-Day Scheduler Screen

7-Day Scheduler Active Indicator

Keypad On/ Off

SYSTEM : Ready

Event # Action

7

8

5

6

3

4

1

2

9

10

Standby

Switch On

Standby

Switch On

Switch Off

-- -- -- --

-- -- -- --

-- -- -- --

-- -- -- --

-- -- -- --

Day

Mon-Fri

Mon-Fri

Mon-Fri

Mon-Fri

Mon-Fri

Everyday

Monday

Tuesday

Wednesday

Thursday

Tue. 3:36 PM

Time

5:00am

6:00am

11:30am

12:30pm

6:00pm

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Enter

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-25

Revised 5/01

Use of the 7-Day Scheduler Programming Screen

Press This

Function Key

To:

Scroll Up, Down or Right (F1, 2, 3) Select an individual action, day or time

Return (F4) Return to the Main Scheduler Screen

(Enter) Enter a chosen selection

Programming

1. Press F3 to scroll to the Action column. Then scroll to the first event you desire to program.

2. Press Enter is displayed.

until the desired Action [ie, Standby, Switch On, Switch Off or -- -- -- (no event)]

3. Scroll (F3) to the Day column.

4. Press Enter until the desired Day (ie, Mon--Fri, Everyday or any individual day) is displayed.

5. Scroll (F3) to the Time column.

6. Press Enter to display the time you desire the event to start. Enter hour, minutes and am/ pm individually.

7. Repeat steps 1 through 6 for each event desired.

8. Press F4 to return to Main Scheduler screen.

Page 5-26 Programming

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming of the Optional Memory Card

Note: Programming of the Memory Card Reader should be performed after all other controller programming is complete. This will assure that all of your setpoints are saved to the memory card.

The optional Memory Card Reader gives convenience and security to your production. Temperature setpoints and start signals are electronically stored on the memory card and transferred to the controller when the card in inserted into its slot to the right of the keypad.

Programming

1. Insert the Memory Card in its slot on the control panel. You will then see this screen -- --

SYSTEM : Ready

Arrow

Keys

Tue. 3:36 PM

Load: From Memo. Card to this Controller.

Save: From this Controller to Memo. Card.

.

LOAD SAVE RETURN

2. Choose Load (F1) or Save (F2). After a few seconds you will see this message -- --

Transmission Done

3. Remove your memory card from its slot. You will return to the Actual Temperatures Screen.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-27

Revised 10/01

Up/Downloading Instructions: Controller to Remote PC (PC Link)

The Upload/ Download functions are used to transfer system information and data from or to the

DynaControl. To do this, the DynaControl must be connected to an external PC or PLC via a serial cable. The data format is an ASCII text with TAB-delimited data. This text can be created with standard word-processing programs or spreadsheet applications and up or downloaded via terminal programs. Both functions are ‘on--demand’-functions, i.e. they must be started on the

DynaControl keypad.

Hardware Hookup

Remove the controller mounting bracket from the ASU via four screws accessed from inside the panel box assembly. Using a standard serial extension cable (Male/Female DB9) (if necessary, utilize a DB25 to DB9 adapter), connect either of the DynaControl controller’s serial ports (on the Display CPU PCB, see illustration on page 7-5) to the remote computer’s COM1 or COM2.

Download Instructions

Download = Transfer data from an external PC to DynaControl

1. DynaControl must be connected to a PC via a Null--Modem--Cable.

2. Start the terminal program on PC.

3. Start PC Link on DynaControl (Function #5 on Service Page 2).

4. If necessary, select Configuration (F3) and change baudrate, than re-enter Function #5.

5. Address setting is not used.

6. Press LOAD (F1).

7. Send ASCII file on terminal program.

8. DynaControl screen should list all received lines.

9. Press RETURN to exit service mode.

10. Customer zone text (command *Text) requires the zone number (temperatures: 1-48, pumps

49-54, pressure 55-66).

Download File Format

The downloaded ASCII text is line-oriented. Pages 29 and 30 show all possible line commands.

Each line starts with ‘*’ and the command, following a number of parameters, depending on the command. Each parameter must be separated with a horizontal tab (char # 09h). A tab-character must be placed after the last parameter in each line.

Examples:

1. Downloading data for the first filterblock zone

*Filterblock [tab] 1 [tab] 325 [tab] 30 [tab] 0 [tab] ON [tab]

This will set the first filterblock to a setpoint of 325 degrees, tolerance = 30, no offset, zone is switched ON.

2. *Text [tab] 50 [tab] Pump 1, Factory Side

This will program the customer pump name for motor #2 (which could be pump #1!) with the string: “Pump 1, Factory Side”

cont.

Page 5-28 Programming

Revised 10/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Important Note: the last command in the download file must be *End#

Notes:

The command lines may be arranged in random order.

Maximum file length is 5000bytes.

Each data field may have a comment text ([tab] Setpoint:325F [tab] = [tab] 325 [tab]).

The DynaControl list screen indicates the commands in abbreviated form.

A ‘?’ after the command on the DynaControl list screen indicates a wrong parameter.

‘ER” indicates unknown command or syntax error.

If downloading system info using the *System command, the controller does not check for validity of the parameters.

Upload Instructions

The upload function will send an ASCII file to the external PC/PLC. The file contains all zone-related information. The size of the file depends on the number of zones, pumps and pressure transducers.

The data format is similar to the download file.

Example:

¼..

*PREME. 1 410 35 --5 ON

¼..

*PUMP 2 M 850 100 900

Premelt #1: setpoint 410, tolerance 35, offset –5, zone is ON

Pump #2: manual mode with 85.0%, min. speed for automatic 10.0%, max. speed 90.0%

Customer zone names will be indicated with: *TXT--TE for temperature zones

*TXT--PU for Pumps

*TXT--PR for Pressure transducers

1. DynaControl must be connected to a PC via a Null--Modem--Cable.

2. Start terminal program on PC.

3. Start PC Link on DynaControl (Function #5 on Service Page 2).

4. If necessary, select Configuration (F3) and change baudrate, then re-enter Function #5.

5. Address setting is not used.

6. Start “Capture Textfile” at terminal program.

7. Press SAVE (F2).

8. Stop and close file on terminal program.

9. Press RETURN to exit service mode.

*Premelt

*Progmelt

*Filterblock

*Hose

*Head

*Aux Zone

*Pressure

*Pump

0--100.0%

*Text

Line Commands

(pag e 1 o f 2)

No#

No#

No#

No#

No#

No#

1--12

No#

1--12

No#

1--6

No#

Temp.:1--48

Pumps: 49--54

Press.: 55--66

Setpoint

Setpoint

Setpoint

Setpoint

Setpoint

Setpoint

50--450

Min--Pressure

0--1500

Mode

Manu/Auto/Stop

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance

5--50

Max--Pressure

0--1500

Manual%

0--100.0%

Customer Name

20 characters

Offset

Offset

Offset

Offset

Offset

Offset

0--50

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

ON / OFF

Automatic--Min%

0--100.0%

Automatic--Max%

Line Commands

(page 2 of 2)

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

1

2

3

8

9

10

11

12

6

7

4

5

13

14

15

16

Setback Premelt Setback Progmelt Setback Filterblock Setback Hose Setback Head Setback Aux.Zone

Setback General Setpoint

Power--On Heater

0/1 (1 = Start)

PI--Loop Premelt

(High= I Low= P)

Gear Ratio Motor. 1

Rpm--Displayn

(0/1)

Limitation

Power--On Motor

0/1 (1 = Start)

PI--Loop Progmelt

(High= I Low= P)

Gear Ratio Motor 2

Pump--Clutches

(Bit0¼Bit5, Bit7)

Heat up Sequence

(0,1,2)

Keypad Lock

Temp.Settings 0= free, 1= locked

PI--Loop Filterblo.

(High= I Low= P)

Gear Ratio Motor 3

Level Control

(0/1)

Electr.Head Hold

Temp.

Keypad Lock Motor Settings 0= free, 1= locked

PI--Loop Hose

(High= I Low= P)

Gear Ratio Motor

4

Bar/PSI

(Bar=0, PSI=1)

°C / °F

(°C=0, °F=1)

Configuration Lock

Page 1 Bit0¼Bit7,

1= lock

PI--Loop Head

(High= I Low= P)

Gear Ratio Motor

5

Pressure Sensortype

Spare

Configuration Lock

Page 2 Bit0...Bit7,

1 =lock

PI--Loop Aux Zone

(High= I Low= P)

Gear Ratio Motor

6

Active Recipe

(1¼4)

Zone# Premelt 1 Zone# Premelt 2 Zone# Premelt 3 Zone# Premelt 4 Zone# Premelt 5 Zone# Premelt 6

Zone#

Progmelt 1

Zone#

2

Progmelt Zone#

3

Progmelt Zone#

4

Progmelt Zone#

5

Progmelt Zone#

6

Progmelt

Zone# Filterblo. 1 Zone# Filterblo. 2 Zone# Filterblo. 3 Zone# Filterblo. 4 Zone# Filterblo. 5 Zone# Filterblo. 6

Zone# Hose 1 Zone# Hose 2 Zone# Hose 3 Zone# Hose 4 Zone# Hose 5 Zone# Hose 6

Zone# Hose 7

Zone# Head 1

Zone# Hose 8

Zone# Head 2

Zone# Hose 9

Zone# Head 3

Zone# Hose 10

Zone# Head 4

Zone# Hose 11

Zone# Head 5

Zone# Hose 12

Zone# Head 6

Zone# Head 7 Zone# Head 8 Zone# Head 9 Zone# Head 10 Zone# Head 11 Zone# Head 12

Zone# Aux.Zo. 1 Zone# Aux.Zo. 2 Zone# Aux.Zo. 3 Zone# Aux.Zo. 4 Zone# Aux.Zo. 5 Zone# Aux.Zo. 6

Zone# Aux.Zo. 7 Zone# Aux.Zo. 8 Zone# Aux.Zo. 9 Zone# Aux.Zo.10

Zone# Aux.Zo. 11 Zone# Aux.Zo. 12

Motor# Pump 1 Motor# Pump 2 Motor# Pump 3 Motor# Pump 4 Motor# Pump 5 Motor# Pump 6

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Programming Page 5-31

Revised 11/01

Optional Dual (Split) Hopper Display & Keypad Reference

Description

Dual Hopper models (available on DM140 and DM210 only) contain two hoppers for the purpose of applying two different adhesives or for applying adhesive at two different temperatures.

On Dual Hopper models, each of the ASU’s pump/ motors are assigned to one hopper or the other.

The DM210’s pump arrangement is 4/2 (illustrated in the following diagrams), meaning that hopper #1 (System 1) has 4 pumps and hopper #2 (System 2) has 2 pumps. A 2/2 arrangement is used on the DM140.

Dual Hopper programming and monitoring is identical to the standard models, with the exception of having more temperature zones divided among the two systems. The controller indicates the active system in the upper status bar. The operator moves from system to system in the same manner that the standard model controller moves from page to page, i.e. by pressing the “C” key.

If the operator desires to see the “Day/Date Clock”, press the Scheduler key, then press #2. Press

Return twice to return to the Actual Temperatures screen.

As indicated below, System 2 temperatures are

READY, but its low temperature thermostat is open.

System 1 Status:

Ready

Heat up

Alarm

Standby

Displayed (active) System

Scheduler Active Indicator

System 2 Status

Scheduler Key:

Day/Date Clock, etc.

SYS 1: READY

Actuals °°°° F System 1

Premelt

Progmelt

Filterblock

1.

300

299

300

274

274

Hose

Head

Aux Zone

Pump

%

Stop

Hold

SETPOINTS

Stop

Hold

PUMP

2.

2

301

299

300

Numeric Entry

Keys

SYS 2: READY lo

Next Page Press C

3.

3

301

273

273

273

273

?

Stop

Hold

Stop

Hold

PRESSURE

4.

4 >

300

274

274

?

CLEAR

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Enter

Enter

Arrow

Keys

Dual Hopper Display & Function Keypad

(Actual Temps Screen shown as example)

All Keypad functions are identical to standard models

Numeric

Keypad

Page 5-32 Programming

Revised 10/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37, 20-38

Optional Dual (Split) Hopper Display & Keypad Reference, cont.

After Pressing “C”, the Display Changes to:

Displayed System

SYSTEM 1: READY

Actuals °°°° F System 1

Premelt

Progmelt

Filterblock

Hose

Head

Aux Zone

Pump

%

Stop

Hold

SETPOINTS

275

274

Stop

Hold

PUMP

SYSTEM 2: READY

Next Page Press C

275

274

273

275

?

Stop

Hold

Stop

Hold

PRESSURE

8.

8 >

274

274

?

CLEAR

On the screen shown above, additional System 1 temperature zones are displayed.

After Pressing “C” again, the Display Changes to:

Displayed System

SYSTEM 1: READY

Actuals °°°° F System 2

Premelt

Progmelt

Filterblock

<

9.

9

299

300

301

Hose

Head

Aux Zone

273

274

Pump

%

Stop

Hold

SETPOINTS

Stop

Hold

PUMP

10.

300

300

SYSTEM 2: READY

Next Page Press C

273

275

274

273

?

Stop

Hold

Stop

Hold

PRESSURE

274

273

?

CLEAR

On the screen shown above, System 2 temperature zones are displayed.

c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Chapter 6

PREVENTIVE MAINTENANCE

Preventive Maintenance Page 6-1

Revised 2/01

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 DYNAMELT

Ò

M SERIES ASU enclosure is finished with an extremely durable polyurethane paint. The enclosure may be cleaned with a variety of industrial cleaners following manufacturers’ directions. To prevent discoloration or deterioration of the ASU’s finish, avoid prolonged contact with strong solvents.

The molded plastic handles may be cleaned with mineral spirits.

Preventive Maintenence Schedule

The Dynamelt M ASU requires little maintenance. 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:

Replacing the Outlet Filter Basket

The outlet filter should be replaced monthly during the first few months of operation. After you gain experience with your system, you can determine how often you need to replace it. The outlet filter is located on the outlet filter manifold on the hose connection panel of the ASU. See illustration of theoutlet filter on page 6-2.

Use the following procedure to replace the standard outlet filter.

cont.

WARNING HIGH PRESSURE

Turn the motor OFF and trigger the applicators to relieve adhesive pressure before performing any outlet filter maintenance.

WARNING

Avoid splashing hot adhesive. The filter screen will be covered with hot adhesive and must be handled with proper tools. Position a heat-resistant container under the manifold before proceeding.

