Dynamelt M35 DCL - Astro Packaging, Inc.

Dynamelt M35 DCL - Astro Packaging, Inc.

ITW Dynatec

An Illinois Tool Works Company

31 Volunteer Drive

Hendersonville, TN 37075 USA

Telephone 615.824.3634

FAX 615.264.5222

ITW Dynatec GmbH

Industiestrasse 28

D-40822 Mettmann, Germany

Telephone 49.2104.915.0

FAX 49.210.2104.915.111

ITW Dynatec K.K.

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

Minata-Ku, Tokoyo 108 Japan

Telephone 81.3.3450.5901

FAX 81.3.3450.8405

Adhesive Application Solutions • ISO 9001 Certified

OPERATIONS & SERVICE MANUAL

Manual 20-36

Revised 9/15/07

DYNAMELT

®

M SERIES ADHESIVE SUPPLY UNIT

OPERATIONS AND SERVICE MANUAL

Model DM M35 DCL

Software V5.11M and up with Expanded DynaControl

For an online copy of this manual, go to www.itwdynatec.com/manuals.htm

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

Moving Forward Through Technology

Page ii

Revised 12/04 c. 2000

DYNAMELT M35 DCL ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36

Table of Contents Page iii

Revised 4/06

TABLE OF CONTENTS

Chapter 1 Safety Precautions

Chapter - Page #

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

High Temperatures

High Pressure

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

Eye Protection & Protective Clothing

Safe Installation and Operation

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

Treatment for Burns From Hot Melt Adhesives

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

Explosion/ Fire Hazard

Lockout/ Tagout

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1-2

1-2

1-2

1-3

1-1

1-1

1-1

1-1

1-3

1-3

Chapter 2 Description & Specifications

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

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

Installation Dimensions

Total System Wattage Capacity

Main Circuit Breaker Determination

Definition of ASU Code

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2-1

2-2

2-4

2-5

2-5

2-6

Chapter 3 Installation & Start Up

Placing the DYNAMELT ASU

To Open/ Close Panel Box Door

Installation

User Connections

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

Hose/ Head Electrical & Adhesive Connections (illustration)

3-1

3-2

3-2

3-3

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3-4

3-6

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

Adding Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Adhesive Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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Adjusting the Pressure Relief Valve

Pump Enable (Ready) Thermostat Calibration

Calibration of the Optional Voltage Tachometer

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Installation of the Optional Tach Generator or DC Tracking Signal

Calibration of the Optional Tach Generator or DC Tracking Signal

Level Control, Capacitive, Sensor with Amp

Typical Start Up and Shut Down Procedures

Storage and Disposal of the Application System

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3-7

3-7

3-7

3-8

3-10

3-11

3-12

3-13

3-14

3-15

3-16

Chapter 4 DynaControl Controller Set-Up

Temperature Control Functions in General

Defining DynaControl Temperature Control Terms

Error Indication and Alarms

Optional System Status Lights

Settings for a Typical Operation

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System Values that are Factory Programmed (not customer accessible)

Customer Programmable Values Preset at the Factory

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4-1

4-1

4-4

4-6

4-6

4-7

4-7

Page iv Table of Contents

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

Default Settings of the DynaControl Controller

Helpful Tips for the User

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

EtherNet/IP Adapter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8

4-9

4-10

4-13

Chapter 5 Programming of DynaControl Controller

Controller Safety Consideration

Software Version

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Display & Keypad Reference

Basic Programming Sequence: Quick Reference

Controller Setup

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Turning the Controller On

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Language Selection

Actual Temperatures Screen

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Temperature Scale Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Use of the Actual Temperatures Screen

Programming Sequence

Monitoring

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Setpoints Programming Screen

Use of the Setpoints Programming Screen

Programming

Monitoring

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Motor Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of the Motor Programming Screen

Programming

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

Optional Clutch Programming Screen

Use of the Optional Clutch Programming Screen

Programming

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Monitoring

Monitoring

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Optional Pressure (PSI/BAR) Programming Screen

Programming

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

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Service Functions Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High/ Low Temperature Deviation

Standby Temperature

Standby/ Sleep Setup

Setpoint Limitation

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Temperature Offset

Sequential Heating

Temperature Scale

Service Page 2

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Power On Configuration

Factory Defaults

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Change Security Lock

Customer Zone Names

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Keypad Locking

PC Link

Language

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5-13

5-13

5-15

5-15

5-15

5-16

5-11

5-11

5-11

5-12

5-13

5-13

5-16

5-17

5-17

5-17

5-17

5-5

5-5

5-6

5-6

5-7

5-7

5-1

5-1

5-2

5-4

5-5

5-5

5-8

5-9

5-9

5-9

5-10

5-18

5-18

5-18

5-18

5-19

5-19

5-19

5-20

5-20

5-20

5-20

c. 2000

DYNAMELT M ASU Manual 20-36

Table of Contents Page v

Revised 4/06

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

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

Change Security Lock

Service Page 3

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Programming at Main Scheduler Screen

Use of the Main Scheduler Screen

Programming of 7-Day Scheduler

Use of the 7-Day Scheduler Screen

Programming

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

5-20

5-20

5-20

5-21

5-22

5-23

5-24

5-25

5-25

5-26

Chapter 6 Preventive Maintenence

General Cleaning

Preventive Maintenance Schedule

Outlet Filter

Outlet Filter Manifold (illustration)

Hose Fittings

Fasteners

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Filter Shutoff Cleaning or Replacement

Pump Shaft Leak

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

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

Summary of Preventive Manintenance Schedule

Flushing the System

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

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

6-3

6-3

6-3

6-4

6-1

6-1

6-1

6-2

6-4

6-5

Chapter 7 Troubleshooting

General Troubleshooting Notes

Preliminary Checks

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

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

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose/ Applicator Troubleshooting Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Motor Speed Control PC Board Re-set

High-Temperature Redundant Overtemp Thermostat

Pump Enable Thermostat

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

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

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

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

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

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

Motor Control Interface Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Motor Speed Control Printed Circuit Board & Layout Illustration

48-Zone Power Printed Circuit Board & Layout Illustration

Optional Clutch Printed Circuit Board & Layout Illustration

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

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

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

Optional Pressure (PSI) Printed Circuit Board & Layout Illustration

Heater and Sensor Resistance Values

Resistance Tables

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

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

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

Error Indication Alarm Troubleshooting Guide

Adjustable Adhesive Pressure Relief Valve

Operation of the ASU’s Gear Pump

Troubleshooting the ASU Pump

Gear Pump Troubleshooting Guide

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

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

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

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

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

7-3

7-4

7-5

7-6

7-7

7-9

7-10

7-10

7-1

7-2

7-2

7-2

7-1

7-1

7-1

7-1

7-11

7-12

7-13

7-14

7-22

7-23

7-24

7-25

Page vi Table of Contents

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

Chapter 8 Disassembly & Re-assembly Procedures

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

To Remove the Access Doors

To Open the Junction Box

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

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

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

To Remove the Manifold Cover

Heater Replacement

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

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

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

To Access the Electrical Components Inside the Panel Box

Fuse Replacement

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

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

Printed Circuit Board Replacement

To Access the Pump or Motor

Motor Removal

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

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

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

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

8-2

8-2

8-2

8-3

8-3

8-1

8-1

8-1

8-2

8-3

8-4

8-4

8-5

8-5

8-5

Chapter 9 Available Options & Accessories

Pressure Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-PSI and Post-PSI Transducers

Drop-in Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Temperature Heater Groups

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

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

Filter Options & Accessories

Level Control

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

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

Pump Options & Accessories

Gear Motor Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return (Re-circulating) Hoses

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

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

Electric Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

9-2

9-2

9-3

9-3

9-3

9-5

9-1

9-1

9-1

9-1

9-1

9-1

Chapter 10 Component Illustrations & Bills of Material

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

Pressure Relief & High Temperature FIlter Block Assembly

Typical Electrical Panel Box Assembly

Cabinet Assembly

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

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

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

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

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

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

Pump Adapter Assemblies

Pressure Gauge Kit

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

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

10-1

10-2

10-4

10-8

10-10

10-12

10-14

10-22

10-24

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

c. 2000

DYNAMELT M ASU Manual 20-36

Table of Contents Page vii

Revised 4/06

Chapter 11 System Schematics & Engineering Drawings

Hose Schematic: all models

Head Schematic: all models

Optional System Status Lights

Optional Level Control

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

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

Flow Diagram, Outlet Filter Manifold/ Cross Channel

Typical Hydraulic Schematic

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

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

Optional Electric Clutch

Grounding Diagram

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

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

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

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

Power Wiring Diagram, 240v

Signal Wiring Diagram, 4Hose/4 Head, 240v

Power Wiring Diagram, 380v

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

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

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

Instruction Sheet for Pump & Zone Configuration

Special Dynamelt M ASU Schematics

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

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

11-2

11-3

11-4

11-5

11-5

11-6

11-7

11-8

11-9

11-10

11-12

11-13 end of chapter

Appendix

Optional Dynatec/ Zenith Standard Accuracy Gear Pumps

Optional Dynatec/ Zenith High Accuracy Gear Pumps

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

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

Optional Zenith Melt Spinning Pumps

High Accuracy Pump Performance Chart

Pressure Transducer

Electric Clutch

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

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

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

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

Optional TSHA Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix 1

Appendix 15

Appendix 28

Appendix 34

Appendix 35

Appendix 37

Appendix 39

Page viii Table of Contents

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

ITW Dynatec c. 1997

ALL MODELS

Page 1-1

Revised 1/07

Chapter 1

SAFETY PRECAUTIONS

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

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

High Temperatures

WARNING

HOT

SURFACE

power is on. Disconnect, lockout and tag external electrical power before removing protective panels.

A secure connection to a reliable earth ground is essential for safe operation.

A disconnect switch with lockout capability must be provided in the line ahead of the unit. Wiring used to supply electrical power should be installed by a qualified electrician.

Severe burns can occur if unprotected skin comes in contact with molten adhesive or hot application system parts.

Safety glasses, gloves and long- sleeved clothing must be worn whenever working with or around adhesive application systems.

High Pressure

WARNING

HIGH PRESSURE

PRESENT

To avoid personal injury, do not operate the equipment 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

Protective Covers

WARNING

DO NOT OPERATE

WITHOUT GUARDS

IN PLACE

ITW Dynatec c. 1997

ALL MODELS

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

Wear safety glasses with side shields which conform to

ANSI Z87.1 or EN166.

Failure to wear safety glasses could result in severe eye injury.

It is important to protect yourself from potential burns when working around hot melt adhesive equipment.

Wear protective gloves and long-sleeved, protective clothing to prevent burns that could result from contact with hot material or hot components.

Always wear steel-reinforced safety shoes.

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

Safe Installation and Operation

To avoid possible failure of hoses, make sure all hoses are routed to avoid kinking, tight radius turns (8” or less) and abrasive contact. Hot-melt hoses should not have prolonged contact with heat-absorbing surfaces such as cold floors or metal troughs. These heat-absorbing surfaces can alter adhesive flow and cause incorrect calibration. Hoses should never be covered with materials that prevent heat dissipation, such as insulation or sheathing.

Read this manual before applying electrical power to the equipment. Equipment may be damaged by incorrect electrical connections.

Do not use adhesive that is dirty or that may be chemically contaminated. Doing so can cause system clogging and pump damage.

When adhesive hand-held applicators or other movable applicators are used, never point them at yourself or at any other person. Never leave a hand-held applicator’s trigger unlocked when not actually in use.

Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C (300 degrees F) or more.

To do so will cause charring of the residual adhesive.

Never activate the heads, hand-held applicators and/ or other application devices until the adhesive’s temperature is within the operating range. Severe damage could result to internal parts and seals.

Treatment for Burns From Hot Melt Adhesives

Burns caused by hot melt adhesive must be treated at a burn center.

Care should be used when working with hot melt adhesives in the molten state. Because they rapidly solidify, they present a unique hazard.

Even when first solidified, they are still hot and can cause severe burns. When working near a hot melt application system, always wear safety gloves, safety glasses and long-sleeved, protective clothing.

ITW Dynatec c. 1997

ALL MODELS

Page 1-3

Revised 1/07

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

Always have first-aid information and supplies available.

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 c. 1997

ALL MODELS

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36

Description & Specifications Page 2-1

Revised 10/00

Chapter 2

DESCRIPTION AND SPECIFICATIONS

Description

The DYNAMELT

Ò

M Series adhesive supply units (ASU) are computer-controlled hot-melt supply units designed on metric standards. Their control panels, with choice of display languages, provide comparative data of all setpoints, motors, etc. on a few convenient, comprehensive display screens.

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

Dynamelt M 35 uses a microprocessor temperature control to closely control the temperature of hotmelt adhesive for up to 4 hoses and 4 heads. Temperature setpoints are operator-selected for up to

16 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions.

The Dynamelt/ DynaControl system provides accurate, proportionate temperature control for the hopper, hoses and applicators. Sequential heating delays may be programmed for turn-on of the hoses and heads. A “standby” temperature may be programmed so that the temperature zones can be maintained at a lower temperature when the ASU is not in active use, enabling rapid return to normal operation. The seven-day scheduler allows programmable automatic startup and shutdown of the ASU throughout the workweek.

With these flexible temperature programming features, the Dynamelt system increases adhesive life by eliminating prolonged high adhesive temperatures. It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time.

A four-layered, shielded CPU board protects the microprocessor from external interference. The temperature control can interlock the parent machine with preselected adhesive temperatures so that production automatically begins when adhesive temperatures are correct for the application. All system temperature values can easily and quickly be programmed. An optional remote control panel gives control and monitoring flexibility.

Digital readout of system conditions is provided. A security code can restrict access to system programming and parameters. The CPU monitors the electronic circuitry and provides alarms for error conditions.

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

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

Page 2-2 Description & Specifications

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36

Specifications

Environmental:

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

Ambient service temperature

Noise emission

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

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

-40 ° C to 70°C (-40° F to 158°F)

-7

° C to 50°C (20° F to 122°F)

< 60 dbA at 1 meter (39 inches)

Physical:

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

Number of heads/ hoses see dimensional layouts on following pages

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

1 to 4 heads/ hoses

Number of return hoses or auxillary zones

Number of hopper temperature zones

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

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

1 to 4

2 or 3 (add 1 for optional drop-in grid)

Number of pumps/ motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of standard drop-in grids

1 or 2

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

1

Number of (optional) drop-in grids

Gear pumps

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

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

1

2.92 cc/rev standard

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

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

Hopper (tank) capacity styled, durable metal,dust and splatter resistant universal 15-pin Amphenol connectors at asu, wrench-secured fluid fittings (#6 JIC)

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

35 kg/ 77 lb

Hopper construction

Filtration

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

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

machined welded aluminum, Teflon impregnated hopper bottom screen, large pleated pump outlet filter

Weight of base unit, empty

Adhesive form

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

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

tbd accepts most forms

Electrical:

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

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

380-400 VAC/ 3p (“Wye”, “Y” or 5-wire connection)/ 50-60 Hz

Minimum supply amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power consumption: hopper and drop-in-grid see circuit breaker size

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

7500 watts

Hopper heater type

Temperature control

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

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

cast-in tubular microprocessor-based proportional integral derivitive (PID)

Temperature sensors

Electrical connectors

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

100 Ohm Platinum RTD standard

120 Ohm Nickel RTD optional

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

durable, latching connectors

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

1/4 hp, alternating current TEFC* motor, direct drive, horizontal orientation

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

10 ampere

* totally enclosed, fan cooled

c. 2000

DYNAMELT M ASU Manual 20-36

Description & Specifications Page 2-3

Revised 5/03

Performance:

Adhesive temperature control range

Standby adhesive temperature range

Hopper ready adhesive temperature deviation

(factory set/ field adjustable)

± 20°C (36°F) from setpoint

Over-temperature cutoff for hopper

Adhesive viscosity

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

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

40°C to 232°C (100°F to 450°F) up to 80°C (150°F) lower than setpoint

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

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

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

232°C (450°F)

500 to 50,000 centipoise approximately 0.5 hour

Typical adhesive melt rate (depends on adhesive used)

Adhesive pressure

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

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

18-65 kg/hr (40-143 lb/hr) up to 68 bar (1000 psi) maximum

DynaControl Temperature Control:

Controller power board

Display type

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

48 zones, modular construction

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

graphic, liquid crystal

Temperature control zones (DM35)

Power output

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

16 maximum with solid state relays

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

hopper: 5000 watt hose: 1200 applicator head: 1200 watt

Solid state relay

Line speed inputs auxiliary: 2000 watt

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

3-15 VDC

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

1 to 2

Other:

Display languages

Operator interface

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

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

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

Portugese and Dutch multi-zone, liquid crystal display with

Temperature standby alpha/numeric keyboard and function keys

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

yes

High and low temp alarms

Ready interlock

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

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

yes yes

Password protection

Sequential heating

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

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

yes yes (hopper, hose, head staged heating)

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

RS232 and RS485 communications capable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Speed Tracking

Seven-day scheduler

CE approval granted

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

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

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

yes yes yes yes yes

Page 2-4 Description & Specifications

Revised 11/02 c. 2000

DYNAMELT M ASU Manual 20-36

F

H

B

E

J

D

A

C

K

G

B

L

DIMENSION

mm inches

A B

863.60

560

34.00

22.05

C D E

800.10

1346.2 177.8

31.5

53.00

7.00

F G H J K

336.55 558.80

228.60

782.32 878

13.25

22.00

9.00

30.80

34.57

L

107.2

4.22

DYNAMELT M35 DCL Installation Dimensions

c. 2000

DYNAMELT M ASU Manual 20-36

Total System Wattage Capacity

MAXIMUM WATTAGE

Hopper + High Temp Heater

Pre-Melt

Optional Drop-in Grid

Up to 4 Hose Zones

(1200 w each)

Up to 4 Applicator Zones

(1200 w each)

Up to 4 AUX Zones

(2000 w each)

Maximum System Wattage: 28,600 w

M35

6000 w

2500w

2500w

4800 w

4800 w

8000 w

Description & Specifications Page 2-5

Revised 10/00

Main Circuit Breaker Determination

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

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

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

Page 2-6 Description & Specifications

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

Definition of Code: DYNAMELT DM 35 ASU w. DynaControl Controller

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

M 3 5 D

N 1 G A S

/

1 Z L S 2

D 2

P 2

-F1 G C

Code PN Base Unit

35 106049 35kg (77 lb) Hopper

Code Power

2 240V/ 3P Delta/ no neutral

3 380V/ 3P Star/ neutral only

D DynaControl Controller

Code PN Grids

N n/a Standard

G 804634 Add Drop-in Grids

O n/a Omit Drop-in Grids

Motor/ Drive Groups (1/ pump)

# =Total number of drives

Drive Setup

# Drives # Front # Rear

1 drive

2 “

1

1

0

1

Code PN Panel Box Assembly

PA 806456 1 drive, 2 hose/ 2 head/ 2 auxilliary, 240v

PB 806457 1 drive, 2 hose/ 2 head/ 2 auxilliary, 380v

PC 806458 2 drive, 4 hose/ 4 head/ 4 auxilliary, 240v

PD 806459 2 drive, 4 hose/ 4 head/ 4 auxilliary, 380v

Qty.

