Dynamini

Dynamini
OPERATIONS & SERVICE MANUAL #20-25
Revised 7/1/11
DYNAMINI ADHESIVE SUPPLY UNIT
OPERATIONS AND SERVICE MANUAL
with Software Version 2.00 and up
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 3/10
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
EC declaration of conformity
according to the EU Machinery Directive 2006/42/EG, Annex II, 1.A
Manufacturer:
ITW Dynatec,
31 Volunteer Drive
TN 37075 Hendersonville
Person residing within the Community authorised to compile the relevant technical documentation:
Dynatec Engineering
ITW Dynatec,
31 Volunteer Dr
Tennessee Hendersonville
Description and identification of the machinery:
Make:
Serial no:
Machine number:
Project number:
Project name:
Commercial name:
Adhesive supply unit
____________________________
____________________________
Dynamini
Dynamini 05/10
Dynamini
It is expressly declared that the machinery the machinery fulfils all relevant provisions of the following
EU Directives:
2006/42/EG:2006-05-17
2006/95/EC:2006-12-12
EU Machinery Directive 2006/42/EG
(Voltage limits) Directive of the european Parliament and of the council of 12 December 2006 on the
harmonisation of the laws of Member States relating to electrical equipment designed for use within
certain voltage limits (codified version)
2004/108/EC:2004-12-15
(Electromagnetic compatibility) Directive 2004/108/EC of the European Parliament and of the Council of
15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic
compatibility and repealing Directive 89/336/EEC
Hendersonville, 2010.06.15
Place, date
Signature
Judson Broome
General Manager
Page 1 / 1
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page iii
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25
TABLE OF CONTENTS
Chapter 1 Safety Precautions
Chapter - Page #
Chapter 2 Specifications & Dimensions
Model Description Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3 Installation & Start Up
Mounting the ASU/ Lifting the ASU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wattage Availability Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding to or Changing the Adhesive Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Control Filter Unit/ Rear Cover: Head & Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Start Up and Shut Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and Disposal of the Application System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
3-4
3-4
3-5
3-6
3-7
Chapter 4 Dynamini Temperature Controller Set-Up
Temperature Control Functions in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defining Dynamini Temperature Control Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Indication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Chip (EPROM) and Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings for a Typical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default Settings of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Helpful Tips for the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-2
4-3
4-3
4-4
4-4
Chapter 5 Programming of the Dynamini Controller
Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning Zones On/ Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Indication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keypad Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram of the Service Functions Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequential Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ready Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-2
5-2
5-2
5-3
5-4
5-4
5-5
5-6
5-6
5-7
5-7
5-8
Chapter 6 Preventive Maintenence
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenanace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose Fittings and Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-1
Page iv
Revised 1/11
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Hopper Filter Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Purging the Filter Manifold of Adhesive and Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chapter 7 Troubleshooting
Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overtemp Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of PCB & Overtemp Thermostat Re-set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Operation & Adjustable Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2
7-3
7-3
7-4
7-5
7-9
7-10
7-14
Chapter 8 Disassembly & Re-assembly Procedures
To Remove the Pump & Electronics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Hopper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Hopper Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTD Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Access & Replace the Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Access & Replace the Pumps or Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note on Cast-in Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-assembly Procedures & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-2
8-2
8-2
8-3
8-5
8-6
8-7
Chapter 9 Available Options & Accessories
Pressure Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Job Aide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-2
9-3
Chapter 10 Component Illustrations & Bills of Material
Electrical Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter & Melt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Pneumatic Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2
10-4
10-6
10-8
10-10
10-12
10-21
Chapter 11 System Schematics & Engineering Drawings
Hose Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Head Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Page 1-1
Revised 1/07
ITW Dynatec c. 1997
ALL MODELS
Chapter 1
SAFETY PRECAUTIONS
All operators and service personnel must read
and understand this manual before operating
or servicing equipment.
All maintenance and service on this equipment must be performed by trained technicians.
Electrical
DANGER
HIGH VOLTAGE
Dangerous voltages exist at several points in this
equipment. To avoid personal injury, do not touch
exposed connections and components while input
power is on. Disconnect, lockout and tag external
electrical power before removing protective panels.
A secure connection to a reliable earth ground is
essential for safe operation.
A disconnect switch with lockout capability must be
provided in the line ahead of the unit. Wiring used to
supply electrical power should be installed by a
qualified electrician.
High Temperatures
WARNING
HOT
SURFACE
Severe burns can occur if unprotected skin comes in
contact with molten adhesive or hot application system
parts.
Safety glasses, gloves and long- sleeved clothing must
be worn whenever working with or around adhesive
application systems.
High Pressure
WARNING
HIGH PRESSURE
PRESENT
To avoid personal injury, do not operate the equipment
without all covers, panels and safety guards properly
installed.
To prevent serious injury from molten adhesive under
pressure when servicing the equipment, disengage the
pumps and relieve the adhesive system’s hydraulic
pressure (e.g., trigger the heads, hand-held applicators,
and/or other application devices into a waste container)
before opening any hydraulic fittings or connections.
IMPORTANT NOTE: Even when a system’s pressure
gauge reads “0” psig, residual pressure and trapped air
can remain within it causing hot adhesive and pressure
to escape without warning when a filter cap or a hose
or hydraulic connection is loosened or removed. For
this reason, always wear eye protection and protective
clothing.
Either of the two High Pressure symbols shown may be
used on equipment.
Page 1-2
Revised 3/97
ITW Dynatec c. 1997
ALL MODELS
Protective Covers
WARNING
DO NOT OPERATE
WITHOUT GUARDS
IN PLACE
Keep all guards in place!
To avoid personal injury, do not operate the application
system without all covers, panels and safety guards
properly installed.
Eye Protection & Protective Clothing
WARNING
EYE PROTECTION
REQUIRED
PROTECTIVE
CLOTHING
REQUIRED
It is very important that you PROTECT YOUR EYES
when working around hot melt adhesive equipment!
Wear safety glasses with side shields which conform to
ANSI Z87.1 or EN166.
Failure to wear safety glasses could result in severe eye
injury.
It is important to protect yourself from potential burns
when working around hot melt adhesive equipment.
Wear protective gloves and long-sleeved, protective
clothing to prevent burns that could result from contact
with hot material or hot components.
Always wear steel-reinforced safety shoes.
Safe Installation and Operation
To avoid possible failure of hoses, make sure all hoses
are routed to avoid kinking, tight radius turns (8” or
less) and abrasive contact. Hot-melt hoses should not
have prolonged contact with heat-absorbing surfaces
such as cold floors or metal troughs. These
heat-absorbing surfaces can alter adhesive flow and
cause incorrect calibration. Hoses should never be
covered with materials that prevent heat dissipation,
such as insulation or sheathing.
Read this manual before applying electrical power to
the equipment. Equipment may be damaged by
incorrect electrical connections.
Do not use adhesive that is dirty or that may be
chemically contaminated. Doing so can cause system
clogging and pump damage.
When adhesive hand-held applicators or other movable
applicators are used, never point them at yourself or at
any other person. Never leave a hand-held applicator’s
trigger unlocked when not actually in use.
Do not operate the hopper or other system components
without adhesive for more than 15 minutes if the
temperature is 150 degrees C (300 degrees F) or more.
To do so will cause charring of the residual adhesive.
Never activate the heads, hand-held applicators and/ or
other application devices until the adhesive’s
temperature is within the operating range. Severe
damage could result to internal parts and seals.
Treatment for Burns From Hot Melt Adhesives
Burns caused by hot melt adhesive must be treated
at a burn center.
Care should be used when working with hot melt
adhesives in the molten state. Because they rapidly
solidify, they present a unique hazard.
Even when first solidified, they are still hot and can
cause severe burns. When working near a hot melt
application system, always wear safety gloves, safety
glasses and long-sleeved, protective clothing.
Page 1-3
Revised 1/07
ITW Dynatec c. 1997
ALL MODELS
Always have first-aid information and supplies
available.
Call a physician and/or an emergency medical
technician immediately.
Service
Refer all servicing to qualified personnel only.
Explosion/ Fire Hazard
Never operate this unit in an explosive environment.
Use cleaning compounds recommended by ITW
Dynatec or your adhesive supplier only. Flash points
of cleaning compounds vary according to their composition, so consult with your supplier to determine the
maximum heating temperatures and safety precautions.
Lockout/ Tagout
Follow OSHA 1910.147 (Lockout/ Tagout Regulation)
for equipment’s lockout procedures and other important lockout/ tagout guidelines.
Be familiar with all lockout sources on the equipment.
Even after the equipment has been locked out, there
may be stored energy in the application system, particularly in the capacitors within the panel box. To ensure
that all stored energy is relieved, wait at least one minute before servicing electrical capacitors.
Use of PUR (Polyurethane) Adhesives
PUR adhesives emit fumes (MDI and TDI) that can be
dangerous to anyone exposed to them. These fumes
cannot be detected by the sense of smell. ITW Dynatec
strongly recommends that an exhaust hood or system
be installed over any PUR system.
Consult with your adhesive manufacturer for specifics
about required ventilation.
CAUTION: Because of the nature of PUR
adhesives to strongly bond in the presence
of moisture, care must be taken to prevent
them from curing inside Dynatec equipment. If PUR
adhesive solidifies in a unit, the unit must be replaced.
Always purge old PUR adhesive from the system per
your adhesive manufacturer’s instructions and timetable. ALLOWING PUR ADHESIVE TO CURE IN A
UNIT VOIDS ITW DYNATEC’S WARRANTY.
In This Manual
WARNINGS and CAUTIONS are found throughout
this manual.
WARNINGS mean that failure to observe the specific
instructions may cause injury to personnel.
CAUTIONS mean that failure to observe the specific
instructions may damage the equipment.
Page 1-4
Revised 3/97
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 1997
ALL MODELS
Page 2 -1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25
Chapter 2
SPECIFICATIONS AND DIMENSIONS
N X 2 XXX X - X X X X
DYNAMINI
5 = 5 kg/ 10 lb.
1 = 10 kg/ 20 lb.
HOSE: 2-hose capable
PUMP TYPE:
P12 = Piston Pump 12:1
GAS = Gear Pump 1.5cc
GBS = Gear Pump 3.2cc
GCS = Gear Pump 4.5cc
GDS = Gear Pump 0.55cc
GES = Gear Pump 10cc
VOLTAGE:
1 = 100 - 120VAC, 1 phase
2 = 200 - 240VAC, 1 phase
OPTIONS:
ACCESSORIES:
F = 100 mesh/ 149 micron outlet filter (40 mesh/ 420 micron is standard)
G = Analog pressure gauge
V = Swirl kit, 1 hose
W = Swirl kit, 2 hose
CONFIGURED SYSTEM OPTIONS:
C24 = 2.4m/ 8 ft. Abrasion resistant hose
C36 = 3.6m/ 12 ft. Abrasion resistant hose
CHB = Hand Bead Applicator
CHS = Hand Swirl Applicator
STACKTITE SYSTEM OPTIONS:
SB = Bead applicator
SS = Swirl applicator
EXAMPLE:
N52GAS2-F = Dynamini 10 lb. hopper w/ 1.5cc gear pump, 240 VAC/ 1 phase and 100 mesh outlet
filter.