Page 6-2 Preventive Maintenance

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Adjustment Screw Cap

O-ring PN A69X133

Spring

Spring Clip

Filter Basket

PN 101246/ 40 mesh

PN 101247/ 100 mesh

Flat Surface

O-ring PN 069X275

Filter Plug

Roll Pin in Groove

Roll Pin

Slide in “Locked” Position

Slide in “Open” Position

Outlet Filter Manifold

Purge Set Screw

Purge Drain

Purge Set Screw

Purge Drain

Standard Outlet Filter Manifold (located at the Hose Connection Panel)

1. The system should be at operating temperature before starting this procedure.

2. Before proceeding, verify that the motor(s) is turned OFF and the applicators have been triggered to relieve pressure.

3. Remove the Manifold Access Cover by unscrewing its screw and lifting it up and off..

4. Position a heat-resistant container below the manifold. With a hex key screwdriver (allen wrench), slowly loosen the manifold’s two purge set screws (do not attempt to remove them).

Allow adhesive and pressure to escape out of the manifold. Adhesive will drain into the container.

5. Wearing insulated gloves, push down on the adjustment screw cap with sufficient force to release the slide. While holding the cap down, pull the slide forward until the groove stops the roll pin.

Note: If the cap moves “up” before the slide opens fully, this is an indication that there is

c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Preventive Maintenance Page 6-3

Revised 2/01 still pressure in the system. Stop and verify that the motor/ pump is turned OFF and the applicator’s valves are open before proceeding. Then repeat step 5.

6. Pull the cap and the filter plug up and out of the filter cavity. Due to adhesive and the o-ring seals, there will be some resitance before the plug exits the cavity.

Note: the filter basket hangs from the plug by a spring clip. If the filter pulls free of the spring clip and remains in the cavity, use a hooked tool to extract it.

7. Pull the filter basket free from the spring clip. The filter should be inspected and replaced as needed. Note the char and debris inside the filter basket.

8. Before replacing the filter basket, inspect the two o-rings on the filter plug. Replace any cut or damaged o-ring. Apply hi-temp lubricant (PN 001U002) to a new o-ring before installing.

CAUTION: The condition of the lower o-ring (PN 069X275) is especially critical to maintaining system pressure. A cut or scuffed (scratched) o-ring can allow system pressure to escape.

9. Replace or re-install the filter basket onto the spring clip. Push the filter onto the clip. The clip should straddle the wire bar located inside the hole at the top of the filter.

10. Lower the filter basket and the filter plug back into the filter cavity.

11. Position the two flat surfaces at the top of the filter plug parallel to the movement of the slide. The slide will not return to its operating (locked) position unless these flat surfaces are aligned properly. If necessary, twist the plug to align.

12. Re-tighten the two purge screws.

Retainer

Plate

Screws

Filter Plug

Replacing the Optional High Flow Outlet Filter Basket

1. The system should be at operating temperature before starting this procedure.

O-ring

2. Before proceeding, verify that the motor(s) is turned OFF and the applicators have been triggered to relieve pressure.

Filter

Basket

3. Remove the Manifold Access Cover. Note: it is not necessary to remove the Lower Manifold Cover.

4. Using insulated gloves and an allen wrench, remove the retainer plate screws.

5. Lift out the retainer plate/ filter plug assembly.

6. Remove the clogged filter(s) and install a replacement filter.

cont.

Outlet

Filter

Manifold

High Flow Filter Manifold

Page 6-4 Preventive Maintenance

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Note: the filter(s) may be cleaned or replaced. If cleaning a filter, use only solvents recommended by your adhesive supplier.

7. Inspect the o-ring. Replace if flat or damaged.

8. Apply a coat of silicone lubricant onto the filter plug before re-inserting it into the manifold.

9. Apply a coat of anti-seize compound onto all screws before re-inserting.

10. Restore application system to normal operation.

Hose Fittings

All hose fittings should be checked for tightness after every three months of operation.

Fasteners

After the first ten hours of operation, check all set screws, socket head and cap screws for tightness.

Thereafter, re-check all fasteners after every three months of operation.

Filter Shutoff Cleaning or Replacement

See the illustrations in Chapter 10 (Melt & Grid Assembly) for location of the filter shutoff(s).

DM70, DM140 and DM210 models have two filter shutoffs.

1. Pump all the adhesive out of the hopper.

2. Lower the temperature of the application system to the adhesive’s softening point.

WARNING HOT SURFACE

The ASU will still be hot for this procedure. Use insulated gloves and protective clothing when removing the filter shutoff.

3. Open the two access doors located at the sides of the ASU. Do not pull out the ground wires attached. The filter shutoff assemblies are located on either side of the hopper. Repeat this procedure for each assembly.

4. Wearing gloves, use a wrench to unscrew the filter shutoff nut and pull the filter shutoff out.

5. a. Replace the clogged filter shutoff assembly, or b. Emerse the assembly in flushing fluid (PN L15653) to loosen contaminants. Remove assembly from fluid and use a hot air gun (if necessary) and rags to clean all contaminants from it.

6. Apply a coat of anti-sieze compound onto the threads of the filter shutoff nut before re-inserting into the ASU.

c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Preventive Maintenance Page 6-5

Revised 2/01

7. Replace the filter shutoff o-ring. Lubricate the new o-ring with lube (PN N07588).

8. When re-installing the filter assembly, turn the filter’s cut out hole toward the pump.

Align the filter shutoff knob in its “open” position. Note: each filter shutoff is stamped “I”

(open) and “0” (closed) to show position.

9. Close the access doors. Restore the ASU to normal operation.

Pump Shaft Leak

There is a cutout in the baseplate, directly below the pump shaft(s), which will allow adhesive from a leaking pump to exit the ASU. Inspect the area under the baseplate cutout every month for 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)

1. Inspect outlet filter basket. Replace as required.

2. Check for leaking adhesive under the baseplate, caused by a worn pump seal. Replace as required.

Every Three Months (or as experience dictates)

1. Check all hose fittings for tightness.

2. Check all fasteners for tightness.

3. Inspect filter shutoff. Clean or replace as required.

Flushing the System

Contaminated adhesive, accumulation of residue in the system and hopper, or changing the adhesive formulation may require the system to be flushed. To flush the system, have at least 6 liters (1.5 gallons) of flushing fluid on hand (PN L15653) per hopper. Repeat this procedure for each hopper of a dual hopper ASU.

WARNING

The flushing fluid will splash easily. Wear protective clothing, gloves and a face shield to prevent severe burns.

1. Pump out as much of the molten adhesive from the hopper as possible.

2. Reduce the ASU’s pump pressure to zero.

Note: the hose used in the following process is merely for the convenience of depositing flushing fluid. This procedure does not have to be repeated for each hose in the system.

3. Disconnect one of the supply hose’s adhesive feed from its applicator head. Do not

cont.

Page 6-6 Preventive Maintenance

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

disconnect the electrical power to the head (since that would disable the pump). Put the hose in a secured position within a container which will catch the used flushing fluid.

4. 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

Avoid splashing the flushing fluid from the end of the hose.

6. Reduce the pump speed to zero.

7. Remove the outlet filter and replace the basket following the procedures outlined in the

”Outlet Filter” section of this chapter.

8. Add new adhesive to the hopper and allow it to reach application temperature.

9. Slowly increase motor speed to the pump.

10. Actuate each of the heads until all the flushing fluid is removed and a steady stream of new adhesive flows.

11. Re-adjust the pump speed for the desired flow.

12. Re-fill the hopper with adhesive. The system is now ready for production.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Chapter 7

TROUBLESHOOTING

Troubleshooting Page 7-1

Revised 4/01

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” in this chapter before handling or attempting service on Dynamelt’s PCBs.

The Dynamelt’s DynaControl includes malfunction self-diagnostics, alerts and error indication alarms. The error indication alarms (the alarms displayed on the 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.

4. Pneumatic and electrical connections are correct.

5. Adhesive is in the hopper.

Error Messages:

See Ch. 4 for complete instructions on Error Alarms and Message

s.

Sensor Failure on Zone # = temperature zone “#” has an open or shorted sensor.

Overtemperature on Zone # = temperature zone “#” has exceeded setpoint limitation.

Communication Error = indicates a serious problem which requires service by Dynatec.

Hopper Overtemp = hopper temperatures have exceeded their thermostat’s setting.

Hose/ Applicator Troubleshooting Tip

Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the 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.

Motor Speed Control PC Board Re-set

Anytime the AC drives’s Motor Speed Control printed circuit board must be re-set due to line surges or over-currenting the motor, turn the ASU OFF by the main power switch and wait at least

20 seconds before attempting to re-start. This will allow the pcb to re-set. See the table on page 7-7 to troubleshoot.

Page 7-2 Troubleshooting

Revised 4/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

High-Temperature Redundant Overtemp Thermostat

The ASU includes a mechanical (redundant) overtemp thermostat that acts as a safety backup. If the

ASU’s hopper temperature should exceed 232

°C (450°F), the thermostat will cause the 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 behind the motor access door (see Chapter 8). To reset: turn

OFF the ASU’s main power switch, push the center of the thermostat’s insulator to re-set, restart the ASU.

Pump Enable Thermostat

The pump enable thermostat is a low-temperature safety feature of the Dynamelt ASU designed to prevent the pump from powering on before the adhesive is molten. It is a cartridge thermostat and it is factory set at 135 °C (275°F). The thermostat is adjustable so that operators using adhesives with extraordinarily high or low melting points can tailor the low-temp setting to their production’s needs.

To access the pump enable thermostat, follow the instructions given in Chapter 8. Refer to Chapter

3 for instructions on calibration of this thermostat.

Lithium Battery on CPU PCB

The CPU Printed Circuit Board contains a lithium battery which serves no function in the Dynamelt

M Series controller configuration.

Lithium Battery on Display CPU PCB

The Display CPU Board contains a lithium battery. The normal life of this battery is about ten years. When the battery needs replacement, the scheduler’s clock does not function, but other controller features remain intact. Return the board to ITW Dynatec for battery replacement.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Troubleshooting Page 7-3

Revised 4/01

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 M Series PCBs.

Page 7-4 Troubleshooting

Revised 5/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

CPU Printed Circuit Board

The CPU board(s) contains the controller’s software chip (EPROM), CPU chip and non-volatile memory. It also contains the optional RTD Expansion PCB (for ASUs with 10 or more zones). Up to three CPU boards may be installed on an ASU, corresponding to up to three hoppers and up to

48 temperature zones (16 per CPU pcb).

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.

Internal connection to Display CPU Board

Audible

Alarm

X5 X6

Relay outputs:

1&2 = alarm contacts

3&4 = low level contacts

Flat cable connect to

Power PCB

3

4

1

2 X1

X9

X16

X11

CPU chip

S4

S3

S2

S1

Non-volatile Memory

Software chip

EPROM

J1

Dip switches: not used

Lithium battery (not used in M Series configuration)

Flat cable connect to motor interface pcb

Terminal connections:

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

X4

5

6

3

4

1

2

7

8

9

10

(cutout)

Flat cable connect to Power PCB

Sensor Inputs for

Zones 6 to 9

Sensor Inputs for

Zones 10 to 15

J6

X2

X7

X14

Sensor Inputs for

Zones 1 to 5

Optional RTD

Expansion PCB

(for ASUs with over 9 zones)

Sensor Inputs for Zone 16

(cutout)

LED1 monitors DC voltage: regulated

+5 volts

LED2 monitors

DC voltage: +12 volts

Layout of Components on CPU Board

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Troubleshooting Page 7-5

Revised 2/03

Display CPU Printed Circuit Board

The Display CPU PCB contains the controller’s CPU module, scheduler battery, serial ports and optional connections. It is located directly behind the controller’s display panel within its mounting bracket (or within the remote pendant assembly (option), if applicable).

When downloading software updates, use the download serial port seen at the lower right of the illustration. While downloading, the J1 jumper is moved temporarily to its #1 position.

To configure the number of (optional) pressure transducers on an ASU, use the dip switches (shown below beneath the expansion board) and the following chart. There are four transducers per PSI

PCB and a maximum of three PSI PCBs per ASU. Note: PSI not available on APS models.

On the RS-Com board, both the J1 and

J2 jumpers must be in upper position for

485 and both in lower position for 232.

Dip Switches to configure

# of opt. PSI PCBs (only switches #1 & 2 are used) or APS model

Switch #

1

2

3

Optional RS232 Serial Connect

(use for PLC/ PC Link)

0

# of PSI PCBs

1 2 3

off off on off off on on on on = APS OFF = nornal

Optional RS485 Serial Connect (use for PLC/ PC Link)

Connect to opt.

Expansion Board

(for Serial Communication)

CAUTION! FOR

EXPANSION

BOARD CON-

NECT ONLY

J1 J2

1

Scheduler

Battery

Reset

Download

Reset

J1

SW2 SW1

Download Jumper

Optional Memory

Card Reader connect

Connect to

CPU PCB

Layout of Components on Display CPU PCB

Software Download Port

Page 7-6 Troubleshooting

Revised 1/03

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Motor Control Interface Printed Circuit Board

For each motor on the ASU, there is a Motor Control Interface PCB and a Motor Speed Control

PCB. The Motor Control Interface PCB (diagrammed below) connects directly to the CPU PCB.

The Motor Speed Control PCB (diagrammed on the following page) connects via a spade connector to the Motor Control Interface PCB. Up to two motor’s pcbs may be connected to one CPU PCB.

Each Motor Control Interface PCB’s jumpers should be set as follows: the J1 and J2 jumpers should always be set in the M1 position diagrammed below for motor #1, #3 and #5. For motor #2, #4 and

#6, jumpers J1 and J2 are set in the M2 position (opposite from those diagrammed below). The M/S selection jumper must be set in the “M” position. The J3 jumper is always set as shown below.

“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.

MAX Speed Adjustment potentiometer

Flat cable connect to

CPU PCB at J1

Transformer Fuse

240 VAC input

M1 M2

J2

J1

X1

F1

M S

Transformer

X5

L1

N

VR1

J3

X2

Motor

10

0

En

En

P

X4

Web

0

5

X3

TR

TR

10

0

X2 connections are internal and not for customer’s use:

0-5 VDC speed reference

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, msx. 40v

Web Speed Scaling potentiometer

Factory Set, Do Not Adjust

Layout of Components on Motor Control Interface Board

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Troubleshooting Page 7-7

Revised 1/03

Motor Speed Control Printed Circuit Board

The Motor Speed Control PCB is connected to the Motor Control Interface Board via spade connctors P1 and P2. P3 is not used.

The three jumpers (FSR, J1 and A/M) are factory set, do not change. The J1 jumper is always set in the upper position. The A/M Jumper is always present.

“CL” adjusting pot: The current limit (CL) adjustment will limit the maximum current available to the AC pump motor during overload. This will protect the motor from damage. The setting is factory set to deliver 100% of the rated horsepower for the ASU. When the motor load exceeds the current limit value, the Status LED (light) will illuminate red (indicating an overload condition). Turning clockwise increases the current limit value; turning counter-clockwise decreases it. The current limit is factory preset, so no adjustment is necessary.