Code PN Pump(s)

# = Quantity of each Type of Pump

GAS 100860 Dynatec 1.54cc single

GBS 100861 Dynatec 3.18cc single

GCS 100862 Dynatec 4.5cc single

GAD 100863 Dynatec 1.54cc dual

GBD 100864 Dynatec 3.18cc dual

ZLS 084E372 Zenith 0.160cc single

ZDS 084E428 Zenith 0.297cc single

ZES 084E374 Zenith 0.584cc single

ZFS 084E430 Zenith 1.168 single

ZGS 084E434 Zenith 2.92cc single

SHS 108875 S&P 8.5cc single

ZLD 084E387 Zenith 0.160cc dual

ZDD 084E388 Zenith 0.297cc dual

ZED 084E 389 Zenith 0.584cc dual

ZFD 084E432 Zenith 1.168 dual

SGD 108874 S&P 2.92cc dual

SPC Special Pump (see sales order)

Code PN Options

D Digital Pressure Readout

E 107945 Electric Clutch Kit

Fx Filter Selection

F1 101246 40 mesh outlet filter

F2 101247 100 mesh outlet filter (Standard)

F3 106273 150 mesh outlet filter

G 805641 Analog Pressure Gauge Kit

K N06642 Signal Isolator

L 802886 One-Point Level Control Assy

P 107643 Remote Display Kit

Q 108475 RS232/485 Communication

R 108313 Digital RPM Readout

Y 108425 Handgun Trigger Kit

Z 106103 Drain Valve

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-1

Revised 4/01

Chapter 3

INSTALLATION

Placing the DYNAMELT M ASU

The DYNAMELT

Ò

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

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

Access

Door

Keylock

Controller Keypad

Main Disconnect

Switch

Hopper Lid

Panel Box

Keylock

Panel

Box

Panel Box

Manifold

Cover

The DYNAMELT M35 DCL ASU

Hose/ Head

Electrical

Connections

Page 3-2 Installation

Revised 4/01 c. 2000

DYNAMELT M ASU Manual 20-36

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

To Open/ Close Panel Box Door

“ON”

Position

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

“Reset”

Position

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

3. Pull door open.

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

5. Lock the panel box door with the key.

Lockout Safety Tab

Installation

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

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

F

R

F

O

E

S

E

T

T

RI

P

ON

Main Disconnect Switch

DANGER HIGH VOLTAGE

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

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

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

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

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

cont.

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-3

Revised 6/01

3. At installation, the customer must make the following terminal connections into the ASU’s printed circuit boards (PCBs). The boards do not need to be removed from the ASU in order to make connections.

See the detailed layout on the next page for locations, and refer to the detailed layout drawings of the PCBs in Ch. 7, if needed.

Terminal Circuit Location

Required connections for standard 240 vac ASU:

PE

Input Power from Main Power 240vac

Ground

Main Power Switch/L1, L2, L3

Terminal rail

Required connections for 380 vac ASU:

N, PE

Input Power, from Main Power, 380 vac

Neutral, Ground

Main Power Switch/L1, L2, L3

Terminal rail

Non-essential connections; connect if feature is desired:

R1, R2

A1, A2

E1, E2

P1, P2

P3, P4

Normally Open Ready

(parent machine interlock)

External Standby

(controller standby mode)

Power PCB/ JS4/ pins 1 & 2 and

Power PCB/ JS2/ pins 1 & 2

Normally Closed Alarm

(controller display alarms)

CPU PCB/ X1/ pins 1 & 2

CPU/ X4/ connect 5 and 9 or 10

Program Select 1&2

(controller program selection)

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

Program Select 3&4

Power On Output

” ” ” CPU/ X4/ connect 7 to 9 or 10**

Power PCB/ JS1/ pins 1 & 2

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

S1, S2

H1, H2

Ribboncable

Tachometer

(line speed tracking)

Hand-Held Applicator, Footswitch

Low Adhesive Level

(output alarm)

Pressure Transducer(s)

(1 to 4 transducers)

Pressure Transducer(s) ( high & low psi alarms)

Clutch Customer Enable

(for motor 1)

Clutch Customer Enable

(for motor 2)

RS232/485 Communication

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

MCI*/ X3/ TR

CPU PCB/ X1/ pins 3 & 4

PSI PCB/ X1, X2, X3, X4

PSI PCB/ X6

Clutch PCB/ JS1/ pins 1 & 2

Clutch PCB/ JS1/ pins 3 & 4

Display CPU PCB

* MCI = Motor Control Interface PC Board

User Connections

** Program Selection Table

P1/P2

Pin 1

P3/P4

Pin 7

Program #

open open closed open

= Program 1

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

Page 3-4 Installation

Revised 6/01 c. 2000

DYNAMELT M ASU Manual 20-36

Printed Circuit Board Location Diagram

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

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

Motor Speed Control

Drive 1

Motor Speed Control

Drive 2

Neutral (for 380v only)

Fuse

Terminals

Ground

Terminals

Main Ground

(PE)Terminal

Side Panel

Level

Control

X3

Motor

Control interface 1

Motor

Control interface 2

RS232/485

Communication

Board

X1

X2

X3

X4

JS1

Pressure

Board

X6

X1

X4

Clutch

Board

CPU Board

JS1

JS4

JS2

Power Board

L1 L2 L3

Circuit

Breakers

L1 L2 L3

Main Circuit

Breaker

Contactor

Typical Panel Box Layout

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-5

Revised 4/01

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

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

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

“auxiliary” ports.

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

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

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

Transducers must be wired into the pressure printed circuit board.

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

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

Page 3-6 Installation

Revised 4/01 c. 2000

DYNAMELT M ASU Manual 20-36

Filter Nut

Hose/ Head

Electrical

Connections

A1

Auxiliary

#1

A2

Auxiliary

#2

F1

F2

#1

#2

Closeable Cross

Channel

Tamper Proof Screw

Bleed Valve Port

Retainer Plate

Purge Drain

Heater Channel

RTD Sensor Channel

Hose/ Head Electrical and Adhesive Connections

Electrical

A 1

A 2

Up to Two Filter Blocks with up to 8 Adhesive Ports

A 1 A 2

A 3 A 4

PSI 1 PSI 2

F 1 F 2

PSI 3 PSI 4

F 3 F 4

Electrical

A 3

A 4

F 1

F 3

F 2

Adhesive supplied by motor/pump #1

Adhesive supplied by motor/pump #2

F 4

Up to Two Filter Blocks with up to 8 Adhesive Ports

Note:

Always connect Auxiliary (Return)

Hose #1 (A1) to Auxiliary Electrical

Connect #1 (A1), Feed Hose #1

(F1) to Feed Electrical Connect #1

(F1), etc. as described on page 3-3.

Dynamelt M35: Electrical Connection and Filter Manifold Arrangement for Maximum

Head/ Hose Configuration

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-7

Revised 11/01

Adding Adhesive

The adhesive level in the melt tank should be maintained at 13mm to 100mm (1/2” to 4”) from the top of the hopper. Where applications demand a high output volume of adhesive, add small amounts of adhesive frequently. Adding large amounts of adhesive to an almost empty hopper will lower the temperature of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint.

Changing the Adhesive Formula

If a different adhesive formulation from the one being currently used is needed, the system will have to be flushed if the two formulations are incompatible. See Chapter 6 of this manual for the proper flushing procedure. When in doubt about adhesive compatibility, flush your system.

Field Installation of Controller Options

Customers who choose to modify their adhesive supply unit with ITW Dynatec manufactured options should assure that only qualified technicians perform such installations. The installation of options that require specific procedures and/ or calibration are outlined in this chapter.

Before controller options are installed, always turn the controller’s main power switch OFF. In most cases, turning the controller OFF will assure that the controller will retain its programmed parameters and configuration. Re-booting is not necessary.

Page 3-8 Installation

Revised 4/01 c. 2000

DYNAMELT M ASU Manual 20-36

Adjusting the Pressure Relief Valve

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

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

WARNING HIGH PRESSURE

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

Chapter 1 and the section entitled

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

To Adjust Pressure Relief:

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

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

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

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

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

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

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

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

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

cont.

Screw cap

Turning the adjustment screw

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

Jam nut

Adjustment screw

Turning the adjustment screw

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

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-9

Revised 4/01

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

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

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

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

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

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

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

11. Replace and tighten the adjustment screw cap.

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

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

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

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

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

The application system is now adjusted for normal operation.

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

Page 3-10 Installation

Revised 4/01 c. 2000

DYNAMELT M ASU Manual 20-36

Pump Enable (Ready) Thermostat Calibration

The Pump Enable (Ready) Thermostat is preset to 132

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

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

CAUTION: DO NOT set the pump enable thermostat lower than the softening point of your adhesive or pump damage may result.

As an example: the operator desires to lower the preset Pump Ready temperature to 107

°C (225°F).

1. At the controller keypad, set the hopper temperature setpoint to the temperature at which you want the pump to start, i.e. 107 °C (225°F).

Hopper

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

3. Wait for the hopper temperature to stabilize at 107 °C (225°F), then: a. For thermostats with purple & black wire leads or tan leads: turn the thermostat’s adjustment screw counter-clockwise to increase

the pump’s

Pump EnableThermostat mo.tor begins turning Adjust no further.

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

4. Replace the side door.

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

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-11

Revised 6/01

Calibration of the Optional Voltage Tachometer

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

DANGER

HIGH VOLTAGE

WARNING

HOT SURFACE

Dynamelt systems use electrical power that can be life threatening and hot-melt adhesives that can cause serious burns. Be sure to read and follow the safety procedures in Chapter 1 of this manual. Only qualified persons accustomed to working with live electrical circuits should per-

form this procedure on the Dynamelt system.

Calibration Procedure

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

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

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

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

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

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

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

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

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

Page 3-12 Installation

Revised 4/01 c. 2000

DYNAMELT M ASU Manual 20-36

Installation of the Optional Tach Generator or a DC Tracking Signal

The installation of a tach generator or a similar DC tracking signal allows speed tracking of the gear pump through voltage following. Multiple motor boards may be wired in parallel to the tach generator. On the controller, voltage following is referred to as the “AUTO” Mode of the motor control.

Installation Procedure

DANGER HIGH VOLTAGE

Dynamelt systems use electrical power that can be life threatening. Disconnect and lock out input power to the application system before starting any installation procedures.

1. Disconnect and lockout input power to the application system.

2. Open the panel box and locate the Motor Control Interface Board (see layout illustrtion in

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

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

or

ii. If, when facing the shaft on the tach generator, the rotation of the shaft is counter-clockwise, connect the black lead wire to the “10” and connect the white lead wire to “0”.

iii.Verify that the gear pump motor is running at full speed when set to 100% in MANUAL mode. The output of the tach generator can be adjusted, depending on the application, but it must be at least 10 VDC to obtain full adhesive gear pump speed.

Note: under no conditions will the motor ever run faster than this speed (100% Manual).

B. To install a similar DC tracking device (not a tach generator):

Connect the DC tracking voltage signals to the terminals so that the negative lead is connected to “0” and the positive lead is connected to “10”.

Note: the tracking voltage must be at least 0-10 VDC, but not more than 0-25 VDC.

4. Close the ASU’s panel box door.

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

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

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-13

Revised 4/01

Calibration of the Optional Tach Generator or DC Tracking Signal

After installation of a tach generator (or a similar DC tracking signal), the device must be calibrated at the DynaControl controller.

Prior to calibration, turn the application system ON and allow all components to warm up to normal operating temperatures (above ready temperatures).

1. Perform the following sequence at the controller keypad for each motor: a. Go to Motors screen.

b. Choose AUTO mode. Press Enter.

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

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

2. Energize the parent line (tracking signal) to its full speed (at least 10 VDC at the “0” and “10” terminals at X3 on the Motor Control Interface printed circuit board).

3. On the Motor Control Interface printed circuit board (see illustration in Chapter 7) locate and adjust the web speed scaling potentiometer (VR1) clockwise until the “SET %” is below 99.8.

Then adjust counter-clockwise until it equals 99.8%.

4. The system is now calibrated so that full parent machine speed corresponds to full speed of the gear pump.

The amount of adhesive dispensed can now be adjusted by trimming the pump RPM at the AUTO menu of the controller by adjusting the “MAX %” value down from the factory default of 100%.

Adjusting the “MIN %” value corresponds to the pump speed when the parent line is stopped (0.0

volts at the “0” and “10” terminals). In most applications, the factory default (MIN % = 0) is used.

Page 3-14 Installation

Revised 11/02 c. 2000

DYNAMELT M ASU Manual 20-36

Level Control, Capacitive, Sensor with Amp

The level control device informs the ASU’s operator, via a “Level Low” message on the Dyna-

Control controller’s System Status display, that the ASU’s hopper adhesive level is low. When the alarm activates, press “C” to reset it. You then have five minutes to refill the hopper before the alarm reactivates and the ASU’s pumps stop.

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

DO NOT CUT the sensor cable.

Adjustment of the PN N08122 Level Control

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

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

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

Sensor

Connect

1 2 3 4 5 6 min max

S

7 8 9 10 11 12

Amplifier

Sensitivity Adjustment Screw

Yellow LED

c. 2000

DYNAMELT M ASU Manual 20-36

Installation Page 3-15

Revised 4/06

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

The following simplified sequence assumes that the DynaControl Controller has been programmed.

Start Up Procedures

1. Fill the ASU’s hopper with clean hot-melt adhesive to within a couple of centimeters (inches) of the top of the hopper. Close the hopper lid immediately to prevent contaminants from falling in. (Cover your bulk supply of adhesive to prevent contaminants also.)

2. Switch ON the Main Disconnect (the circuit breaker located on the panel box).

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

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

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

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

At the pump screen:

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

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

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

ii. Enter desired speed value. Press Enter.

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

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

Shut Down Procedures

At the pump screen:

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

b. Turn OFF the Main Disconnect Switch.

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

b. Turn OFF the Main Disconnect Switch.

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

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

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

Page 3-16 Installation

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

Storage and Disposal of the DYNAMELT M Application System

Temporary Storage of the Unit

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

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

3. Shut OFF all pressure and power sources.

4. Release residual air pressure (if applicable).

5. Remove all residual adhesive and wipe components clean.

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

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

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

Disposal of the Unit

1. Shut OFF all pressure and power sources.

2. Release residual air pressure (if applicable).

3. Remove all residual adhesive.

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

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

6. Arrange for all components to be recycled.

ITW Dynatec c. 2000

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

Controller Setup Page 4-1

Revised 10/00

Chapter 4

DynaControlä CONTROLLER SET-UP

Temperature Control Functions in General

The DynaControl microprocessor-based proportional temperature control in the ASU performs a number of functions that help to maintain adhesive setpoints in all temperature zones of the DYNA-

MELT

Ò system. It maintains permanent system values (fixed proportional and integration values that have been programmed at the factory, such as the maximum temperature setpoint). It enables the user to program temperature settings and heater on/off sequencing that are appropriate to a specific application. It displays all programmed values, and it includes self-diagnostic malfunction alerts and failure alarms. Note: Some DynaControl functions are direct temperature conversions between de-

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

Defining DynaControl Temperature Control Terms

Adhesive Temperature Control Range

The temperature limits within which the ASU, hoses and applicators may be programmed and maintained.

CPU Module

The central processing unit (CPU) of the microprocessor temperature control.

Cold Start

When the ASU resets itself to default setting due to either a malfunction or to a deliberately initiated cold start procedure. When the ASU is turned ON via the Main Power Disconnect Switch.

Default Settings

The factory-set programmable system values that will be in effect if the user does not enter new values. The controller will revert to its defaults whenever it is reset. The DynaControl controller’s defaults are listed in this chapter.

Error Indication Alarms

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

Mechanical High-Temperature Protection

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

(450 °F).

Microprocessor-based Proportional Temperature Control

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

cont.

Page 4-2 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

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

Over-Temperature Setpoint

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

PC Link

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

P-I Loop

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

Power I/O PCBs

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

Pump Enable Temperature

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

RTD Sensors

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

Ready Temperature

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

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

Recipe

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

Control controller.

Sequential Heating

The heating sequence which allows the slower-heating hopper to reach operating temperature without unnecessary use of electricity for faster-heating hoses and applicators. Sequential heating is the time period during which the hoses and applicators remain OFF while the hopper (and optional drop-in grids) heats up. Hoses and applicators may be independently programmed. If hopper temperature is above ready temperature when the ASU is turned ON, the hose and applicator

cont.

ITW Dynatec c. 2000

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

Controller Setup Page 4-3

Revised 5/01

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

Standby Condition

The system condition where the ASU, hose and head temperatures are maintained at predetermined reduced temperature values. Standby temperatures are set lower than setpoint temperatures in order to reduce adhesive degradation and energy consumption when the system is temporarily inactive, and to permit rapid system warm-up when run condition is selected.

Setpoint

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

Setpoint Limitation

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

System Logbook

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

1,000 controller events

,

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

Temperature Zone Enable

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

Temperature Zone Offset

Due to the separation between the heaters and sensors in some systems, the controller can be programmed to display a temperature for a zone which is different from the sensor’s actual temperature. The temperture zone offset mathematically corrects for these temperature differences. Each zone may have an individual offset.

Page 4-4 Controller Setup

Revised 5/01

ITW Dynatec c. 2000

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

Error Indication & Alarms

Error Indication (Blinking Up and Down Arrows)

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

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

Blinking up arrow indicates overtemp.

Blinking down arrow indicates undertemp.

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

274

HOLD

Hose

Head

Aux Zone

Pump

%

SETPOINTS

MANU

HOLD

PUMP

2.

310

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

MANU

HOLD

STOP

HOLD

PRESSURE

?

?

STOP

HOLD

HELP

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

“?” indicates no sensor (open circuit).

ITW Dynatec c. 2000

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

Controller Setup Page 4-5

Revised 11/02

Error Alarms (Message Window)

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

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

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

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

Examples of Error Alarms

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

The controller will shut off power to the heaters. Press

F4 and troubleshoot the problem.

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

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

Press F4 and troubleshoot the problem.

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

Dynatec for assistance.

Overtemperature

Zone Name ##

Sensor Failure

Zone Name ##

Hopper Overtemp

Communication error

Page 4-6 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

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

Optional System Status Lights

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

The lower, white light illuminates when the system is turned ON. The middle, green light indicates that the system has warmed up to temperature setpoints (“ready”). The upper, red light illuminates only in an alarm condition and is accompanied by an audible alarm. The audible alarm is housed within the upper (black) section of the stack.

Red

Green

White

Audible

Alarm

Alarm

System

Ready

Power

“ON”

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

Settings for a Typical Operation

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

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

Hose and head temperature: 177

°C (350°F).

Hopper setpoint temperature: 163

°C (325°F).

Hi/ Lo limit deviation: 12

°C (20°F).

ASU operating range: 149

°C to 177°C (300°F to 350°F).

Standby condition temperature (deviation): 30

°C (50°F).

Hopper over-temperature setpoint : 177

°C (350°F)

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

°C (425°F)

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

ITW Dynatec c. 2000

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

Controller Setup Page 4-7

Revised 10/00

System Values That Are Factory Programmed (not customer programmable)

Minimum setpoint value: 10 °C (50°F).

Maximum setpoint value (Setpoint limitation): 218 °C (425°F).

” ” ” for high temp mode enabled ASUs: 232

°C (450°F)

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

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

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

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

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

Customer Programmable Values Preset At The Factory

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

If customer’s specs are not provided, the following values will be entered into the DynaControl controller at the factory. They may be changed by reprogramming through the keypad. (These are not the “default” settings, see following section).

Applicator (head) and hose setpoints: varies from 138 to 149 °C (280 to 300°F).

Hopper setpoint: 143 °C (290°F).

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

Motor rpm: 0 in the “OFF” mode.