DYNAMINI Model Designation Matrix
Page 2 -2
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25
Specifications
Environmental:
Storage/ shipping temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40° C to 70°C (-40° F to 158°F)
Ambient service temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7° C to 50°C (20° F to 122°F)
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBD < db(A)
Physical:
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see dimensional layouts on following pages
Number of heads/ hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Number of hopper temperature zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Number of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Piston pump ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12:1
Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see options on page 2-1
Enclosure . . . . . . . . . . . . . . . . . styled, durable metal and high temp plastic, dust and splatter resistant
Hose connections . . . . . . . . . . . . . . . . . . . . . Electrical: universal 15-pin Amphenol connectors at asu,
Mechanical: wrench-secured fluid fittings (#6 JIC)
Hopper (tank) capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 05: 5 kg/ 11 lb
Model 10: 10 kg/ 20 lb
Hopper construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast-in heaters, TFE Teflon impregnated
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hopper bottom screen, manifold basket filter
Weight, empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tbd kg/ tbd lb
Adhesive form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard grades (non-water based only)
Electrical:
Power Supply Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-120 VAC/ 1p/ 50-60 Hz/ 15 Ampere
or 200-240 VAC/ 1p/ 50-60 Hz/ 30 Ampere
Hopper heater type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast-in tubular
Power consumption, system maximum . . . . . . . . . . . . . . . . . . . . . . 100-120 VAC system: 1800 watts
200-240 VAC system: 6800 watts (w. piston pump)
200-240 VAC system: 7200 watts (w. gear pump)
Hopper Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-120 VAC system: 600 watts at 120 VAC
200-240 VAC system: 1200 watts at 240 VAC
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . microcontroller
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ohm Platinum RTD standard
Gear pump Motor . . . . . . . . . . . . . . . . 1/4 hp, constant speed, AC, direct drive, horizontal orientation
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 2-3
Revised 1/05
Pressurized Air:
Air pressure supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 to 6.8 bar (20 to 100 psig)
Air consumption at 60 pump cycles per minute . . . . . . . . . . . . . . . . . . . . . . 90 normal liters/ minute
(3.2 SCFM at 100 psig)
Performance:
Adhesive temperature control range . . . . . . . . . . . . . . . . . . . . . . . . 40°C to 218°C (100°F to 425°F)
Adhesive temperature control accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 1°C (± 1°F)
Over-temperature cutoff for hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232°C (450°F)
Adhesive viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 to 50,000 centipoise
Warm-up time, full hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately .5 hour
Adhesive delivery rate, open line . . . . . . . . . . . . . . . . . . . .91 kg/min (2 lb/min)(12:1 piston pump)
Adhesive melt rate (depends on adhesive used) . . . . . . . . . . . . . . . . . . . . . . . . . . 8 kg/hr (17.3 lb/hr)
Adhesive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 68 bar (1000 psi) maximum
Maximum pump speed, piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 pump cycles per minute
Maximum pump speed, gear pump . . . . . . . . . . . . 87 revolutions per minute, 60 Hz, constant speed
73 revolutions per minute, 50 Hz, constant speed
Dynamini Temperature Control:
Controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 printed circuit board
Display type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . long-life, light-emitting diode (LED)
Temperature control zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 triac-output
Other:
Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . digital display with simplified, all-icon keypad
Temperature offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no
Sensor open error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
CE approval granted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Page 2 -4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25
A
F
E
D
A
B
G
C
H
DIMENSION
A
B
C
D
E
F
MODEL 05 (mm)
MODEL 05 (inches)
289
11.38
527
20.75
540
21.25
238
9.37
451
17.75
MODEL 10 (mm)
MODEL 10 (inches)
289
11.38
527
20.75
540
21.25
238
9.37
654
25.75
* All Mounting holes are 10mm diameter.
DYNAMINI Installation Dimensions
G
H
635
25.0
249
9.8
381
15.0
838
33.0
249
9.8
381
15.0
mounting holes*
Page 3-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25
Chapter 3
INSTALLATION & START-UP
Mounting the DYNAMINI ASU
The DYNAMINI ASU can be mounted on most flat surfaces, on either an open or a solid frame (as
shown below). The main electrical power and the serial communication connections come in from
below the unit and connect under the keypad. Access to the underside of the ASU is not a necessary
consideration in mounting the unit.
The Dynamini’s hinged hopper lid may be rotated 90 degrees in any direction.
For installation dimensions, see illustration on page 2-4.
Lifting the ASU
WARNING
The unit must be lifted by two persons, using proper lifting technique, one
person at either end. Securely hold it under its base plate. No belts or hooks
should be used. Never allow anyone to stand on the ASU.
Hopper Lid
Access Cover
Pump & Electronics Cover
Pump ON/OFF
Switch
Hopper Cover
Main ON/OFF
Power Switch
Controller
Keypad
Captive Cover Screws
Base
Plate
Page 3-2
Revised 8/08
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Installation
NOTE: Re-read Chapter 1 “Safety Precautions” before performing any installation procedures. All
installation procedures must be performed by qualified, trained technicians.
After the DYNAMINI ASU has been properly mounted, the following general sequence should be
followed for installation:
1. Make sure that incoming line power to the ASU is turned OFF at a customer-provided circuit
breaker. Incoming line power must be overcurrent-protected.
DANGER HIGH VOLTAGE
Disconnect and lockout input power to the application system before starting any installation procedures. Make sure there is no electrical power on the
leads you will be connecting. THE UNIT’S MAIN SWITCH DOES NOT SHUT OFF
ALL POWER WITHIN UNIT!! Make sure incoming line power is turned off at the
customer-provided circuit breaker before opening unit.
2. For 200-240 VAC units, power supply wires should be rated for 30 Amperes service and
should include an earth ground conductor.
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 equipment.
3. 100-120 VAC units are supplied with a line cord and a plug suitable for use in North America
on 15 AMP power supplies. For other types of 100-120 VAC power wiring, supply wires should
be rated for 15 Amp service and include an earth ground conductor.
4. Acceptable power supplies are either 100-120 VAC 1-Ph 50/60 Hz with a neutral wire, or
200-240 VAC 1-Ph 50/60 Hz. The information plate on the ASU (adhesive supply unit) will
indicate the required power supply.
5. Power supply wires are to be connected to the removable plug at header X1 on the printed
circuit board, as shown below.
Printed
Circuit
Board
GROUND
X1
L2/ N
L1
POWER IN
Supply Power Installation Diagram
ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25
Page 3-3
Revised 8/08
6. Reassemble the pump and electronics cover to the ASU.
7. Gear Pump models: omit this step.
Piston Pump models: Install the Air Control/ Filter Unit (containing the air regulator, the
coalescing filter and pre-filter). See illustration on page 3-5. The air control/ filter unit is
mounted directly to the ASU via a threaded hole on the rear cover. Wrap Teflon tape around
the nipple fitting before installing in the ASU. The unit requires clean, dry air. NEVER use
lubricated air.
For operator convenience, the air pressure gauge can be mounted to either side of the air
control regulator.
With the air pressure regulator, a clockwise turn increases pressure. A counter-clockwise
turn decreases pressure. The recommended pressure is 1.4 to 5.6 bar (20 to 82 psi).
8. Refer to the Wattage Availability Chart on the next page to determine the hose and head
power available for the various configurations of the Dynamini ASU.
9. The adhesive hoses are connected at the rear cover (see illustration on page 3-5). Make
your electrical hose connections at the two numbered connects on the left side of the cover.
Route hoses so that there is at least an eight-inch radius at any bend. Do not hang hoses
without proper support. Do not crimp, clamp, squeeze or tie hoses.
The hose adhesive ports are located at the bottom of the filter block, to the right of the
electrical connections. There are three ports for the use of up to two hoses and for the
(optional) adhesive pressure gauge.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.
Refer to the hose and applicator manuals for further details on these items.
10. Install the hose manifold outlet cover by sliding it into place and attaching with the two M4
screws provided.
Page 3-4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Wattage Availability Chart
Wattage Available for
All Hoses and Heads
Piston Pump
Gear Pump
ASU Voltage
Max. System
Wattage
Hopper
Wattage
Gear Pump
Motor Wattage
100-120 VAC
1800 @ 120VAC
600 @ 120VAC
370 @120VAC
1200 @ 120VAC
830 @ 120VAC
200-240 VAC
7200 @ 240VAC
1200 @ 240VAC
370 @ 240VAC
6000 @ 240VAC
5630 @ 240VAC
Notes:
1. Assume 33 Watts per foot of hose, #6 hose at 120VAC or 240VAC.
2. Assume 100 Watts per inch of head width, at 120VAC or 240VAC.
3. The power available for any one hose or head is 720 Watts at 120VAC or 1440 Watts at 240VAC.
4. At reduced voltage, less wattage is available. For example: 120 volt equipment operated on 100
volts or 240 volt equipment on 200 volts, will develop wattage 31% lower than the wattage available
at 120 or 240 volts.
Adding Adhesive
WARNING HOT ADHESIVE
Do not overfill the hopper (melt tank) since adhesive generally expands as it
melts and a full hopper will overflow.
CAUTION: Using adhesive with viscosity over 50,000 centipoise could cause
motor stall and/ or pump failure.
The adhesive level 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 page 6-3 of this manual for the
proper flushing procedure. When in doubt about adhesive compatibility, flush your system.
Page 3-5
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25
Air Pressure Regulator (clockwise increases)
Pressurized Air In
Air Flow
1/4 NPT female
Air pressure gauge
Pre-filter
Coalescing filter
Air Control/ Filter Unit
Maintain adhesive level 13mm-100mm (1/2”4”) from top of hopper.
Adjustable Pressure
Relief Valve
Air Control/ Filter Unit
Pressure Gauge (optional)
Hose/ Head
Electrical Connections
120v
Hose/ Head Adhesive Ports
240v
Output Filter Manifold
Electrical #1
Adhesive Port Connections
#1
Gauge
Electrical #1
Adhesive Supply
Hose
Electrical #2
Electrical #2
Rear Cover: Hose and Head Electrical and Adhesive Connections
#2
Page 3-6
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Typical Start-Up and Shut Down of the DYNAMINI Application System
Start Up Procedures
1. Fill the ASU’s hopper with clean hot-melt adhesive as described on page 3-4. Close the
hopper lid immediately to prevent contaminants from falling in. (Cover your bulk supply of
adhesive to prevent contaminants also.)
2. At the control panel, turn ON the Main Power Switch. The controller will perform its initial
calibration cycle. The display will read “CAL”. Each of the five temperature zone’s LEDs will
flash as a lamp test.
3. Program your adhesive setpoints (see instructions on page 5-2) or use the factory settings listed
below. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the
temperatures of the temperature zones to stabilize.
Note: When the ASU leaves the ITW Dynatec factory, it is programmed with the following
factory settings (unless special factory settings were requested):
Hopper:
150°C (300°F)
Hose:
177°C (350°F)
Applicator: 177°C (350°F)
Sequential Startup: ON
4. Once the ASU has reached temperature, turn ON the Pump ON/ OFF Switch. The ASU will
begin to pump adhesive.
5. a. On piston pump units: use the air pressure regulator, located at the rear of the ASU, to
regulate adhesive output.
b. On gear pump units: use the pressure relief valve, located on the filter outlet manifold, to
regulate adhesive output.
Shut Down Procedures
1. Turn OFF the Pump Switch.
2. Turn OFF the Main Power Switch.
ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25
Page 3-7
Revised 1/05
Storage and Disposal of the DYNAMINI 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 output filter and the primary filter, following instructions detailed
in chapter 6.
3. Shut OFF all pressure and power sources.
4. Release residual air pressure.
5. Remove all residual adhesive and wipe components clean.
6. Remove all air lines and all power supply cables.
7. Pack the unit in a corrosion-proof manner.
8. Store the unit in such a way that it is protected from damage.
Disposal of the Unit
1. Shut OFF all pressure and power sources.
2. Release residual air pressure.
3. Remove all residual adhesive.
4. Remove all air and adhesive supply hoses and all power supply cables.
5. Dismantle all components and sort into mechanical and electrical components.
6. Arrange for all components to be recycled.
Page 3-8
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 4-1
Revised 11/04
Chapter 4
DYNAMINI TEMPERATURE CONTROLLER SET-UP
Temperature Control Functions in General
The Dynamini temperature controller provides accurate temperature control for the hopper, hoses
and applicators. Setpoints are programmed at the user-friendly, all-icon keypad. The controller will
display an error message any time an open or shorted sensor condition occurs.
Defining Dynamini Temperature Control Terms
Adhesive Temperature Control Range
The temperature limits within which the ASU, hoses and applicators may be programmed and maintained.
Printed Circuit Board (PCB)
The Dynamini contains one pcb. It contains the central processing unit (CPU) of the microprocessor
temperature control as well as providing control signals to, and monitoring signals from, the hopper,
hoses and applicators. It features lighted LEDs to indicate that heater power is ON. The ASU’s fuses
are located on this board.