“ACC” and “DEC/B” adjusting pots: These pots change the time required for the pump motor to accelerate (ACC) or de-accelerate. Turning full counter-clockwise equals 0.3 seconds. Turning full clockwise equals 20.0 seconds. Factory default for either pot is 10.0 seconds.

cont.

FSR Jumper & connection to drive enable of Motor Interface PCB

Spade connectors (3) from Motor

Interface PCB

P1

P2

P3

Potentiometers:

Factory Set, Do Not Adjust

CL = Current Limit

J1 Jumper

A/M Jumper = Auto/ Manual

PWR = Power LED. Green = unit is ON

Line

L2

MAX = inactive

AC

L1

MIN = Minimum RPM

DEC/B = Decelerate

ACC = Accelerate

COMP = IR Comp

W

Motor

V

U

Spade connectors

(2) to incoming

Main Power

Spade Connectors

(3) to Motor

ST = Status Led. Red/ yellow/ green. See table below.

ST LED Color State

Green

Red

Red

Red

Slow Flash

ON

Function

Normal Operation

Current Limit

Quick Flash Overload

Slow Flash Short Circuit

ST LED Color State

Red/Yellow

Red/Yellow

Yellow

Function

Quick Flash Undervoltage

Slow Flash

ON

Overvoltage

Stop

Layout of Components on Motor Drive Board

Page 7-8 Troubleshooting

Revised 7/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

“MIN” adjusting pot: This pot adjusts the minimum speed of the pump motor when it is enabled.

The pot is factory preset to exactly zero RPM when the speed setting is 0.00% full scale. Turning clockwise increases the minimum RPM above zero RPM when the motor is enabled. This adjustment can be utilized to “creep” the motor (also referred to as “auto preload”) so that positive adhesive pressure is always maintained in the system.

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Troubleshooting Page 7-9

Revised 9/01

48-Zone Power Printed Circuit Board

The 48-Zone Power PCB has the capacity to monitor adhesive temperatures for multiple hoses, applicators, hoppers and auxillary zones.

The LEDs for each temperature zone (1 through 48 illustrated below) will flash on and off as their heaters output to maintain setpoint temperature. The Power On and Hopper LEDs will light continuously once the hopper(s) are up to temperature.

The settings of the JP1 and JP2 jumpers correspond to the number of hoppers on the ASU. For an

ASU with one hopper, both jumpers must be set to position 1-2 (shown). For two hoppers, JP1 must be set at 1-2 and JP2 must be set at 2-3.

System

Ready outputs to customersupplied

PLC

Power ON for PLC

Power ON contactor

System 1

{

System 2

{

Future

{

{

{

System

Ready

(snubbed) power outputs

System 1

{

System 2

Future

{

{

Input

Power

240 VAC

{

L1

L2/N

PE

JS3

Jumper JP1

1&2 = 1 hopper

2&3 = 3 hoppers

Low temperature thermostats for

Hoppers 1, 2

Jumper JP2:

1&2 = 1 hopper

2&3 = 2 hoppers

High temperature thermostats for

Hoppers 1, 2

Connect to

CPU 1 at

X16

Connect to

Clutch pcb

12 11 10 9 8 7 6 5 4 3 2 1

JF1

JS1

JS4

LED

LED

JS5

1 3

1

JP1

Power ON

Hopper 1 Ready

JP2

3

JF5

CPU 1

Connect to

CPU 2 at

X16

CPU 2

JF6

LED

LED

Hopper 2 Ready

Future

JS2

Transformer

F1

JH1

2

1

4

3

6

5

8

7

12

11

10

9

16

15

14

13

JH2

20

19

18

17

24

23

22

21

28

27

26

25

32

31

30

29

JF2

JF3

Connect to

CPU 3 at

X16

CPU 3

JF7

JF4

JH3

36

35

34

33

40

39

38

37

44

43

42

41

48

47

46

45

Solid state relay driver outputs

(1 per zone)

LED:

Green = zone is heating

Transformer Fuse

(5x20 1 amp)

Connect to

CPU 1 at

J6

Connect to

CPU 2 at

J6

Connect to

CPU 3 at

J6

Layout of Components on 48-Zone Power Board

Page 7-10 Troubleshooting

Revised 6/01

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Optional Clutch Printed Circuit Board

The Clutch PCB allows installation of up to six (optional) clutches on the ASU.

The dip switches (SW1) are turned ON to reflect the number of clutches on the system.

Relay

Green LED = clutch is activated

Clutch 1

#1 cl

JS2

JS1

Clutch 3

Clutch 2

Clutch 4

Clutch 5 Clutch 6

Green LED = System Power ON

Clutch Coil Leads Connects

Customer Enable Switches: for a footswitch, hand-held applicator, etc.

Board

Fuse

#6 cl

F1

L1 L2

JS3

240 VAC Input

Layout of Components on Clutch Board

SW1

ON

1

6

JF1

Connect to 48-Zone

Power Board at JF1

Dip Switches:

1 clutch = switch #1 is ON

2 clutches = switch #1 & 2 are ON

3 clutches = switch #1, 2 & 3 are ON

4 clutches = switch #1, 2, 3 & 4 are ON

5 clutches = switch #1, 2, 3, 4 & 5 are ON

6 clutches = all switches are ON

Optional RS232/485 Printed Circuit Board

Pin Configuration:

RS232

2 RxD

3 TxD

5 Gnd

S Shield

RS485

3 TxB

4 TxA

8 RxB

9 RxA

S Shield

(Pins not listed are not used)

3

2

5

4

1

7

6

9

8

Shield

Ribboncable connect to

Display CPU PCB

Layout of Components on Communication Board

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Troubleshooting Page 7-11

Revised 4/01

Optional Pressure (PSI) Printed Circuit Board

Each Pressure (PSI) PCB on the ASU allows the controller to monitor up to four pressure transducers. The DM35 ASU can accept one PSI PCB (four transducers), the DM70/140 ASUs can accept up to two PSI PCBs (up to eight transducers) and the DM210 ASU can accept up to three PSI PCBs

(up to 12 transducers). Each CPU board can accomodate one PSI PCB.

The 8 pairs of terminals at the top edge of the board (as seen below) are for the high and low alarm outputs of the relays. The eight jumpers for the high/ low alarm output relays (E1 thru E8) are 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).

Note: the quantity of pressure transducers on an ASU is configured at the dip switches on the Display CPU PCB.

Input connections from Transducers:

Transducer #1

X1

X2

High & Low Alarm Outputs

4 High 4 Low 3 High 3 Low 2 High 2 Low 1 High 1 Low

X6

E8

E7 E6 E5 E4 E3 E2 E1

Transducer #2

X3

Transducer #3

X5

X4

Transducer #4

Jumpers for

High/Low Alarms:

Normally Open (default)= no alarm/ no continuity

Normally Closed = no alarm/ has continuity

Flat cable to

CPU PCB

Green LED = Board logic power is OK

Layout of Components on Pressure Board

Page 7-12 Troubleshooting

Revised 5/02

ITW Dynatec c. 2000

DYNAMELT M ASU Manual #20-36, 20-37 and 20-38

Heater and Sensor Resistance Values

The resistance values given in the four tables on the following page will aid in troubleshooting when a sensor or heater malfunction is suspected. The “Temperature Sensor Resistance” table gives values for various temperatures. If you know the approximate temperature of the suspected sensor, you can check to see if the sensor resistance approximates the value given in the table by unplugging the affected head or hose connection and measuring resistance across the affected pins (see wiring diagram in Chapter 11 for pin numbers).

DANGER HIGH VOLTAGE

Disconnect input power to the application system before disconnecting/ re-connecting electrical connections. Make sure there is no electrical power on the leads you will be connecting.

The “Nominal Hose Heater 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 M Series model and for the (optional) drop-in grids.

The “Nominal Filter Manifold Heater Resistance” table gives heater resistance for the heater located in the (optional) filter manifold/ pressure relief block. The heater inside the manifold varies depending on the number of filter manifolds mounted on the ASU, therefore resistance varies also.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Troubleshooting Page 7-13

Revised 10/00

°

F

Temperature

°

C

Resistance in Ohms

176

194

212

230

248

268

284

302

32

50

68

86

104

122

140

158

320

338

356

374

392

410

428

80

90

100

110

120

130

140

150

40

50

60

70

0

10

20

30

160

170

180

190

200

210

220

131

135

139

142

146

150

154

157

100

104

108

112

116

119

123

127

161

164

168

172

176

180

183

Temperature Sensor Resistance

(0.00385 PT 100 RTD)

Hose Length

Meters Feet

Resistance in Ohms

1.2

1.8

2.4

3

3.7

4.9

7.3

4

6

8

10

12

16

24

323-358

201-223

155-172

120-133

102-114

75-84

51-57

Nominal Hose Heater Resistance for DynaFlex Hoses

Watts Resistance in Ohms

200

270

350

500

700

288

213

165

115

82

Nominal Head Heater Resistance

Note: Resistance is measured at ambient temperature (20

Model :

Qty. Hopper Heaters

Max. # of Drop-in Grids

Resistance (Ohms) for each Hopper Heater

Resistance (Ohms) for each Drop-in Grid Heater

M35

1

2

11.5

23

M70/ 140

2

4

11.5

23

Nominal Hopper Heater Resistance in Ohms

°C/ 68°F).

M210

3

6

11.5

23

# of Filter Manifolds on ASU

Model: M35 M70/ 140 M210

1

2

3

4

5

6

115.2

51.6

not available not available not available not available

115.2

51.6

38.4

28.8

not available not available

115.2

51.6

38.4

28.8

TBD

186

Nominal Filter Manifold Heater (optional) Resistance in Ohms

Page 7-14 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Error Indication Alarm Troubleshooting Guide

The operation of error indication alarms is described in Chapter 4. When checking for correct equipment operation in the following guide, be aware that all heaters will go off immediately after an error indication alarm occurs if the operator takes no action. With the exception of the fuses, there are no user-replaceable parts on the printed circuit boards. If there is a non-fuse failure on any of the PCBs, the PCB must be replaced.

Problem

Hopper (tank)

Overtemp

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.

Hopper Sensor

Possible Cause Solution

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.

3. Hopper control solid state relay inoperative.

2. Replace hopper sensor if resistance does not comply with the resistance table in this chapter.

3. a. Verify that the relay is not shorted by removing all of its output wires and verifying that resistance is greater than zero.

b. Verify condition of relay by disconnecting, then re-connecting properly.

Then, when Temperature Zone is OFF, use a VOM AC voltmeter to verify that

240 volts are not present at the heater terminal.

Solid State

Relay

Solid State

Relay

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

Hopper Sensor Open

Possible Cause Solution

Troubleshooting Page 7-15

Revised 10/00

1. Sensor cable has become unplugged from CPU PCB

1. Verify that hopper sensor cable is properly connected on X14 on the CPU

PCB.

2. Inoperative hopper sensor.

2. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

Hopper Sensor

X14

Hopper Sensor Short

CPU PCB

1. Short-circuit caused by debris where sensor plugs into CPU PCB.

2. Pinched sensor lead wire.

3. Inoperative hopper sensor.

1. Verify that sensor plug is clean and correctly connected on X14 on the CPU

PCB.

2. Visually inspect sensor lead wire for break, kink, damage, etc. If no obvious damage, use an ohmmeter to measure continuity from the sensor lead to the plug at the CPU PCB. Repair or replace any damaged wire.

3. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

Page 7-16 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

Hopper Heater Open

Hopper

Sensor

Thermostat

Hopper

Heater Wire

Hopper Circuit Breaker

Possible Cause Solution

1.Disconnection in hopper heater circuit.

1. Inspect hopper heater wiring for proper connections.

2. Disconnection between

Power PCB and CPU PCB.

2. Verify that all connections are properly made on the CPU PCB.

3. Hopper circuit breaker tripped.

4. Open hopper heater element.

3. Refer to the schematic in Chapter 11 to locate the hopper circuit breaker. If it is tripped, do not re-set it without checking for causes. Visually and electrically inspect for a shortcircuit to ground in the hopper heater circuit. This will be limited to between the hopper control relay and the hopper heater.

4. At the terminal rail: use an ohmmeter to measure resistance across H3A and

N (380v) or across H3A and H3B

(240v). See the resistance table in this chapter for normal resistance values. Infinitely high reisistance values indicate an open heating element which must be replaced.

NOTE A: DM70/140 models may have up to two hopper heaters.

If the ASU has a second heater, measure this heater’s resistance across H15A and

N (380v) or across H15A and H15B

(240v) as outlined above.

NOTE B: DM210 models may have up to three hopper heaters.

If the ASU has a second heater, see Note

A. If the ASU has a third heater, measure this heater’s resistance across H27A and

N (380v) or across H27A and H27B

(240v) as outlined above.

(Optional) Drop-in

Grid Overtemp

2500w

Heater

Leads

1. Setpoints have been programmed without enough deviation.

2. Grid sensor inoperative.

Grid

Sensor

1. Re-program setpoints, allowing a larger deviation between the high and low limits.

2. Examine grid sensor assembly for intermittent break in sensor lead.

Remove sensor bulb from grid.

Replace grid sensor if resistance does not comply with the resistance table in this chapter.

X14

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

(Optional) Drop-In

Grid Sensor Open

(Optional) Drop-in

Grid Sensor Short

CPU PCB

Troubleshooting Page 7-17

Revised 10/00

Possible Cause

3. Grid control solid state relay inoperative.

Solution

3. Use a clamp-on ammeter to monitor current. Replace inoperative solid state relay.

1. Sensor cable has become unplugged from CPU PCB.

1. Verify that grid sensor cable is properly connected at X14 on the

CPU PCB.,

2. Disconnection between

Power PCB and the CPU

PCB.

3. Drop-in grid sensor inoperative.

2. Verify that all connections are properly made on the CPU PCB.

3. Replace sensor if resistance does not comply with the resistance table in this chapter.

1. Short-circuit caused by debris where sensor plugs into CPU PCB.

2. Pinched sensor lead wire.

3. Drop-in grid sensor inoperative.

1.Verify that sensor plug is clean and correctly connected at X14 on the

CPU PCB.

2. Visually inspect sensor lead wire for break, kink, damage, etc. If no obvious damage, use an ohmmeter to measure continuity from the sensor lead to the plug at X14 on the Power PCB. Repair or replace any damaged wire.

3. Replace sensor if resistance does not comply with the resistance table in this chapter

Page 7-18 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

(Optional) Drop-in

Grid Heater Open

Grid

Sensor

2500w

Heater

Leads

Possible Cause Solution

1. Disconnection in grid’s heater circuit.

2. Disconnection between

Power PCB and solid state relay.