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

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

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

Page 4-8 Controller Setup

Revised 10/00

ITW Dynatec c. 2000

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

Default Settings of the DynaControl Controller

Default settings are the manufacturer’s preset values to which the system will return if the Dyna-

Control is subjected to an internal memory reset (also referred to as a “re-boot”). While you can change your programmed values to anything within the system’s limits, the default settings cannot be changed.

Defaults

Language: English

Setting for Customer Access Code: “9999”.

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

Hopper ready temperature: 135

°C (270°F).

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

For example: if your setpoint limitation is 218

°C (425°F), then your over-temp limit = 228°C (435°F).

Standby temperature for all zones: 80 °C (140°F) lower than programmed setpoints.

Hi/ lo limit deviation for all temperature zones: ± 20°C (36°F).

Temperature zone offset: 0 °C (0°F).

Sequential heating: first hopper zones, then hose/ head zones and auxiliary zones.

Setpoint limitation: 218 °C (425°F).

Minimum pump speed: 0% of full speed.

Maximum pump speed: 100% of full speed.

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

ITW Dynatec c. 2000

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

Controller Setup Page 4-9

Revised 11/01

Helpful Tips for the User

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

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

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

Page 4-10 Controller Setup

Revised 9/02

ITW Dynatec c. 2000

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

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

Specifications

-- RS232C, no handshake

-- RS485, 4 wires

-- baud rate 1200 ¼57600 baud

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

-- parity: no parity check

General information

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

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

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

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

-- Used control characters:

STX 02 Start of Text

ETX 03 End of Text

EOT 04 End of Transmission

ENQ 05 Enquiry

ACK 06 Positive Acknowledge

NAK 15 Negative Acknowledge

Structure of commands

-- Master transmits to DynaControl:

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

-- DynaControl responds:

STX, 1...n data bytes, ETX

Address Setting

Each telegram sent to the DynaControl contains the slave address.

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

Examples:

Controller address = 37

1.

Write temperature setpoints

Zone 3 = 250_F

Zone 4 = 280_F

Zone 5 = 300_F

Zone 6 = 350_F, but temporarily not in use

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

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

2.

Read actual temperatures

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

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

ITW Dynatec c. 2000

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

Controller Setup Page 4-11

Revised 7/01

Return String:

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

¼¼¼.ETX

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

¼.

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

3.

Read actual pump speed

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

Return String:

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

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

4.

Read System Status

EOT, 3 , 7 , f , ENQ

Return String:

STX , F , ETX --> ‘F’ = 46hex

Bit wise: 0

7

Always

!

1

6

0

5

0

4

0

3

1

2

1

1

0

0

No setback, normal mode

Controller is on

Enable thermostat closed

Hopper not empty

No low temper.

No high temper.

= Ready

è

è

è

è

5.

Read status of all temperature zones

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

Return String:

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

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

cont.

DynaControl Version V5M Serial Protocol

Opcode

Parameter

Syntax*

0x41 / 'A' zz.n*dddd

0x46 / 'F' zz.n*dddd

0x61 / 'a' zz

0x64 / 'd'

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

0x62 / 'b' zz

0x43 / 'C' zz.n*dddd

0x63 / 'c'

0x65 / 'e'

0x6c / 'l'

0x67 / 'g' zz zz zz zz

0x50 / 'P' zz.n*dddd

0x70 / 'p' zz

0x4d / 'M'

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

0x66 / 'f'

0x6a / 'j'

0x69 / 'i'

0x48 / 'H' n.a.

n.a.

zz d

0x52 / 'R'

0x72 / 'r'

0x4c / 'L' d n.a.

n.a.

Return String

ACK / NAK

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

ACK / NAK dd (n*dd)

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

ACK / NAK dddd (n*dddd)

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

ACK

ACK / NAK d

ACK / NAK

Function

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

Version: V5.00e

Date: 09.27.01

Option

1 zone / multiple zones

1 zone / multiple zones

1 zone / all zones

1 zone / all zones

1 zone / multiple zones

1 zone / all zones

1 pump / multiple pumps

1 pump / all pumps

1 pump / all pumps

1 pump / all pumps

1 transducer / all transd.

1 transd. / multiple transd.

1 transducer / all transd.

1 pump / multiple pumps

1 pump / all pumps

1 zone / all zones

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

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

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

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

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

13ITW Dynatec c. 2005

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

Page 4-13

Revised 8/05

PN 112224 M Series DynaControl EtherNet/IP Adapter Option, V1.06

General

This optional adapter provides an EtherNet/IP connection for Dynamelt M Series hot melt ASUs.

This connection makes it possible to monitor and control the basic functions of the hot melt unit from a remote PLC or PC.

This adapter uses an ODVA approved module. In order to fully operate, the Dynamelt M must be equipped with firmware rev. V5.15M or later.

Basic Features:

- 10/100 Mbit/s

- DHCP/BootP

- Access to basic process parameters

- Local and remote access

- Watchdog signal

Page 4-14 ITW Dynatec c. 2005

Revised 8/05 DYNAMELT M ASU Manuals 20-36, 20-37, 20-38

Installing the EtherNet/IP-Adapter in a ControlLogix5000 System

These installation steps assume that RSLogix5000 and ControlLogix5000 with an EtherNet/IP module/bridge (1756 ENBT or similar) are set up and working properly.

1. Connect the Dynatec Hot melt unit (ASU) to the Ethernet network using a standard RJ45cable.

2. Start RsLogix5000 with a new or existing project. Set to “Offline” mode.

3.

Add the EtherNet/IP-Adapter to the PLC Configuration:

- Start by right clicking the EtherNet/IP module/bridge in the configuration

- Select “New Module”

- Select “Generic Ethernet Module”

- Press OK

4.

Configure the EtherNet/IP-Adapter:

- Enter the name of the module. (for example “Dynatec_Melter”. If you desire to import the controller tags provided on the CD-ROM, the module name must be exactly

“Dynatec_Melter”. See step #6 following).

- Set Comm Format to “Data-INT”, since all data are 16-bit words

- Set Connection Parameter Assembly Instance to 100 for Input and 150 for Output

- Set Size for 180 input/ 80 output (16 bit)

- Set the Configuration Instance to 1 but the size to 0 since this instance is not supported

- Set the IP-Address to 192.168.23.180. For more details about IP-Address see the following section, “Changing the IP-Address”

- Press Next >

- On next dialog, select Requested Packet Interval: 100ms

- Do not Inhibit Module

- Press Finish >>. On the main screen you should see the ETHERNET-MODULE under the I/O Configuration

- Select “ Go Online” from the “Communications” menu

- Select “ Download” in the next window

- Confirm the Download

5. Checking the I/O Tags

After successful configuration of the EtherNet/IP-Adapter, it is possible to access the input/output data. There are three Controller Tags: “Dynatec Melter: C”, “Dynatec Melter: I” and “Dynatec Melter: O”. The input/output tags consist of 180/ 80 words each.

“Dynatec Melter: C” is the configuration tag (not used).

“Dynatec Melter: I” is the data coming from the Dynatec hot melt unit

“Dynatec Melter :O” holds the data going to the hot melt unit.

The definitions of the data tags are explained on the last pages of this section.

15ITW Dynatec c. 2005

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

Page 4-15

Revised 8/05

6. Importing Controller Tags

The CD-ROM that is provided with the EtherNet/IP option contains a pre-defined controller tag table. In order to save time, this table may be imported.

- In the RSLogix5000 go offline

- Select Tools -> Import Tags

- Select the “Dynatec-Controller-Tags_DMM. CSV” from the CD-ROM

- Click Import

- If the import was successful, the Report Window in the lower part of the screen should indicate 242 imported tags.

- Go online again

- Go back to the controller tag screen and verify the tags.

Details on the Communication

General Information

The In- and Out- data table (Controller Tags) contain all parameters for a maximum equipped hot melt machine. In most of the cases, only parts of the parameters are needed.

The temperature zones are logically organized, first all premelt zones, progmelt zones (= hopper), then filter blocks up to the auxiliary zones. The number of actually available zones depends on the type of machine.

- Setting LocalAccessTemps to 1 allows the user to make changes to the temperature setpoints on the hotmelt unit. The PLC can read the changes from the corresponding INwords but the temperatures in the OUT area will not be effective on the hot melt unit.

- Setting LocalAccessTemps to 0 switches the control back to PLC control. All temperature OUT-words will be transferred to the hot melt unit. A local change of temperature setpoints is not possible since the PLC will instantly overwrite the entry.

- LocalAccessMotors controls the access to pump settings analog to the description above.

- After a local change of setpoints, the PLC first must read the new setpoints before switching back to PLC control.

- It is not possible to deactivate a temperature zone locally on the hot melt unit since the

PLC always sends the ZoneEnable/Disable information.

Zones Enabling/Disabling

Temperature zones that are temporarily not used can be remotely deactivated by setting a corresponding value to OUT-word 70 to 75. Each bit of this word represents one temperature zone. Bit0 = zone1, Bit1 = zone2 etc. Setting the bit will activate the zone. Resetting will deactivate the zone.

Pump Control

There are several ways to control pump speed:

1. Manual Mode: the pump speed can be programmed locally on the hot melt machine. In order to allow this mode, the OUT-word 50 (for pump 1) must be set to 77

Page 4-16 ITW Dynatec c. 2005

Revised 8/05 DYNAMELT M ASU Manuals 20-36, 20-37, 20-38

(ASCII “M”). Local Access PUMP (OUT-word 63) does not have to be set.

2. Automatic Mode: the pump speed is controlled via a 0 to 10V signal, connected to the hot melt machine. In order to activate this mode, the OUT-word 50 (for pump

1) must be set to 65 (ASCII “A”).

The pump speed, which follows the line speed can be read in IN-word 134

(for pump 1). This value shows 0.1% resolution.

3. Stop Mode: The pump is stopped.

4. Bus Mode: the pump speed is controlled via OUT-word 56 (for pump 1). Out-word 50

(for pump 1) must be set to 66 (ASCII “B”). On the keypad of the hot melt machine, the pump speed can be fine tuned by using the min. and max. scaling, similar to the Automatic Mode.

The speed setting must be transmitted in increments of 0.1% (0 to 1000 =

0.0 to 100.0%).

Adhesive Level Indication

Word 142/ 143 (142 = single hopper/ 142 & 143 = dual hopper) shows the state of the optional adhesive level control. A 0 indicates the level is O.K. and a 1 indicates a low-level situation.

This signal is an instantaneous non-latched indication.

In order to avoid local low-level indications, which have to be reset on the keypad, the low-level detection should be disabled in the customer set-up menu of the Dynamelt M hot melt unit.

Zone Status Indication

The status of all temperature zones can be read in IN-word 146 to 175. This information is bit-wise coded and organized in zone type.

Examples:

IN-word 146: 0003h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 1 1

IN-word 150: 003Fh 0 0 0 0 . 0 0 0 0 . 0 0 0 0 .0 0 1 1 .1 1 1 1

IN-word 156: 003Fh 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 1 1 1 1

IN-word 159:

0001h

0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 1

IN-word 167: 0020h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 .0 0 1 0 .0 0 0 0

IN-word 175: 0011h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 1 .0 0 0 1 premelt 1& 2 are switched ON

6 heads are switched ON

4 heads are in waiting position the progmelt (hopper) is heating hose 6 is ready auxiliary zones 1 & 5 show alarm

17ITW Dynatec c. 2005

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

Page 4-17

Revised 8/05

Identification Word

OUT-word 79 is used as an identification word. This word must be set to a certain value to validate the communication. If this word is set differently, the hot melt unit will not accept the

OUT area although the IN-area will show proper values. Dynamelt M hot melt units require IDword set to 68.

Examples for a typical communication

Initializing: Set OUT 76 to 1 : Switches the controller on

Set OUT 79 to 68 :

Set OUT 77 to 0 :

Identifies the communication

No standby, normal mode

4-Hose Operation: Set OUT 73 to 15 : Hoses 1 to 4 are switched ON

Set OUT 74 to 15 : Heads 1 to 4 are switched ON

6-Hose Operation: Set OUT 73 to 63 : Hoses 1 to 6 are switched ON

Set OUT 74 to 63 : Heads 1 to 6 are switched ON

Check Ready Condition: Compare IN 146 with 164

Compare IN 147 with 165

Compare IN 148 with 166

Compare IN 149 with 167

Compare IN 150 with 168

Compare IN 151 with 169: If all comparisons are equal, the system

is ready

Check Alarm Condition: Read In 170 to 175 If any word does not equal 0, an alarm is

present

Changing the IP-Address

The EtherNet/IP-Adapter will be factory set to 192.168.23.180 but the DHCP/BOOTP function is enabled. That means the module will request a new IP-address after power up. If this request is not serviced, the old IP-address will be valid.

There are several ways to change the IP-address. In any case, a PC must be connected to the module, either directly via crossover cable or via hub/switch to the network with the module.

Configuration Program ‘Anybus IPconfig’

On the EtherNet/IP support disc you will find a configuration tool to change the IP-Address.

Start the Anybus IPconfig installation program. Follow the instructions on the screen.

Once the configuration tool is running, press the scan button to search for any Dynatec-

EtherNet/IP modules. If a module is detected, it will show up in the window. Double clicking on it will allow changing the settings for this Module.

Page 4-18 ITW Dynatec c. 2005

Revised 8/05 DYNAMELT M ASU Manuals 20-36, 20-37, 20-38

Using the Configuration File

The file ethcfg.cfg can be used to change the IP-address. This method is possible only if the actual IP-address is known (e.g. the factory set 192.168.23.180), See also section “Configuration

File”.

- Open a FTP connection to the module (e.g. Windows Explorer™ FTP://192.168.23.180

)

- Locate the ethcfg.cfg

- Copy this file to a folder on your PC

- Open the file with any text editor

- Change the IP-address

- Save the file using the same name

- Copy the file back to the module

- Re-cycle power on the module (hot melt unit)

Note: If the configuration file ethcfg.cfg is not found, the module will automatically activate a

Using the BootP-Server Function

The BOOTP-Server comes with the RSLinx Tools of the Rockwell Automation™ Software or can be downloaded as a stand-alone application. Version V2.3.2 or newer allows to change the

IP-address of the EtherNet/IP module.

Note: The EtherNet/IP module only requests an IP-address assignment for approx. 30 sec.

If this request is not serviced within this time (by entering the desired IP-address in the relation list) the module’s power (hot melt machine) must be re-cycled.

19ITW Dynatec c. 2005

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

Diagnostic LED’s

Page 4-19

Revised 8/05

PN 112224 EtherNet/IP-Adapter

MAC-Addr.

1. Net Stat. = Network Status

State Summary Description

Steady Off

No power or no IP address

The module has no power or no IP address has been assigned.

Steady Green Connected

Flashing Green

Flashing Red

Steady Red

Flashing

Green/Red

No connections

Connection Timeout

Duplicate IP Address

Self-Test

The module has at least one established

EtherNet/IP connection.

There are no EtherNet/IP connections established to the module.

One or more of the connections in which this module is the target has timed out. This state is only left if all timed out connections are re-established or if the module is reset.

The module has detected that its IP address is already in use

The module is performing a power on self test

2. Active

This led flashes green each time a packet is received or transmitted.

3. Mod. Stat. = Module Status

State Summary Description

Steady Off

No power The module has no power.

Steady Green

Flashing Green

Flashing Red

Steady Red

Flashing

Green/Red

Device operational

Standby

Minor Fault

Major Fault

Self-Test

The module is operating correctly.

The module has not been configured.

A minor recoverable fault has been detected

A major internal fault has been detected

The module is performing a power on self test

Page 4-20 ITW Dynatec c. 2005

Revised 8/05 DYNAMELT M ASU Manuals 20-36, 20-37, 20-38

4. Link = Link Activity

Color State

Green On

Description

The module has a link

Off The module does not sense a link

Configuration File

The EtherNet/IP module contains a file (ethcfg.cfg) that is read by the module at start up. This file defines the network properties of the module. Any text editor can be used to edit the parameters.

Note: It is very important to follow the exact syntax specification, otherwise the module might have problems interpreting it, which can result in a faulty or non-expected behavior.

The file can be uploaded and after modification, downloaded using the FTP function.

(e.g. open a Windows Explorer window. Type ‘FTP://192.168.23.180’)

The format of the file is shown as follows:

[IP address]

EXPLANATION

IP Address

192.168.23.180

[Subnet mask]

Subnet mask

255.255.255.0

[Gateway address]

Gateway address

0.0.0.

[DHCP/BOOTP]

DHCP/BootP

ON

ON

- Enabled

OFF

– Disabled

[SPEED] Speed

Auto

Auto

– Default. Auto Negotiation will be used.

100

10

– Forces the module to operate at 100Mbit/s only

– Forces the module to operate at 10Mbit/s only

21ITW Dynatec c. 2005

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

Page 4-21

Revised 8/05

EXPLANATION

Duplex

[Duplex]

Auto

Auto

– Default. Auto negotiation will be used.