Dynamini Temperature Controller
The built-in control system that controls, monitors and displays all system temperature values of the
Dynamini adhesive application system.
Mechanical High-Temperature Protection
A mechanical, redundant thermostat located on the hopper that will turn off the system above 232°C
(450°F).
RTD Sensors
The Dynamini system uses 100-ohm platinum resistance temperature detector sensors for all temperature controls.
Sequential Startup
This feature allows the temperature zones to come on in sequence (hopper, followed by hose, followed by head). When activated, and the ASU is turned ON from a cold start, the hopper heats first.
When the hopper is within the programmable tolerance of setpoint, the Head(s) and hose(s) begin to
heat. No other features of the ASU are affected by sequential startup.
Note: sequential startup is rarely used. In most cases, it should be de-activated to ensure rapid warm
up.
Page 4-2
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Setpoint
A programmable temperature that has been selected for hopper, hoses and applicators.
Setpoint Limitation
This is a universal maximum temperature for all zones (218°C [425°F]). The programmer cannot
program a temperature setpoint higher than the setpoint limitation.
Stepped Function (Future feature, not on V2.0)
Used on systems with electric applicators only. After programming the temperature (to the softening
point of your adhesive, see your adhesive manufacturer), the controller holds all electric heads at
the operator-selected temperature for ten minutes before releasing them to operating setpoint. This
feature allows for the stabilization of the electric valves.
Error Indication Messages
A controller display of “EO1” indiates that the selected zone (ie, a hose, applicator or the hopper)
has an open sensor. A display of “EO2” indicates a shorted sensor.
If either alarm occurs, first verify that the following three connections are made correctly:
1. The ASU-to-hose connection(s) located at the back of the ASU,
2. The hose-to-applicator connection(s),
3. The RTD Input connections (X4) located on the Control Printed Circuit Board.
If the problem is not with a connection, check the sensor and replace if necessary.
Software Chip (EPROM) and Checksum
The software EPROM is on the Control Printed Circuit Board (see Ch. 7). Inscribed on the controller’s software chip is information that is required if your controller needs service, including the controller’s checksum.
Software chip example:
Software chip (EPROM)
Part Number of
Control PCB
102434 OEF8
Date: 12-7-04
The date this Software EPROM was manufactured
Checksum example
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 4-3
Revised 11/04
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 163°C (325°F):
·
Hose and head temperature: 177°C (350°F).
·
Hopper setpoint temperature: 150°C (300°F).
·
ASU operating range: 135°C to 177°C (275°F to 350°F).
·
Mechanical thermostat (for the hopper) over-temperature: 232°C (450°F)
System Values That Are Permanently Programmed
·
Minimum setpoint value: 40°C (100°F).
·
Maximum setpoint value: 218°C (425°F).
System Values as Programmed by the Factory
ITW Dynatec can set the controller’s system values to customer’s specs, if provided.
If customer’s specs are not provided, the following values will be entered into the Dynamini temperture controller at the factory. They may be changed by reprogramming through the keypad.
(These are not the “default” settings, see following section).
·
Temperature scale: displayed in degrees Farenheit.
·
Applicator (head) and hose setpoints: 177°C (350°F).
·
Hopper setpoint: 150°C (300°F).
·
All zones are switched off, except for the hopper.
Page 4-4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Default Settings of the Controller
Default settings are the manufacturer’s preset values to which the system will return if the Dynamini tempearture control is subjected to an internal memory reset. While you can change your programmed values to anything within the system’s limits, the default settings cannot be changed.
To cause an internal memory reset (ie, to restore the defaults) of a temperature zone, turn that temperature zone ON and then OFF.
Defaults
·
Temperature setpoint for each zone: 93°C (200°F).
·
Sequential Startup: SSO (OFF)
Helpful Tips for the User
·
When the ASU is turned on, all temperature setpoints and other operating parameters will
be exactly where they were when the ASU was turned off.
·
When the ASU is turned on, all system heaters go on unless they have previously been set
below 40°C (100°F).
Page 5-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 5
PROGRAMMING INSTRUCTIONS FOR DYNAMINI CONTROLLER
Dynamini Keypad
Scroll Keys:
to increase value to reduce value
Temperature
Scale
Pump Switch
I
Temperature
Display
O
Main Power Switch
Service Key
Hopper
Temperature
Zone
1
1
2
2
I
O
Dynamini 
Temperature Zones: Hose #1
Hose #2
Application Head #2
Application Head #1
Programming
Turn controller ON
I
O
Turn ON the main power switch.
System will go through its self-diagnostics (CAL).
Temperature zone LEDs will flash.
Controller will display “SS 1” (On) or “SS 0” (Off) to
indicate status of the Sequential Statup feature
(see info on “Sequential Startup” later in this chapter).
Controller will display it’s software version, ie.
V.2.XX
or
Page 5-2
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Programming temperature setpoints
or
Choose a temperature zone.
or
or
Scroll to “increase value” or ”reduce value”,
in order to adjust the setpoint temperature.
After two seconds the display will read the
actual temperature. The setpoint is stored.
Turning temperature zones ON/OFF
or
or
Choose a temperature zone.
Scroll to “reduce value” until temperature
setpoint is 0. The temperature zone is now
turned OFF.
To turn ON the temperature zone, increase
the setpoint.
Error indication messages
The temperature sensor is open or has high resistance.
The temperature sensor is shorted or has low resistance.
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 5-3
Revised 1/05
Keypad Locking
It is possible to lock or unlock the controller in order to restrict programming changes. To change the
code which is necessary to over-ride or unlock the keypad lock, see Service Functions.
Note: the ASU is shipped with de-activated keypad lock. If the keypad lock must be used, an access
code must be programmed prior to locking the keypad.
Locking or Unlocking the Keypad
Important Note: the controller must be in the Temperature Display mode in order to allow
locking or unlocking of the keypad.
Locking the Keypad
&
Press the Down Scroll key, then hold and press the
Service icon key.
You will see “Loc” to indicate that the Keypad Lock is
active.
Unlocking the Keypad
&
Press the Down Scroll key, then hold and press the
Service icon key.
You will see “Cod” to indicate that the access code is
required.
or
Enter your access code by scrolling up or down. Default
code = “ -- -- --”.
Confirm your code input by pressing Tank key.
Notes:
1. Once the keypad lock is active, unauthorized programming is not possible, even after turning the
ASU OFF, then back ON again.
2. Once the keypad lock is unlocked, programming is possible until the ASU is turned OFF, then back
ON or the keypad is locked again.
3. If the keypad must be unlocked permanently, the access code must must be de-activated in the Service Functions.
Page 5-4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Service Functions
After the basic programming of Temperature Setpoints is complete, the programmer proceeds to
programming of the Service Functions, if desired.
The Service Functions are a continuous loop of programming steps (”functions”) which the programmer moves through by pressing the “Service” key. These steps are described in this section
of the chapter. The Service Functions loop and basic programming is diagrammed below.
There are three ways to exit the Service Functions loop:
1. Just wait (approx. 10 seconds) and the controller will automatically return to the actual temperatures display,
2. Press the Service key until you are back to the actual temperatures display, or
3. Press any Hose or Head key and you will return to the actual temperatures screen.
Diagram of the
Service Functions Loop
C
F
Actual Temperature Display
Activate De-activate Temperature Setback
Change Setback Temperature Value
Change Hi/ Lo Tolerance Value
Activate/ De-activate Sequential Startup
Select Temperature Scale
Change Ready Delay
Change Access Code
C
F
Actual Temperature Display
Page 5-5
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Service Functions, cont.
Standby Programming
“Standby” is a temperature value by which all temperature zones will lower when Standby mode
is activated. For example, if your temperature setpoints are all 300 degrees, and you program a
100 degree Standby, then the Standby temperature of all zones will be 200 degrees. Similarly, if
your temperature zones setpoints vary, and you program a 100 degrees Standby, each zone’s
Standby temperature will be 100 degrees lower than its setpoint.
Press Service icon to enter Service Functions.
You will see either “S--1” (standby is On) or “S--0”
(standby is Off).
or
Press the Tank icon to activate/ de-activate Standby.
If desired, you may set the Standby temperature by
scrolling up or down to desired temperature.
When programming is complete, wait a few seconds
and the controller will return to the ASU’s actual
temperature.
Note: When Standby is active, the display will alternate between the ASU’s actual temperature
and S--1.
Page 5-6
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Service Functions, cont.
To Set Tolerance (Hi & Low Temperature Limits)
The Tolerance (high/ low alarm) setpoint is a range (+ and -- the zone’s temperature setpoint) between which your ASU can safely operate. It’s lower temperature represents the ASU’s ready
temperature. It’s upper value represents the over-temperature point.
Setting the Tolerance range, for example: if the temperature setpoint is 200 degrees, and the Tolerance setpoint is 10 degrees, then the high alarm (overtemp) equals 210 degrees and the low alarm
(ready temp) equals 190 degrees.
x2
Press the Service icon twice to select the Tolerances of your
temperature zones. An display of “t--1” indicates the Tolerance
function has been selected.
Press the Tank button to display the Tolerance.
Use the scroll buttons to change the Tolerance range for all zones.
Note: your Tolerance range must be a value between ± 50 degrees
or
for Fahrenheit (± 27 degrees for Celsius).
When Tolerance programming is complete, wait a few seconds and
the controller will return to the ASU’s actual temperature.
Turning Sequential Startup ON/OFF
The Sequential Startup feature programs the order in which the temperature zones will come on at
startup. A Sequential Startup” of “SS1” (On) means the tank will begin heating first, then, when the
tank is ready, the other zones will begin heating. A Sequential Startup of “SSO” means Sequential
Startup is Off and all zones will begin heating immediately.
x3
Press the Service icon three times to set Sequential Startup.
The display will flash either “SS1” (sequential startup is ON) or
“SS0” (sequential startup is OFF).
Scroll to choose between ON and OFF. When programming is
or
complete, wait a few seconds and the controller will return to
the ASU’s actual temperature.
Note: Any time the ASU is switched ON, you will briefly see
“SS1” or “SS0” displayed.
or
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 5-7
Revised 1/05
Service Functions, cont.
To Set Temperature Scale
The Temperature Scale may be set to display temperature either in degrees Celsius or Fahrenheit.
x4
Press the Service icon four times to set the Temperature
Scale.
Scroll to choose between Celsius (”C”) or Fahrenheit
(”F”) as indicated by the Temperature Scale LED. When
programming is complete, wait a few seconds and the
or
controller will return to the ASU’s actual temperature.
To Set Ready Delay
When the system is ready (all temperature zones are within tolerance), a ready delay may be programmed to delay the system’s ready output signal.
x5
Press the Service icon five times to set a Ready Delay.
You will see “d--1” to indicate you are in Ready Delay
programming mode.
Press the Tank icon to display the Ready Delay.
To change a Ready Delay, scroll up or down to the
desired length (in minutes) of delay.
or
0 = Default, no delay
99 minutes = maximum length of delay
When programming is complete, wait a few seconds and
the controller will return to the ASU’s actual temperature.
Page 5-8
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Service Functions, cont.
To Change Access Code (De-activate Keypad Locking)
x6
To change the Access Code, press the Service icon six
times.
You will see “C--1” to indicate you are in Access Code
programming mode.
Press the Tank icon to see the programmed Access
Code. For example, “999”.
or
To change the Access Code, scroll up or down to the desired
numeric value.
“-- -- --” = no Access Code (Access code is de-activated),
“-- -- --” = no Keypad Locking
1 - 999 = possible Access Code values
When programming is complete, wait a few seconds and the controller will return to
the ASU’s actual temperature.
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 5-9
Revised 1/05
Controller Features
System Ready Indicator Light
When not in programming mode, a flashing temperature scale light
(LED) indicates that the ASU is not “Ready” for production. This LED
will cease to flash when all temperature zones are within the programmed temperature tolerance window.
Error Indication Messages
“EO1” = the temperature sensor is open (no sensor attached) or has
high resistance.