3 Drop-in grid circuit breaker tripped.

1. Inspect grid’s heater wiring for proper connections.

2. Verify that the Power PCB is properly connected to the solid state relay.

3. Refer to the schematic in Chapter 11 to locate the grid’s circuit breaker. If it is tripped, do not re-set it without checking for causes. Visually and electrically inspect for a shortcircuit 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.

NOTE: The DM35 ASU may have 1 or 2 grids. The

DM70/140 ASU may have from 1 to 4 grids.

The DM210 ASU may have from 1 to 6 grids.

4. At the terminal rail, use an ohmmeter to measure resistance as follows:

For 1 grid: H1A & N (380v)

H1A & H1B (240v)

For 2nd grid: H2A & N (380v)

H2A & H2B (240v)

For 3rd grid: H13A & N (380v)

H13A & H13B (240v)

For 4th grid: H14A & N (380v)

H14A & H14B (240v)

For 5th grid: H25A & N (380v)

H25A & H25B (240v)

For 6th grid: H26A & N (380v)

See the resistance table in this chapter for normal resistance values. Infinitely high reisistance values indicate an open heating element which must be replaced.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Troubleshooting Page 7-19

Revised 10/00

Problem Possible Cause Solution

Hose/ Head

(No.) Overtemp

Note: Vertical configuration is for

DM 35 only. Larger ASUs are arranged horizontally.

Aux.

#1

Aux.

#2

#1

#2

Sensor

Heater

Plug

Sensor &

Heater

Hose/ Head (No.)

Sensor Open

1. Hose/ Head setpoints incorrectly programmed.

1. Re-program setpoints to allow a larger deviation.

2. Inoperative or shorted hose/ head triac or dual solid state relay.

2. Refer to the schematic in Chapter 11 to locate the correct head/ hose triac or relay. Use a clamp-on ammeter to monitor hose/ head current. If current does not cycle on and off, then the triac or relay has failed and must be replaced.

3. Disconnection between the

Power PCB’s and the CPU board’s flat cables.

3. Verify that all PCBs are properly mounted inside the panel box.

4. Hose/ Head sensor circuit inoperative.

4. a. Visually examine socket connection where hose/ head attaches to ASU.

Verify that pins are properly seated. If pins or plug housing are damaged, repair or replace hose. If socket is damaged, repair or replace harness.

b. If hose-to-ASU plug and socket are okay, hose may have intermittent short or open circuit. Repair or replace hose, hose harness or Power PCB as appropriate.

Alternately, problem can be isolated by connecting the effected hose to a different ASU hose socket to tell whether the problem is in the hose or in the Power PCB.

1. Disconnection between hose and ASU.

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 as appropriate.

1. Visually examine connection where hose plugs into ASU socket for proper contact and seating. If pins or housings are damaged, repair or replace hose or hose harness (in ASU).

Page 7-20 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Aux.

#2

#1

#2

Problem

Note: Vertical configuration is for

DM 35 only. Larger ASUs are arranged horizontally.

Aux.

#1

Possible Cause Solution

2. Hose sensor harness unplugged from Power

PCB.

2. Verify that effected hose is properly connected to Power PCB. Replace or repair damaged hose harness as necessary.

3. Disconnection between the

Power PCB’s and the CPU

PCB’s flat cables.

3. Verify that all PCBs are properly mounted inside the panel box.

4. Hose/ Head sensor circuit inoperative.

4. Replace head sensor if resistance does not comply with resistance table in this chapter. Use hose schematic to check hose sensor at ASU socket. Repair or replace hose, hose harness or Power

PCB as appropriate.

Hose/ Head (No.)

Sensor Short

1. Debris at connection between hose/ head and

ASU.

2. Hose/ Head sensor circuit inoperative.

1. Visually inspect hose plug and ASU socket for cleanliness and proper contact and seating of pins.

2. a. Using the hose schematic, check hose sensor resistance at ASU socket. An ohmmeter can be used to isolate a pinched wire in the hose harness.

When cause is isolated, replace hose, hose harness or Power PCB as appropriate.

b. If head-to-hose and hose-to-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 as appropriate.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

Hose/ Head (No.)

Heater Open

Sensor

Heater

Plug

Sensor &

Heater

Troubleshooting Page 7-21

Revised 10/00

Possible Cause Solution

1. Disconnection between hose/ head and ASU.

1. Visually examine effected hose plug and ASU socket for cleanliness and proper contact and seating. Refer to the wiring diagram for pin identification. The problem can be isolated by plugging the effected 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, head or ASU hose harness as appropriate.

2. Disconnection between solid state relay and

Power PCB or inoperative relay.

2. Check connection. Verify that solid state relay is operative: check schematic in Chapter 11 for relay location. Use a clamp-on ammeter to monitor hose/

Head current. If current does not cycle on and off, the relay has failed and must be replaced.

3. Disconnection between 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. Inoperative hose/ head circuit breaker.

4. Refer to schematic in Chapter 11 for location of circuit breaker. If it is found to be tripped, do not re-set it without first finding cause. Visually inspect and use an ohmmeter to check for a possible short circut to ground in the hose/ head heater circuit.

5. Open hose/ head heater element.

5. Use an ohmmeter to measure hose/ head heater resistance. See resistance table in this chapter for resistance values. Infinitely high resistance indicates an open heater element.

6. Open wiring inside ASU.

6. Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate open wires in head heater circuit. Repair or replace ASU hose head harness or other ASU wiring as necessary.

Page 7-22 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Adjustable Adhesive Pressure Relief Valve

Dynamelt pumps are outfitted with a high-pressure relief valve located on the outlet filter manifold.

The valve is adjustable and it does not affect adhesive pressure under normal operating conditions.

The adjustable pressure relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.

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. The check valve, seen below, is not instrumental in pressure relief. It serves as an overflow valve, preventing adhesive from flowing out of the hopper when the filter plug is removed.

Normally Closed (Unrelieved):

In the drawing below, the pressure relief valve is closed.

Open (Relieved):

In this drawing, pressure has exceeded the setting of the valve, causing it to open and discharge adhesive to the hopper.

Adjustment

Screw Cap

Check Valve

Check Valve return to hopper from pump

Spring

Pressure

Relief

Valve return to hopper from pump to hose

Adhesive flow through filter block to hose

Adhesive flow through filter block to hose

Operation of the Adjustable Adhesive Pressure Relief Valve

Pressure

Relief

Valve

Filter

Basket to hose

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Troubleshooting Page 7-23

Revised 10/00

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 controller’s keypad. When the Dynamelt’s pump is to be operated manually (that is, without a line following signal), the manual mode is used to control pump speed (and adhesive output). For the gear pump to be operated in the automatic mode, a tach generator, or equivalent (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 to 10 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 PCB (for a tach generator) or at terminals 9 (+) and 10 (-) of the 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 motor speed can be adjusted (trimmed) in automatic mode by setting maximum and minimum percent of full speed values on the controller’s keypad. MAX % of Full Speed will be the true motor speed at 10 volts input. This value cannot exceed 100%.

To make the motor speed adjustment, follow the programming instructions in Chapter 5.

Pump Output Adjustment

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 controller’s keypad. However, if less pressure is needed, maximum pressure of the pump can be decreased (or increased) by adjusting the pressure relief valve installed on the pump output manifold. To change the setting of this valve, refer to instructions in Chapter 3.

The relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.

Page 7-24 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Troubleshooting the ASU’s Gear Pump

No special tools are needed for working on the ASU pump. See Chapter 8 of this manual for 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.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Troubleshooting Page 7-25

Revised 10/00

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.

Note: Each motor and Motor Interface PCB in the system can run independently (or dependently). Each Motor Interface PCB may have its own operating parameters. Therefore, each motor and Motor Interface PCB should be troubleshot independently.

Problem Possible Cause

Pump doesn’t operate 1. Motor On/Off is OFF at in “Manual” mode, the controller keypad.

power light doesn’t light.

ON/OFF Led

2. Hopper temperature is below ready setpoint.

Solution

1. Check keypad setting.

3. No incoming electrical power.

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. Check to see if ASU temperature control is operating. If not, check for presence of incoming supply voltage.

Pump doesn’t operate 1. “Manual” motor is set at in “Manual” mode, zero (at the keypad).

power light is ON, hopper is at “ready” condition.

2. If pump On/Off is being controlled by a remote switch (i.e., a hand-held, applicator), the switch or switch circuit may be open.

1. Re-program motor.

2. Check condition of the remote switch

(the hand-held applicator).

3. Low temp alarm.

4. Faulty Motor Control

Interface Board.

3. Verify that ASU is warmed up and that hopper temperature is above the factoryset pump enable temperature.

4. If the board is faulty it must be replaced.

Page 7-26 Troubleshooting

Revised 6/01 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem Possible Cause

Solution

Pump doesn’t operate 1. Parent machine is not in “Auto” mode, running.

power light is ON, hopper is at ready conditon.

2. “Auto” motor is set at zero (at controller keypad).

1. Check parent machine.

2. Re-program motor.

Motor Control Interface PCB

X3

3. No incoming line following signal.

4. Internal ASU connections or Motor Control Interface

PCB inoperative.

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. Check for the presence of 0 to 10 VDC control signal at X3 of Motor Control

Interface PCB. Check ASU connections

(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. System is not ready, temperatures are too low.

5. Verify that ASU is warmed up and that hopper temperature is above the low temperature thermostat.

Pump runs but there is 1. ASU is out of adhesive.

no adhesive output.

2. If pump has been serviced and leads reversed, pump will run with no output.

1. Add adhesive to hopper.

2. Check pump wiring to schematic.

Low or inconsistent adhesive output.

Filter Basket

1. Filter(s) clogged.

2. Adhesive used is too viscous.

3. Clogged hose.

4. Clogged applicators.

1. Remove and inspect filter basket and primary filter.

2. Verify that system components are at appropriate temperatures and that the selected adhesive is correct for the application.

3. Inspect hose for kinks or internal plugs of debris or char. Clean or replace hoses as necessary.

4. Inspect applicators for plugged nozzles or filters. Clean or repair applicators as necessary.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

Problem

Troubleshooting Page 7-27

Revised 10/00

Possible Cause

5. The fixed pressure relief valve is opening.

6. Inoperative lower o-ring in filter plug is allowing pressure to escape.

Solution

5. When fully closed (clockwise) and all applicators are off, adhesive pressure should be around 34 bar

(500 psi). If it is significantly less, the pressure relief valve should be replaced.

6. Replace o-ring. Follow diagram and instructions in Chapter 6 for “Outlet

Filter” to locate the o-ring.

Adhesive leak at pump 1. Pump seal is incorrectly shaft seal.

positioned inside the seal and bearing assembly.

Seal Assembly

Rear Plate

O-ring

2. Pump seal inoperative.

1. Remove seal and bearing from pump.

Verify that all components are correctly positioned.

2. Remove seal from pump, inspect it and replace it if worn or damaged.

Be sure there are no burrs or other sharp edges on 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.

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 missing or loose.

2. Verify that all four pump screws are tightly assembled to the hopper.

3. Helicoil insert pulled out of hopper.

3. Remove pump and inspect hopper.

Repair or replace hopper as necessary.

Page 7-28 Troubleshooting

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37 and 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

Disassembly & Re-assembly Page 8-1

Revised 6/01

Chapter 8

DISASSEMBLY & RE-ASSEMBLY PROCEDURES

Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All disassembly and repair procedures must be performed by qualified, trained technicians.

Disassembly Procedures

Note: Use the exploded-view drawings referenced with each procedure in conjunction with the instructions outlined in this chapter. Read the “cautions” on page 8-5 before re-assembling the ASU.

To Remove the Access Doors

There are two access doors, one on either side of the ASU. Use the key to unlock the door, then lift it off, being careful not to pull off the ground wire attached. Remove the ground wire and re-attach when the door is re-installed. These doors allow access to: the motor, pump, junction boxes, (optional) drop-in grids, filter shutoffs and (optional) ball valves.

To Open Junction Boxes

There are two junction boxes, one on either side of the hopper(s). A junction box cover is removed by two screws at the bottom of the box. Within the juction boxes are thermostats, heater terminals and the hopper sensor. See also the detailed illustration on the following page.

Panel Box

Assembly

Access

Door

Keylock

Filter Shutoff

Assembly

Pump Enable

Thermostat

Over-Temp Reset

Thermostat

Filter Shutoff Assembly

Ball Valve

Assembly

(option)

Pump Enable Thermostat

Over-Temp Reset Thermostat

Filter Manifold

Manifold Cover

Page 8-2 Disassembly & Re-assembly

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

Junction

Box cover

Hopper

Junction

Box

Cutouts for conduit connectors for filter manifold heater and sensor.

Over Temp

Reset

Thermostat

Cutouts for drop-in grid assembly

Filter Shutoff

Junction Box

Hopper Sensor

Port

Heater

Terminals

Side View

Pump Enable-

Thermostat Port

Sensor or Thermostat Replacement

Remove the junction box cover.

a.

Over-Temperature Thermostat Replacement:

Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper.

b.

Pump Enable Thermostat Replacement:

Disconnect two wires from the terminal strip and slide the thermostat out.

c.

RTD Sensor Replacement:

Disconnect two wires from the terminal strip and slide the sensor out.

To Remove the Manifold Cover

Unscrew its captive screw and slide cover off. Cover allows access to the hose connections on the filter manifold, outlet filters, heaters and the pressure relief.

Heater Replacement

Cartridge heaters are located underneath the filter manifolds:

For models DM70 & 140: Remove the manifold cover (see previous page). Remove the cover located at the end of the heater retainer plate (4 screws). Disconnect heater wires from the terminal rail. Loosen the heater retainer plate, then allow the cartridge heaters to slide out.

For model DM210: Replace heaters on the outer four manifolds as described above. To access heaters on the two inner manifolds, remove the two manifold covers, then remove the cover located at the end of the heater retainer plate (4 screws). Disconnect heater wires from the terminal rail. Remove the heater retainer plate, then remove the heater(s).

Heater plates are kocated underneath the hopper(s):

Remove the access door. Use a hex head socket wrench to remove the six heater plate bolts through the holes drilled in the base plate. Disconnect the heater wires. Slide the old heater plate out. Connect heater wires to new plate. Slide new plate in place and fasten with the six bolts.

Note: the DM70 & 140 models have two heater plates; the DM210 model has three heater plates.

c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

Disassembly & Re-assembly Page 8-3

Revised 6/01

To Remove Rear Cover

No customer replaceable components are behind the rear cover. To remove: remove the two access doors in order to access and remove the five screws which hold the rear cover in place. Two screws are located in the upper corners of the rear cover. Three screws are located across the bottom of the cover.

To Access the RTD Sensor in the Optional Drop-in Grid

Remove the access door. Remove the screws on the drop-in grid’s junction box cover in order to remove the cover. Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter.

To Access Electrical Components inside the Panel Box

DANGER HIGH VOLTAGE

Dynamelt systems use electrical power that can be life threatening. Disconnect and lock out input power to the application system before starting any disassembly procedure.