Full

– Forces the module to operate at full duplex only

Half

- Forces the module to operate at half duplex only

SMTP server/ login settings

[SMTP address]

0.0.0.0

[SMTP username] username

SMTP server/ login settings

SMTP server/ login settings

[SMTP password] password

[DNS1 address]

0.0.0.0

[DNS2 address]

Primary and Secondary DNS

Primary and Secondary DNS

0.0.0.0

[Domain name] hms.se

[Host name]

Domain Name (Optional)

Host Name (Optional)

Function

Setpoint Head 4

Setpoint Head 5

Setpoint Head 6

Setpoint Head 7

Setpoint Head 8

Setpoint Head 9

Setpoint Head 10

Setpoint Head 11

Setpoint Head 12

Setpoint Auxiliary 1

Setpoint Auxiliary 2

Setpoint Auxiliary 3

Setpoint Auxiliary 4

Setpoint Auxiliary 5

Setpoint Auxiliary 6

Setpoint Auxiliary 7

Setpoint Auxiliary 8

Setpoint Auxiliary 9

Setpoint Auxiliary 10

Setpoint Auxiliary 11

Setpoint Auxiliary 12

Motor Mode 1

Motor Mode 2

Motor Mode 3

Motor Mode 4

Motor Mode 5

Motor Mode 6

Motor Speed 1

Motor Speed 2

Motor Speed 3

Motor Speed 4

Motor Speed 5

Motor Speed 6

Reserved

Reserved

Setpoint Premelt 1

Setpoint Premelt 2

Setpoint Premelt 3

Setpoint Premelt 4

Setpoint Premelt 5

Setpoint Premelt 6

Setpoint Progmelt 1

Setpoint Progmelt 2

Setpoint Progmelt 3

Setpoint Filterblock 1

Setpoint Filterblock 2

Setpoint Filterblock 3

Setpoint Hose 1

Setpoint Hose 2

Setpoint Hose 3

Setpoint Hose 4

Setpoint Hose 5

Setpoint Hose 6

Setpoint Hose 7

Setpoint Hose 8

Setpoint Hose 9

Setpoint Hose 10

Setpoint Hose 11

Setpoint Hose 12

Setpoint Head 1

Setpoint Head 2

Setpoint Head 3

42

43

44

45

38

39

40

41

33

34

35

36

37

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

55

56

57

58

59

60

61

50

51

52

53

54

46

47

48

49

Word

Address

9

10

11

12

7

8

5

6

2

3

0

1

4

Dynacontrol - EtherNet/IP Data Table

IN-Area (Dynacontrol to PLC)

Zone Name

Valid Range

Date: 08.11.05

Page 1 of 5

Version: V5.15a

100°F - 425°F

S' (83) = Stop

'M' (77) = Manual ( Local manual speed)

'A' (65) = Auto (0 to 10V)

'B' (66) = Bus (EtherNet/IP: OUT 56 to 61)

0 to 1000 = 0.0 to 100.0% [500 = 50.0%]

(Local manual speed)

Word

Address

62

63

64

65

92

93

94

95

88

89

90

91

84

85

86

87

80

81

82

83

75

76

77

78

79

71

72

73

74

66

67

68

69

70

113

114

115

116

117

118

119

120

121

122

123

104

105

106

107

108

109

110

111

112

100

101

102

103

96

97

98

99

Function

Pressure Channel 1

Pressure Channel 2

Pressure Channel 3

Pressure Channel 4

Pressure Channel 5

Pressure Channel 6

Pressure Channel 7

Pressure Channel 8

Pressure Channel 9

Pressure Channel 10

Pressure Channel 11

Pressure Channel 12

Actual Temp. Premelt 1

Actual Temp. Premelt 2

Actual Temp. Premelt 3

Actual Temp. Premelt 4

Actual Temp. Premelt 5

Actual Temp. Premelt 6

Actual Temp. Progmelt 1

Actual Temp. Progmelt 2

Actual Temp. Progmelt 3

Actual Temp. Filterblock 1

Actual Temp. Filterblock 2

Actual Temp. Filterblock 3

Actual Temp. Hose 1

Actual Temp. Hose 2

Actual Temp. Hose 3

Actual Temp. Hose 4

Actual Temp. Hose 5

Actual Temp. Hose 6

Actual Temp. Hose 7

Actual Temp. Hose 8

Actual Temp. Hose 9

Actual Temp. Hose 10

Actual Temp. Hose 11

Actual Temp. Hose 12

Actual Temp. Head 1

Actual Temp. Head 2

Actual Temp. Head 3

Actual Temp. Head 4

Actual Temp. Head 5

Actual Temp. Head 6

Actual Temp. Head 7

Actual Temp. Head 8

Actual Temp. Head 9

Actual Temp. Head 10

Actual Temp. Head 11

Actual Temp. Head 12

Actual Temp. Auxiliary 1

Actual Temp. Auxiliary 2

Actual Temp. Auxiliary 3

Actual Temp. Auxiliary 4

Actual Temp. Auxiliary 5

Actual Temp. Auxiliary 6

Actual Temp. Auxiliary 7

Actual Temp. Auxiliary 8

Dynacontrol - EtherNet/IP Data Table

IN-Area (Dynacontrol to PLC)

Zone Name

Valid Range

Date: 08.11.05

Page 2 of 5

Version: V5.15M

0 to 1500 PSI

(requires digital pressure readout option)

0 to 500°F (1999 = open sensor / 999 = shorted sensor)

Dynacontrol - EtherNet/IP Data Table

IN-Area (Dynacontrol to PLC)

Zone Name

Valid Range

162

163

164

165

166

167

168

169

154

155

156

157

158

159

160

161

145

146

147

148

149

150

151

152

153

137

138

139

140

141

142

143

144

170

171

172

173

174

175

176

177

178

179

Word

Address

129

130

131

132

133

134

135

136

124

125

126

127

128

Function

Actual Temp. Auxiliary 9

Actual Temp. Auxiliary 10

Actual Temp. Auxiliary 11

Actual Temp. Auxiliary 12

Actual Pump Speed 1

Actual Pump Speed 2

Actual Pump Speed 3

Actual Pump Speed 4

Actual Pump Speed 5

Actual Pump Speed 6

Line Speed 1

Line Speed 2

Line Speed 3

Line Speed 4

Line Speed 5

Line Speed 6

Controller ON/OFF

Standby ON/OFF

Adhes. Level Status 1

Adhes. Level Status 2

Premelts On/Off

Progmelts On/Off

Filterblocks On/Off

Hoses On/Off

Heads On/Off

Aux. Zones On/Off

Premelts Waiting

Progmelts Waiting

Filterblocks Waiting

Hoses Waiting

Heads Waiting

Aux. Zones Waiting

Premelts Heating

Progmelts Heating

Filterblocks Heating

Hoses Heating

Heads Heating

Aux. Zones Heating

Premelts Ready

Progmelts Ready

Filterblocks Ready

Hoses Ready

Heads Ready

Aux. Zones Ready

Premelts Alarm

Progmelts Alarm

Filterblocks Alarm

Hoses Alarm

Heads Alarm

Aux. Zones Alarm

Watchdog

Each zone is represented by the corresponding bit in these words

Date: 08.11.05

Page 3 of 5

Version: V5.15M

0 to 1500 = 0.0 to 150.0 RPM

(requires RPM readout option)

0-1000 = 0 to 100.0% (0 to 10V)

0 = Controller is OFF / 1 = Controller is ON

0 = Normal Mode / 1 = Standby is active

0 = Level is OK / 1 = Level is low (requires level control option)

Bit0 to Bit 5

Bit0 to Bit2

Bit0 to Bit2

Bit0 to Bit11

Bit0 to Bit11

Bit0 to Bit11

0 = Zone is OFF / 1 = Zone is ON

0 = Zone is not waiting / 1 = Zone is waiting

0 = Zone is not heating / 1 = Zone is heating

0 = Zone is not ready/ 1 = Zone is ready

0 = Zone has no alarm / 1 = Zone has alarm

Signal toggles every 0.5sec. (0/1)

Function

Setpoint Head 2

Setpoint Head 3

Setpoint Head 4

Setpoint Head 5

Setpoint Head 6

Setpoint Head 7

Setpoint Head 8

Setpoint Head 9

Setpoint Head 10

Setpoint Head 11

Setpoint Head 12

Setpoint Auxiliary 1

Setpoint Auxiliary 2

Setpoint Auxiliary 3

Setpoint Auxiliary 4

Setpoint Auxiliary 5

Setpoint Auxiliary 6

Setpoint Auxiliary 7

Setpoint Auxiliary 8

Setpoint Auxiliary 9

Setpoint Auxiliary 10

Setpoint Auxiliary 11

Setpoint Auxiliary 12

Pump Mode 1

Pump Mode 2

Pump Mode 3

Pump Mode 4

Pump Mode 5

Pump Mode 6

Set Speed Pump 1

Set Speed Pump 2

Set Speed Pump 3

Set Speed Pump 4

Set Speed Pump 5

Set Speed Pump 6

Reserved

Reserved

Setpoint Premelt 1

Setpoint Premelt 2

Setpoint Premelt 3

Setpoint Premelt 4

Setpoint Premelt 5

Setpoint Premelt 6

Setpoint Progmelt 1

Setpoint Progmelt 2

Setpoint Progmelt 3

Setpoint Filterblock 1

Setpoint Filterblock 2

Setpoint Filterblock 3

Setpoint Hose 1

Setpoint Hose 2

Setpoint Hose 3

Setpoint Hose 4

Setpoint Hose 5

Setpoint Hose 6

Setpoint Hose 7

Setpoint Hose 8

Setpoint Hose 9

Setpoint Hose 10

Setpoint Hose 11

Setpoint Hose 12

Setpoint Head 1

40

41

42

43

36

37

38

39

31

32

33

34

35

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

57

58

59

60

53

54

55

56

48

49

50

51

52

44

45

46

47

61

Word

Address

7

8

9

10

5

6

3

4

0

1

2

Dynacontrol - EtherNet/IP Data Table

OUT-Area (PLC to Dynacontrol)

Zone Name

Valid Range

Date: 08.11.05

Page 4 of 5

Version: V5.15M

100°F - 425°F only active if Local Access Temps. O.Data[62] is set to 0

S' (83) = Stop

'M' (77) = Manual ( Local manual speed)

'A' (65) = Auto (0 to 10V)

'B' (66) = Bus (EtherNet/IP: OUT 56 to 61)

0 to 1000 = 0.0 to 100.0% [500 = 50.0%] only active when pump in in Bus-Mode

Word

Address

62

63

64

65

66

67

68

73

74

75

76

77

69

70

71

72

78

79

Function

Local Access Temps.

Local Access Pumps

Premelts On/Off

Progmelts On/Off

Filterblocks On/Off

Hoses On/Off

Heads On/Off

Aux. Zones On/Off

Controller ON/OFF

Standby ON/OFF

Identification Word

Dynacontrol - EtherNet/IP Data Table

OUT-Area (PLC to Dynacontrol)

Zone Name

all temp. zones all pumps

Each zone is represented by the corresponding bit in these words

Date: 08.11.05

Page 5 of 5

Version: V5.15M

Valid Range

set to 1 enables setpoint changes on keypad set to 0 enables setpoint changes via EtherNet/IP

Bit0 to Bit 5

Bit0 to Bit2

Bit0 to Bit2

Bit0 to Bit11 each bit: 1 = zone enabled

Bit0 to Bit11

Bit0 to Bit11 set to 0 to switch off / set to 1 to switch on set to o for normal mode / set to 1 for standby mode

DM-M: 68, has to be set to validate communication

ITW Dynatec c. 2000

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

Programming Page 5-1

Revised 5/01

Chapter 5

PROGRAMMING INSTRUCTIONS

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

Controller Safety Consideration

DANGER HIGH VOLTAGE

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

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

Software Version

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

Help Screen or on the display at startup:

* * * ITW Dynatec * * *

M-Control V 5.00c

Current Software Version

Page 5-2 Programming

Revised 12/02

ITW Dynatec c. 2000

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

Display & Keypad Reference

System Status:

Ready

Heat up

Alarm

Standby

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

Hose

Head

Aux Zone

274

HOLD

Pump

%

SETPOINTS

AUTO

HOLD

PUMP

Scheduler Active Indicator

Day of Week

Time of Day

Numeric Entry Keys

2.

310

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

PRESSURE

?

?

CLEAR

Scheduler Key:

Standby

Day/Date Clock

7-Day Scheduler

Program Recipes

Service Key

On/Off Key & LED

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Delete

Enter

Enter

“%” or

“RPM” if optional actual

RPM readout is installed

Display & Function Keypad

(Actual Temps Screen shown as example)

Arrow

Keys

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

Continued

< >

Numeric

Keypad

Enter

0 = toggle from numeric

(1,2,3) to alphabetic

(A,B,C) entry

Program #:

P1, P2, P3 or P4 current software version

SYSTEM: Alarm

P#

Tue.

3:36 PM

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

C

1, 2, 3

Press Enter to activate or confirm

Enter a numeric value with 0 - 9 keys

A,B,C

Enter a letter on the alpha-numeric

< >

F

This item or this screen is locked

This item is factory setup* only

Press button C to see more zones

HELP Screen

(F4 on Actual Temperatures Screen)

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

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

ITW Dynatec c. 2000

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

Programming Page 5-3

Revised 5/01

Display Reference, cont.

Condition of Pump Enable Thermostat

Black box = item is selected for programming

System Status Line

Zone Names

Information lines

Function keys:

Scroll Up, Down or Right

“Return” to last screen

Go to “Pressure” screen

Go to “Pump” screen

Toggle “On/Off”

“All _ _ _” = all in category

“ABC/abc” = letter case

“Clear” an alarm or message

“Copy” = copy word(s) to a clipboard

“Paste” = paste copied words into text

“CLR Line” = clear entire line

SYSTEM: Alarm Lo

SETPOINTS °°°°F

Premelt

Progmelt

Filterblock

1

300

2

301

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

380

Numeric Entry

Keys

Tue. 3:36 PM

Next Page Press C

3 4 >

Hose

Head

Aux Zone

274

------

INFO: UPPER PREMELT GRID

Set: 300°F Act: 300°F Tol:±30°F

273

------

251

------

------

273

------

------

Zo: 1

1, 2, 3

RETURN

Setpoint Programming Screen

Screen continues, press “C” to view

Zone Status:

### = Temperature

HOLD = In priority queue, waiting for release

= Over temp

= Under temp

-- -- -- = Off

? = no sensor

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

Programming entry:

1,2,3 = numeric only

A,B,C = alpha only

Function keys:

F1, 2, 3, 4

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

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

User-chosen name

Function key:

“Manual”, “Automatic” or

“Stop” = pump modes

“Restart” pump

“All Stop” = stop all pumps

SYSTEM: Ready Tue. 3:36 PM

Press Enter and Select Mode

Set

Pump Mode %

Min

%

Max

%

Actual

RPM

1 MANU.

2 AUTO.

3 STOP

5.0

5.0

80.0

RUN

RUN

RUN

90.5

87

INFO: RIGHT PUMP

MANUAL AUTOMATIC STOP

Mtr 1

Enter

Arrow

Motor Programming Screen

Pump Programming Screen

Actual RPM = optional display

(tach generator required)

Lock = this screen is locked from further programming

Page 5-4 Programming

Revised 4/06

ITW Dynatec c. 2000

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

Basic Programming Sequence: Quick Reference

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

Press

Turn Controller On

F4 x2, 6

Language Selection x1, 8

Temperature Scale Selection

Actual Temperatures:

F1 To Program Setpoints

F2 To Program Pump/ Motor(s)

F2 To Program Optional Clutch(es) x1 x2

F3 To Program Optional Pressure Transducers

Service Page 1:

1 = High Low Temperature Deviation

2 = Setback Temperature

3 = Setback/ Sleep Setup

4 = Setpoint Limitation

6 = Temperature Offset

7 = Sequential Heating

8 = Temperature Scale

9 = Change Security Lock or Access Code

Service Page 2:

1 = Customer Zone Names

2 = Power On Configration

3 = Factory Defaults

4 = Keypad Locking

5 = PC Link

To Program Scheduler

1 = Manual Standby Activation

2 = Time & Date Clock

3 = Program 7-Day Scheduler

6 = Language

7 = LCD Contrast

8 = System Logbook

9 = Change Security Lock

4 = Select Program Recipes

5 = Manual Scheduler Activation

End

ITW Dynatec c. 2000

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

Programming Page 5-5

Revised 5/01

Controller Setup

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

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

tact your local repsentative.

Turn the Controller ON

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

Language Selection

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

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

Press #6 on the numeric keypad, followed by Enter

.

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

(OR Scroll to your choice, then press Enter .

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

Temperature Scale Selection

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

Press #8 on the numeric keypad, followed by Enter

.

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

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

Enter.

Page 5-6 Programming

Revised 5/01

ITW Dynatec c. 2000

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

Actual Temperatures Screen

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

System Status 7-Day Scheduler Active

Scheduler Key

Service Key

Controller

On/Off Key

SYSTEM: Alarm

Actuals °°°° F

Premelt

Progmelt

Filterblock

1.

300

299

300

274

HOLD

Hose

Head

Aux Zone

Pump

%

SETPOINTS

AUTO

78.0

PUMP

2.

301

Tue. 3:36 PM

Next Page Press C

273

HOLD

251

HOLD

?

?

?

PRESSURE HELP

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Pump Info Lines

Use of the Actual Temperatures Screen

To: Press This

Function Key

On/Off

Setpoints (F1)

Pumps (F2)

Pressure (F3)

Help (F4)

Service

Scheduler

Toggle display, pumps and heaters power ON or OFF

Go to the setpoints programming screen

Go to the pumps programming screen

Go to the pressure screen

Go to the Help screen.

Go to the first of the three service screens

Go the the Main Scheduler screen

ITW Dynatec c. 2000

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

Programming Page 5-7

Revised 5/01

Use of the Actual Temperatures Screen, cont.

Programming Sequence

(details on following pages)

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

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

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

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

Scheduler and/ or Program Recipes.

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

Monitoring

:

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

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

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

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

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

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

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

c. Arrow up: zone is over temperature.

d. Arrow down: zone is under temperature.

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

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

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

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

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

Page 5-8 Programming

Revised 5/01

Setpoints Programming Screen

ITW Dynatec c. 2000

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

SYSTEM: Alarm Lo

SETPOINTS °°°°F

Premelt

Progmelt

Filterblock

1.

300

350

380

1

2.

300

Hose

Head

Aux Zone

275

275

INFO: UPPER PREMELT GRID

Set: 300°F Act: 300°F Tol:±30°F

275

275

Tue. 3:36 PM

3 4

275

275

------

275

275

Zo: 1

RETURN

Delete

Enter

Controller identification number for zone

Zone Info Lines

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

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

Programming Page 5-9

Revised 5/01

Use of the Setpoints Programming Screen

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

Press This To:

Function Key

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

Return (F4) Return to the Actual Temperatures Screen

(Enter)

All -- -- -- (F1)

On/Off (F3)

Clear (F4)

Enter a numeric value

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

Toggle a zone on or off

Eliminate an error message or alarm

Programming

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

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

3. Press Enter .

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

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

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

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

OFF).

Monitoring

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

This number cannot be changed by user.

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

Page 5-10 Programming

Revised 5/01

Pump Programming Screen

Optional

RPM

Display

SYSTEM: Ready

Arrow

Tue. 3:36 PM

Press Enter and Select Mode

Keys

Set Min Max Actual

Pump Mode % % % RPM

1 MANU.

2 AUTO.

3 STOP

78.0

5.0

5.0

80.0

RUN

RUN

HOLD

90.5

87

INFO: RIGHT PUMP

MANUAL AUTOMATIC STOP

Mtr 1

1, 2, 3

RETURN

Delete Enter

ITW Dynatec c. 2000

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

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Alternative programming function keys:

STOP ALL RETURN

CLUTCHES RE-START

ITW Dynatec c. 2000

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

Programming Page 5-11

Revised 5/01

Use of the Pump(s) Programming Screen

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

Press This

Function Key

To:

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

Stop All (F3) To stop all pumps in system

Re-Start (F4)

Manual (F1)

To re-start all pimps

Choose Manual Mode for the selected pump

Automatic (F2)

Stop (F3)

Clutches (F2)

Return (F4)

(Enter)

Choose Automatic Mode for the selected pump

Choose Stop Mode for the selected pump

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

Return to the Actual Temperatures Screen

Enter a numeric value

Programming

1. Scroll to select a pump. Press Enter.

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

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

b. Press Enter.

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

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

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

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

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

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

Monitoring

1. RUN indicates the pump/ motor is enabled.

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

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

Page 2, menu item 1).

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

Temperatures Screen.

Page 5-12 Programming

Revised 5/01

ITW Dynatec c. 2000

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

Optional Clutch Programming Screen

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

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

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

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

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

SYSTEM : Ready

Arrow

Tue. 3:36 PM

Press Enter and Select Mode

Keys

Switch Clutches ON/OFF with button 1 . . 6

Pump - Clutch 1

Pump - Clutch 2

Pump - Clutch 3

Pump - Clutch 4

Pump - Clutch 4

Pump - Clutch 6

RE-START

ON

ON

OFF

OFF

OFF

OFF

STOP ALL

1, 2, 3

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Turn Clutch ON/OFF using numeric keys 1 thru 6

ITW Dynatec c. 2000

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

Use of the Optional Clutch Programming Screen

To: Press This

Function Key

Re-start (F2)

Stop All

Return (F4)

Turn ON all clutches at once

Turn OFF all clutches

Return to the Pump Screen

Programming Page 5-13

Revised 5/01

Programming

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

Monitoring

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

Optional Pressure (PSI/ BAR) Programming Screens

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

Screen.

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

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

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

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

Pressure Screen #1

cont.

SYSTEM : Ready

Arrow

Keys

Pressure PSI (BAR)

Sensor Act.

3

4

1

2

100

100

?