“EO2” = the temperature sensor is shorted or has low resistance.
To Copy and Paste Setpoints
The Copy/ Paste feature of the controller copies the tank setpoint and pastes it as the setpoint of
other temperature zones. The paste will apply to only temperature zones that are switched ON.
Set your Tank setpoint as described earlier in this chapter.
&
Push and hold the Tank icon. While holding, press the #1 Hose icon. Release.
then
&
Push and hold the Tank icon again. While holding, press the #1 Head icon. Release.
The manually programmed setpoint has now been pasted in to all turned on hose and
head zones. When programming is complete, wait a few seconds and the controller
will return to the ASU’s actual temperature.
Page 5-10
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 6-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 6
PREVENTIVE MAINTENANCE
Note: Re-read Chapter 1 “Safety Precautions” before performing any maintenance procedures. All
maintenance procedures must be performed by qualified, trained technicians.
General Cleaning
Follow the manufacturer’s directions when using industrial cleaners on the enclosure.
Preventive Maintenence
Output Filter
During the first weeks of operation, the output filter must be replaced monthly.
To replace the output filter:
1. Follow instructions “Purging the Filter
Manifold of Adhesive and Pressure”, page 6-2.
2. Unscrew and remove the filter nut
(15.8 mm or 5/8” nut).
3. With pliers, pull the filter basket out.
4. Replace the o-ring on the filter nut. Apply
o-ring lubricant (PN N07588) to the new
o-ring.
Filter Nut
O-ring
Filter Basket
Output Filter
Manifold
5. Replace the filter basket.
6. Apply anti-seize to the threads of the filter
nut and re-install. Tighten the filter nut until
it is seated firmly, taking care not to cut the
o-ring.
Hose Fittings & Fasteners
Periodically check all hose fittings and screws for tightness.
Purge Screw
Purge Drain (on underside)
Page 6-2
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Hopper FIlter Inspection & Cleaning
The hopper filter is a coarse screen located in the bottom of the hopper. It fits over the hopper’s
drain hole and prevents any large debris from leaving the hopper.
1. Pump all adhesive out of the ASU.
2. Open the hopper lid and inspect the hopper filter.
3. If cleaning the filter is necessary, lower the temperature of the hopper 20-30°C (35-50°F)
from operating temperature.
WARNING HOT SURFACE
The ASU will still be hot during this procedure. Use insulated gloves and
protective clothing when handling the hopper filter.
4. Use a hook to pull the hopper filter out.
Hopper
Filter
5. Emerse the clogged filter in flushing fluid (PN L15653),
then use a hot air gun and rags to clean it.
6. Re-insert the filter into the hopper.
7. Refill the hopper and resume production.
Purging the Filter Manifold of Adhesive and Pressure
As a safety precaution, purge the filter manifold before changing the output filter or before removing any of the hoses or applicators from their manifold port.
Refer to the illustration on page 6-1 while following these instructions.
HIGH PRESSURE
WARNING
During the purging procedure, hot adhesive can come out of the manifold under
high pressure. Wear safety glasses, gloves and protective clothing. Stand clear
of the ASU until all pressure is relieved.
HOT ADHESIVE
Avoid splashing hot adhesive. Position a heat-resistant container under the
manifold’s purge drain before proceeding.
1. The system should be at operating temperature. Turn the pump/ motor OFF.
2. With a hex key screwdriver (allen wrench), slowly loosen the purge screw (do not remove
it). Allow the adhesive and pressure to escape. All the adhesive will flow into the heatresistant container.
3. Re-tighten the purge screw.
Page 6-3
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Flushing the System
Contaminated adhesive, accumulation of residue, or changing the adhesive formulation may require
the system to be flushed. At least 6 liters (1.5 gallons) of flushing fluid is required (PN L15653).
WARNING
The flushing fluid will splash easily. Wear protective clothing, gloves and
goggles to prevent severe burns.
1. Pump out as much of the molten adhesive as possible.
2. Reduce the pump pressure to zero by first turning the pump switch to OFF. Then open the
purge screw, following the instructions given in “Purging the Filter Manifold of Adhesive
and Pressure” on page 6-2.
3. Disconnect one of the supply hoses’ adhesive feed from its applicator head. Do not
disconnect electrical power to the head. Put the hose in a secured position within a container
to 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 remaining adhesive.
5. For Piston Pumps: Slowly turn the air pressure regulator clockwise.
For Gear Pumps: Slowly turn the pressure relief control valve clockwise.
6. Pump about half of the fluid into the container.
7. For Piston Pumps: Turn the regulator counter-clockwise.
For Gear Pumps: Turn the motor OFF.
Pressure
Regulator
Pressure
Relief Valve
8. Remove the output filter and replace the basket. Install a new o-ring on the filter nut
(lubricate the new o-ring with o-ring lubricant prior to installation) and tighten the brass nut.
9. Add new adhesive to the hopper and heat to application temperature.
10. For Piston Pumps: Slowly turn the air pressure regulator clockwise.
For Gear Pumps: Turn the motor ON.
11. Actuate each applicator until all flushing fluid is removed and a steady stream of new
adhesive flows.
12. For Piston Pumps: Re-adjust the pump air pressure for desired flow.
For Gear Pumps: Re-adjust the pressure relief for desired flow.
13. Re-fill the hopper and resume production.
Page 6-4
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 7-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 7
TROUBLESHOOTING
General Troubleshooting Notes
Note: Re-read Chapter 1 “Safety Precautions” before performing any troubleshooting or repair procedures. All troubleshooting or repair must be performed by qualified, trained technicians.
DANGER
HIGH VOLTAGE
WARNING
HOT SURFACE
Dynamini systems use electrical power that can be life threatening and hot-melt adhesives that
can cause serious burns. Only qualified persons should perform service on the Dynamini system.
Handling Printed Circuit Boards (PCBs)
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.
Page 7-2
Revised 6/10
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Printed Circuit Board
The PC board contains the controller’s software/ CPU chip and non-volatile memory.
The green, temperature zone LEDs cycle on and off as each heater outputs.
The PCB is mounted under the ASU’s cover.
The fuses are designated F1 thru F13 below. See diagram for sizes. The fuses are the only replaceable parts on the pc board. Each temperature zone is fused with two fuses.
Software/
CPU chip
Connect to RTDs:
1&2 = Hopper
3&4 = Hose 1
5&6 = Head 1
7&8 = Hose 2
9&10 = Head 2
Connect to
Keypad at J1
Ready
No Com NC
10
X5
X6
1
X4
Pump
LED1 (5v OK)
X7
LED2 (12v OK)
Over Temp
Thermostat
{
Transformer
LED3
Hopper
LED5
LED4
LED6
N
L
LED7
2 pump fuses
(5A slow)
X3
F7
PCB fuse
(1A fast)
....
F2
F3
F4
F5
F6
HOSE1 HEAD1 HOPPER HOSE2 HEAD2
120
F1
Connect to
Main Switch
Relay
X2
Customer’s
Power Input
240
F8
1
HOSE1
L
X1
N
F9
HEAD1
F10
X11
Relay
Temperature
zone fuses,
2 per zone
(6.3AF fast)
HOSE2 HEAD2
HOPPER
F11 F12
F13
X8
X9
X10
1
1
Mounting
Bracket/
Heat Sink
Voltage Selector:
upper position = 200/240v
lower position = 100/120v
(set by factory, selector is
shown on upper position)
Ground
Lug
Mounting
Holes (2)
Heater Output for
Hose/ Head 1
Connect to
Hopper Heater
Layout of Components on PC Board
Heater Output for
Hose/ Head 2
Page 7-3
Revised 7/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Overtemp Thermostat
The overtemp thermostat cuts off power to all temperature zones if the tank temperature exceeds
224°C (435°F). The overtemp thermostat must be re-set manually, by opening the ASUs front panel
and pressing the reset button in the center of the overtemp switch (note: the reset button is protected
by a plastic insulator).
Heater
Control PC Board
Sensor
Overtemp Thermostat
PCB Board
Overtemp Thermostat
Location of Printed Circuit Boards and Overtemp Thermostat
Page 7-4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Resistance Tables
°F
Temperature
°C
Resistance
in Ohms
32
50
68
86
104
122
140
158
176
194
212
230
248
268
284
302
320
338
356
374
392
410
428
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
100
104
108
112
116
119
123
127
131
135
139
142
146
150
154
157
161
164
168
172
176
180
183
Hose Length
Meters Feet
1.2
1.8
2.4
3
3.7
4.9
7.3
Resistance in Ohms
120V
240V
4
6
8
10
12
16
24
102-125
63-77
50-61
39-48
31-37
23.6-29
N.A.
400-490
291-355
204-249
155-189
125-153
98-120
61-75
Nominal Hose Heater Resistance
for DynaFlex Hoses
Watts
Resistance in Ohms
120V
240V
200
270
350
500
700
72
53
41
29
N.A.
288
213
165
115
82
Nominal Head Heater Resistance
Temperature Sensor Resistance
Qty. Heaters
Resistance in Ohms
for each heater
2
25
Nominal Hopper Heater Resistance
Note: Resistance is measured at ambient temperature (20°C/ 68°F).
Page 7-5
Revised 6/10
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Troubleshooting Guide
Preliminary Checks: Verify the following before proceeding
1. The ASU is switched on.
2. The ASU is supplied with power.
3. The ASU is supplied with pneumatic air.
4. Pneumatic and electrical connections are correct.
5. Adhesive is in the hopper.
Error Messages (see also Chapter 4)
EO1 = temperature zone has an open sensor
EO2 = temperature zone has a shorted sensor
Hose/ Applicator Troubleshooting Tip
Hose or applicator problems can be isolated by electrically connecting the
applicator and hose to an alternate socket on the ASU. If the malfunction
goes with the applicator and hose, the problem will usually be in the applicator
or hose that was moved. If the malfunction does not move with the applicator
and hose, the problem is probably in the ASU.
Problem
Possible Cause
Solution
1. Main Power switch OFF.
1. Switch ON.
2. PCB inoperative.
2. Replace PCB.
3. Keypad locked.
3. Unlock.
All channels display
error message or wrong
actual temperatures.
1. PCB inoperative.
1. Replace PCB.
System is not working,
display is OFF.
1. Power supply plug at X1
is not plugged in.
1.Check power supply plug
connection.
2. Ribbon connector J1 is
disconnected from back
of PCB or display panel.
2 Check connection.
Controller setpoints are
not adjustable.
Display
Panel
3. F1 fuse on the PCB is
inoperative.
J1 ribbon connector to display panel
ON
F1
X2
X1
Incoming AC power
3. Insert new fuse, if it blows, the
PCB is inoperative.
Page 7-6
Revised 6/10
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Hopper temperature is
higher than setpoint
(overtemp).
Possible Cause
Solution
1. Hopper sensor not fully
inserted.
1. Check hopper sensor.
2. Hopper sensor (X4)
inoperative.
2. Replace hopper sensor if resistance does not comply with resistance table.
3. Inoperative PCB.
3. Replace PCB.
1. Plug connection X4 on
PCB is loose.
1. Restore connection.
2. Temperature sensor inoperative.
2. Replace sensor if resistance does
not comply with resistance table.
1. Hopper sensor short circuit.
1. Replace sensor if resistance does
not comply with resistance table.
2. Short circuit at plug connection X4 on PCB.
2. Check and eliminate short circuit.
X4
ON
Display for Hopper =
EO1.
Display for Hopper =
EO2.
3. Inoperative PCB.
Hopper does not heat,
but LED is ON.
Heater
25 Ohms
25 Ohms
3. Replace PCB.
1. Hopper fuses (F4 & F11)
inoperative on PCB.
1. Insert new fuse(s) and observe
ASU. If fuse(s) blows again, check
for a short circuit in heater.
2. Hopper heater element
is inoperative.
2. Replace hopper if element’s resistance does not comply with resistance table. Note: remove wires
from both heater elements when
measuring.
3. Disconnection in hopper
heater circuit.