Verify again that the main power is OFF. On the outside of the panel box, use the main disconnect switch to open the panel box door (see Chapter 3 for instructions on opening door).

a.

Fuse Replacement:

Fuses are located in the upper right corner of the inside of the panel box assembly. The following printed circuit boards are fused: Motor Control Interface, Power I/O and the optional Clutch board.

b.

Printed Circuit Board Replacement:

Reference the section entitled “Handling Printed Circuit Boards” in Chapter 7. The PCBs are located in the panel box assembly. Refer to detailed layout in Chapter 3.

The PCBs snap into and out of their standoffs. To remove: place your fingertips under one corner of the PCB and pull out firmly from the standoff. Repeat for each corner of the PCB.

Note: aside from fuses and the Lithium battery on the M Series CPU PCB (see Chapter 7), there are no replaceable parts on the PCBs.

Optional Memory Card Reader Battery Replacement

Refer to instructions outlined in the Appendix of this manual. See Ch. 3 for installation of

Memory Card Reader.

Page 8-4 Disassembly & Re-assembly

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

To Access the Pump or Motor

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.

Remove access door(s) using the key, being careful not to pull off the ground wire attached. Turn

OFF the filter shutoff valve by turning it to its closed “0” position.

a.

Motor Removal:

Open the motor junction box cover (2 screws). Inside the junction box, disconnect the wires leading to the motor. On the outside of the junction box, unscrew the hex nut conduit fitting. Slide the wires through the conduit fitting. Remove the four bolts which attach the motor to the gear box. Lift the motor up and out of the ASU.

For re-assembly: torque should be approximately 1.8 Nm (16 foot/lbs) at room temperature.

With hopper at 177

°C (350°F), the maximum allowable torque on screws is 4.1 Nm (36 foot/lbs).

Motor

Access

Door

Motor

Junction

Box

Gear Box

c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

Disassembly & Re-assembly Page 8-5

Revised 6/01

c.

Pump Removal:

Verify that the filter shutoff is in its closed “0” position. Remove the release pin and retainer clip, slide the shaft out of the gear box. Slide the coupling off the pump shaft.

Remove the four pump mounting bolts.

d.

Pump Seal (O-ring) Replacement:

Remove the pump from the ASU (see instructions above,

“c”). Remove the external pump seal from its groove on the back of the pump adapter plate

(this is the seal located between the adapter plate and the hopper). Install the new seal.

Pump

Release pin &

Retainer clip

Coupling

Shaft

Re-Assembly Procedures

Unless noted, the M Series ASU’s re-assembly is simply the reverse sequence of the disassembly procedures. However, the following precautions should be followed (whenever they apply) for proper re-assembly:

WARNING HOT SURFACE

It order to protect personnel and equipment, it is important to replace all insulation whenever it is removed from the ASU.

CAUTION: In general, all O-RINGS AND SEALS should be replaced whenever hot-melt equipment is re-assembled. All new o-rings should be lubricated with o-ring lube (PN N07588).

CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the pump air supply (if applicable) and on the outlet filter manifold. Apply thread sealant (PN N02892) whenever tapered pipe threaded parts are re-assembled.

CAUTION: SOME FITTINGS used for adhesive on the ASU have straight threads and o-ring seals. Use of thread sealant is not necessary with these parts, but the o-ring seals should be clean and lubricated. Tighten straight-threaded parts and fittings until their shoulders are firmly seated against the pump body (or other surface). Excessive torque may damage straight-threaded parts and the use of power wrenches is not recommended

CAUTION: HOT-MELT RESIDUE should be cleaned from parts before they are re-assembled, particularly from threaded parts. As a precaution against adhesive residue preventing proper re-assembly, threaded parts should always be re-tightened at operating temperature.

Page 8-6 Disassembly & Re-assembly

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37 & 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Chapter 9

AVAILABLE OPTIONS & ACCESSORIES

Options & Accessories Page 9-1

Revised 10/01

Pressure Gauge Assembly PN 805641

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. Fittings and adapter are included in the assembly.

Pre-PSI & Post-PSI Transducers PN 800225; Transducer Assembly PN 108825

A pressure transducer is an electronic probe that allows the melted adhesive’s pressure to be processed by the ASU’s control system. They are used to monitor system operating pressures and their limits. The Pre-PSI transducer measures adhesive pressure in the filter manifold before the filter basket. The Post-PSI transducer measures the pressure after the filter basket. By comparing the two readings, the operator can determine if the filter basket is clogged.

Drop-in Grids PN 104802

The drop-in grid is an extra heated grid(s) which is installed near the bottom of the ASU’s hopper.

The additional grid(s) allows faster melting of adhesive for applications requiring higher melt rates and higher volumes of adhesive. When installed, the drop-in grid becomes an auxiliary temperature zone on the controller.

High-Temperature Heater Groups

More accurate temperature control may be gained by using a High-Temp Heater Group in the filter manifold/ pressure relief block. A heater and sensor are contained inside the block and become their own temperature zone on the controller. Six groups are available depending on the number of filter manifolds on the ASU.

Filter Options and Accessories:

40 Mesh Outlet Filter PN 101246

Some situations do not call for a fine mesh outlet filter. A “clean” adhesive or one with a long pot life are examples. Systems utilizing lower temperatures or systems running in a clean environment can also utilize a 40 mesh filter. Standard equipment on Dynamelt is a 100 mesh filter (PN 101247).

Level Control

Single-Point Level Control PN N08122

Available on all models

Multi-Point Level Control: PN 084Q192 (DMM140 & DMM210 only)

These devices inform the operator, via a message on the controller, that the hopper’s adhesive level is low. They may also be wired to stop production, turn on an alarm light or signal, or signal a PLC.

Page 9-2 Options & Accessories

Revised 6/03 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Pump Options and Accessories:

Gear Pumps

For higher tolerances and precision, several gear pumps are available for the Dynamelt. Gear pumps give better service for continuous applications or applications which require more control over the volume of adhesive pumped. Gear pumps available are:

Single Pumps:

PN 100860: 1.54 cc/rev single, standard accuracy gear pump

PN 100861: 3.2 cc/rev single, standard accuracy gear pump

PN 100862: 4.5 cc/rev single, standard accuracy gear pump

PN 109690: 10 cc/rev single, standard accuracy gear pump

PN 108875: 8.5 cc/rev single, high accuracy gear pump

PN 084E374: 0.584 cc/rev single, high accuracy gear pump

PN 084E376: 1.752 cc/rev single, high accuracy gear pump

PN 084E428: 0.297 cc/rev single, high accuracy gear pump

PN 084E430: 1.168 cc/rev single, high accuracy gear pump

PN 084E434: 2.920 cc/rev single, high accuracy gear pump

Dual Pumps:

Note: all dual pumps require PN 102049, see below.

PN 100863: 1.54 cc/rev dual, standard accuracy gear pump

PN 100864: 3.18 cc/rev dual, standard accuracy gear pump

PN 084E389: 0.584 cc/rev dual, high accuracy gear pump

PN 084E432: 1.168 cc/rev dual, high accuracy gear pump

PN 108874: 2.920 cc/rev dual, high accuracy gear pump

Hi-Flow Pumps:

PN 084E411: 20cc/rev single, gear pump

PN 084E412: 30cc/rev single, gear pump

PN 084E413: 45cc/rev single, 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.

Feinpruf Gear Pumps

Feinpruf pumps are commonly used in the European marketplace.

Gear Pump Repair Kit PN 103151

Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps:

PN Description Qty.

PN Description

N00198 O-ring

018X031 Ball Bearing

069X061 Seal

2

5

1

069X064 O-ring

078F017 Ring, Clip

078I001 Key, Woodruff

Qty.

3

4

1

c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Options & Accessories Page 9-3

Revised 9/01

Return (re-circulating) Hoses

Available on all models. Use of return hoses allows higher adhesive pressures from the head to the substrate because the head is “overfed” adhesive. The overflow adhesive is re-circulated to the hopper.

Pneumatic Clutch PN 106877

A pneumatic clutch is available for the Dynamelt M70/ 140/ 210 ASUs. A clutch relieves adhesive pressure quickly in applications where there are periods of time when adhesive is not being applied.

Dual Hopper

Available on DM M140 and M210. The adhesive hopper on the dual hopper models is divided into two separate chambers to allow the application of two different adhesives simultaneously. Each chamber is an independent temperature zone, allowing them to operate at different adhesive temperatures.

High Flow ASUs

These ASUs are available as DM M140 or M210 units for applications requiring a pump rate up to

2,625 cc/min per pump. The high flow models are equipped with high flow grid groups, including high flow hoppers, filter shutoff assemblies, filter manifolds and filter baskets.

DynaControl Options:

Pendant Control Panel PN 107643

The pendant control option gives the DynaControl keypad mobility via a 9 meter (30 ft), 6 meter

(20 ft) or 3 meter (10 ft) cable. The Pendant Control Panel replaces the standard display panel.

Pressure Display PN 108389 = DM 70/140, PN 108390 = DM 210

The pressure board option enables the controller to read and display adhesive pressure PSI values in the outlet filter manifold. The option consists of a PSI printed circuit board which is used with a pressure reading device (transducer or gauge) mounted on the filter manifold.

Actual Digital RPM Readout PN 107946

This option provides a controller readout for actual motor or pump revolutions per minute. No additional programming is necessary. Installation on an encoder is required.

System Status Lights PN 104280

Remote monitoring of system status is made easier with this tri-color light. The stack light is mounted on a 6”x 6” box, which is itself mounted on a stand with a 10’ cable. Wired into the 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 either high/low temperature, low adhesive level or open/short sensor.

cont.

Page 9-4 Options & Accessories

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

Memory Card Reader: PN 10

7993

The Memory Card Reader is an option which gives the ability to store and transmit system parameters, start signals and setpoints on a credit-card sized card. It is useful for systems which utilize multiple Dynamelt units.

Production security is assured since, with the keypad locked, the card reader prohibits unauthorized changes to the production process, except for a

± 5°C flexibility adjustment. (For example, if a

175 °C production setpoint is programmed, the card reader allows the operator to make adjustments only between 170 and 180

°C.)

Line Speed Tracking Options

Line speed tracking is a standard feature of the M Series ASUs which allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage input. When operated as the standard feature, a 0-10v signal from a PLC or a similar line speed output device is utilized.

However, it may also be operated utilizing one of the following optional devices:

PN 015D050 Tach Generator: a mechanically operated device which produces a reference voltage that allows the ASU’s gear pump to track a parent machine’s production line speed.

PN N06642 Signal Isolator: a device which conditions a parent machine’s production line’s DC speed reference voltage to allow the ASU’s gear pump to track line speed.

Serial Communication (PC Link / Remote I/O Interface) PN 108475

Bi-directional data transfer to a remote computer is available for the controller. The ASU’s standard

RS232 serial port connection allows remote interface up to 50 meters from the DynaControl controller. The RS485 serial port connection offers remote interface over a much longer distance. Either connection enables all system parameters to be monitored and/ or controlled from the remote station.

c. 2001

DYNAMELT M ASU Manual #20-37

Options & Accessories Page 9-5

Revised 6/03

Recommended Service Parts List

Category

Electrical:

O-rings:

Filters:

Misc:

Part No.

Description

102762

104117

103184

804535

036B103

104166

036B015

102411

048H384

109857

Fuse, 1 amp (motor control interface pcb)

Fuse, T6.3ALx 5x20 (pcbs)

Fuse GDC4 (terminal rail)

Fuse, 15a, LP-CC

RTD Sensor, PT (heater control)

Over-Temp Thermostat & Insulator

Pump Enable Thermostat

Boot, Insulator

Solid State Relay, Dual

CPU Printed Circuit Board, V5

108258

107440

106149

107853

110090

107438

106147

036A170

036A079

102149

036A077

N00181

A69X133

N00185

N00187

069X275

N00199

103770

103771

Display CPU PC Board

48-Zone Power (I/O) PC Board

Auxiliary RTD PC Board (optional)

Motor Speed Control AC Drive Board

Motor Control Interface PC Board

Clutch PC Board (optional)

Pressure PC Board (optional)

Heater, 500w (for 1 filter block)

Heater, 1000w (for 2 filter blocks)

Heater, 1500w (for 3 filter blocks)

Heater, 2000w (for 4 filter blocks)

O-ring 014 (outlet filter/ manifold)

O-ring 124 (outlet filter/ manifold)

O-ring 018 (outlet filter/ manifold)

O-ring 020 (outlet filter/ manifold)

O-ring 122 (outlet filter/ manifold)

O-ring 114 (outlet filter/ manifold)

O-ring 5-005 (outlet filter/ manifold)

O-ring 5-254 (outlet filter/ manifold)

N00192

807729

069X061

069X289

069X064

O-ring 032

Pump Shaft Seal (Zenith/ TSHA pump models)

Pump Shaft Seal (ITW Dynatec pump models)

Pump Shaft Seal (Hi Flow pump models)

O-ring 041 (optional pump block off assembly) see IBOM Pump Adapter O-rings

101247

101246

Filter Basket, 100 mesh

Filter Basket, 40 mesh (optional)

109482

006C156

105968

105969

N07588

L15653

001U002

102717

101340

106313

108012

Filter Basket, 200 mesh (optional)

High Flow Filter Basket (optional)

Filter Shutoff Assembly, Right

Filter Shutoff Assembly

Lubricant, O-ring

Kit, Flushing Fluid, 1 gallon

Hi-Temp Lubricant, tube

Check Valve (pressure relief)

Motor Bushes, Baldor (optional DC motor)

Motor Bushes (optional Lenze motor)

Filter/ Pressure Relief Plug Assembly

Qty.

5

5

5

3

3

1

1

1

6 to 16

1

1

1

1

1

1

1

1

1

1

1

1

8 + 6 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

6

2 per pump

2 per pump

2 per pump

1

1 of each per pump

2 per manifold

2 per manifold

2 per manifold

2 per manifold

1

1

2

1

1

1

2 per motor

2 per motor

1

Page 9-6 Options & Accessories

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37, 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c.2001

DYNAMELT M ASU Manual #20-37

Component Illustrations & BOM’s Page 10-1

Revised 6/01

Chapter 10

COMPONENT ILLUSTRATIONS & BILLS OF MATERIAL

Chapter Format

This chapter contains the component illustrations (exploded-view drawings) for each assembly of the DYNAMELT M SERIES ASU. These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit.

Page 10-2 Component Illustrations & BOM’s

Revised 1/04 c. 1999

DYNAMELT M ASU Manual All Models

7

8

5

6

3

4

1

2

9

10

39

40

41

42

35

36

37

38

43

44

45

46

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

31

32

33

27

28

29

30

Bill of Materials for Pressure Relief & High Temp. Filter Block Assembly #102710

(Items from Heater Control Groups: 103571, 103572, 103573, 103574 are also

Included in this illustration and bill of material.)