100

Tue. 3:36 PM

Pre Filter Pump 1

Post Filter Pump 1

Pre Filter Pump 2

Post Filter Pump 2

PR.LIMITS

SETUP RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Page 5-14 Programming

Revised 5/01

ITW Dynatec c. 2000

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

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

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

Access Code: ________

Pressure Sensor Type: max.

Bar/PSI Calibrat.

System depressurized ?

PSI/BAR

RETURN

CONFIRM RETURN

Pressure Screen #2

SYSTEM : Ready

Arrow

Keys

Pressure PSI (BAR)

Sensor Act.

3

4

1

2

100

100

?

100

Tue. 3:36 PM

Alarm PSI (BAR)

Low High

10

10

10

110

HI <--> LO

500

90

500

500

1, 2, 3

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

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

Programming Page 5-15

Revised 5/01

Use of the Optional Pressure Programming Screens

Press This

Function Key

Pr. Limits (F2)

Setup (F3)

To:

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

Enter access code in order to advance to calibration

Return (F4) Return to the Actual Temperatures Screen

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

Hi <--> Lo ((F3)

Bar/PSI (F1)

Calibrat. (F2)

Select the screen’s high or low column

Choose pressure scale

Calibrate all transducers

Programming

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

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

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

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

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

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

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

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

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

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

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

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

Monitoring

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

2. Over pressure or Under pressure arrows indicate conditions.

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

Page 5-16 Programming

Revised 7/02

ITW Dynatec c. 2000

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

Service Functions Screens

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

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

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

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

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

Functions coded

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

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

Service Page 1

Service Key

SYSTEM : Ready

Service Page 1 Press

Keys

Hi/Lo Temperature

Standby Temperature

Standby/ Sleep Setup

Setpoint Limitation

N/A

Temperature Offset

Sequential Heating

°C / °F

Change Security Lock

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

CODE

----

----

----

----

----

----

----

9

1, 2, 3

RETURN

Delete Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Alpha/Numeric

Keypad

Enter

ITW Dynatec c. 2000

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

Programming Page 5-17

Revised 7/02

Service Functions Screens,

Page 1 cont.

Function #

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

The High/ Low Temperature Deviation is a range (

±) representing the high and low temperature

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

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

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

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

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

° and you program a 100

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

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

°C and -150°C (-30°F and -150

°F).

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

Delay. Press Enter. Press Return (F4).

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

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

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

Mode, press Disable (F3).

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

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

ASU enters Sleep Mode three hours after entering Standby.

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

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

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

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

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

Page 5-18 Programming

Revised 7/02

ITW Dynatec c. 2000

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

Service Functions Screens,

Page 1 cont.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Press Service Key to advance to Service Page 2.

ITW Dynatec c. 2000

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

Programming Page 5-19

Revised 11/01

Service Functions Screens, cont.

Service Page 2

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

SYSTEM : Ready

Service Page 2

Keys

Press

Customer Zone Names

PowerOn Configuration

Factory Defaults

Keypad Locking

PC Link

Language

LCD Contrast

System Logbook

Change Security Lock

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

CODE

----

----

----

----

----

----

----

----

9

1, 2, 3

RETURN

Function #

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

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

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

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

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

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

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

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

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

Page 5-20 Programming

Revised 12/02

ITW Dynatec c. 2000

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

Service Functions Screens,

Page 2 cont.

Press #3 to program Factory Defaults.

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

Factory Defaults unprogrammed

.

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

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

Repeat until all lines are programmed.

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

Setup for setpoints and parameters* if required.

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

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

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

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

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

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

Press F4 to Return to menu.

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

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

“Load: from Computer to this Controller” or

“Save: From this Controller to Computer.

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

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

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

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

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

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

ITW Dynatec c. 2000

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

Programming Page 5-21

Revised 5/01

Service Functions Screens,

Page 2 cont.

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

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

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

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

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

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

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

SYSTEM : Ready

Arrow

Keys

Select Zones:

2

4

Enter Time Interval: 0.1 min.

Mode Run/Stop: RUN

.

Premelt 1

12

Tue. 3:36 PM

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

RETURN

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

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

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

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

Screen.

Service Page 3

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

SYSTEM : Ready

Service Page 3 Press

Keys

Zone Arrangement

PI Loop Setup

Split Hopper Setup

Gear Ratio

RPM Display Yes/No

Pump/Clutch Yes/No

Level Control Yes/No

I/O Troubleshooting

.

7

8

5

6

3

4

1

2

Tue. 3:36 PM for Next Page

F

F

F

F

F

Change Security Lock 9 1, 2, 3

RETURN

Page 5-22 Programming

Revised 5/01

ITW Dynatec c. 2000

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

Programming at Main Scheduler Screen

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

Program Recipes.

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

Main Scheduler Screen

Scheduler Key

SYSTEM : Ready

Arrow

Keys

Activate/ Deactivate Standby 1

Change Time & Date

Program Scheduler

Select Recipes 4

Activate/ Deactivate Scheduler 5

2

3

.

Tue. 3:36 PM

1, 2, 3

RETURN

Delete Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

ITW Dynatec c. 2000

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

Programming Page 5-23

Revised 11/01

Use of the Main Scheduler Screen

Function #

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

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

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

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

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

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

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

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

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

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

Press F4 to return to the Actual Temperatures Screen.

Shortcuts

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

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

Page 5-24 Programming

Revised 5/01

ITW Dynatec c. 2000

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

Programming of 7-Day Scheduler

7-Day Scheduler

The Seven-Day Scheduler allows the operator to program main power ON and OFF times which coincide with his daily production schedule throughout the work week. Up to ten “events” may be scheduled. An event is a specific day and time or every day at the same time.

An ASU which has an active seven-day scheduler should be turned ON at the main power switch.

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

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

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

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

7-Day Scheduler Screen

7-Day Scheduler Active Indicator

Keypad On/ Off

SYSTEM : Ready

Event # Action

7

8

5

6

3

4

1

2

9

10

Standby

Switch On

Standby

Switch On

Switch Off

-- -- -- --

-- -- -- --

-- -- -- --

-- -- -- --

-- -- -- --

Day

Mon-Fri

Mon-Fri

Mon-Fri

Mon-Fri

Mon-Fri

Everyday

Monday

Tuesday

Wednesday

Thursday

Tue. 3:36 PM

Time

5:00am

6:00am

11:30am

12:30pm

6:00pm

RETURN

Delete

Enter

SYM ABC

DEF

GHI JKL MNO

PRS TUV WXY

<

C

>

ABC/123

Enter

ITW Dynatec c. 2000

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

Programming Page 5-25

Revised 5/01

Use of the 7-Day Scheduler Programming Screen

Press This

Function Key

To:

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

Return (F4) Return to the Main Scheduler Screen

(Enter) Enter a chosen selection

Programming

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

2. Press Enter is displayed.

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

3. Scroll (F3) to the Day column.

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

5. Scroll (F3) to the Time column.

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

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

8. Press F4 to return to Main Scheduler screen.

ITW Dynatec c. 2000

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

Programming Page 5-26

Revised 10/01

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

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

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

DynaControl keypad.

Hardware Hookup

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

Download Instructions

Download = Transfer data from an external PC to DynaControl

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

2. Start the terminal program on PC.

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

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

5. Address setting is not used.

6. Press LOAD (F1).

7. Send ASCII file on terminal program.

8. DynaControl screen should list all received lines.

9. Press RETURN to exit service mode.

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

49-54, pressure 55-66).

Download File Format

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

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

Examples:

1. Downloading data for the first filterblock zone

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

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

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

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

cont.

Page 5-27 Programming

Revised 10/01

ITW Dynatec c. 2000

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

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

Notes:

The command lines may be arranged in random order.

Maximum file length is 5000bytes.

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

The DynaControl list screen indicates the commands in abbreviated form.

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

‘ER” indicates unknown command or syntax error.

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

Upload Instructions

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

The data format is similar to the download file.

Example:

¼..

*PREME. 1 410 35 --5 ON

¼..

*PUMP 2 M 850 100 900

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

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

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

*TXT--PU for Pumps

*TXT--PR for Pressure transducers

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

2. Start terminal program on PC.

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

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

5. Address setting is not used.

6. Start “Capture Textfile” at terminal program.

7. Press SAVE (F2).

8. Stop and close file on terminal program.

9. Press RETURN to exit service mode.

*Premelt

*Progmelt

*Filterblock

*Hose

*Head

*Aux Zone

*Pressure

*Pump

0--100.0%

*Text

Line Commands

(pag e 1 o f 2)

No#

No#

No#

No#

No#

No#

1--12

No#

1--12

No#

1--6

No#

Temp.:1--48

Pumps: 49--54

Press.: 55--66

Setpoint

Setpoint

Setpoint

Setpoint

Setpoint

Setpoint

50--450

Min--Pressure

0--1500

Mode

Manu/Auto/Stop

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance

5--50

Max--Pressure

0--1500

Manual%

0--100.0%

Customer Name

20 characters

Offset

Offset

Offset

Offset

Offset

Offset

0--50

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

ON / OFF

Automatic--Min%

0--100.0%

Automatic--Max%

Line Commands

(page 2 of 2)

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

*System

1

2

3

8

9

10

11

12

6

7

4

5

13

14

15

16

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

Setback General Setpoint

Power--On Heater

0/1 (1 = Start)

PI--Loop Premelt

(High= I Low= P)

Gear Ratio Motor. 1

Rpm--Displayn

(0/1)

Limitation

Power--On Motor

0/1 (1 = Start)

PI--Loop Progmelt

(High= I Low= P)

Gear Ratio Motor 2

Pump--Clutches

(Bit0¼Bit5, Bit7)

Heat up Sequence

(0,1,2)

Keypad Lock

Temp.Settings 0= free, 1= locked

PI--Loop Filterblo.

(High= I Low= P)

Gear Ratio Motor 3

Level Control

(0/1)

Electr.Head Hold

Temp.

Keypad Lock Motor Settings 0= free, 1= locked

PI--Loop Hose

(High= I Low= P)

Gear Ratio Motor

4

Bar/PSI

(Bar=0, PSI=1)

°C / °F

(°C=0, °F=1)

Configuration Lock

Page 1 Bit0¼Bit7,

1= lock

PI--Loop Head

(High= I Low= P)

Gear Ratio Motor

5

Pressure Sensortype

Spare

Configuration Lock

Page 2 Bit0...Bit7,

1 =lock

PI--Loop Aux Zone

(High= I Low= P)

Gear Ratio Motor

6

Active Recipe

(1¼4)

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

Zone#

Progmelt 1

Zone#

2

Progmelt Zone#

3

Progmelt Zone#

4

Progmelt Zone#

5

Progmelt Zone#

6

Progmelt

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

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

Zone# Hose 7

Zone# Head 1

Zone# Hose 8

Zone# Head 2

Zone# Hose 9

Zone# Head 3

Zone# Hose 10

Zone# Head 4

Zone# Hose 11

Zone# Head 5

Zone# Hose 12

Zone# Head 6

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

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

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

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

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

c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

Chapter 6

PREVENTIVE MAINTENANCE

Preventive Maintenance Page 6-1

Revised 9/00

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

General Cleaning

The DYNAMELT

Ò

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

The molded plastic handles may be cleaned with mineral spirits.

Preventive Maintenence Schedule

The Dynamelt M ASU requires little maintenance. The hopper is fitted with a coarse screen to prevent large debris from entering the system. Normally this screen does not require cleaning. The

ASU parts that require regular, periodic maintenance are as follows:

Outlet Filter

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

Use the following procedure to replace the outlet filter.

cont.

WARNING HIGH PRESSURE

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

WARNING

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

Page 6-2 Preventive Maintenance

Revised 3/01 c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

Adjustment Screw Cap

O-ring PN A69X133

Spring

Spring Clip

Filter Basket

PN 101246/ 40 mesh

PN 101247/ 100 mesh

Flat Surface

O-ring PN 069X275

Filter Plug

Roll Pin in Groove

Roll Pin

Slide in “Locked” Position

Slide in “Open” Position

Outlet Filter Manifold

Purge Set Screw

Purge Drain

Purge Set Screw

Purge Drain

Outlet Filter Manifold (located at the Hose Connection Panel)

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

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

3. Remove the Manifold Access Cover by unscrewing one screw. Then lift up and off.

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

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

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

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

c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

Preventive Maintenance Page 6-3

Revised 9/00 still pressure in the system. Stop and verify that the motor/ pump is turned OFF and the applicator’s valves are open before proceeding. Then repeat step 5.

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

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

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

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

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

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

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

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

12. Re-tighten the two purge screws.

Hose Fittings

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

Fasteners

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

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

Filter Shutoff Cleaning or Replacement

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

1. Pump all the adhesive out of the hopper.

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

cont.

Page 6-4 Preventive Maintenance

Revised 3/01 c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

WARNING HOT SURFACE

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

3. Open the two access doors located at the sides of the ASU. Do not pull out the ground wires attached. The filter shutoff assembly is located on the side of the hopper.

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

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

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

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

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

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

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

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

Pump Shaft Leak

There is a cutout in the baseplate, directly below the pump shaft(s), which will allow adhesive from a leaking pump to exit the ASU. Inspect the area under the baseplate cutout every month for adhesive. A leaking pump shaft indicates a worn pump seal. See instructions in Chapter 8 for replacement of this seal.

Summary of Preventive Maintenance Schedule

Monthly (or as experience dictates)

1. Inspect outlet filter basket. Replace as required.

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

Every Three Months (or as experience dictates)

1. Check all hose fittings for tightness.

2. Check all fasteners for tightness.

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

c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

Preventive Maintenance Page 6-5

Revised 9/00

Flushing the System

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

WARNING

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

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

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

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

3. Disconnect one of the supply hose’s adhesive feed from its applicator head. Do not disconnect the electrical power to the head (since that would disable the pump). Put the hose in a secured position within a container which will catch the used flushing fluid.

4. Add flushing fluid to the hopper and allow approximately fifteen minutes for it to reach hopper temperature. Carefully stir the flushing fluid to mix with any adhesive remaining in the hopper.

5. Slowly increase the pump pressure. Pump about half of the fluid through the hopper, pump and adhesive supply hose into the flushing container.

WARNING

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

6. Reduce the pump speed to zero.

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

”Outlet Filter” section of this chapter.

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

9. Slowly increase motor speed to the pump.

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

cont.

Page 6-6 Preventive Maintenance

Revised 3/01 c. 2000

DYNAMELT M ASU Manual 20-28 and 20-36

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

12. Re-fill the hopper with adhesive. The system is now ready for production.

ITW Dynatec c. 2000

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

Chapter 7

TROUBLESHOOTING

Troubleshooting Page 7-1

Revised 4/01

General Troubleshooting Notes

DANGER

HIGH VOLTAGE

WARNING

HOT SURFACE

Dynamelt systems use electrical power that can be life threatening and hot-melt adhesives that can cause serious burns. Re-read Chapter 1 “Safety Precautions” before performing any troubleshooting or repair procedures. All troubleshooting and repair procedures must be performed by qualified, trained technicians.

CAUTION: Printed circuit boards (PCBs) are prone to damage from static electrical charges during handling. Read “Handling Printed CIrcuit Boards” in this chapter before handling or attempting service on Dynamelt’s PCBs.

The Dynamelt’s DynaControl includes malfunction self-diagnostics, alerts and error indication alarms. The error indication alarms (the alarms displayed on the DynaControl readout) are triggered whenever there is a sensor failure and whenever there is an over-temperature condition. The operation of the error indication alarms is described in Chapter 4 of this manual.

Preliminary Checks: Verify the following before proceeding:

1. The ASU is switched on.

2. The ASU is supplied with power.

3. The ASU is supplied with pneumatic air.

4. Pneumatic and electrical connections are correct.

5. Adhesive is in the hopper.

Error Messages:

See Ch. 4 for complete instructions on Error Alarms and Message

s.

Sensor Failure on Zone # = temperature zone “#” has an open or shorted sensor.

Overtemperature on Zone # = temperature zone “#” has exceeded setpoint limitation.

Communication Error = indicates a serious problem which requires service by Dynatec.

Hopper Overtemp = hopper temperatures have exceeded their thermostat’s setting.

Hose/ Applicator Troubleshooting Tip

Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU. If the malfunction goes with the applicator and hose, the problem will usually be in the applicator or hose that was moved. If the malfunction does not move with the applicator and hose, the problem is probably in the ASU.

Motor Speed Control PC Board Re-set

Anytime the AC drives’s Motor Speed Control printed circuit board must be re-set due to line surges or over-currenting the motor, turn the ASU OFF by the main power switch and wait at least

20 seconds before attempting to re-start. This will allow the pcb to re-set. See the table on page 7-7 to troubleshoot.

Page 7-2 Troubleshooting

Revised 4/01

ITW Dynatec c. 2000

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

High-Temperature Redundant Overtemp Thermostat

The ASU includes a mechanical (redundant) overtemp thermostat that acts as a safety backup. If the

ASU’s hopper temperature should exceed 232

°C (450°F), the thermostat will cause the ASU’s circuit breaker to open and power to the hopper and all hoses and heads will be cut off. The mechanical thermostat must be manually re-set after the hopper temperature falls below 204

°C (400°F).

The overtemp thermostat is located behind the motor access door (see Chapter 8). To reset: turn

OFF the ASU’s main power switch, push the center of the thermostat’s insulator to re-set, restart the ASU.

Pump Enable Thermostat

The pump enable thermostat is a low-temperature safety feature of the Dynamelt ASU designed to prevent the pump from powering on before the adhesive is molten. It is a cartridge thermostat and it is factory set at 135 °C (275°F). The thermostat is adjustable so that operators using adhesives with extraordinarily high or low melting points can tailor the low-temp setting to their production’s needs.

To access the pump enable thermostat, follow the instructions given in Chapter 8. Refer to Chapter

3 for instructions on calibration of this thermostat.

Lithium Battery on CPU PCB

The CPU Printed Circuit Board contains a lithium battery which serves no function in the Dynamelt

M Series controller configuration.

Lithium Battery on Display CPU PCB

The Display CPU Board contains a lithium battery. The normal life of this battery is about ten years. When the battery needs replacement, the scheduler’s clock does not function, but other controller features remain intact. Return the board to ITW Dynatec for battery replacement.

ITW Dynatec c. 2000

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

Troubleshooting Page 7-3

Revised 4/01

Handling Printed Circuit Boards (PCBs)

The Dynamelt ASU and DynaControl controller utilize several printed circuit boards (PCBs). These boards are extremely sensitive to electrostatic charges. When working near or with any PCBs, the following procedures must be followed to avoid damage to them.

DANGER HIGH VOLTAGE

Before unplugging connectors from the I/O PCBs, ground yourself to the

ASU by touching any available unpainted cool metal surface, mounting screws, etc. This will avoid electrical discharge to the PCB assembly when you are removing and replacing connectors.

CAUTION: Printed circuit boards (PCBs) should be handled using the following procedures:

1. Wear a wrist grounding strap. If a grounding strap is not available, frequently touch a bare metal part of the ASU (unpainted frame, mounting screw, etc.) to safely discharge any electrostatic buildup on your body.

2. Handle a PCB by its edges only. Don’t grip a PCB across its surface.

3. When removed from the ASU, each PCB must be individually packaged inside a metallized, static drain envelope. Do not place the removed PCB on a table, counter, etc. until it has first been placed in or on a static drain envelope.

4. When handing a PCB to another person, touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the PCB to him.

5. When unwrapping a PCB from its static drain envelope, place the envelope on a

grounded, nonmetallic surface.