3. Check and repair (see wiring diagram).
4. Inoperative PCB.
4. Replace PCB.
Page 7-7
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Possible Cause
Solution
Hopper does not heat,
and LED is OFF.
1. Inoperative Control PCB.
1. Replace PCB.
Hose (or Head) is not
heating. Hose (or
Head) LED on the
PCB is ON.
1. Disconnection between
ASU and Hose (or
between Hose and Head).
1. Check plug connections.
2. Hose (or Head) fuse(s) on
the PCB is inoperative.
2. Insert new fuse(s). If fuse blows
again, check for a short circuit in
heater.
3. Loose plug connection on
PCB.
3. Check connectors X8 and X11
and restore connection.
4. Heating element inoperative.
4. Check resistance and compare to
resistance table.
a. For head: if heater cartridge
is inoperative, replace heater.
b. For hose: if heating element
is inoperative, replace hose.
Hose (or Head) is not
heating. Hose (or
Head) LED on the PCB
is OFF.
1. Inoperative PCB.
1. Replace PCB.
2. Sequential Startup is
active.
2. Wait until hopper has reached
setpoint or re-program the heat-up
mode (see pg. 5-6).
Hose (or Head) actual
temperature is much
higher than setpoint.
1. Inoperative Hose (or
Head) triac on PCB
(corresponding PCB LED
is OFF).
1. Replace PCB.
2. Inoperative Hose (or
Head) temperature sensor
(corresponding PCB LED
is ON).
2. Check resistance and compare to
resistance table.
a. For head: if sensor is
inoperative, replace sensor.
b. For hose: if sensor is
inoperative, replace hose.
Fuses:
F2 & F9 = Hose 1
F3 & F10 = Head 1
F5 & F12 = Hose 2
F6 & F13 = Head 2
Page 7-8
Revised 1/05
Problem
Display for Hose (or
Head) = EO1
ASU Socket
&
Hose Plug
Sensor
Heater
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Possible Cause
Solution
1. No Hose (or Head) is
connected.
1. Connect Hose (or Head) if needed. If not needed, ignore display.
2. Disconnection between
ASU and Hose (or between Head and Hose).
2. Check plug connection.
3. Disconnection at X4 on
PCB.
3. Make proper connection.
4. Hose (or Head) sensor is
inoperative.
4. Check resistance and compare to
resistance table.
a. For head: if sensor is
inoperative, replace sensor.
b. For hose: if sensor is
inoperative, replace hose.
1. Hose (or Head) sensor
short circuit.
1. Check resistance and compare to
resistance table.
a. For head: if sensor is
inoperative, replace sensor.
b. For hose: if sensor is
inoperative, replace hose.
2. Short circuit in plug connection between ASU
and Hose (or between
Hose and Head).
2. Make proper connection.
3. Inoperative PCB.
3. Replace PCB.
Plug
Sensor &
Heater
Display for Hose (or
Head) = EO2
Page 7-9
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Pump Operation & Adjustable Pressure Relief
When the ASU’s hopper reaches setpoint, the controller places the hopper in “Ready” condition and
power is supplied to the pump.
An adjustable pressure relief valve is located on the output filter manifold.
When adhesive pressure exceeds the set limit, adhesive flows back to the hopper. Therefore, the
greater the setting on the pressure relief valve, the greater the adhesive output.
To change the setting of this valve, loosen the lock nut and turn the adjustment screw clockwise to
increase pressure or counterclockwise to decrease pressure. The relief valve is factory set at 27 bar
(400 psi) for gear pumps and 68 bar (1000 psi) for piston pumps.
Normally Closed (Unrelieved):
Open (Relieved):
In the drawing below, the valve
is closed.
In this drawing, pressure has
exceeded the setting of the valve,
causing the valve to open and
discharge adhesive to the hopper.
Adjustment screw
Lock nut
Mounting nut
return to
hopper
to
hose
from
pump
Adhesive flow through
filter block to hose
to
hose
from
pump
Adhesive flow through
filter block to hose
Operation of the Adjustable Adhesive Pressure Relief Valve
Page 7-10
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Piston Pump Troubleshooting Guide
WARNING
HOT SURFACE & ADHESIVE
Some of the procedures in the following Troubleshooting Guide require working
near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing
and use proper tools for handling hot melt components.
Problem
Possible Cause
Solution
Pump Will Not Stroke
1. No air pressure.
1. Verify system has been provided
with at least 0.5 SCFM of air at
20-100 PSIG (.014 std. cubic meters/
minute at 6.8 bar).
2. 3-way solenoid valve is
closed.
2. Verify that valve is properly connected (electrically) inside ASU.
Verify that valve is properly connected to Air Control/ Filter Unit.
Disconnect valve electrical leads
and verify that air is passed through
when 240 VAC is applied to the
valve terminals. Replace valve if
defective.
3. Fault in compressed air
fitting on ASU.
3. Inspect the system for improper
connections, loose tubing or fittings, or kinked tubing. Repair or
replace tubing or fittings as
necessary.
4. Hopper temperature
not ready.
4. Air valve cannot pass air until hopper
has reached setpoint window. Wait until
this has occurred. Check also the
programming of the ready time delay.
The default for this is “0”.
5. Inoperative air valve (on
back end of pump air
cylinder).
5. Remove air valve from pump.
Inspect, clean and repair as necessary.
6. Inoperative air cylinder
4-way solenoid valve.
6. Remove 4-way valve. Inspect,
clean and repair as necessary.
7. System is not ready.
7. Wait until temperature scale (F/C) light
is steady ON (not flashing).
Relief
Valve
Regulator
Air Tubes
Solenoid
Air fittings
Air
valve
Page 7-11
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Possible Cause
Solution
Pump Quick-Strokes in
Both Directions
1. No adhesive in hopper.
1. Verify that hopper has an adequate
level of hot melt adhesive.
2. Adhesive too cold to flow
into pump.
2. Check ready temperature to
make sure there has been enough
time for the adhesive to rise to the
hopper setpoint temperature.
3. Adhesive used is too
viscous.
3. Verify that adhesive selection and
hopper setpoint temperature are
compatible and that both are
appropriate for your application.
4. Pump needs priming.
4. Prime the pump by first lowering the
air pressure, then letting the pump
cycle very slowly until primed.
5. Problem with pump shaft
piston.
5. Remove the shaft and piston from
the pump. See Chapter 8 for disassembly/ assembly procedures.
Verify that piston diameter is
correct: 19.63mm to19.66mm
(0.773” to 0.774”) and that piston is
tightly assembled to end of shaft.
6. Large opening in system
downstream of pump.
6. Inspect system for open filter drain,
disconnected or ruptured hose, or
disconnected head. Repair as
necessary.
1. Inlet check valve blocked
open.
1. Clean inlet check valve. This may
be possible without removing the
pump by cleaning debris through
the pump inlet hole at bottom of
hopper.
Loosen
set screw
Open
drain
Inlet check valve
Outlet
check valve
Pump Quick-Strokes
on the Forward-Stroke
Only (shaft moving
into pump body)
Page 7-12
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Possible Cause
Solution
Pump Motion on the
Forward Stroke (shaft
moving into pump) is
very slow or stopped.
1. Outlet check valve is
blocked closed.
1. Clean outlet check valve.
Pump Quick-Strokes on 1. Outlet check valve is
the Reverse Stroke
blocked open.
(shaft moving out of
pump)
1. Clean outlet check valve.
Low or Inconsistent
Adhesive Output
Inlet check valve
Outlet
check valve
Output
filter
1. Output filter clogged.
2. Adhesive used is too
viscous.
2. Verify that system components are
at proper temperature and that
selected adhesive is correct for your
application.
3. Blocked hose.
3. Inspect hose for kinks, internal plugs
of debris or char (degraded adhesive).
Clean or replace hoses as required.
4. Blocked applicator heads.
4. Inspect heads for plugged nozzles,
proper air valve operation or plugged
filters. Clean or repair heads as
needed.
5. Pressure relief valve in
output block is opening.
5. Verify that air supplied to pump is
less than 6.8 bar (100 PSIG). If
relief valve is opening with air pressure less than 6.8 bar (100 PSIG),
remove pump and replace pressure
relief valve.
1. Filter drain valve not
tightly closed.
1. Close and tighten filter drain valve.
2. Filter drain valve blocked
open.
2. Remove filter plug assembly from
output manifold, clean and re-install.
Output
Manifold
Adhesive Leak at
Filter Drain Spout
Loosen
set screw
Open
drain
1. Remove and inspect output filter.
Clean or replace as necessary. See
Chapter 6 “Preventive Maintenance”
for procedure.
Page 7-13
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Possible Cause
Adhesive Leak at Pump 1. Pump seal out of proper
Shaft Seal
position inside air motor
assembly.
Seal assembly
2. Seal inoperative.
Adhesive Leak at Pump- 1. Pump assembly nuts
Mounting Block
missing or loose.
Interface
O-rings
Tighten
Solution
1.Remove seal from air motor and in
spect it. Replace worn or damaged
seal. Be sure there are no burrs or
other sharp edges on pump shaft or
on installation tools that could dam
age the new seal.
2. Remove seal from air motor and in
spect it. Replace worn or damaged
seal. Be sure there are no burrs or
other sharp edges on pump shaft or
on installation tools that could dam
age the new seal.
1. Verify that both pump nuts are
tightly assembled to the pump
mounting block thru the base plate
with the proper hi-collar washer.
2. Inoperative mounting
block o-ring(s).
2. Inspect the three o-rings and replace
if worn or damaged. Be sure there
are no burrs or other sharp edges in
the o-ring grooves or on installation
tools that could damage a new seal.
3. Helicoil insert pulled out
of hopper.
3. Remove pump and inspect bottom
of hopper. Repair or replace hopper
as necessary.
Page 7-14
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Gear Pump Troubleshooting Guide
WARNING HOT SURFACE & ADHESIVE
Some of the procedures in the following Troubleshooting Guide require working
near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing
and use proper tools for handling hot melt components.
Problem
Possible Cause
Solution
Pump doesn’t operate.
1. Motor on/off is off at the
controller keypad.
1. Check keypad switch.
2. Hopper temperature is
below setpoint window.
2. Pump cannot operate until hopper has
reached ready condition. Verify that
hopper has reached ready. Re-program
hopper operating setpoint and tolerance
(hi/low) if necessary.
3. No incoming electrical
power.
3. Check to see if ASU temperature
control is operating. If not, check
for presence of incoming supply
voltage.
4. System is not ready.
4. Wait until temperature scale (F/C) light
is steady ON (not flashing).
1. ASU is out of adhesive.
1. Add adhesive to hopper.
2. If pump has been serviced
and motor leads reversed,
pump will run with no
output.
2. Check motor wiring to schematic.
1. Filter(s) clogged.
1. Remove and inspect filter basket and
hopper screen.
2. Adhesive used is too
viscous.
2. Verify that system components are
at appropriate temperatures and that
the selected adhesive is correct for
the application.
3. Clogged hose.
3. Inspect hose for kinks or internal
plugs of debris or char. Clean or
replace hoses as necessary.
4. Clogged applicators.
4. Inspect applicators for plugged
nozzles or filters. Clean or repair
applicators as necessary.
Pump runs but there is
no adhesive output.
Low or inconsistent
adhesive output.
Hopper screen
Output
filter
Output Manifold
Page 7-15
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Problem
Pressure
relief valve
Adhesive leak at pump
shaft seal.
Seal assembly
Possible Cause
Solution
5. The adjustable pressure
relief valve is opening.
5. When fully closed (clockwise) and
all applicators are off, adhesive
pressure should be around 68 bar
(1000 psi). If it is significantly less,
the pressure relief valve should be
replaced.
1. Pump seal is incorrectly
positioned inside the seal
and bearing assembly.
1. Remove seal and bearing from pump.
Verify that all components are
correctly positioned.
2. Pump seal inoperative.
2. Remove seal from pump, inspect it
and replace it if worn or damaged.
Be sure there are no burrs or other
sharp edges on pump shaft or on
installation tools that could damage
a new seal.
Adhesive leak at pump- 1. O-ring in pump’s rear
to-hopper interface.
plate is inoperative.