Item No.

Part Number

Description

Qty.

34

103574

036A170

036A079

102149

036A077

036E032

036B103

107754

107645

106156

104163

101833

104852

N00199*

107751

N06883

103570

Note:

104733

078D027*

101246

102711

102713

102714*

102715

N04349

102716

102718*

102719*

103770

103771

103571

103572

103573

102710

N00181

N00185

N00753

N00187

N00754

103626

102712

102717

NPN

103623

108928

A69X133*

A78A282*

N02969*

105099

Filter Block Top Assembly

O-ring, 014

O-ring, 018

1/8 NPT Level Seal Plug

O-ring, 020

1/4 NPT Level Seal Plug

3/8 BSPP Plug

Filter Block Insulator Plate

Check Valve, .655 Cart, 1 way

M8-1.25 x 90 SHC Screw

Straight Fitting, BSPP

Manifold Sub Assembly

O ring, 124

#0 x 1/8 Drive Screw

Pin Spring .125 x 1

M8 x 25 SHC Screw

N07429

006G112*

M8-1.25 x 30mm

Cap, Adjustment Screw

012E002* Pressure Relief Spring

109244* Pressure Relief Adjustment Screw 2

2

6

2

109245* Bullet, Hi-Pressure 2

069X275* O-ring, 122

Plug, Pressure Transducer, 1/2-20

3/4-16 Jam Nut

Filter Basket, 40 Mesh

Filter Block

Filter Block Heater Retainer Plate

Pressure Relief/ Filter Plug

Filter Plug Retainer Slide

Pin, Spring, .250 x .875

Slide Housing Frame

Filter Pull Clip

Filter Preload Wave Spring

O-ring, 5-005

O-ring, 5-254

Heater Control Section 240v, 1 block

Heater Control Section 240v, 2 block

Heater Control Section 240v, 3 block

Heater Control Section 240v, 4 block

2

2

2

1

2

2

2

2

2

6

2

1

2

6

2

1

2

3

2

1

1

6

2

2

1

1

2

2

2

4

Heater,5/8 x 5”, 240v, 500w (used with 1 Filter Block Assembly) 1

Heater, 5/8 x 10”, 240v, 1000w (used with 2 Filter Block Assemblies) 1

Heater, 5/8 x 15”, 240v, 1500w (used with 3 Filter Block Assemblies) 1

Heater,5/8 x 20”,240v,2000w (Used with 4 Filter Block Assemblies) 1

Sensor Adapter

Temperature Sensor

Cover, Hi-Temp Sensor & Heater Section

Conduit, 10”

M4 x 6mm SHSS

M6 x 25mm SHC Screw

10-32 x 1/2 Tamper Proof screw

M10 x 12 cone, Relief, Set Screw

O-ring, 114

Conduit Fitting (located in junction box)

Jam Nut (located in junction box)

M5 x 8 x 6, CUD SH Set Screw

*These items are included in 108012 Plug Assembly

2

2

1

2

1

1

1

1

1

1

2

1

c. 1999

DYNAMELT M ASU Manual All Models

Component Illustrations & BOM’s Page 10-3

Revised 11/01

43

26

31

12

11

13

20

30

23

19

16

22

18

17

7

Plug Assembly 108012

15

29

1

2

5

27

28

1

4

8

1

33

6

24

9

21

10

32

33

6

21

32

10

42

41

21

41

42

34

14

25

35

36

39

44

45

5

3

5

37

46

38

40

Component Illustration: Filter & Pressure Relief Assembly # 102710

Page 10-4 Component Illustrations & BOM’s

Revised 2/01 c. 2001

DYNAMELT ASU Manual #20-37

Bill of Materials for Pressure Relief & High Flow Filter Block Assembly #101767

Used On The 106696 High Flow Grid Assembly.

Item No.

Part Number

Description

Qty.

078A099

078A109

078A164

078A178

078A.337

078A379

078C004

078D027

078D037

036B033

036E043

036E079

078C021

078C017

078C013

078A005

072X057

072X262

048D141

048D142

048J007

048J022

048J117

060E090

069X169

072X093

006G112

078A005

078A030

078A039

078A079

N00185

003D105

006B043

006B072

006C120

006C156

006C135

006G064

006G078

012G001

012G010

32

33

34

35

36

37

25

26

27

28

29

30

31

38

39

40

41

42

19

20

21

22

23

24

13

14

15

16

17

18

8

9

6

7

10

11

12

3

4

5

1

2

O-ring, #018

Heater Plate

Heat Isolator

Block, Filter

Filter Plug

Large Filter Basket

Filter Cap

Block, Pressure Relief

Spring, Pressure Relief

Relief Piston

Pressure Relief Screw

Junction Box

Cover

Snap-In Hole Plug

3/8” St, Conduit Fitting

Grommet

Hose Support Bracket

O-Ring #039

1/2 NPT Level Seal Plug

Cap Nut, Adjustment Screw

10-24 x 1/2 SHCS

1/4-20 x 1 SHCS

3/8-16 x 1 FHSCS

1/4-20 x 1/2 HHCS

3/8-16 x 1 3/4 SHCS

5/16-18 x 1 SHCS

10-24 x 1/2 HHSMS

3/8-16 x 4 1/4 SHCS

3/8-16 x 5 1/2 SHCS

1/4-20 x 4 1/2 SHCS

Flat Washer, 1/4 SAE

3/4-16 Jam Nut

3/8-16 Eye Nut

Temperature Sensor

Sensor Adapter

Heater 5/8 x 10, 240v,1000w

Flat Washer

Lock Washer, 3/8 USS

Flat Washer, 3/8 SAE

Flat Washer, #8

3/8 NPT x 3/4-16 JIC Hex Nipple

3/4 NPT x 3/8 NPT Reducer

3

2

1

1

4

4

4

8

16

2

8

8

12

2

2

8

2

2

8

4

4

4

4

4

4

2

4

1

1

1

1

4

4

4

4

4

2

2

2

4

12

2

Bill of Materials

c. 2001

DYNAMELT M ASU Manual #20-37

40

27

21

12

14

33

38

39

26

22

7

23

5

18

6

34

35

13

28

29

15

37

19

25

1

3

36

Component Illustrations & BOM’s Page 10-5

Revised 2/01

8

1

20

32

11

9

10

1

2

16

17

24

31

30

41

42

4

Component Illustration for: Pressure Relief & High Flow Filter Block Assembly #101767

Used on the 106694 High Flow Grid Assembly.

Page 10-6 Component Illustrations & BOM’s

Revised 2/03 c. 2001

DYNAMELT M ASU Manual #20-37

Bill of Materials for Typical Electrical Panel Box Assembly

806465

6

11

12

13

14

15

16

7

8

9

10

Item No.

3

4

5

1

2

Part Number

802102

107625

802626

102328

103377

103378

103439

103438

104382/ 104383

107641

104384

103075

802657

802658

048H384

107993

102326

109770

Description

Mounting Bracket

Bezel

Heat Sink

Panel Box Lock Kit

Wire duct, 1.5” W x 3” H

Wire duct, 2” w x 3”H

Wire Duct Cover, 1.5.”

Wire Duct Cover, 2.25”

Rotary Handle & Shaft

Block-off Plate Used with pendant control)

Mechanical Operator, Circuit Breaker

Circuit Breaker ( See PN Unique to your system IBOM)

Panel Box

Insert Panel (Layout 108583)

SSR Dual 40A, 240VAC

Memory Card Assembly (option)

Cover, Memory Card

Pendant Control Assembly (option

Continued on pages 6 thru 7.

1

1

1

1

1

1

6--32

1

1

1

Qty.

2

2

1

1

c. 1999

DYNAMELT M ASU Manual #20-37

Optional Pendant Control

7

16

8

Component Illustrations & BOM’s Page 10-7

Revised 2/03

2

1

11

15

14

13

3

4

7

9

10

5 6

12

Page 10-8 Component Illustrations & BOM’s

Revised 2/03 c. 2001

DYNAMELT M ASU Manual #20-37

Bill of Materials for Typical Electrical Panel Box Assembly 806465 (Cont. from pg. 4)

Item No.

Part Number

Description

Quanities model driven

40

41

42

43

44

36

37

38

39

29

30

31

32

33

34

35

50

51

52

53

54

45

46

47

48

49

22

23

24

25

26

27

28

17

18

19

20

21

102762

103183

103184

106093

103069

103070

104193

108306

106978

106111

048H212

103663

107466

806512

806555

1 Amp Fuse

Fuse Block, Lever Open

Fuse, GDC4, 250VAC

Terminal Rail

Control Processor Board (CPU)

Circuit Breaker, CB,16A,2P,690V,ABB,CC

Circuit Breaker, CB,20A,100F,690V,2P,ABB

Ground, Small Dual

Side Insert panel

Filter, RFI (EMI)

M4 x 12 Button head Screw

Contact, Nor Open

Ground BUS

2Amp Fuse

2ND MAIN CB, 40 amp

Contactor, 3P, 50A-RES, 240VCOIL

108144

048I126

104780

804535

805198

107440

106147

804691

804696

107893

107922

108256

Ribbon Cable Assm., 15PinM, 9 PinF Serial, 8 conductor crimp-on

Control Assembly

1

1

107891

Key Pad Label

Cable Assembly Bracket

1

1

110090 Motor Control Interface 1--4

107033

107853

048E162

107438

Motor Choke, RFI, EMI, 30AC

Motor Speed Control

Stand Off

Clutch Board

1--4

1--4

4--16

1--4

TBD

804890

Snap-on Stand-off

Fuse Holder

Nuetral Block

Fuse, 15A LP-CC,

Ground Bar

Power Board

Pressure Board

Bus, 65A, CB, L1, L2, L3

Endcap, Bus, PSB12N, 65A

Eprom Chip

KBSI Board

Ground Lug

NEU BLK, 350M CM / 4.14X12 (380V units only)

1

1

1

1

29

2

1

1

1

1

1

1

1

1

1

1

1

3

1

1--4

4--16

2

1

4

2

1--2

14

2

c. 1999

DYNAMELT M ASU Manual #20-37

21

33

42

44

45

2

Backside Of Control Panel or Pendant Control

46

43

17

19

18

24

36

34

38

39

37

Component Illustrations & BOM’s Page 10-9

Revised 2/03

49

48

50

47

26

27

53

35

54

7

9

10

22

23

28

20

41

40

22

23

28

52

25

51

30

30

51

31

32

Page 10-10 Component Illustrations & BOM’s

Revised 4/03 c. 2001

DYNAMELT M ASU Manual #20-37

Bill of Materials for DYNAMELT M70 Series Cabinet Assembly (Base Unit 106045)

Item No.

Part Number

Description

Qty.

18

19

20

21

22

14

15

16

17

10

11

12

13

8

9

6

7

3

4

1

2

5

35

36

37

38

39

31

32

33

34

27

28

29

30

23

24

25

26

40

41

42

106770

106771

101842

106769

806399

808682

106321

108297

808778

078C008

106111

101304

104279

105111

106048

105117

106236

106876

106319

105865

106772

106773

105152

106892

105101

101843

105880

105886

105978

107890

108128

105891

105882

105975

802657

802102

106110

009E006

009E009

101074

103866

103516

Handle, Side Panel

Panel, Top, Bracket

Access Cover

Rear Cover M70

Manifold Cover

Manifold Cover, Hi Flow Only

Base Plate M70/140

Top Panel M70/140

Heat Barrier, Panel Box, M70

Panel Box

DCL Mounting Bracket

M5 Hex Nut

Swivel Caster

Rigid Caster

Receptacle

Bracket, Connector Bank, Amphenol

M8 HHC screw

M8 Star Washer

5/16 Flat Washer

M4 x 12 BHC Screw

Blank Plate, Dual

Blank Plate, Single

M3 Hex Nut

Lid Assembly

M4 x 8 Pan Head Screw

M4 Star Washer

Retaining Clip

M6 Star Washer

M6 Hex Nut

Inner Hinge

Outer Hinge

M3 x 6mm PHLC Screw

M3 Flat Washer

M6 x 16mm HHC Screw

Hinge, Hopper lid

Heat Deflector,

Collar, Hopper

Handle, Hopper, Lid

Lid Hopper

Lid (with level cnt. mnt.) (807141 Lvl Cnt Assm.) (option)

Optional ASU Leg Assembly 5.5”

Washer, Flat, M8, 9 x 17 x 1.6

M8-1.25 x 20mm, HH Ser Fl

Leg, Machine Support, 5.5”

1

1

1

1

1

2

1

6

2

2

6

4

2

2

4

4

4

4

16 or 64

0, 1 or 7

0 or 4

4

4

8

1

0, 4 or 16

2

2

2

1

8

1

1

1

1

12

12

4

2

1

4

1

2

1

c. 2001

DYNAMELT M ASU Manual #20-37

9

10

30

30

2

28

31

30

Component Illustrations & BOM’s Page 10-11

Revised 11/03

38

37

33

34

27

26

32

36

11

35

29

33

25 24 23

7

22

15

14

19

21 20

3

8

3

4

6

39

42

40

41

18 17

16

12

13

Component Illustration: DM M70 Cabinet Assembly

5

Page 10-12 Component Illustrations & BOM’s

Revised 9/01 c. 2001

DYNAMELT M ASU Manual #20-37

Bill of Materials for DYNAMELT M140 Series Cabinet Assembly 106046

Item No.

Part Number

Description

Qty.