6. To cushion PCBs for shipment, use only static-drain bubble pack. Do not use foam peanuts or bubble pack not known to be static draining.

The following pages detail the Dynamelt M Series PCBs.

Page 7-4 Troubleshooting

Revised 10/07

ITW Dynatec c. 2000

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

CPU Printed Circuit Board

The CPU board contains the controller’s CPU chip (built into the board) and optional 7-Day

Scheduler chip. It also contains the optional Memory Card Reader interface and ribbon cable connection. The CPU chip (EPROM) can only be reprogrammed at ITW Dynatec’s factory.

The Low Level relay is fixed at normally open. The High/ Low Alarm relay is fixed at normally closed. During normal operation, the two red indicator lights are always ON.

Triac control for Hopper, Head/ Hose 1 & 2

PC/PLC Serial Channel

EPROM (not removable or programmable by user)

X5 X6

Audible

Alarm

BT1

+

Battery

Connect to Operator

Panel PCB

Relay outputs:

1&2 = alarm contacts

3&4 = low level contacts

Flat cable connect to

Auxiliary PCB or

Relay Output PCB

3

4

1

2 X1

X9

X16

X11

J2

IC5

S4

S3

S2

S1

ON

J1

LEDs

Optional Scheduler chip

(Dynatec factory use)

Dip switches

Flat cable connect to optional motor board

Flat cable connect to optional Memory

Card Reader

Terminal connections:

1 = Program Select 1 (1/2) Input

2, 4, 6, 8 = +12V

3 = Low Level Detect Input

5 = External Setback Input

7 = Program Select 2 (3/4) Input

9&10 = Ground

Flat cable connect to Power PCB

Sensor Inputs for

Head/ Hose 3 & 4

Sensor Inputs for

Head/ Hose 5 & 6 and Aux 1, 2 & 3

X4

X2

X7

X14

4

5

6

1

2

3

7

8

9

10

(cutout)

J6

X3

Sensor Inputs for

Hopper &

Head/ Hose 1 & 2

(cutout)

Sensor Input for channel 16

Layout of Components on CPU Board

ITW Dynatec c. 2000

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

Troubleshooting Page 7-5

Revised 4/06

Display CPU Printed Circuit Board

The Display CPU PCB contains the controller’s CPU module, scheduler battery, serial ports and optional connections. It is located directly behind the controller’s display panel within its mounting bracket (or within the remote pendant assembly (option), if applicable).

When downloading software updates, use the download serial port seen at the lower right of the illustration. While downloading, the J1 jumper is moved temporarily to its #1 position.

To configure the number of (optional) pressure transducers on an ASU, use the dip switches (shown below beneath the expansion board) and the following chart. There are four transducers per PSI

PCB and a maximum of three PSI PCBs per ASU. Note: PSI not available on APS models.

On the RS-Com board, both the J1 and

J2 jumpers must be in upper position for

485 and both in lower position for 232.

Dip Switches to configure

# of opt. PSI PCBs (only switches #1 & 2 are used) or APS model

Switch #

1

2

3

Optional RS232 Serial Connect

(use for PLC/ PC Link)

# of PSI PCBs

0 1 2 3

off on off on off off on on on = APS OFF = nornal

Optional RS485 Serial Connect (use for PLC/ PC Link)

Connect to opt.

Expansion Board

(for Serial Communication)

CAUTION! FOR

EXPANSION

BOARD CON-

NECT ONLY

J1 J2

1

Scheduler

Battery

Reset

Download

Reset

J1

SW2 SW1

Download Jumper

Connect to

CPU PCB

Layout of Components on Display CPU PCB

Software Download Port

Page 7-6 Troubleshooting

Revised 1/03

ITW Dynatec c. 2000

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

Motor Control Interface Printed Circuit Board

For each motor on the ASU, there is a Motor Control Interface PCB and a Motor Speed Control

PCB. The Motor Control Interface PCB (diagrammed below) connects directly to the CPU PCB.

The Motor Speed Control PCB (diagrammed on the following page) connects via a spade connector to the Motor Control Interface PCB. Up to two motor’s pcbs may be connected to one CPU PCB.

Each Motor Control Interface PCB’s jumpers should be set as follows: the J1 and J2 jumpers should always be set in the M1 position diagrammed below for motor #1, #3 and #5. For motor #2, #4 and

#6, jumpers J1 and J2 are set in the M2 position (opposite from those diagrammed below). The M/S selection jumper must be set in the “M” position. The J3 jumper is always set as shown below.

“MAX” speed adjusting pot: This pot adjusts the maximum output voltage of the motor speed control board. It is factory preset to full pump motor rpm (100%). Normally, this pot does not need adjustment. Turning clockwise increases the voltage. To verify adjustment, set the motor to “manual” mode and to 100% speed. Then adjust the pot to desired maximum speed ( ±5%).

NOTE: Do not attempt to use the MAX pot adjustment to trim the line speed to a given value.

Proper automatic line speed following is accomplished with correct motor programming into the controller (see Chapter 5).

“ENCODER” connections: the optional Digital RPM Readout’s encoder is installed onto these board connections.

MAX Speed Adjustment potentiometer

Flat cable connect to

CPU PCB at J1

Transformer Fuse

240 VAC input

M1 M2

J2

J1

X1

F1

M S

Transformer

X5

L1

N

VR1

J3

X2

Motor

10

0

En

En

P

X4

Web

0

5

X3

TR

TR

10

0

X2 connections are internal and not for customer’s use:

0-5 VDC speed reference

Ground not used

Pump enable

Pump enable

Encoder pulse not used

Ground

Encoder supply voltage

Handgun trigger input & pump enable

Handgun trigger input & pump enable

0-10 VDC input, web speed, msx. 40v

Web Speed Scaling potentiometer

Factory Set, Do Not Adjust

Layout of Components on Motor Control Interface Board

ITW Dynatec c. 2000

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

Troubleshooting Page 7-7

Revised 1/03

Motor Speed Control Printed Circuit Board

The Motor Speed Control PCB is connected to the Motor Control Interface Board via spade connctors P1 and P2. P3 is not used.

The three jumpers (FSR, J1 and A/M) are factory set, do not change. The J1 jumper is always set in the upper position. The A/M Jumper is always present.

“CL” adjusting pot: The current limit (CL) adjustment will limit the maximum current available to the AC pump motor during overload. This will protect the motor from damage. The setting is factory set to deliver 100% of the rated horsepower for the ASU. When the motor load exceeds the current limit value, the Status LED (light) will illuminate red (indicating an overload condition). Turning clockwise increases the current limit value; turning counter-clockwise decreases it. The current limit is factory preset, so no adjustment is necessary.

“ACC” and “DEC/B” adjusting pots: These pots change the time required for the pump motor to accelerate (ACC) or de-accelerate. Turning full counter-clockwise equals 0.3 seconds. Turning full clockwise equals 20.0 seconds. Factory default for either pot is 10.0 seconds.

cont.

FSR Jumper & connection to drive enable of Motor Interface PCB

Spade connectors (3) from Motor

Interface PCB

P1

P2

P3

Potentiometers:

Factory Set, Do Not Adjust

CL = Current Limit

J1 Jumper

A/M Jumper = Auto/ Manual

PWR = Power LED. Green = unit is ON

Line

L2

MAX = inactive

AC

L1

MIN = Minimum RPM

DEC/B = Decelerate

ACC = Accelerate

COMP = IR Comp

W

Motor

V

U

Spade connectors

(2) to incoming

Main Power

Spade Connectors

(3) to Motor

ST = Status Led. Red/ yellow/ green. See table below.

ST LED Color State

Green

Red

Red

Red

Slow Flash

ON

Function

Normal Operation

Current Limit

Quick Flash Overload

Slow Flash Short Circuit

ST LED Color State

Red/Yellow

Red/Yellow

Yellow

Function

Quick Flash Undervoltage

Slow Flash

ON

Overvoltage

Stop

Layout of Components on Motor Drive Board

Page 7-8 Troubleshooting

Revised 7/01

ITW Dynatec c. 2000

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

“MIN” adjusting pot: This pot adjusts the minimum speed of the pump motor when it is enabled.

The pot is factory preset to exactly zero RPM when the speed setting is 0.00% full scale. Turning clockwise increases the minimum RPM above zero RPM when the motor is enabled. This adjustment can be utilized to “creep” the motor (also referred to as “auto preload”) so that positive adhesive pressure is always maintained in the system.

ITW Dynatec c. 2000

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

Troubleshooting Page 7-9

Revised 9/01

48-Zone Power Printed Circuit Board

The 48-Zone Power PCB has the capacity to monitor adhesive temperatures for multiple hoses, applicators, hoppers and auxillary zones.

The LEDs for each temperature zone (1 through 48 illustrated below) will flash on and off as their heaters output to maintain setpoint temperature. The Power On and Hopper LEDs will light continuously once the hopper(s) are up to temperature.

The settings of the JP1 and JP2 jumpers correspond to the number of hoppers on the ASU. For an

ASU with one hopper, both jumpers must be set to position 1-2 (shown). For two hoppers, JP1 must be set at 1-2 and JP2 must be set at 2-3.

System

Ready outputs to customersupplied

PLC

Power ON for PLC

Power ON contactor

System 1

{

System 2

{

Future

{

{

{

System

Ready

(snubbed) power outputs

System 1

{

System 2

Future

{

{

Input

Power

240 VAC

{

L1

L2/N

PE

JS3

Jumper JP1

1&2 = 1 hopper

2&3 = 3 hoppers

Low temperature thermostats for

Hoppers 1, 2

Jumper JP2:

1&2 = 1 hopper

2&3 = 2 hoppers

High temperature thermostats for

Hoppers 1, 2

Connect to

CPU 1 at

X16

Connect to

Clutch pcb

12 11 10 9 8 7 6 5 4 3 2 1

JF1

JS1

JS4

LED

LED

JS5

1 3

1

JP1

Power ON

Hopper 1 Ready

JP2

3

JF5

CPU 1

Connect to

CPU 2 at

X16

CPU 2

JF6

LED

LED

Hopper 2 Ready

Future

JS2

Transformer

F1

JH1

2

1

4

3

6

5

8

7

12

11

10

9

16

15

14

13

JH2

20

19

18

17

24

23

22

21

28

27

26

25

32

31

30

29

JF2

JF3

Connect to

CPU 3 at

X16

CPU 3

JF7

JF4

JH3

36

35

34

33

40

39

38

37

44

43

42

41

48

47

46

45

Solid state relay driver outputs

(1 per zone)

LED:

Green = zone is heating

Transformer Fuse

(5x20 1 amp)

Connect to

CPU 1 at

J6

Connect to

CPU 2 at

J6

Connect to

CPU 3 at

J6

Layout of Components on 48-Zone Power Board

Page 7-10 Troubleshooting

Revised 6/01

ITW Dynatec c. 2000

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

Optional Clutch Printed Circuit Board

The Clutch PCB allows installation of up to six (optional) clutches on the ASU.

The dip switches (SW1) are turned ON to reflect the number of clutches on the system.

Relay

Green LED = clutch is activated

Clutch 1

#1 cl

JS2

JS1

Clutch 3

Clutch 2

Clutch 4

Clutch 5 Clutch 6

Green LED = System Power ON

Clutch Coil Leads Connects

Customer Enable Switches: for a footswitch, hand-held applicator, etc.

Board

Fuse

#6 cl

F1

L1 L2

JS3

240 VAC Input

Layout of Components on Clutch Board

SW1

ON

1

6

JF1

Connect to 48-Zone

Power Board at JF1

Dip Switches:

1 clutch = switch #1 is ON

2 clutches = switch #1 & 2 are ON

3 clutches = switch #1, 2 & 3 are ON

4 clutches = switch #1, 2, 3 & 4 are ON

5 clutches = switch #1, 2, 3, 4 & 5 are ON

6 clutches = all switches are ON

Optional RS232/485 Printed Circuit Board

Pin Configuration:

RS232

2 RxD

3 TxD

5 Gnd

S Shield

RS485

3 TxB

4 TxA

8 RxB

9 RxA

S Shield

(Pins not listed are not used)

3

2

5

4

1

7

6

9

8

Shield

Ribboncable connect to

Display CPU PCB

Layout of Components on Communication Board

ITW Dynatec c. 2000

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

Troubleshooting Page 7-11

Revised 4/01

Optional Pressure (PSI) Printed Circuit Board

Each Pressure (PSI) PCB on the ASU allows the controller to monitor up to four pressure transducers. The DM35 ASU can accept one PSI PCB (four transducers), the DM70/140 ASUs can accept up to two PSI PCBs (up to eight transducers) and the DM210 ASU can accept up to three PSI PCBs

(up to 12 transducers). Each CPU board can accomodate one PSI PCB.

The 8 pairs of terminals at the top edge of the board (as seen below) are for the high and low alarm outputs of the relays. The eight jumpers for the high/ low alarm output relays (E1 thru E8) are factory set to Normally Open (default) and are illustrated below in default position.

The leads from the pressure transducers are connected at the left of the board (as seen below).

Note: the quantity of pressure transducers on an ASU is configured at the dip switches on the Display CPU PCB.

Input connections from Transducers:

Transducer #1

X1

X2

High & Low Alarm Outputs

4 High 4 Low 3 High 3 Low 2 High 2 Low 1 High 1 Low

X6

E8

E7 E6 E5 E4 E3 E2 E1

Transducer #2

X3

Transducer #3

X5

X4

Transducer #4

Jumpers for

High/Low Alarms:

Normally Open (default)= no alarm/ no continuity

Normally Closed = no alarm/ has continuity

Flat cable to

CPU PCB

Green LED = Board logic power is OK

Layout of Components on Pressure Board

Page 7-12 Troubleshooting

Revised 5/02

ITW Dynatec c. 2000

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

Heater and Sensor Resistance Values

The resistance values given in the four tables on the following page will aid in troubleshooting when a sensor or heater malfunction is suspected. The “Temperature Sensor Resistance” table gives values for various temperatures. If you know the approximate temperature of the suspected sensor, you can check to see if the sensor resistance approximates the value given in the table by unplugging the affected head or hose connection and measuring resistance across the affected pins (see wiring diagram in Chapter 11 for pin numbers).

DANGER HIGH VOLTAGE

Disconnect input power to the application system before disconnecting/ re-connecting electrical connections. Make sure there is no electrical power on the leads you will be connecting.

The “Nominal Hose Heater Resistance” table gives the heater resistance for hoses. A suspected hose heater problem can be quickly isolated by measuring hose heater resistance and comparing it to the correct resistance for your hose length and voltage as shown.

The “Nominal Head Heater Resistance” table gives values for several different head wattages. A suspected head heater problem can be isolated by measuring head heater resistance and comparing it to the resistance for the appropriate wattage of your system.

The “Nominal Hopper Heater Resistance” table gives heater resistance for the hopper heaters of each Dynamelt M Series model and for the (optional) drop-in grids.

The “Nominal Filter Manifold Heater Resistance” table gives heater resistance for the heater located in the (optional) filter manifold/ pressure relief block. The heater inside the manifold varies depending on the number of filter manifolds mounted on the ASU, therefore resistance varies also.

c. 2000

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

Troubleshooting Page 7-13

Revised 10/00

°

F

Temperature

°

C

Resistance in Ohms

176

194

212

230

248

268

284

302

32

50

68

86

104

122

140

158

320

338

356

374

392

410

428

80

90

100

110

120

130

140

150

40

50

60

70

0

10

20

30

160

170

180

190

200

210

220

131

135

139

142

146

150

154

157

100

104

108

112

116

119

123

127

161

164

168

172

176

180

183

Temperature Sensor Resistance

(0.00385 PT 100 RTD)

Hose Length

Meters Feet

Resistance in Ohms

1.2

1.8

2.4

3

3.7

4.9

7.3

4

6

8

10

12

16

24

323-358

201-223

155-172

120-133

102-114

75-84

51-57

Nominal Hose Heater Resistance for DynaFlex Hoses

Watts Resistance in Ohms

200

270

350

500

700

288

213

165

115

82

Nominal Head Heater Resistance

Note: Resistance is measured at ambient temperature (20

Model :

Qty. Hopper Heaters

Max. # of Drop-in Grids

Resistance (Ohms) for each Hopper Heater

Resistance (Ohms) for each Drop-in Grid Heater

M35

1

2

11.5

23

M70/ 140

2

4

11.5

23

Nominal Hopper Heater Resistance in Ohms

°C/ 68°F).

M210

3

6

11.5

23

# of Filter Manifolds on ASU

Model: M35 M70/ 140 M210

1

2

3

4

5

6

115.2

51.6

not available not available not available not available

115.2

51.6

38.4

28.8

not available not available

115.2

51.6

38.4

28.8

TBD

186

Nominal Filter Manifold Heater (optional) Resistance in Ohms

Page 7-14 Troubleshooting

Revised 10/00 c. 2000

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

Error Indication Alarm Troubleshooting Guide

The operation of error indication alarms is described in Chapter 4. When checking for correct equipment operation in the following guide, be aware that all heaters will go off immediately after an error indication alarm occurs if the operator takes no action. With the exception of the fuses, there are no user-replaceable parts on the printed circuit boards. If there is a non-fuse failure on any of the PCBs, the PCB must be replaced.

Problem

Hopper (tank)

Overtemp

DANGER HIGH VOLTAGE

Some of the procedures in the following Troubleshooting Guide require potentially dangerous electricity to be present. Only qualified service personnel should perform these procedures.

Hopper Sensor

Possible Cause Solution

1. Setpoints have been programmed without enough deviation.

1. Re-program setpoints, allowing a larger deviation between the high and low limits.

2. Hopper sensor inoperative.

3. Hopper control solid state relay inoperative.

2. Replace hopper sensor if resistance does not comply with the resistance table in this chapter.

3. a. Verify that the relay is not shorted by removing all of its output wires and verifying that resistance is greater than zero.

b. Verify condition of relay by disconnecting, then re-connecting properly.

Then, when Temperature Zone is OFF, use a VOM AC voltmeter to verify that

240 volts are not present at the heater terminal.

Solid State

Relay

Solid State

Relay

c. 2000

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

Problem

Hopper Sensor Open

Possible Cause Solution

Troubleshooting Page 7-15

Revised 10/00

1. Sensor cable has become unplugged from CPU PCB

1. Verify that hopper sensor cable is properly connected on X14 on the CPU

PCB.

2. Inoperative hopper sensor.

2. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

Hopper Sensor

X14

Hopper Sensor Short

CPU PCB

1. Short-circuit caused by debris where sensor plugs into CPU PCB.

2. Pinched sensor lead wire.

3. Inoperative hopper sensor.

1. Verify that sensor plug is clean and correctly connected on X14 on the CPU

PCB.

2. Visually inspect sensor lead wire for break, kink, damage, etc. If no obvious damage, use an ohmmeter to measure continuity from the sensor lead to the plug at the CPU PCB. Repair or replace any damaged wire.

3. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

Page 7-16 Troubleshooting

Revised 10/00 c. 2000

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

Problem

Hopper Heater Open

Hopper

Sensor

Thermostat

Hopper

Heater Wire

Hopper Circuit Breaker

Possible Cause Solution

1.Disconnection in hopper heater circuit.

1. Inspect hopper heater wiring for proper connections.

2. Disconnection between

Power PCB and CPU PCB.

2. Verify that all connections are properly made on the CPU PCB.

3. Hopper circuit breaker tripped.

4. Open hopper heater element.

3. Refer to the schematic in Chapter 11 to locate the hopper circuit breaker. If it is tripped, do not re-set it without checking for causes. Visually and electrically inspect for a shortcircuit to ground in the hopper heater circuit. This will be limited to between the hopper control relay and the hopper heater.