2. Pump assembly screws
are missing or loose.
2. Verify that all four pump screws are
tightly assembled to the pump
mounting block.
3. Helicoil insert pulled out
of hopper or pump
interface plate.
3. Remove pump and inspect bottom
of hopper. Repair or replace hopper or
pump mounting block as necessary.
Pump
Rear Plate
o-ring
1. Remove seal from pump, inspect it
and replace it if worn or damaged.
Be sure there are no burrs or other
sharp edges in the o-ring groove or on
installation tools that could damage
a new seal.
Page 7-16
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 8-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 8
DISASSEMBLY & RE-ASSEMBLY PROCEDURES
Disassembly Procedures
Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All
dissassembly procedures must be performed by qualified, trained technicians.
When needed, cross-reference the exploded-view component drawings in Chapter 10 with each procedure in addition to the instructions and illustrations given in this chapter. Read the
“Cautions” on page 8-7 before re-assembling the ASU.
Pump & electronics cover
To Remove the Pump & Electronics Cover
(See illustration on page 10-7)
1. Loosen the four captive screws (two on each
side) along the bottom of the pump and electronics cover.
2. Lift the cover straight up and out of its slots
in the base.
Captive screw
To Remove the Hopper Cover
(See illustration on page 10-7)
1. Loosen the two captive screws along the
bottom of the hopper cover.
2. Remove the access cover screw, then lift the
access cover out of its slots in the base.
3. Remove the screw that attaches to the heat
shield.
4. Remove the two screws that attach the back
panel to the hopper cover.
5. Lift the hopper cover up and out of its slots
in the base.
Hopper cover
Pump access cover
Captive screw
Page 8-2
Revised 7/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
To Remove the Hopper Lid
(See illustration on page 10-7)
1. Remove the four flat head screws which are
located one on each side of the lid base.
2. Pull the lid up to remove.
a. Lid Seal Replacement: The lid seal (oring) is located inside the lid base.
1. Remove the old seal, which rests against the
top of the hopper.
2. Install the new seal into the groove provided.
Lid
Lid base
Lid seal
Thermostat Replacement
(See illustration on pages 10-7.)
1. Remove the access cover screw.
2. Lift the access cover out of its slots in the
base.
Sensor
Overtemp Thermostat Replacement:
1. Remove the two screws and slip the terminals and the hopper ground wire off of the
thermostat.
2. Remove the thermostat from the base of the
hopper.
3. Install new thermostat with two secrews and
re-install the terminals and hopper ground
wire.
RTD Sensor Replacement
Overtemp
Thermostat
(See illustration on page 10-11)
1. Remove the pump and electronics cover. The RTD sensor is centered between the cast-in heaters on the base of the hopper.
2. Slip the sensor out of its adapter.
3. Unplug the sensor wires from pins 1 and 2 at X4 on the Control PCB (see PCB illustration on
page 7-2).
Page 8-3
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
To Access the Electrical Components
(See also illustrations on pages 10-3 & 8-2)
Remove the pump and electronics cover.
a. Main On/ Off Switch Replacement:
Note: there are two main switches (pump
and ASU).
Switches are located on the display panel.
1. From the back of the switch, free it by
squeezing it from either side.
2. Remove the switch through the back of the
panel.
3. Disconnect four color-coded plug-in leads
from the old switch and connect them to new
switch.
b. Fuse Replacement:
Note: Use fuses as specified on page 7-2.
i. Fuses on PC Board: (see also detailed
illustration on page 7-2 sizes and locations of
fuses). Note on PCB fuses: each temperature
zone is fused with two fuses, either one of
which can blow causing the zone to not heat.
c. Diode Replacement: The diode slides
onto a screw on the panel divider. Tighten
down the two screws.
Note: only the 100-120VAC ASU has a
diode.
d. Control (Keypad) Board Replacement:
1. Disconnect electrical connections to the
printed circuit board and main switch.
2. Remove the four screws in the control
board’s corners to remove the board.
Control (Keypad) Board
Pump
On/Off
Switch
ASU
On/Off
Switch
PC Board
Fuses
Diode (on 100-120
VAC model only)
Page 8-4
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
d. Printed Circuit Board Replacement:
Reference the manual section entitled “Handling Printed Circuit Boards” on page 7-1 before proceeding.
1. Disconnect the ground spade on the pcb’s mounting bracket.
2. Disconnect all electrical connections to the board.
3. Remove the two mounting bracket screws.
4. Lift the old pcb and mounting bracket from the ASU.
Note: Do not attempt to separate the pcb from its mounting bracket. It is all one assembly.
5. Place the new pcb and mounting bracket in the ASU.
6. Re-install the two mounting bracket screws.
7. Re-install the ground spade on mounting bracket.
8. Re-install electrical connectors onto the board (refer to pg. 7-2, if necessary).
Remove bracket screws (2)
Remove ground spade
Page 8-5
Revised 3/06
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
PUMP DISASSEMBLY WARNINGS
HOT SURFACE
If the pump is not operable but the heating system will function, raise the
temperature of the application system to the operating temperature to aid in the
pump disassembly process. Otherwise, a controlled heating method is
recommended to melt hardened hot melt adhesive. Never use a torch or an open
flame on any of the components of the application system.
HIGH VOLTAGE
Once the system is up to temperature, disconnect and lockout all incoming
power before proceeding.
HIGH PRESSURE
BEFORE PERFORMING ANY PUMP REPAIR, YOU MUST PURGE ALL ADHESIVE
AND PRESSURE FROM THE DYNAMINI SYSTEM. Position a heat-resistant
container under the filter manifold’s purge drain. Carefully loosen the purge
screw located in the port of the outlet filter manifold and allow adhesive and
pressure to escape. See page 6-2 for detailed instructions.
Disconnect airline from solenoid at the quick
disconnect fitting
To Access the Pump or Motor
(See illustrations on page 10-9 or 8-1)
Remove the pump and electronics cover.
a. Piston Pump Removal:
1. Turn OFF air pressure, then disconnect the
air line from the solenoid valve mounted on
the top of the airmotor.
2. Disconnect the two wires that run from the
solenoid to the circuit board.
3. Loosen set screw to drain excess glue from
filter manifold.
4. Remove the two socket head cap screws that
connect the filter manifold to the pump adapter.
5. Remove the three screws that hold the pump
to the pump adapter.
6. Remove the pump/ airmotor assembly from
the end of the unit.
7. To re-assemble: Replace three o-rings
between pump & pump adapter and filter manifold and pump adapter. Tighten the three
pump adapter screws to the pump. Torque
should be approximately 22.6 Nm (16.7 ft/lb)
at room temperature. With pump and hopper at
177°C (350°F), the maximum allowable torque
on pump assembly screws is 18.8 Nm (13.9
ft/lb). A Piston Pump Rebuild Kit is available.
Remove screws
to release piston
pump from
adapter.
Permanent
retaining
screw.
Loosen
set screw.
O-rings
Filter manifold
Adhesive drains from below manifold.
Remove two screws to
release filter manifold.
Piston Pump
Page 8-6
Revised 6/10
b. Gear Pump and Motor Removal:
1. Disconnect the motor’s electrical cable
from the ASU by unplugging it at the circuit
board
2. Remove the bolts and lockwashers which
connect the motor to the base of the unit.
3. Remove the two set screws located in the
coupling.
4. Loosen the coupling and lift out the motor.
5. To replace the gear pump, remove the four
nuts and lockwashers that hold the pump to
the pump adapter block.
6. Disconnect the coupling.
7. Remove the pump assembly from the end
of the unit.
8. For re-assembly: slide new pump onto the
four studs. Tighten the four nuts to secure the
pump. Torque should be approximately 40.7
Nm (30 ft/lb) at room temperature. With
pump and hopper at 177°C (350°F), the maximum allowable torque on these nuts is 33.9
Nm (25 ft/lb).
c. Gear Pump Seal (O-ring) Replacement:
1. Remove the pump from the ASU (see instructions above, “a” or “b”).
2. Remove the external pump seal (PN
069X064) from its groove on the back of the
pump adapter plate (this is the seal located
between the adapter plate and the hopper).
Reference the pump exploded-view illustration in Chapter 10 for your specific pump.
3. Install the new seal.
d. Gear Pump Shaft Seal Replacement:
Remove the shaft key and the four socket
head cap screws holding the seal retainer
plate. The seal (069X061) is located between
the retainer plate and the front plate assembly.
Note on the Cast-in Heaters
(See illustration on page 10-11)
The cast-in heaters installed in the base of the
hopper are not replaceable and will last the
life of the ASU.
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Disconnect from terminal rail.
Capacitor
Motor bracket screws
Remove set
screws to loosen
coupling.
Retainer plate
Front plate
assembly
O-ring
069X064
Motor mount
bracket
Shaft Seal
Shaft Key
Remove nuts to
release pump
from adapter.
Gear Pump
7
Capacitor
RED
BROWN
ORANGE
BLACK
WHITE
BLUE (120v)
BLUE (240v)
JUMPER (120v)
3
240vac: Blue Wire in
Terminal Block, No
other Jumpers used.
120vac: Blue Wire in
Capacitor, Jumper
between Terminal
Blocks.
Gear Motor Wiring Diagram
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 8-7
Revised 1/05
Re-Assembly Procedures
Unless noted, the ASU’s re-assembly is simply the reverse sequence of the disassembly procedures.
However, the following “cautions” should be followed (whenever they apply) for proper re-assembly:
CAUTION: In general, all O-RINGS AND SEALS must be replaced whenever
hot-melt equipment is re-assembled. All new o-rings must be lubricated with
o-ring lube (PN N07588).
CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the
pump air supply and on the outlet filter manifold. Apply thread sealant (PN
N02892) whenever tapered pipe threaded parts are re-assembled.
CAUTION: SOME FITTINGS used for adhesive on the ASU have straight threads
and o-ring seals. Use of thread sealant is not necessary with these parts, but the
o-ring seals should be clean and lubricated. Tighten straight-threaded parts and
fittings until their shoulders are firmly seated. Excessive torque may damage
straight-threaded parts and the use of power wrenches is not recommended.
CAUTION: HOT-MELT RESIDUE must 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 must be re-tightened at
operating temperature.
Page 8-8
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 9-1
Revised 7/09
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 9
AVAILABLE OPTIONS & ACCESSORIES
Pressure Gauge Kit: PN 101175
An optional analog pressure gauge can be mounted on the outlet filter manifold. Reading the
adhesive pressure at the manifold, rather than in-line on a hose, allows for more precise monitoring
of system pressure. It is also useful for troubleshooting and maintenance.
The gauge is installed at one of the adhesive ports on the manifold (see illustration on page 3-5).
There is no “dedicated” port for the gauge, any one of the three ports on the manifold may be used.
Fittings are included in the kit.
Filter Option:
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 Dynamini is a 100 mesh filter (PN 101247).
Pump Options and Accessories:
12:1 Piston Pump: PN 105072 (120v) or 105073 (240v)
The ASU is available with a constant-pressure, air-operated piston pump. It provides smooth output
pressure and insures a high pressure adhesive output from a low pressure, compressed air input. A
piston pump is superior for intermittent applications which require no volumetric control.
Piston Pump Repair Kit: PN 105328
The Piston Pump Repair Kit contains the following items needed to rebuild the 12:1 piston pump:
PN
Description
Qty.
PN
Description
Qty.
L16569
108772
108700
N01703
N01618
N07121
Bearing & Shaft Seal Kit
O-ring, Adapter Plate
Lube, Seal, 1/4 oz.
Fitting
Fitting
Ring, Seal, 111
1
1
1
3
1
1
N00183
N01614
N00190
N01702
N00187
069X270
O-ring, 016
O-ring, 910
O-ring, 024
O-ring, 904
O-ring, 020
O-ring, 025
1
1
1
3
1
1
Piston Pump Rebuild Kit: PN 109969
This kit contains a PN 105328 Pump Repair Kit, a PN 109968 Pump & Airmotor Seals Kit, a
L16534 Pump Shaft, a L21189 Inlet Check Valve Assembly and a L21188 Outlet Check Valve
Assembly.