078C008

106111

101304

104279

105111

106048

105117

106236

106876

106319

105865

106772

106773

105152

106892

101843

105880

105887

105979

107890

108128

105891

105882

105976

802657

802102

105101

105865

009E006

009E009

101074

103866

103516

106770

106771

101842

106769

806399

18

19

20

21

14

15

16

17

22

23

10

11

12

13

8

9

6

7

3

4

1

2

5

36

37

38

32

33

34

35

28

29

30

31

24

25

26

27

Handle, Side Panel

Panel, Top, Bracket

Access Cover, M140

Rear Cover, M140

Manifold Cover

Manifold Cover, Hi Flow Only

Base Plate M70/140

Top Panel, M70/140

Heat Barrier, Panel Box, M140

Panel Box

DCL Mounting Bracket

M6 x 16mm SHC Screw

M6 Hex Nut

Swivel Caster

Rigid Caster

Receptacle

Bracket, Connector Bank, Amphenol

M8 HHC screw

M8 Star Washer

5/16 Flat Washer

M4 x 12 BHC Screw

Blank Plate, Dual

Blank Plate, Single

M3 Hex Nut

Lid Assembly

M4 x 8 Pan Head Screw

M4 Star Washer

Retaining Clip

M6 Star Washer

M6 Hex Nut

Inner Hinge

Outer Hinge

M3 x 6mm PHLC Screw

M3 Flat Washer

Hinge, Hopper Lid

Heat Deflector

Collar, Hopper

Handle, Hopper, Lid

Lid Hopper

Lid (with level cnt. mnt.) (807141 Lvl Cnt Assm.) (option)

1

1

2

1

1

1

6

6

2

2

0 or 4

0, 4 or 16

2

4

4

4

4

2

4

4

16 or 64

0, 1 or 7

4

4

2

8

8

2

1

4

1

1

1

1

2

1

4

1

2

1

9

c. 2001

DYNAMELT M ASU Manual #20-37

10

2

31

31

7

8

29

32

31

Component Illustrations & BOM’s Page 10-13

Revised 11/03

37

33

34

36

11

27

28

30

12

38

35

26 25 24

33

3

23

16

15

20

22

21

4

3

5

6

19 18 17

13

14

Component Illustration: DM M140 Cabinet Assembly

Page 10-14 Component Illustrations & BOM’s

Revised 12/03 c. 2001

DYNAMELT M ASU Manual #20-37

20

21

22

23

16

17

18

19

24

25

26

27

28

10

11

12

13

14

15

8

9

6

7

33

34

35

36

37

29

30

31

32

N07677

N08236

110504

110503

N00093

N00753

101692

106198

N00933

N00687

106342

078A183

106341

108313

805095

030A013

048J184

072X004

106877

N00099

N02745

104663

106714

106658

108018

106661

106662

109226

106754

106659

103517

106235

106237

801679

106324

106319

N00732

Bill of Materials for DYNAMELT M70/ 140 AC Drive Assembly 106660 Front

106663 Rear

Item No.

Part Number

Description

3

4

5

1

2

106874

106875

Coupling Half, Pump Side (Option, not part of this assembly)

Coupling Center (Option, not part of this assembly)

Drive Assembly, M70/ M140/ M210

M6‘--1,0 x 25mm

Coupling, Half, Motor Side

Shaft, Gearbox, 20:1 (Front Drive Assembly 106660)

Shaft, Gearbox, 20:1 (Front Drive Assem. 106660,4.5cc pump)

Shaft (Rear Drive Assembly 106663)

Gear Box, 20:1

Key, 1/4 Sq. x.75

Ring Clip

Motor Mounting Bracket

Bolt M8 x 40mm HHC Screw

Washer, Flat, M8

External Tooth Lock Washer, M8

Motor, AC, 3P, 240v, 1HP, K256

Flat Washer, M6

External Tooth Lock Washer, M6

5/16-18 x 3/4 SHC Screw

5/16 Lock Washer

5/16 Flat Washer

Adapter Plate

3/8-16 x 1 HHC Screw‘

M8-1.25 x 40mm SH Set Screw

Ring Kit (option)

Optional Pneumatic Clutch Assembly

Solenoid, 240V, 3--way

Cord Grip, 1/8 --1/4

1/8 Hex Nipple

Clutch Kit, 56C, In line

Fitting, Elbow, 90deg., Brass

Muffler, Pneumatic Exhaust, 1/8 NPT

Tubing, TFE, .25 OD x .125 ID cable, 18ga, 3C, SV

Optional Clutch Air Manifold Assembly

Air manifold

Fitting, 1/4 tube x 1/8 NPT

1/8 NPT Level Seal Plug

M4-0.7 x 35mm SHC Screw

Lockwasher, 4mm

Qty.

1

1

1

1

4

1

1

2

2

2

2

1

1

3

1

1

4

1

1

4

8

8

1

1

1

1

1

8

4

8

4

4

7

1

1

1

4’

10’

To Melt

Section

c. 2001

DYNAMELT ASU M Manual #20-37

1

2

4

8

5

20

13

6

7

22

27

Component Illustrations & BOM’s Page 10-15

Revised 12/03

37 36

34 33

To Heat

Barrier

Panel

26

31

25

34

35

29

24

3

28

30

15

14

16

17

18

10

11

12

21

9

19

106660 Front 106663 Rear to Base Plate

Component Illustration: DYNAMELT AC Drive Assembly 106660 &106663

Page 10-16 Component Illustrations & BOM’s

Revised 2/03 c. 2001

DYNAMELT M ASU Manual #20-37

Bill of Materials for DYNAMELT M70 Single 106038, M70 Single Hi Temp 804470, M70 Dual 106037, M70

Single Hi- Flo109239, M140 Single 106040, M140 Single High Flow 106694 and M140 Dual 106039 Melt &

Grid Assemblies.

Item No.

Part Number

Description

Qty.

22

23

24

25

18

19

20

21

26

27

28

29

30

12

13

14

15

8

9

10

11

16

17

5

6

7

3

4

1

2

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

036B015

036B103

105999

105883

105884

105889

109238

106620

105881

L00006

101156

103517

N00686

N00697

103749

N00210

106103

105885

106001

078C021

048J018

048F125

048F136

048F137

048F021

048F069

107751

N06883

107645/ 107646

048J014

108829/ 108830

104166

104165

104164

103538

N00181

N007081

104696

003E023

036E103

160174

104802

048J048

NN00192

069X285

102446

N07416

078A055

084Q465

069X064

012G009

N00834

N00754

105967

804464

105968

804465

105149

N00192

108297

N00181

Pump Enable Thermostat

Temperature Sensor

Hopper Support

Hopper, Weldment, Dual, M70 (106037)

Hopper, Weldment, Dual, M140 (106039)

Hopper, Weldment, M70, Single (106038)

Hopper, Weldment, M70, Single Hi-Flo (109239)

Hopper, Weldment, M140, Single, High Flow (106694)

Heater Plate, M70/ 140

Spacer

M6 x 20mm SHC Screw

M8 x 30 HHC Screw

Flat Washers, 1/4

Lock Washer, 1/4

Filter Shut-off plug (fits in place of or opposite Filter shut-off)

O-ring, -912 (fits in place of or opposite Filter shut-off)

Filter Block Assembly (See Your order for part Number and Qty.)

Ball Valve Assembly (Option)

Junction Box Assembly

Junction Box, Prog-Melt, M70/ 140

Cover, Junction Box,

Flat Washer, .88X1.0X.13

Bushing, Plastic Cap, 1/2”

Terminal Rail, 11.5” (one of each)

Block, Terminal 35 Amp

Cover End

Ground Terminal

End Clamp

5/16 Conduit Fitting

Jam Nut

5/16 Conduit, 12 /25” (one for each conduit fitting)

3/4” 45 deg. Connector

Over Temp. Switch Assembly (Sold as an assembly only)

Insulator, Over Temp Thermostat

Overtemp Reset Thermostat

M4 X 6mm Pan Head

Grid Group

O-ring, -014

O-ring, (-014 Kalrez)

Flange

Cover

Temperature Sensor

Sensor Adapter

Cast Heater

1/4 ID Conduit

O-ring, -032

O-ring, -032 (kalrez)

M4-0. 70 x 10mm SHC Screw

M8 x 35mm SHC Screw

10-24 x 3/16 SHS Screw

Pump Block-off Assembly (option)

O-ring, #-041

Block-off Plate

3/8-16 x 1.25 SHC Screw

1/4 Level Seal Plug

Filter Shutoff Assembly (Left)

Filter Shutoff Assembly (Left) (HI-Temp Option)

Filter Shutoff Assembly (Right)

Filter Shutoff Assembly (Right) (HI-Temp Option)

Grid Block Off Assembly

Block off Plate

O-ring, #-032

M8 x 20mm HH Flange Screw

O-ring, -#014

2

12

24

12

48

48

2-4

2-4

1

1

2

1

4

2

2

4

1

1

1

1

4

2

1

1

1

4

2

1

4

4’

2--4

2--4

4

8

2

2

2

1

2

2

2

2

2

2

8--16

8--16

2

2

2

2

44

1

1

2

2

2

4

6

2

4

2

2

1/2”Sealtite Conduit, 36” / 1/2”Sealtite Conduit, 40” (opposite side) 1ea

c. 2001

DYNAMELT M ASU Manual #20-37

42

54

53

36

43

35

or

44

40

19

21

20

30

28

27

49

14

15

47

46

45

18

17

31

32 33

27

28

29

2

1

8

20

22 23

24

25 26

12

13

11

12 13 10

9

12 13 10

3

to base plate

52

51

48

Component Illustrations & BOM’s Page 10-17

Revised 1/03

34

9

41

3

12

10

13

5

16

17

4

1

2

37

38

39

31

32 33

50

Note the dual progmelt for the

M70 is identical to the dual

M140 with a shorter hopper.

7

12 13 10

6

Note the Single progmelt for the

M70/ M140 is identical to the dual with only one melting compartment.

Page 10-18 Component Illustrations & BOM’s

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37

12

13

14

15

8

9

6

7

10

11

16

17

3

4

5

1

2

Bill of Materials for 1.54 cc / Rev. , Single Gear Pump Assembly # 100860

Bill of Materials for 3.2 cc / Rev. , Single Gear Pump Assembly # 100861

Item No.

Description

Part Number

#100860 / #100861

012D079 / 012D077

078I001

101626

069X160

069X061

018X041

100866 / 100867

012D080 / 012D078

018X031

012C020 / 012C019

069X064

078F017

018X041

100865

100908

104775/ 104776

NPN

Drive Shaft

Key, Woodruff

M5 x 12 SHC Screw

Seal Retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Diameter ( See illustration for quantity)

Drive Gear, 1.54 cc/rev

Pump Seal

Shaft Retaining Ring

Bearing Sleeve, Rear Plate

Rear Plate Assembly

M4 x 25 SHC Screw

M10-1.5 x 75mm/ 80mm

M10 Flat Washer

1

2

4

2

4

4

2

2

2

1

1

2-4

4

1

1

1

1

Qty.

c. 2001

DYNAMELT M ASU Manual #20-37

Component Illustrations & BOM’s Page 10-19

Revised 2/01

2

9

Pump # 100860 has one bearing in this Shaft

Pump # 100861 has two bearing in this shaft

1

3

4

5

16

17

9

10

Pump # 100861 has two bearing in this Shaft

Pump # 100860 has one bearing in this shaft

7

6

8

12

10

13

11

14

11

15

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

Component Illustration: 1.54 cc / Rev, Single Gear Pump Assembly #100860

Page 10-20 Component Illustrations & BOM’s

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37

Item No.

7

8

9

10

11

12

13

3

4

5

6

1

2

14

15

16

17

Bill of Materials for 4.50 cc / Rev. , Single Gear Pump Assembly # 100862

Part Number

012D072

078I001

101626

069X160

069X061

018X041

100868

012D073

018X031

012C018

069X064

078F017

018X041

100865

100908

104776

NPN

Description

Drive Shaft

Key, Woodruff

M5 x 12 SHC Screw

Seal Retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Diameter

Drive Gear, 4.5 cc/rev

Pump Seal

Shaft Retaining Ring

Bearing Sleeve, Rear Plate

Rear Plate Assembly

M4 x 25 SHC Screw

M10-1.5 x 80mm

M10 Flat washer

Qty.

4

4

1

2

2

2

4

2

1

4

4

1

1

1

1

2

1

c. 2001

DYNAMELT M ASU Manual #20-37

2

9

Component Illustrations & BOM’s Page 10-21

2/01

16

1

3

4

5

17

9

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

7

6

8

12

10

13

11

14

15

11

Component Illustration: 4.50 cc / Rev, Single Gear Pump Assembly #100862

Page 10-22 Component Illustrations & BOM’s

Revised 2/01 c. 2001

DYNAMELT M ASU Manual 20-37

Item No.

7

8

9

10

11

12

13

3

4

5

6

1

2

14

15

16

17

18

19

Bill of Materials for 1.54 cc / Rev. , Dual Gear Pump Assembly # 100863

Part Number

012D083

078I001

101626

069X160

069X061

018X041

100866

012D082

018X031

012C020

069X064

078F017

018X041

100865

101692

NPN

100869

N00198

NPN

Description

Drive Shaft

Key, Woodruff

M5 x 12 SHCS

Seal retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Dia.

Pump Gear, 1.5 cc/Rev

O-ring, -041

Shaft Retaining Ring

Bearing Sleeve, rear Plate

Rear Plate Assembly

M4 x 35 SHCS

M10-1.5 x 85mm SHC Screw

Middle Plate

O-ring, -113

M10 Flat Washer

Qty.

4

1

1

2

2

4

4

3

4

2

1

3

4

1

1

1

1

2

1

c.2001

DYNAMELT M ASU Manual 20-37

9

2

1

Component Illustrations & BOM’s Page 10-23

2/01

3

4

5

16

19

9

10

7

6

8

12

10

11

17

18

10

13

11

14

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

15

11

Component Illustration: 1.54 cc / Rev, Dual Gear Pump Assembly #100863

Page 10-24 Component Illustrations & BOM’s

Revised 8/02

2

1

9

3

4

5

16

19

c. 1999

DYNAMELT M ASU Manual #20-37

9

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

7

6

8

12

10

11

17

18

10

13

11

14

10

11

15

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

Bill of Materials for 3.2 cc / Rev. ,

Dual Gear Pump Assembly # 100864

Item No.

Part Number Description

012D088

078I001

101626

069X160

069X061

018X041

100867

012D087

018X031

012C019

069X064

078F017

018X041

100865

101691

NPN

100870

N00198

NPN

Drive Shaft

Key, Woodruff

M5 x 12 SHCS

Seal retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Dia.

Drive Gear, 4.5 cc/Rev

O-ring, -041

Shaft Retaining Ring

Bearing Sleeve, rear Plate

Rear Plate Assembly

M4 x 40 SHCS

M10-1.5 x 85mm

Middle Plate

O-ring, -113

M10 Flat Washer

Qty.

2

4

2

1

3

4

5

4

1

2

4

1

1

1

2

4

1

1

1

c. 1999

DYNAMELT M ASU Manual #20-37

Component Illustrations & BOM’s Page 10-25

8/02

10

5

11

2

1

4

6

3

12

13

8

5

7

Bill of Materials for 10cc Single Gear Pump Assembly # 109690

Item No.

11

12

13

14

7

8

9

10

1

2

3

4

5

6

Part Number

018X031

078F017

078I001

069X061

069X064

100908

101626

109685

109686

109689

109687

109688

069X160

001U002

Description

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

Pump Body10cc 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)

9

Qty.

1

2

4

1

1

1

1

6

4

1

1

2

2

Page 10-26 Component Illustrations & BOM’s

Revised 7/03 c. 1999

DYNAMELT M ASU Manual #20-37

Bill of Materials for Assorted Pump Adapter Assemblies

Item No.