4. At the terminal rail: use an ohmmeter to measure resistance across H3A and

N (380v) or across H3A and H3B

(240v). See the resistance table in this chapter for normal resistance values. Infinitely high reisistance values indicate an open heating element which must be replaced.

NOTE A: DM70/140 models may have up to two hopper heaters.

If the ASU has a second heater, measure this heater’s resistance across H15A and

N (380v) or across H15A and H15B

(240v) as outlined above.

NOTE B: DM210 models may have up to three hopper heaters.

If the ASU has a second heater, see Note

A. If the ASU has a third heater, measure this heater’s resistance across H27A and

N (380v) or across H27A and H27B

(240v) as outlined above.

(Optional) Drop-in

Grid Overtemp

2500w

Heater

Leads

1. Setpoints have been programmed without enough deviation.

2. Grid sensor inoperative.

Grid

Sensor

1. Re-program setpoints, allowing a larger deviation between the high and low limits.

2. Examine grid sensor assembly for intermittent break in sensor lead.

Remove sensor bulb from grid.

Replace grid sensor if resistance does not comply with the resistance table in this chapter.

X14

c. 2000

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

Problem

(Optional) Drop-In

Grid Sensor Open

(Optional) Drop-in

Grid Sensor Short

CPU PCB

Troubleshooting Page 7-17

Revised 10/00

Possible Cause

3. Grid control solid state relay inoperative.

Solution

3. Use a clamp-on ammeter to monitor current. Replace inoperative solid state relay.

1. Sensor cable has become unplugged from CPU PCB.

1. Verify that grid sensor cable is properly connected at X14 on the

CPU PCB.,

2. Disconnection between

Power PCB and the CPU

PCB.

3. Drop-in grid sensor inoperative.

2. Verify that all connections are properly made on the CPU PCB.

3. Replace sensor if resistance does not comply with the resistance table in this chapter.

1. Short-circuit caused by debris where sensor plugs into CPU PCB.

2. Pinched sensor lead wire.

3. Drop-in grid sensor inoperative.

1.Verify that sensor plug is clean and correctly connected at X14 on the

CPU PCB.

2. Visually inspect sensor lead wire for break, kink, damage, etc. If no obvious damage, use an ohmmeter to measure continuity from the sensor lead to the plug at X14 on the Power PCB. Repair or replace any damaged wire.

3. Replace sensor if resistance does not comply with the resistance table in this chapter

Page 7-18 Troubleshooting

Revised 10/00 c. 2000

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

Problem

(Optional) Drop-in

Grid Heater Open

Grid

Sensor

2500w

Heater

Leads

Possible Cause Solution

1. Disconnection in grid’s heater circuit.

2. Disconnection between

Power PCB and solid state relay.

3 Drop-in grid circuit breaker tripped.

1. Inspect grid’s heater wiring for proper connections.

2. Verify that the Power PCB is properly connected to the solid state relay.

3. Refer to the schematic in Chapter 11 to locate the grid’s circuit breaker. If it is tripped, do not re-set it without checking for causes. Visually and electrically inspect for a shortcircuit to ground in the grid’s heater circuit. This will be limited to between the grid’s control relay and the grid’s heater.

4. Open drop-in grid heater element.

NOTE: The DM35 ASU may have 1 or 2 grids. The

DM70/140 ASU may have from 1 to 4 grids.

The DM210 ASU may have from 1 to 6 grids.

4. At the terminal rail, use an ohmmeter to measure resistance as follows:

For 1 grid: H1A & N (380v)

H1A & H1B (240v)

For 2nd grid: H2A & N (380v)

H2A & H2B (240v)

For 3rd grid: H13A & N (380v)

H13A & H13B (240v)

For 4th grid: H14A & N (380v)

H14A & H14B (240v)

For 5th grid: H25A & N (380v)

H25A & H25B (240v)

For 6th grid: H26A & N (380v)

See the resistance table in this chapter for normal resistance values. Infinitely high reisistance values indicate an open heating element which must be replaced.

c. 2000

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

Troubleshooting Page 7-19

Revised 10/00

Problem Possible Cause Solution

Hose/ Head

(No.) Overtemp

Note: Vertical configuration is for

DM 35 only. Larger ASUs are arranged horizontally.

Aux.

#1

Aux.

#2

#1

#2

Sensor

Heater

Plug

Sensor &

Heater

Hose/ Head (No.)

Sensor Open

1. Hose/ Head setpoints incorrectly programmed.

1. Re-program setpoints to allow a larger deviation.

2. Inoperative or shorted hose/ head triac or dual solid state relay.

2. Refer to the schematic in Chapter 11 to locate the correct head/ hose triac or relay. Use a clamp-on ammeter to monitor hose/ head current. If current does not cycle on and off, then the triac or relay has failed and must be replaced.

3. Disconnection between the

Power PCB’s and the CPU board’s flat cables.

3. Verify that all PCBs are properly mounted inside the panel box.

4. Hose/ Head sensor circuit inoperative.

4. a. Visually examine socket connection where hose/ head attaches to ASU.

Verify that pins are properly seated. If pins or plug housing are damaged, repair or replace hose. If socket is damaged, repair or replace harness.

b. If hose-to-ASU plug and socket are okay, hose may have intermittent short or open circuit. Repair or replace hose, hose harness or Power PCB as appropriate.

Alternately, problem can be isolated by connecting the effected hose to a different ASU hose socket to tell whether the problem is in the hose or in the Power PCB.

1. Disconnection between hose and ASU.

c. If head-to-hose and hose-to-ASU plugs and sockets are okay, head sensor may have an intermittent short or open circuit. Examine connections inside the service block area of the head and monitor head sensor resistance with an ohmmeter while flexing sensor leads. Repair or replace as appropriate.

1. Visually examine connection where hose plugs into ASU socket for proper contact and seating. If pins or housings are damaged, repair or replace hose or hose harness (in ASU).

Page 7-20 Troubleshooting

Revised 10/00 c. 2000

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

Aux.

#2

#1

#2

Problem

Note: Vertical configuration is for

DM 35 only. Larger ASUs are arranged horizontally.

Aux.

#1

Possible Cause Solution

2. Hose sensor harness unplugged from Power

PCB.

2. Verify that effected hose is properly connected to Power PCB. Replace or repair damaged hose harness as necessary.

3. Disconnection between the

Power PCB’s and the CPU

PCB’s flat cables.

3. Verify that all PCBs are properly mounted inside the panel box.

4. Hose/ Head sensor circuit inoperative.

4. Replace head sensor if resistance does not comply with resistance table in this chapter. Use hose schematic to check hose sensor at ASU socket. Repair or replace hose, hose harness or Power

PCB as appropriate.

Hose/ Head (No.)

Sensor Short

1. Debris at connection between hose/ head and

ASU.

2. Hose/ Head sensor circuit inoperative.

1. Visually inspect hose plug and ASU socket for cleanliness and proper contact and seating of pins.

2. a. Using the hose schematic, check hose sensor resistance at ASU socket. An ohmmeter can be used to isolate a pinched wire in the hose harness.

When cause is isolated, replace hose, hose harness or Power PCB as appropriate.

b. If head-to-hose and hose-to-ASU plugs and sockets are okay, head sensor may have an intermittent short or open circuit. Examine connections inside the service block area of the head and monitor head sensor resistance with an ohmmeter while flexing sensor leads. Repair or replace as appropriate.

c. 2000

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

Problem

Hose/ Head (No.)

Heater Open

Sensor

Heater

Plug

Sensor &

Heater

Troubleshooting Page 7-21

Revised 10/00

Possible Cause Solution

1. Disconnection between hose/ head and ASU.

1. Visually examine effected hose plug and ASU socket for cleanliness and proper contact and seating. Refer to the wiring diagram for pin identification. The problem can be isolated by plugging the effected hose/ head into another ASU socket. If the new hose number is then displayed as malfunctioning, the problem is in the hose that was moved. Repair or replace hose, head or ASU hose harness as appropriate.

2. Disconnection between solid state relay and

Power PCB or inoperative relay.

2. Check connection. Verify that solid state relay is operative: check schematic in Chapter 11 for relay location. Use a clamp-on ammeter to monitor hose/

Head current. If current does not cycle on and off, the relay has failed and must be replaced.

3. Disconnection between cartridge heater and cable assembly inside head.

3. Visually inspect wiring inside head.

Verify that cartridge heater leads are properly connected in the service block area.

4. Inoperative hose/ head circuit breaker.

4. Refer to schematic in Chapter 11 for location of circuit breaker. If it is found to be tripped, do not re-set it without first finding cause. Visually inspect and use an ohmmeter to check for a possible short circut to ground in the hose/ head heater circuit.

5. Open hose/ head heater element.

5. Use an ohmmeter to measure hose/ head heater resistance. See resistance table in this chapter for resistance values. Infinitely high resistance indicates an open heater element.

6. Open wiring inside ASU.

6. Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate open wires in head heater circuit. Repair or replace ASU hose head harness or other ASU wiring as necessary.

Page 7-22 Troubleshooting

Revised 10/00 c. 2000

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

Adjustable Adhesive Pressure Relief Valve

Dynamelt pumps are outfitted with a high-pressure relief valve located on the outlet filter manifold.

The valve is adjustable and it does not affect adhesive pressure under normal operating conditions.

The adjustable pressure relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.

When adhesive pressure exceeds the set limit, the pressure forces the valve to move away from its seat, compressing the spring and allowing adhesive to flow back to the hopper. This adhesive flow reduces pressure. When the pressure falls below the set limit, the spring forces the valve against its seat, cutting off adhesive flow. The check valve, seen below, is not instrumental in pressure relief. It serves as an overflow valve, preventing adhesive from flowing out of the hopper when the filter plug is removed.

Normally Closed (Unrelieved):

In the drawing below, the pressure relief valve is closed.

Open (Relieved):

In this drawing, pressure has exceeded the setting of the valve, causing it to open and discharge adhesive to the hopper.

Adjustment

Screw Cap

Check Valve

Check Valve return to hopper from pump

Spring

Pressure

Relief

Valve return to hopper from pump to hose

Adhesive flow through filter block to hose

Adhesive flow through filter block to hose

Operation of the Adjustable Adhesive Pressure Relief Valve

Pressure

Relief

Valve

Filter

Basket to hose

c. 2000

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

Troubleshooting Page 7-23

Revised 10/00

Operation of the ASU’s Gear Pump

Manual or Automatic Pump Operation

Choose “Manual”, “Stop” or “Automatic” gear pump operation via the “Motor” pushbutton (see icon above) on the controller’s keypad. When the Dynamelt’s pump is to be operated manually (that is, without a line following signal), the manual mode is used to control pump speed (and adhesive output). For the gear pump to be operated in the automatic mode, a tach generator, or equivalent (attached to the parent conveyor line) must be provided and the following set-up procedure should be performed:

1. The tach generator or the signal isolator must be adjusted so that the voltage from the speed controller is 0 to 10 VDC (but not more than +10 VDC when the conveyor is at maximum speed). This voltage is measured at either X3 on the Motor Control Interface PCB (for a tach generator) or at terminals 9 (+) and 10 (-) of the Signal Isolator Board.

2. The “Automatic” setting then changes pump speed for any given 0 to +10 VDC incoming tachometer signal. Voltage will vary given production speed.

The motor speed can be adjusted (trimmed) in automatic mode by setting maximum and minimum percent of full speed values on the controller’s keypad. MAX % of Full Speed will be the true motor speed at 10 volts input. This value cannot exceed 100%.

To make the motor speed adjustment, follow the programming instructions in Chapter 5.

Pump Output Adjustment

When the adhesive in the ASU’s hopper has reached a temperature high enough for the pump to operate safely, the controller will place the hopper in “Ready” condition and power will be supplied to the pump. The pump is self-priming.

Pump output is adjusted by the motor speed control on the controller’s keypad. However, if less pressure is needed, maximum pressure of the pump can be decreased (or increased) by adjusting the pressure relief valve installed on the pump output manifold. To change the setting of this valve, refer to instructions in Chapter 3.

The relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.

Page 7-24 Troubleshooting

Revised 10/00 c. 2000

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

Troubleshooting the ASU’s Gear Pump

No special tools are needed for working on the ASU pump. See Chapter 8 of this manual for diaassembly/ assembly procedures for the ASU pump, and Chapter 10 for locating pump parts on the component illustrations (exploded-view drawings).

Gear Pump Priming/ Start-Up

The pump is self priming.

CAUTION: DO NOT continue to run the pump if no glue is coming out. This could damage the pump since it uses the glue as a lubricant. Stop and troubleshoot.

c. 2000

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

Troubleshooting Page 7-25

Revised 10/00

Gear Pump Troubleshooting Guide

WARNING HOT SURFACE & ADHESIVE

Some of the procedures in the following Troubleshooting Guide require working near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing and use proper tools for handling hot melt components.

Note: Each motor and Motor Interface PCB in the system can run independently (or dependently). Each Motor Interface PCB may have its own operating parameters. Therefore, each motor and Motor Interface PCB should be troubleshot independently.

Problem Possible Cause

Pump doesn’t operate 1. Motor On/Off is OFF at in “Manual” mode, the controller keypad.

power light doesn’t light.

ON/OFF Led

2. Hopper temperature is below ready setpoint.

Solution

1. Check keypad setting.

3. No incoming electrical power.

2. Pump cannot operate until hopper has reached “ready” condition. Verify that hopper has reached ready. Re-program hopper operating setpoint and ready setpoint if necessary.

3. Check to see if ASU temperature control is operating. If not, check for presence of incoming supply voltage.

Pump doesn’t operate 1. “Manual” motor is set at in “Manual” mode, zero (at the keypad).

power light is ON, hopper is at “ready” condition.

2. If pump On/Off is being controlled by a remote switch (i.e., a hand-held, applicator), the switch or switch circuit may be open.

1. Re-program motor.

2. Check condition of the remote switch

(the hand-held applicator).

3. Low temp alarm.

4. Faulty Motor Control

Interface Board.

3. Verify that ASU is warmed up and that hopper temperature is above the factoryset pump enable temperature.

4. If the board is faulty it must be replaced.

Page 7-26 Troubleshooting

Revised 6/01 c. 2000

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

Problem Possible Cause

Solution

Pump doesn’t operate 1. Parent machine is not in “Auto” mode, running.

power light is ON, hopper is at ready conditon.

2. “Auto” motor is set at zero (at controller keypad).

1. Check parent machine.

2. Re-program motor.

Motor Control Interface PCB

X3

3. No incoming line following signal.

4. Internal ASU connections or Motor Control Interface

PCB inoperative.

3. Check for presence of 0 to 10 VDC control signal at X3 of Motor Control

Interface PCB. If signal is not present, check connection at X3 and tachometer drive connections. If control signal is present there, the problem is within the

ASU.

4. Check for the presence of 0 to 10 VDC control signal at X3 of Motor Control

Interface PCB. Check ASU connections

(S1 & S2). If the signal is not present, the problem is in the connection. If the signal is present there, the problem is most likely a faulty Motor Control Interface Board.

5. System is not ready, temperatures are too low.

5. Verify that ASU is warmed up and that hopper temperature is above the low temperature thermostat.

Pump runs but there is 1. ASU is out of adhesive.

no adhesive output.

2. If pump has been serviced and leads reversed, pump will run with no output.

1. Add adhesive to hopper.

2. Check pump wiring to schematic.

Low or inconsistent adhesive output.

Filter Basket

1. Filter(s) clogged.

2. Adhesive used is too viscous.

3. Clogged hose.

4. Clogged applicators.

1. Remove and inspect filter basket and primary filter.

2. Verify that system components are at appropriate temperatures and that the selected adhesive is correct for the application.

3. Inspect hose for kinks or internal plugs of debris or char. Clean or replace hoses as necessary.

4. Inspect applicators for plugged nozzles or filters. Clean or repair applicators as necessary.

c. 2000

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

Problem

Troubleshooting Page 7-27

Revised 10/00

Possible Cause

5. The fixed pressure relief valve is opening.

6. Inoperative lower o-ring in filter plug is allowing pressure to escape.

Solution

5. When fully closed (clockwise) and all applicators are off, adhesive pressure should be around 34 bar

(500 psi). If it is significantly less, the pressure relief valve should be replaced.

6. Replace o-ring. Follow diagram and instructions in Chapter 6 for “Outlet

Filter” to locate the o-ring.

Adhesive leak at pump 1. Pump seal is incorrectly shaft seal.

positioned inside the seal and bearing assembly.

Seal Assembly

Rear Plate

O-ring

2. Pump seal inoperative.

1. Remove seal and bearing from pump.

Verify that all components are correctly positioned.

2. Remove seal from pump, inspect it and replace it if worn or damaged.

Be sure there are no burrs or other sharp edges on pump shaft or on installation tools that could damage a new seal.

Adhesive leak at pump- 1. O-ring in pump’s rear to-hopper interface.

plate is inoperative.

1.Remove seal from pump, inspect it and replace it if worn or damaged. Be sure there are no burrs or other sharp edges on the rear plate o-ring groove that could damage a new o-ring.

2. Pump assembly screws are missing or loose.

2. Verify that all four pump screws are tightly assembled to the hopper.

3. Helicoil insert pulled out of hopper.

3. Remove pump and inspect hopper.

Repair or replace hopper as necessary.

Page 7-28 Troubleshooting

Revised 10/00 c. 2000

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

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36

Disassembly & Re-assembly Page 8-1

Revised 4/01

Chapter 8

DISASSEMBLY & RE-ASSEMBLY PROCEDURES

Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All disassembly and repair procedures must be performed by qualified, trained technicians.

Disassembly Procedures

Note: Use the exploded-view drawings referenced with each procedure in conjunction with the instructions outlined in this chapter. Read the “cautions” on page 8-4 before re-assembling the ASU.

To Remove the Access Doors

There are two access doors, one on either side of the ASU. Use the key to unlock the door, then lift it off, being careful not to pull off the ground wire attached. Remove the ground wire and re-attach when the door is re-installed. These doors allow access to: the motor, pump, junction box, (optional) drop-in grids, filter shutoff and (optional) ball valve.

To Open Junction Box

The junction box is on the right-hand side of the hopper. Within the juction box are the thermostats, heater terminals and the hopper sensor. The junction box cover is removed via the two screws at the bottom of the cover.

Panel Box

Assembly

Access

Door

Keylock

Filter Shutoff Assembly

Ball Valve Assembly

(option)

Junction Box

Over-Temp Reset

Thermostat

Pump Enable

Thermostat

Filter Manifold

Manifold Cover

Page 8-2 Disassembly & Re-assembly

Revised 9/00 c.2000

DYNAMELT M ASU Manual 20-36

Junction

Box cover

Hopper

Junction

Box

Cutouts for conduit connectors for filter manifold heater and sensor.

Over Temp

Reset

Thermostat

Cutouts for drop-in grid assembly

Filter Shutoff

Junction Box

Hopper Sensor

Port

Heater

Terminals

Side View

Pump Enable-

Thermostat Port

Sensor or Thermostat Replacement

Remove the junction box cover.

a.

Over-Temperature Thermostat Replacement:

Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper.

b.

Pump Enable Thermostat Replacement:

Disconnect two wires from the terminal strip and slide the thermostat out.

c.

RTD Sensor Replacement:

Disconnect two wires from the terminal strip and slide the sensor out.