Piston Pump Bearing and Shaft Seal Kit: PN L16569
This kit contains all items needed to replace the piston pump’s shaft seal and bearing, including
seals, o-ring, pump shaft bearing and retaining ring. A seal pedestal and o-ring lubricant are also
included.
Page 9-2
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Gear Pumps
For higher tolerances and precision, a choice of gear pumps is available for the Dynamini. Gear
pumps give better service for continuous applications or applications which require more control
over the volume of adhesive pumped. Gear pumps available are:
PN 109908: 0.55cc/rev single, standard accuracy, cast iron Gear Pump
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
Gear Pump Repair Kit: PN 103151
Contains the following items needed to repair the PN 100860, 100861 and 100862, and the 109908
gear pumps:
PN
Description
Qty.
PN
Description
Qty.
N00198
018X031
069X061
O-ring
Ball Bearing
Pump Shaft Seal
2
5
1
069X064
078F017
078I001
O-ring
Ring, Clip
Key, Woodruff
3
4
1
Capacitor Kit: PN 106063
Consists of the following items for the 1/4 HP motor (PN 103020): capacitor, clamp, boot, screw,
installation instructions and wiring diagram.
Motor Seal & Gasket Kit: PN 106370
Consists of the following items for the 1/4 HP motor (PN 103020): output seal, input seal and
gasket.
Troubleshooting Job Aide
A set of six 8.5” x 5.5” illustrated, laminated cards (12 pages front and back) which attach to the
ASU and are used for troubleshooting the Dynamini.
Stand Assembly: PN 111243
This static Stand Assembly comes pre-drilled with front and back mounting plates for the installation of customer-selected auxiliary controls. Designed with square holes for carriage bolts that allow for one-wrench assembly. Assembly instructions enclosed.
Swirl Kits
A swirl kit is needed for the addition of one or two handheld applicator(s) to the system.
PN 111892: Dynamini Swirl Kit, Single 120V
PN 111893: Dynamini Swirl Kit, Dual 120V
PN 111894: Dynamini Swirl Kit, Single 240V
PN 111895: Dynamini Swirl Kit, Dual 240V
Page 9-3
Revised 10/8
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Recommended Service Parts List
Category
Part No.
Description
Qty.
Electrical:
111668
108566
102762
102763
105279
104166
105032
Printed Circuit Board w. heat sink
Fuse, 6.3 A/ Super Fst 5x20 (on pc board)
Fuse, 1 amp, 5x20, fast
Fuse, 5 amp, 5x20 (on pc board)
RTD Sensor, PT 100
Over-Temperature Thermostat
Diode (120VAC model only)
1
10
5
5
1
1
1
Filters:
101246
101247
103041
Filter Basket, 40 mesh/ 420 micron (optional)
Filter Basket, 100 mesh/ 149 micron
Hopper Filter
2
2
1
Misc:
069X058
N00181
N00188
N00191
069X270
N00196
L15653
N07588
114852
O-ring 028 (filter plug)
O-ring 014 (outlet filter manifold)
O-ring 022
O-ring 027
O-ring 024
O-ring 111 (for optional pressure gauge)
Kit, Flushing Fluid, 1 gallon
O-ring Lubricant
Hopper Collar Gasket
1
3
1
1
1
1
1
2
1
Kits:
L16569
105328
109969
103151
109982
106063
Piston Pump Bearing & Shaft Seal Kit
Piston Pump Repair Kit
Piston Pump Rebuild Kit
Gear Pump Repair Kit
Pressure Relief Valve Repair Kit
Capacitor Kit (motor)
1
1
1
1
1
1
Page 9-4
Revised 1/05
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 10-1
Revised 3/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 10
COMPONENT ILLUSTRATIONS & BILLS OF MATERIAL
WARNING
All parts must be periodically inspected and replaced if worn or broken. Failure
to do this can affect equipment’s operation and can result in personal injury.
Chapter Format
This chapter contains the component illustrations (exploded-view drawings) for each assembly of
the DYNAMINI ASU. These drawings are useful for finding part numbers as well as for use when
maintaining or repairing the unit.
Note: most common nuts, bolts and fasteners can be obtained locally at your hardware store. Specialty fasteners are available by contacting Dynatec’s Customer Service.
Page 10-2 Component Illustrations & BOM’s
Revised 11/10
c. 2004
DYNAMINI ASU Manual #20-25
Bill of Materials for DYNAMINI Electrical Panel Assembly
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Part Number
102241
102240
102239
102246
105032
111668
111660
111678
108297
105562
108745
105113
111677
106157
111363
107391
108566
102762
102763
105164
105199
102245
112676
103537
110747
Description
Front Cover End (part of 111669 Front Panel Assy.)
Back Cover End
Base, DYNAMINI
Panel Divider
Diode (120V models only)
Printed Circuit Board/ Heat Sink Assembly
Receptacle And Wiring Harness (240V)
Receptacle And Wiring Harness (120V)
M8-10 x 20mm Hex Flange Screw
Ground Lug
Screw Ground Spade
M4 X 8mm SHC Screw
Ground Spade Assy.
Lock Washer, Int. Tooth
Control Panel (of 111669 Front Panel Assy.)
Hex Nut
Fuse, PCB, 6.3 amp
Fuse 1 amp Fast
Fuse, 5 amp, 5 x 20, Slow
Washer, #8
Straight Conduit Fitting
Heat Shield
Terminal Block
M3 x 16mm SHC Screw
Switch, Rocker, DPDT, Sealed
Qty.
1
1
1
1
1
1
2
2
2
2
2
18
1
10
1
7
10
1
2
2
1
1\1
1
2
2
Component Illustrations & BOM’s Page 10-3
Revised 5/10
c.2004
DYNAMINI ASU Manual #20-25
13
4
11
5
14
21
15
12
10
24
1
22
23
8
17
6
16
18
3
9
13
19
11
11
20
11
7
2
Component Illustration: DYNAMINI Electrical Panel Assembly
Page 10-4 Component Illustrations & BOM’s
Revised 1/11
c. 2004
DYNAMINI ASU Manual #20-25
21
5
23
26
21
22
19
17
22
16
10
15
3
to air
filter kit
26
13
10
3
8
14
25
12
9
21
4
7
6
1
24
11
5
20
18
3
26A
2
26B
Piston Pump
Assembly
Piston Pump & Air Motor Assembly PN 105072 (120V) & PN 105073 (240V)
Item
1
2
3*
4*
5*
6
7*
8
9
10
11
12
13
14*
15
16*
17*
18
19
20
21
22
23
24
25
26*
26A
26B
Part Number
109970
NPN
NPN
NPN
108379
NPN
NPN
NPN
105726
NPN
104437
106931
109953
NPN
L16534
N06918
N01739
110213
030B108
104479
104101
14
Description
Air Motor Assembly (replaces PN 105070)
2” Pump Piston
2” Piston Seal 60030-4238
2” Wear Strip 60624
Valve Gasket
2” Strke Pump Tube
Pump Gasket A01046-02 (old-style pump only)
Mounting Flange A01046-11
Mounting Flange with Float Seal
O--ring, -224
Valve
Valve Manifold
Pump Shaft (Pump Shaft Old, 105070 Assembly)
Gasket Air Motor Cap
Piston, Pump Shaft
Belleville Washer, 1/4
1/4-20 x .50 HHC Screw
Solenoid Nipple
Breathing Vent
Solenoid, 120v (included in PN 105072)
Solenoid, 240v (included in PN 105073)
O-ring, -011
N06913
O-ring, -118
NPN*
Seal, Rod Wiper ,.625 Viton
072X098
Street Elbow, 1/8 NPT
N06436
Elbow, 1/4 tube, Push-in x 1/8
L16569
Seal And Bearing Assembly
115497
1/8 NPT Street Tee
N06506
Airline Plug (used only on ASUs equipped with mechanical pressure relief valve)
Note:*These items are included in Piston Pump Rebuild Kit 109969 (replaces 105330**)
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
cont.
c. 2004
DYNAMINI ASU Manual #20-25
Component Illustrations & BOM’s Page 10-5
Revised 1/11
39
44
43
42
29
40
30
33
41
29
30
32
34
31
40
28
27
29
30
17
45
16
15
47
46
51
48
49
47
45
Piston Pump & Air Motor Assembly #105072 (cont.)
Item
27 *
28
29 *
30 *
31
32 *
33 *
34 *
35 *
36
37
38
39 *
40
41 *
42
43 *
44
45
46
47
48
49
50
Part Number
109970
N00183
102243
N01703
N01702
100344
N01614
N00190
N01618
L16543
L16534
N06918
N00723
069X270
101156
L21188
N07121
L21189
N00187
N07677
100380
N06430
105113
101888
N01067
Note:
Description
Qty.
Air Motor Assembly
1
O-ring, -016
1
Piston Pump Mounting Block
1
Plug Fitting
3
O-ring , -904
3
Piston Pump Body
1
O-ring, -910
1
O-ring, #-024
1
Plug Fitting
1
Pump Shaft
1
Piston, Pump Shaft
1
Bellevue Washer, 1/4
1
1/4-20 x .50 HHC Screw
1
O-ring, -025
1
M6 x 20 SHC Screw (Note: torque to 90 in/lbs (10nm))
8
Outlet Check Valve, Service Assembly (available as an assembly only)
1
O-ring, -111
1
Inlet Check Valve Assembly (available as an assembly only)
1
O-ring, -020
1
Fittings For Coalescing Air Filter
1
TFE Tubing, .250 Diameter
2.5’
Filter Assembly
1
Brass Male Connect Fitting
1
M4 x 8 SHC Screw
2
Air Block
1
Brass Nipple
2
*These items are included in Piston Pump Rebuild Kit 109969 (replaces 105330)
c. 2004
DYNAMINI ASU Manual #20-25
Page 10-6 Component Illustrations & BOM’s
Revised 2/10
Bill of Materials for DYNAMINI Cabinet Assembly
Item No.
Part Number
18
Qty.
1
102241
Front Cover End
1
2
102240
Rear Cover End
1
3
102242
Hopper Cover (Model 05, 5 Kg / 11 lb)
1
103242
Hopper Cover (Model 10, 10 Kg / 20 lb) (not shown)
1
4
102245
Heat Shield
1
5
105113
M4 x 8mm SHC Screw (keypad panel)
2
6
102239
Base, DYNAMINI
1
7
102247
Pump and Electrical Cover
1
8
102911
Access Cover
1
9
115051
M4 x 6mm Flat Head Screw
4
10
106157
Lock Washer, M4, Int. Tooth
2
11
105164
Washer, #8, Flat
10
Hopper Collar Gasket (included in Lid Assembly)
1
12
18
Description
13
102614
Cover, Hose, Single Filter
1
14
105113
M4 x 8mm SHC Screw
6
15
102246
Panel Mount
1
16
103289
Lid Assembly (available as an assembly only)
1
17
106198
Lock Washer, M4.2, M7.6, .9, SS
2
Component Illustrations & BOM’s Page 10-7
Revised 2/10
c. 2004
DYNAMINI ASU Manual #20-25
1
7
16
4
10
12
9
15
3
6
14
11
11
17
2
5
14
8
13
11
14
Component Illustration: DYNAMINI Cabinet Assembly
Page 10-8 Component Illustrations & BOM’s
Revised 4/10
c. 2004
DYNAMINI ASU Manual #20-25
Bill of Materials for DYNAMINI Drive Section
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part Number
102244
102243
102615
105072
105073
102591
103241
102584
102239
109537
114969
114809
locally available
locally available
L00006
103020
L00475
105126
105061
104570
069X270
N00188
105135
104530
100475
106157
105113
105166
105167
104073
104158
102998
N00191
N00688
locally available
locally available
Description
Gear Pump Mounting Block
Piston Pump Mounting Block
Spacer
Piston Pump Assembly, 120v
Piston Pump Assembly, 240v
Hopper, Model 05, 5 kg / 11 lb
Hopper, Model 10, 10 kg / 20 lb
Filter and Pressure Relief Section (reference melt section for details)
Pump (reference your order for specific part number)
Coupling
Base
M6 x 16mm Screw, Hex Flange Head
Motor Bracket Assembly
Motor Bracket
Screw, SHC, M6x1.0x25 SST (adjusting screw)
Nut, M6x1.0, Hex SST
Spacer (used w/ alum. block for piston pump)
Motor, 1/4 HP, 115/230, 90rpm
Spacer
M8 Lock Nut
M8 x 50 Stud
M8 x 150mm, Stud
O-ring, #-024
O-ring, #-022
Ceramic Spacer
Aluminum Spacer
Washer, Insulating
Lock Washer, M4, Int. Tooth
Screw, SHC Screw, M4 x 8mm
Heat Transfer Block
M3 Set Screw
M10 x 105 Stud
M10 Flange Nut
Heat Transfer Plate, Piston Pump (option)
O-ring, #-027
Flat Washer
Nut, M6x1.0, KEPS
Washer, 9/32 x 5/8 x 1/16, steel
Qty.