7

8

5

6

3

4

1

2

20

21

22

17

18

19

12

13

14

15

16

9

10

11

084E428

084E374

084E430

084E434

108875

084E438

084E389

084E432

108874

084E419

012G027

069X064

069X230

069X270

078A618

078C141

069X289

084E411

084E412

084E413

103923

103624

103924

N00181

069X270

102927

Part Number

084E406

012G024

069X058

N00179

069X274

N00190

078C130

NPN

103917

103918

103919

104351

Description

TSHA Pump Adapter Assembly

Pump Adapter

O--Ring #28

O--Ring #12

Seal Dual Pump to Progmelt (not part of this assembly)

O-Ring #24

3/8 Washer, 3/4 OD

M10 x 85mm SHC screw

Zenith Pump

THSA .297 cc Single Outlet

THSA .584 cc Single Outlet

THSA 1.168 cc Single Outlet

THSA 2.292 cc Single Outlet

THSA 8.5 cc Single Outlet

THSA 30.0 cc Single Outlet

THSA .584 cc Dual Outlet

THSA 1.168 cc Dual Outlet

THSA 2.292 cc Dual Outlet

Zenith Pump Adapter Assembly

Adapter, Z Pump

O-Ring, #041

O-Ring, #021

O-Ring, #025

Screw, Pump Mounting

7/16 ss Washer, 3/4 OD

Drive Shaft Seal

THSA Pump

THSA 20 cc Single Outlet

THSA 30 cc Single Outlet

THSA 45 cc Single Outlet

Feinpruef Pump Adapter Assembly

Adapter Plate

O-ring Plate

O-ring, -014

O-ring-025

O-ring, -133

Feinpruef Pump

Feinpruef Pump .3 cc

Feinpruef Pump 1.2 cc

Feinpruef Pump 2.4 cc

Coupling Half (Not Shown, See drive Section)

1

1

1

1

4

1

2

4

1

1

1

4

1

1

Qty.

1

4

2

1

4

1

1

1

c. 1999

DYNAMELT M ASU Manual #20-37

THSA Pump Adapter Assembly 084E406

5

3

4

1

2

8

6

THSA Pump Adapter Assembly 084E419

7

11

16

12

9

10

15

14

13

Feinpruef Pump Adapter Assembly 103923

Component Illustrations & BOM’s Page 10-27

Revised 7/03

21

17

19

18

20

19

22

Page 10-28 Component Illustrations & BOM’s

Revised 7/01

5

2

4

1

3 or

3

6

Item No.

1

2

3

4

5

6

Part Number

806883

101174

104325

805632

102987

N00104

Pressure Gauge Assembly-805641

Description

Fitting, 1/4 NPTM x #6 JIC x 90

Pressure Guage, 1000 PSI

Fitting Adapter, Swivel, 6J x 1/4 MPT

Fitting, 1/4 NPT 1/2-20 Tranducer

Insulator

Fitting, 1/4 NPTM x #6, ST

c. 2001

DYNAMELT M ASU Manual #20-37

2

1

1

1

1

Qty.

1

1

5

4

c. 2001

DYNAMELT M ASU Manual #20-37

Chapter 11

SCHEMATICS &

ENGINEERING DRAWINGS

Drawing:

Hose Schematic, ASU to Applicator

Applicator Head Schematic

Flow Diagram, Outlet Filter Manifold

Typical Hydraulic Schematic

Optional System Status Lights Schematic

Optional Level Control Schematic

Grounding Diagram, CE Mark

Pneumatic Clutch Schematic

Instruction Sheet for Pump & Zone Configuration

ASU Schematics

Found on:

page 11-2 page 11-3 page 11-4 page 11-5 page 11-5 page 11-6

Page 11-7 page 11-8 page 11-9 end of chapter

Schematics Page 11-1

Revised 12/02

Page 11-2 Schematics

Revised 3/03 c. 2001

DYNAMELT M ASU Manual #20-37

HOSE SCHEMATIC PN 101082 REV. E

ASU to Applicator, Dynacontrol

c. 2001

DYNAMELT M ASU Manual #20-37

Schematics Page 11-3

Revised 6/01

Notes:

1. ALL WIRE MIL-W-22759/10 OR 12, MINIMUM 600 VOLTS, 260 DEG. C

2. SOLENOID(S) VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION.

3. RTD WILL BE PLATINUM 100 OHM.

HEAD SCHEMATIC PN 103117 REV. B

Page 11-4 Schematics

Revised 6/01 c. 2001

DYNAMELT M ASU Manual #20-37

Function of Outlet Filter Manifold’s Closeable Cross Channel

A Closeable Cross Channel Plug is located inside the Outlet Filter Manifold to prevent adhesive flow between the two outlet filters when a dual pump is in use.

When a single pump is used, ITW Dynatec removes the Cross Channel Plug.

When changing an ASU from a single to a dual pump, or vice versa, consult ITW Dynatec for complete instructions.

When Cross

Channel Plug is removed, one adhesive outlet must be plugged.

Adhesive

Outlet To

Hose

Adhesive

Outlet To

Hose

Closeable Cross

Channel Plug

FLOW DIAGRAM, OUTLET FILTER MANIFOLD

Check Valve

Adhesive Return Port*

Adhesive In Port*

Cross Channel

Plug is removed thru port on side of manifold.

* The second Adhesive In and Adhesive

Return ports are not shown.

c. 2001

DYNAMELT M ASU Manual #20-37

Transducer

Filter

Basket

Schematics Page 11-5

Revised 6/01

Bypass

Gauge

Pump

Motor

TYPICAL HYDRAULIC SCHEMATIC: Single Pump, Motor, Bypass, Filter, optional Transducer & optional

Pressure Gauge

WIRING DIAGRAM FOR PN 108266 OPTIONAL SYSTEM STATUS LIGHTS

c. 2001

DYNAMELT M ASU Manual #20-37

Schematics Page 11-7

Revised 10/01

GROUNDING DIAGRAM, CE MARK, PN 804704 REV. E

Page 11-8 Schematics

Revised 12/02 c. 2001

DYNAMELT M ASU Manual #20-37

PNEUMATIC CLUTCH SCHEMATIC PN 108410 REV. A

Page 11-12 Schematics

Revised 12/02 c. 2001

DYNAMELT M ASU Manual #20-37

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

DYNATEC/ ZENITH STANDARD ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E427, 084E429, 084E431, 084E433, 084E435, 084E437

Appendix 1

Revised 3/01

Part Number

084E427

084E429

084E431

084E433

084E435

084E437

Material Type/Accuracy

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Single/ Standard

Single/ Standard

Dual/ Standard

Single/ Standard

Dual/ Standard

Single/ Standard

Output/Rev Shaft Seal PN

0.29cc

1.17cc

1.17cc

2.92cc

2.92cc

8.5cc

069X251

069X251

069X251

069X251

069X251

069X251

Thoroughly read and understand this entire manual before installation and operation of pump.

Note: The instructions given herein cover the description, installation, operation and maintenance of subject equipment. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.

Manual revised 8/94

Appendix 2

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow 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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 3

Revised 3/01

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 4

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 5

Revised 3/01

these pumps require careful maintenence and handling, especially of component parts. The slightest burr, nick or particle of foreign matter can cause scoring or even seizure. 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 6

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

STANDARD ACCURACY PUMP DISASSEMBLY

If pumps are to be disassembled on a regular basis, we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate

“clean” area for assembly, testing and storing of rebuilt pumps.

If maintenence is required due to low delivery or seizure, the following procedure is 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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 7

Revised 3/01

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.

Appendix 8

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

from the packing housing.

12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or worn. Worn shafts will result in premature seal leakage and should be replaced.

13. Inspect lip seals for wear, cracks and abrasions. Replace if needed.

14. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-O-

Lubricate or an equivalent silicone-based oil.

tion.

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 rota-

SCREW TORQUE VALUES (Standard Alloy Steel)*

Screw Size & Thread

(UNC Alloy Steel)

Torque (Lubricated Threads)

Lbs.-in.

Nxm Lbs.-ft.

#10-24 (w/ carbon seal gasket)

#10-24 (w/o carbon seal gasket)

#12-24

1/4-20

5/16-18

3/8-16

7/16-14

into aluminum block (hopper)

[50]

[64]

[120]

[150]

[305]

[360]

[480]

5.7

[4.2]

7.2

[5.3]

13.6

[10]

16.9

[12.5]

33.9

[25]

40.6

[30]

54.2

[40]

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.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 9

Revised 3/01

TROUBLESHOOTING GUIDE

Trouble

Pump will not turn.

Probable Cause

1. Low pump temperature.

Remedy

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.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Return pump to ITW Dynatec for repair.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 1. Worn gear(s).

2. Worn bearings.

Return pump to ITW Dynatec.

for repair.

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.

Appendix 10

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 11

Revised 3/01

Appendix 12

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 13

Revised 3/01

Appendix 14

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

DYNATEC/ ZENITH HIGH ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E428, 084E430, 084E432, 084E434, 084E436

Appendix 15

Revised 3/01

Part Number

084E428

084E430

084E432

084E434

084E436

Material

Tool Steel

Tool Steel

Tool Steel

Tool Steel

Tool Steel

Type/Accuracy

Single/ High

Single/ High

Dual/ High

Single/ High

Dual/ High

Output/Rev Shaft Seal PN

0.297cc

1.168cc

1.168cc

2.920cc

2.920cc

069X251

069X251

069X251

069X251

069X251

Thoroughly read and understand this entire manual before installation and operation of pump.

Note: The instructions given herein cover the description, installation, operation and maintenance of subject equipment. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.

Manual revised 8/94

Appendix 16

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow 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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 17

Revised 3/01

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 18

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Since these pumps are not self-priming, a flooded suction is usually the minimum inlet 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 26 for torque values.

The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact ITW Dynatec.

cont.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 19

Revised 3/01

TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.

2. Filters should be installed prior to the pump inlet that filter ideally to half the pump 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 20

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 21

Revised 3/01

4. Separate the plates by pry slots. Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart.

5. After disassembly, clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning. Alternative, non-destructive cleaning methods such as water jet or solvents are also acceptable.

6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang parts together.

7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and faces of the gears may be hand blocked on 400/600 grit paper and any nicks, burrs or sharp edges can be lightly removed with a honing stone. Be careful not to round off the edges of the gear teeth while lapping.

CAUTION: 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 22

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

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).

gear.

5. Place the driven metering gear on its arbor and carefully mesh with the drive metering

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-O-

Lubricate 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.

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 23

Revised 3/01

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

7/16-14

into aluminum block (hopper)

Torque (Lubricated Threads)

Lbs.-in.

[50]

[64]

[120]

[150]

[305]

[360]

[480]

Nxm Lbs.-ft.

5.7

[4.2]

7.2

[5.3]

13.6

[10]

16.9

[12.5]

33.9

[25]

40.6

[30]

54.2

[40]

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

Pump will not turn.

Probable Cause

1. Low pump temperature.

Remedy

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.

Appendix 24

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

TROUBLESHOOTING GUIDE,

continued

Trouble Probable Cause Remedy

5. Possible internal damages.

Return pump to ITW Dynatec for repair.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Return pump to ITW Dynatec for repair.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 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. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 25

Revised 3/01

Appendix 26

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 27

Revised 3/01

Appendix 28

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

ZENITH MELT SPINNING PUMPS MANUAL

Covers ITW Dynatec part numbers:

084E374 0.584cc, single pump

084E376 1.752cc, single pump

084E388 0.297cc, dual pump

084E389 0.58cc, dual pump

084E411* 20cc, single, high flow

084E412* 30cc, single, high flow

084E413* 45cc, single, high flow

*available on models DM 70/140/210 only

Appendix 29

Revised 3/01

Pump PNs 084E374 thru 084E389 use PN 069X251 pump shaft seal.

Pump PNs 084E411 thru 084E413 use PN 069X289 pump shaft seal.

Appendix 30

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 31

Revised 3/01

Appendix 32

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

c. 2000

DYNAMELT M ASU Manual 20-36, 20-37, 20-38

Appendix 33

Revised 3/01

HIGH ACCURANCY PUMP PERFORMANCE

100

90

80

70

60

50

40

30

20

084E387

.160 cc/rev

084E388

084E428

.297 cc/rev

084E374

084E389

.584 cc/rev

10

.01

.02

.05

VOLUMETRIC EFFICIENCY FACTOR

D

P

m

N

.10

.2

.5

D

P = DIFFERENTIAL PRESSURE (PSI) m

= APPARENT VISCOSITY (CENTIPOISES)

N = RPM

1.0

084E434

084E436

2.92 cc/rev

084E376

1.752 cc/rev

084E430

084E432

1.168 cc/rev

c. 2000

DYNAMELT M ASU Manual 20-36

PN 800225 Pressure Transducer

(used in PN 800260 Pressure Transducer Assy.)

Appendix 35

Revised 10/00

(page 1 of 2 pg. pasteup of PN 800225)

Note: Transducers installed on

ITW Dynatec ASUs have been factory calibrated.

cont.

Appendix 36

Revised 10/00 c.2000

DYNAMELT M ASU Manual 20-36

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 37

Revised 12/99

Appendix 38

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 39

Revised 12/99

Appendix 40

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 41

Revised 12/99

Appendix 42

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 43

Revised 12/99

Appendix 44

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 45

Revised 12/99

Appendix 46

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36

Appendix 47

Revised 10/00

APPENDIX

Optional Memory Card Reader

The following important instructions pertain to the controller’s optional Memory Card Reader.

For instructions on installation of the memory card, see Chapter 3: Installation & Start-Up.

CAUTIONS:

1. When not in use, keep the card in its protective case.

2. Keep the card away from high temperatures and direct sunlight.

3. Do not bend the card or subject it to strong shocks.

4. Keep the card dry at all times.

5. Avoid direct contact with the connector terminal of the card.

6. Keep the card from away from fire.

Write Protect Function

The Memory Card has a write protect function. The write protect switch is set to

OFF when it is shipped from the factory, in order to allow data writing. When the write protect switch is set to the “WP” arrow, protection is ON and it will not allow data to be written.

Connector terminal

Parts Reference

Initial Installation of the Lithium Battery

The Memory Card’s battery is installed at the factory prior to shipment.

Write protect swotch

Hook

Battery cover

To Replace the Lithium Battery

CAUTION: When replacing the battery, the Memory

Card MUST BE INSERTED INTO ITS SLOT ON THE

CONTROL PANEL SO THAT YOUR CONTROLLER

DATA IS RETAINED.

1. Insert the Memory Card into its slot on the control panel.

2. With your finger, pull the hook downward and remove the battery cover.

3. Remove the old battery.

4. Confirm the position of the new battery’s polarity, as shown in the illustration, and insert the battery.

5. Replace the battery cover.

Replacement Battery

The lithium battery may be obtained locally. Specify CR 2330.

Plus (+) mark

Battery Installation

Appendix 48

Revised 10/00 c.2000

DYNAMELT M ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

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