1
1
2
1
1
1
1
1
1
1
1
4
1
1
4
4
1
1
4
4
4
2
1
1
4
1
4
1
1
1
2
4
4
1
1
4
4
4
Component Illustrations & BOM’s Page 10-9
Revised 4/09
c. 2004
DYNAMINI ASU Manual #20-25
30
19
1
3
4
Piston Pump Option
13
14
22
20
1
26
11
9
27
31
5
12
10
7
6
29
34
28
33
17
2
21
25
24
8
12
Component Illustration: DYNAMINI Drive Section
15
16
32 16 23
18
c. 2004
DYNAMINI ASU Manual #20-25
Page 10-10 Component Illustrations & BOM’s
Revised 2/11
Bill of Materials for DYNAMINI Filter And Melt Section
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Part Number
102591
103241
104166
105279
not replaceable
103041
No Part Number
No Part Number
No Part Number
102411
111670
104852
101833
101840
105110
N00181
101624
102236
101625
101247
101246
069X058
006C024
N00754
101175
101174
104325
103330
101624
N07830
102987
L07348
Description
Hopper (Model 05, 5 Kg/ 11 lb)
Hopper (Model 10, (10 Kg/ 20 lb)
Mechanical Overtemp Thermostat Assembly
Temperature Sensor, RTD, PT 100
Cast-In Heater
Hopper Filter
Nut, M4
Washer, M4
Porcelain Spacer
Cap,Hi Temp, .60 ID x 1.5L
Filter Manifold Assembly
Drain Plug
10-32 x 1/2 Tamper Proof Retaining Screw
Pressure Relief Valve
M8 x 55 SHC Screw
O-ring, -014
BSP Hose Fitting x # 6 JIC
Manifold Output Filter
1/4-18 BSP Plug
Filter Basket, 100 mesh/ 149 micron
Filter Basket, 40 mesh/ 420 micron (option)
O-ring, -028
Filter Nut
Flush Plug
Pressure Gauge Assembly (Option)
Pressure Gauge (option)
Fitting Adapter, #6 x 1/4 NPT (option)
Fitting, Adapter, 1/4 BSPP x 1/4 NPT
Fitting, Adapter, #6 JIC x 1/4 BSPP (includes N00196 O-ring)
Fitting, 90 deg., #6 JIC Male x #6 JIC Female
Insulator Cuff
Weir, Hopper, N05/N10 (piston pump only)
Qty.
1
1
1
1
4
1
8
8
4
2
1
1
1
1
2
3
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
Component Illustrations & BOM’s Page 10-11
Revise 7/09
c. 2004
DYNAMINI ASU Manual #20-25
5
Pressure Gauge
Assembly Option
28
22
1
23
23
9
24
3
25
25
26
27
4
7
6
8
20
19
2
18
12
14
21
14
16
21
13
15
24
Component Illustration: DYNAMINI Filter & Melt Section
17
14
10
11
Page 10-12 Component Illustrations & BOM’s
Revised 1/98 Rev. C Eng: JW
c.2004
DYNAMINI ASU Manual #20-25
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
Part Number
#100860 / #100861
Description
1
012D079 / 012D077
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100866
Front Plate Assembly
1
8
012D080 / 012D078
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Diameter ( See illustration for quantity)
2-4
10
012C020 / 012C019
Drive Gear,
2
11
069X064
Pump Seal
2
12
078F017
Shaft Retaining Ring
4
13
018X041
Bearing Sleeve, Rear Plate
2
14
100865
Rear Plate Assembly
1
15
100908
M4 x 25 SHC Screw
2
16
104158
M10 Flange Nut
4
17
104073
M10-1.5 x 105 All Thread
4
Item No.
/ 100867
Qty.
Component Illustrations & BOM’s Page 10-13
Rev. C Eng: JW Revised 1/98
c. 2004
DYNAMINI ASU Manual #20-25
Pump # 100860 has one bearing in this Shaft
Pump # 100861 has two bearing in this shaft
9
2
1
7
3
6
12
8
10
4
13
5
11
14
16
9
10
11
Pump # 100861 has two bearing in this Shaft
Pump # 100860 has one bearing in this shaft
15
17
Component Illustration: 1.54 cc / Rev, Single Gear Pump Assembly #100860
c. 2004
DYNAMINI ASU Manual #20-25
Page 10-14 Component Illustrations & BOM’s
Revised 12/97 Rev. C Eng: JW
Bill of Materials for 4.50 cc / Rev. , Single Gear Pump Assembly # 100862
Item No.
Description
Part Number
Qty.
1
012D072
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHC Screw
4
4
069X160
Seal Retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100868
Front Plate Assembly
1
8
012D073
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Diameter
4
10
012C018
Drive Gear, 4.5 cc/rev
2
11
069X064
Pump Seal
2
12
078F017
Shaft Retaining Ring
4
13
018X041
Bearing Sleeve, Rear Plate
2
14
100865
Rear Plate Assembly
1
15
100908
M4 x 25 SHC Screw
2
16
104158
M10 Flange Nut
4
17
104073
M10-1.5 x 105 All Thread
4
c. 2004
DYNAMINI ASU Manual #20-25
2
Component Illustrations & BOM’s Page 10-15
Rev. C Eng: JW Revised 12/97
9
1
7
3
6
12
8
10
4
5
13
11
14
16
9
10
11
15
17
Component Illustration: 4.50 cc / Rev, Single Gear Pump Assembly #100862
Page 10-16 Component Illustrations & BOM’s
Revised 6/02
c. 2004
DYNAMINI ASU Manual #20-25
Bill of Materials for 3.2 cc / Rev. , Dual Gear Pump Assembly # 100864
Part Number
Description
Qty.
1
012D088
Drive Shaft
1
2
078I001
Key, Woodruff
1
3
101626
M5 x 12 SHCS
4
4
069X160
Seal retainer & Bearing Housing
1
5
069X061
Lip Seal
1
6
018X041
Bearing Sleeve
2
7
100867
Front Plate Assembly
1
8
012D087
Driven Gear Shaft
1
9
018X031
Ball, 1/8” Dia.
5
10
012C019
Drive Gear, 3.2 cc/Rev
4
11
069X064
O-ring, -041
3
12
078F017
Shaft Retaining Ring
4
13
018X041
Bearing Sleeve, rear Plate
2
14
100865
Rear Plate Assembly
1
15
101691
M4 x 40 SHCS
2
16
104158
M10 Flange Nut
4
17
100870
Middle Plate
1
18
N00198
O-ring, -113
2
19
107749
M10-1.5 x 118 STUD
4
Item No.
Component Illustrations & BOM’s Page 10-17
Revised 8/00
c. 2004
DYNAMINI ASU Manual #20-25
9
2
1
7
3
6
12
8
11
10
4
17
5
18
16
10
13
11
14
9
10
10
11
15
19
Component Illustration: 3.2 cc / Rev, Dual Gear Pump Assembly #100864
Page 10-18 Component Illustrations & BOM’s
Revised 8/10
c. 2004
DYNAMINI ASU Manual #20-25
10
2
5
1
11
4
6
12
9
3
5
13
8
7
Bill of Materials for 10cc Single Gear Pump Assembly # 109690
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Number
018X031
078F017
078I001
069X061
069X064
108588
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
M4x25mm, Blk 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)
Qty.
6
4
1
1
2
2
4
1
1
2
1
1
1
Component Illustrations & BOM’s Page 10-19
Revised 11/02
c.2004
DYNAMINI ASU Manual #20-25
10
2
5
1
11
4
12
3
13
7
9
6
5
8
Bill of Materials for 0.55 cc Rev. Single Gear Pump Assembly # 109908
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Number
018X031
078F017
078I001
069X061
069X064
100908
101626
109906
100865
109907
012D079
012D080
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
Plate Front, .55cc/ Rev.
Rear Bearing Plate .55cc Rev.
Gear .55cc Rev
Drive Shaft 1.5cc Dual
Driven shaft, 1.5 cc Dual
Shaft seal retainer
Dow Corning 112 Lubricant (Not Shown)
Qty.
6
4
1
1
2
2
4
1
1
2
1
1
1
Page 10-20 Component Illustrations & BOM’s
Revised 11/02
c. 2004
DYNAMINI ASU Manual #20-25
5
2
12
11
12
1
13
4
6
5
14
5
3
9
10
8
15
7
Bill of Materials for 0.55cc/ Rev. Dual Gear Pump Assembly # 109909
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Part Number
Description
Qty.
018X031
078F017
078I001
069X061
069X064
101692
101626
109906
100865
109905
N00198
109907
012D083
012D082
069X160
001U002
Ball bearing, 1/8 Dia.
Snap ring, 1/2”
Key Woodruf, #404
Shaft Seal
O-ring, -041
M4-0.7 x 35mm SHC Screw
M5-0.8 x 12mm SHC Screw
Plate Front, .55cc/ Rev.
Rear Bearing Plate .55cc Rev.
Plate, Middle Gear, 0.55/ Rev.
O-ring, -113
Gear .55cc Rev
Drive Shaft 1.5 cc Dual
Driven Shaft, 1.5 cc Dual
Shaft Seal Retainer
Dow Corning 112 Lubricant (Not Shown)
6
4
1
1
2
2
4
1
1
1
2
4
1
1
1
Component Illustrations & BOM’s Page 10-21
Revised 1/11
c.2004
DYNAMINI ASU Manual #20-25
Optional Pneumatic Pressure Relief Valve
Item No.
Part Number
Description
*
* See detailed drawing on following pages.
Qty.
Page 10-22 Component Illustrations & BOM’s
Revised 1/11
c. 2004
DYNAMINI ASU Manual #20-25
Bill of Materials for PN 115540 Pneumatic Pressure Relief Valve
Item No. Part Number
Qty.
Description
Bill of Materials for PN 116326 Repair Kit for Pneumatic Pressure Relief Valve (PN 115540)
Item No. Part Number
Qty.
Description
c.2004
DYNAMINI ASU Manual #20-25
Component Illustrations & BOM’s Page 10-23
Revised 1/11
Component Illustration: PN 115540 Pneumatic Pressure Relief Valve
Page 10-24 Component Illustrations & BOM’s
Revised 1/11
c. 2004
DYNAMINI ASU Manual #20-25
Page 11-1
Revised 1/05
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Chapter 11
SYSTEM SCHEMATICS
& ENGINEERING DRAWINGS
Page 11-2
Revised 7/07
HOSE SCHEMATIC PN 101082 REV. G
ASU to Applicator
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 11-3
Revised 1/05
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
Revised 7/06
Item #12 = PN 112678 Dynamini Swirl
Kit Wire Group
SINGLE & DUAL SWIRL KITS PN 111892 REV. C
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
Page 11-5
Revised 1/07
Item #7 = PN 112684 Motor Enable
Kit Wire Group
Item #8 = PN 112685 2nd Relay Kit
Wire Group
SINGLE & DUAL MOTOR ENABLE KITS PN 112679 REV. B
Page 11-6
Revised 7/07
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions
ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25
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