To Remove the Manifold Cover

Unscrew its captive screw and slide cover up and off. Cover allows access to the hose connections on the filter manifold, outlet filters, heaters and the pressure relief.

Heater Replacement

One heater is located in the heater plate underneath the hopper:

Remove the access door. Use a hex head socket wrench to remove the six heater plate bolts through the holes drilled in the base plate. Disconnect the heater wires. Slide the old heater plate out. Connect heater wires to new plate. Slide new plate in place and fasten with the six bolts.

One cartridge heater is located under the filter manifold:

At the rear of the ASU, remove the filter manifold cover. Remove the cover located at the end of the heater retainer plate (4 screws). Disconnect heater wires from the terminal rail. Loosen the heater retainer plate and slide the cartridge heater out.

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

Remove the access door. Remove the screws on the drop-in grid’s junction box cover in order to remove the cover. Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter.

c. 2000

DYNAMELT M ASU Manual 20-36

Disassembly & Re-assembly Page 8-3

Revised 4/06

To Access Electrical Components inside the Panel Box

Verify again that the main power is OFF. On the outside of the panel box, use the main disconnect switch to open panel box door (see Chapter 3 for instructions for opening door).

a.

Fuse Replacement:

Fuses are located in the upper right corner of the inside of the panel box assembly. The following printed circuit boards are fused: Motor Control Interface, Power I/O and the optional Clutch board.

b.

Printed Circuit Board Replacement:

Reference the section entitled “Handling Printed Circuit Boards” in Chapter 7. The PCBs are located in the panel box assembly. Refer to detailed layout in Chapter 3.

The PCBs snap into and out of their standoffs. To remove: place your fingertips under one corner of the PCB and pull out firmly from the standoff. Repeat for each corner of the PCB.

Note: aside from fuses and the Lithium battery on the M Series CPU PCB (see Chapter 7), there are no replaceable parts on the PCBs.

Page 8-4 Disassembly & Re-assembly

Revised 9/00 c.2000

DYNAMELT M ASU Manual 20-36

To Access the Pump or Motor

DANGER HOT SURFACE & HIGH VOLTAGE

If the pump is not operable but the heating system will function, raise the temperature of the application system to the operating temperature to aid in the pump disassembly process. Otherwise, a heat gun or other controlled heating method is recommended to melt hardened hot melt material. Never use a torch or an open flame on any of the components of the application system. Once the system is up to temperature, disconnect all incoming power before proceeding.

Remove access door(s) using the key, being careful not to pull off the ground wires attached.

Turn OFF the filter shutoff valve by turning it to its closed “0” position.

a.

Motor Removal:

Disconnect the wires leading to the motor. Unscrew the hex nut on the cord grip. Slide the wires through the fitting. Remove the four bolts which attach the motor to the mounting bracket. Slide the motor out of the ASU.

For re-assembly: torque should be approximately 1.8 Nm (16 foot/lbs) at room temperature.

With hopper at 177 °C (350°F), the maximum allowable torque on screws is 4.1 Nm (36 foot/lbs).

Panel Box

Assembly

Motor Mounting Bolts

Motor

c. 2000

DYNAMELT M ASU Manual 20-36

b.

Pump Removal:

Verify that the filter shutoff is in its closed “0” position. Loosen motor adapter plate screws and slide adapter plate with motor away from pump and coupling. Slide the coupling off the pump shaft. Remove the four pump mounting bolts.

c.

Pump Seal (O-ring) Replacement:

Remove the pump from the ASU (see instructions above,

“b”). Remove the external pump seal from its groove on the back of the pump adapter plate

(this is the seal located between the adapter plate and the hopper). Install the new seal.

Pump

Disassembly & Re-assembly Page 8-5

Revised 4/01

coupling

Shaft Key

Motor

Adapter

Plate

Screws

Re-Assembly Procedures

Unless noted, the M Series ASU’s re-assembly is simply the reverse sequence of the disassembly procedures. However, the following precautions should be followed (whenever they apply) for proper re-assembly:

WARNING HOT SURFACE

It order to protect personnel and equipment, it is important to replace all insulation whenever it is removed from the ASU.

CAUTION: In general, all O-RINGS AND SEALS should be replaced whenever hot-melt equipment is re-assembled. All new o-rings should be lubricated with o-ring lube (PN N07588).

CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the pump air supply (if applicable) and on the outlet filter manifold. Apply thread sealant (PN N02892) whenever tapered pipe threaded parts are re-assembled.

CAUTION: SOME FITTINGS used for adhesive on the ASU have straight threads and o-ring seals. Use of thread sealant is not necessary with these parts, but the o-ring seals should be clean and lubricated. Tighten straight-threaded parts and fittings until their shoulders are firmly seated against the pump body (or other surface). Excessive torque may damage straight-threaded parts and the use of power wrenches is not recommended

CAUTION: HOT-MELT RESIDUE should be cleaned from parts before they are re-assembled, particularly from threaded parts. As a precaution against adhesive residue preventing proper re-assembly, threaded parts should always be re-tightened at operating temperature.

Page 8-6 Disassembly & Re-assembly

Revised 9/00 c.2000

DYNAMELT M ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual 20-36

Chapter 9

AVAILABLE OPTIONS & ACCESSORIES

Options & Accessories Page 9-1

Revised 7/02

Pressure Gauge Assembly PN 805641

An optional analog pressure gauge can be mounted on the outlet filter manifold. Reading the adhesive pressure at the manifold, rather than in-line on a hose, allows for more precise monitoring of system pressure. It is also useful for troubleshooting and maintenance.

The gauge is installed at one of the adhesive ports on the manifold. Fittings and adapter are included in the assembly.

Pre-PSI & Post-PSI Transducers PN 800225; Transducer Assembly PN 108825

A pressure transducer is an electronic probe that allows the melted adhesive’s pressure to be processed by the ASU’s control system. They are used to monitor system operating pressures and their limits. The Pre-PSI transducer measures adhesive pressure in the filter manifold before the filter basket. The Post-PSI transducer measures the pressure after the filter basket. By comparing the two readings, the operator can determine if the filter basket is clogged.

Drop-in Grids PN 104802

The drop-in grid is an extra heated grid(s) which is installed near the bottom of the ASU’s hopper.

The additional grid(s) allows faster melting of adhesive for applications requiring higher melt rates and higher volumes of adhesive. When installed, the drop-in grid becomes an auxiliary temperature zone on the controller.

High-Temperature Heater Groups

More accurate temperature control may be gained by using a High-Temp Heater Group in the filter manifold/ pressure relief block. A heater and sensor are contained inside the block and become their own temperature zone on the controller. Six groups are available depending on the number of filter manifolds on the ASU.

Filter Options and Accessories:

40 Mesh Outlet Filter PN 101246

Some situations do not call for a fine mesh outlet filter. A “clean” adhesive or one with a long pot life are examples. Systems utilizing lower temperatures or systems running in a clean environment can also utilize a 40 mesh filter. Standard equipment on Dynamelt is a 100 mesh filter (PN 101247).

Level Control PN N08122

This device informs the operator, via a message on the DynaControl’s readout, that the hopper’s adhesive level is low. It may also be wired to stop production, turn on an alarm light or signal, or signal a PLC.

Baseplate Standoff PN 109585

When casters are not desired on the ASU, baseplate standoffs may be used to make the unit stationary. The standoff features a flange on its bottom to allow spot welding and it is open in the center to allow bolt-through mounting.

Page 9-2 Options & Accessories

Revised 9/07 c. 2000

DYNAMELT M ASU Manual 20-36

Pump Options and Accessories:

Gear Pumps

For higher tolerances and precision, several gear pumps are available for the Dynamelt. Gear pumps give better service for continuous applications or applications which require more control over the volume of adhesive pumped. Gear pumps available are:

Single Pumps:

PN 100860: 1.54 cc/rev single, standard accuracy gear pump

PN 100861: 3.2 cc/rev single, standard accuracy gear pump

PN 100862: 4.5 cc/rev single, standard accuracy gear pump

PN 109690: 10 cc/rev single, standard accuracy gear pump

PN 108875: 8.5 cc/rev single, high accuracy gear pump

PN 084E374: 0.584 cc/rev single, high accuracy gear pump

PN 084E376: 1.752 cc/rev single, high accuracy gear pump

PN 084E428: 0.297 cc/rev single, high accuracy gear pump

PN 084E430: 1.168 cc/rev single, high accuracy gear pump

PN 084E434: 2.920 cc/rev single, high accuracy gear pump

Dual Pumps:

Note: all dual pumps require PN 102049, see below.

PN 100863: 1.54 cc/rev dual, standard accuracy gear pump

PN 100864: 3.18 cc/rev dual, standard accuracy gear pump

PN 084E389: 0.584 cc/rev dual, high accuracy gear pump

PN 084E432: 1.168 cc/rev dual, high accuracy gear pump

PN 108874: 2.920 cc/rev dual, high accuracy gear pump

Feinpruf Gear Pumps

Feinpruf pumps are commonly used in the European marketplace.

Gear Pump Repair Kit PN 103151

Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps:

PN Description

N00198 O-ring

018X031 Ball Bearing

069X061 Seal

Qty.

2

5

1

PN Description

069X064 O-ring

078F017 Ring, Clip

078I001 Key, Woodruff

Qty.

3

4

1

Gear Motor Options

Lenze DC Motors PN 103843

These European 1/4 hp motors are equipped with tachometer feedback and a closed loop control. They are required for the Actual Digital RPM Readout option.

DC Motors PN 101418

These 1/4 hp American motors are rated at 83 rpm, 180v.

c. 2000

DYNAMELT M ASU Manual 20-36

Options & Accessories Page 9-3

Revised 9/01

Return (re-circulating) Hoses

Available on all models. Use of return hoses allows higher adhesive pressures from the head to the substrate because the head is “overfed” adhesive. The overflow adhesive is re-circulated to the hopper.

Electric Clutch PN 105729; Clutch Kit PN 107945

An electric clutch is available for the Dynamelt M35 ASU. A clutch relieves adhesive pressure quickly in applications where there are periods of time when adhesive is not being applied.

DynaControl Options:

Pendant Control Panel PN 107643

The pendant control option gives the DynaControl keypad mobility via a 9 meter (30 ft), 6 meter

(20 ft) or 3 meter (10 ft) cable. The Pendant Control Panel replaces the standard display panel.

Pressure Display PN 108388

The pressure board option enables the controller to read and display adhesive pressure PSI values in the outlet filter manifold. The option consists of a PSI printed circuit board which is used with a pressure reading device (transducer or gauge) mounted on the filter manifold.

Actual Digital RPM Readout PN 107946

This option provides a controller readout for actual motor or pump revolutions per minute. No additional programming is necessary. Installation on an encoder is required.

System Status Lights PN 104280

Remote monitoring of system status is made easier with this tri-color light. The stack light is mounted on a 6”x 6” box, which is itself mounted on a stand with a 10’ cable. Wired into the controller, the lights illuminate to indicate “Power On”, “Ready” and “Alarm”. An audible signal accompanies the “Alarm” light. The alarm may be wired to indicate either high/low temperature, low adhesive level or open/short sensor.

Line Speed Tracking Options

Line speed tracking is a standard feature of the M Series ASUs which allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage input. When operated as the standard feature, a 0-10v signal from a PLC or a similar line speed output device is utilized.

However, it may also be operated utilizing one of the following optional devices:

PN 015D050 Tach Generator: a mechanically operated device which produces a reference voltage that allows the ASU’s gear pump to track a parent machine’s production line speed.

PN N06642 Signal Isolator: a device which conditions a parent machine’s production line’s DC speed reference voltage to allow the ASU’s gear pump to track line speed.

Page 9-4 Options & Accessories

Revised 4/06 c. 2000

DYNAMELT M ASU Manual 20-36

Serial Communication (PC Link/ Remote I/O Interface) PN 108475

Bi-directional data transfer to a remote computer is available for the controller. The ASU’s standard

RS232 serial port connection allows remote interface up to 50 meters from the DynaControl controller. The RS485 serial port connection offers remote interface over a much longer distance. Either connection enables all system parameters to be monitored and/ or controlled from the remote station.

Ethernet/ IP Adapter Kit: PN 112224

This kit adapts the DMM ASU for an Ethernet network so that all system parameters can be transmitted and received, allowing full remote operation of the ASU.

c. 2000

DYNAMELT M ASU Manual 20-36

Options & Accessories Page 9-5

Revised 10/05

Recommended Service Parts List

Category Part No.

Electrical:

Description

103184

048I016

102762

108566

Fuse GDC4 (terminal rail)

Fuse KTK 15 (terminal rail)

Fuse, 1 amp (motor control interface pc board)

Fuse, T6.3AL 5x20, fast (pc boards)

036B103 RTD Sensor, PT

104166 Over-Temp Thermostat & Insulator Assy.

036B015 Pump Enable Thermostat

102411 Boot, Insulator

048H384 Solid State Relay, Dual

036A170 Heater, 500w (for 1 filter block)

036A079 Heater, 1000w (for 2 filter blocks)

109857

108256

107440

106149

106395

110090

107438

106147

CPU Printed Circuit Board, V5

Control Assy. (w. PCB)

48-Zone Power (I/O) PC Board

Auxiliary RTD PC Board (optional)

Motor Speed Control AC Drive Board

Motor Control Interface PC Board

Optional Clutch PC Board

Optional Pressure PC Board

O-rings:

Filters:

Misc:

N00181 O-ring 014 (outlet filter/ manifold)

A69X133 O-ring 124 (outlet filter/ manifold)

N00185

N00187

O-ring 018 (outlet filter/ manifold)

O-ring 020 (outlet filter/ manifold)

069X275 O-ring 122 (outlet filter/ manifold)

N00199

103770

103771

807729

O-ring 114 (outlet filter/ manifold)

O-ring 5-005 (outlet filter/ manifold)

O-ring 5-254 (outlet filter/ manifold)

Pump Shaft Seal (Zenith/ TSHA pump models)

069X061 Pump Shaft Seal (optional ITW Dynatec pumps) see IBOM Pump Adapter O-rings

101247

101246

109482

105967

Filter Basket, 100 mesh

Filter Basket, 40 mesh (optional)

Filter Basket, 200 mesh (optional)

Filter Shutoff Assembly, Left

N07588

L15653

001U002 Hi-Temp Lubricant, tube

102717

101340

106313

108012

Lubricant, O-ring

Kit, Flushing Fluid, 1 gallon

Check Valve (pressure relief)

Motor Brushes, Baldor (optional DC motor)

Motor Brushes, Lenze (optional Lenze motor)

Filter/ Pressure Relief Plug Assembly

Qty.

1

1

1

1

1

1

8

1

1

1

1

1

1

1

1

5

5

4

2

8 + 6 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per pump

2 per pump

1 of ea. per pump

2 per manifold

2 per manifold

2 per manifold

1

1

1

2

1

2 per motor

2 per motor

1

Page 9-6 Options & Accessories

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

DYNAMELT M ASU Manual #20-36

Component Illustrations Page 10-1

Revised 3/05

Chapter 10

COMPONENT ILLUSTRATIONS & BILLS OF MATERIAL

WARNING

All parts must be periodically inspected and replaced if worn or broken. Failure to do this can affect equipment’s operation and can result in personal injury.

Chapter Format

This chapter contains the component illustrations (exploded-view drawings) for each assembly of the DYNAMELT M SERIES ASU. These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit.

Note: most common nuts, bolts and fasteners can be obtained locally at your hardware store. Specialty fasteners are available by contacting Dynatec’s Customer Service.

Page 10-2 Component Illustrations & BOM’s

Revised 08/06

c. 1999

DYNAMELT M ASU Manual All Models

7

8

5

6

3

4

1

2

9

10

39

40

41

42

35

36

37

38

43

44

45

46

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

31

32

33

27

28

29

30

Bill of Materials for Pressure Relief & High Temp. Filter Block Assembly #102710

(Items from Heater Control Groups: 103571, 103572, 103573, 103574 are also

Included in this illustration and bill of material.)

Item No.

Part Number

Description

Qty.

34

102719*

103770

103771

103571

103572

103573

103574

036A170

036A079

102149

036A077

036E032

036B103

107754

107645

106156

104163

101833

104852

N00199*

107751

N06883

103570

Note:

N07429

006G112*

012E002*

109244*

109245*

112666*

104733

078D027*

101246

102711

102713

102714*

102715

N04349

102716

102718*

102710

N00181

N00185

N00753

N00187

N00754

103626

102712

102717

NPN

803173

108928

112667*

A78A282*

N02969*

105099

Filter Block Top Assembly

O-ring, 014

O-ring, 018

1/8 NPT Level Seal Plug

O-ring, 020

1/4 NPT Level Seal Plug

3/8 BSPP Plug

Filter Block Insulator Plate

Check Valve, .655 Cart, 1 way

M8-1.25 x 90 SHC Screw

1/2 BSPP Plug (803984 #06, 804155 #08, 803142 #12 hose fitting) 2

Manifold Sub Assembly

2

6

O ring, 124

#0 x 1/8 Drive Screw

Pin Spring .125 x 1

M8 x 25 SHC Screw

M8-1.25 x 30mm

Cap, Adjustment Screw

Pressure Relief Spring

Pressure Relief Adjustment Screw

Bullet, Hi-Pressure

O-ring, 122

Plug, Pressure Transducer, 1/2-20

3/4-16 Jam Nut

Filter Basket, 40 Mesh

Filter Block

Filter Block Heater Retainer Plate

Pressure Relief/ Filter Plug

Filter Plug Retainer Slide

Pin, Spring, .250 x .875

Slide Housing Frame

Filter Pull Clip

Filter Preload Wave Spring

O-ring, 5-005

O-ring, 5-254

Heater Control Section 240v, 1 block

Heater Control Section 240v, 2 block

Heater Control Section 240v, 3 block

Heater Control Section 240v, 4 block

Heater,5/8 x 5”, 240v, 500w (used with 1 Filter Block Assembly) 1

Heater, 5/8 x 10”, 240v, 1000w (used with 2 Filter Block Assemblies) 1

Heater, 5/8 x 15”, 240v, 1500w (used with 3 Filter Block Assemblies) 1

Heater,5/8 x 20”,240v,2000w (Used with 4 Filter Block Assemblies) 1

Sensor Adapter

Temperature Sensor

Cover, Hi-Temp Sensor & Heater Section

Conduit, 10”

M4 x 6mm SHSS

M6 x 25mm SHC Screw

10-32 x 1/2 Tamper Proof screw

M10 x 12 cone, Relief, Set Screw

O-ring, 114

Conduit Fitting (located in junction box)

Jam Nut (located in junction box)

M5 x 8 x 6, CUD SH Set Screw

*These items are included in 108012 Plug Assembly

2

2

1

2

1

1

1

1

1

1

2

1

2

1

2

3

2

1

1

6

2

1

2

2

1

1

2

2

2

2

2

2

2

4

2

2

2

2

2

6

6

2

1

2

c. 1999

DYNAMELT M ASU Manual All Models

Component Illustrations & BOM’s Page 10-3

Revised 6/03

43

26

31

12

11

13

20

30

23

19

16

22

18

17

7

Plug Assembly 108012

15

29

1

2

5

27

28

1

4

8

1

9

33

6

24

21

10

33

6

21

10

42

41

21

41

42

34

14

25

35

36

39

44

45

5

3

5

37

46

38

40

Component Illustration: Filter & Pressure Relief Assembly # 102710

Page 10-4 Component Illustrations & BOM’s

Revised 9/02

c. 1999

DYNAMELT M ASU Manual #20-36

11

12

13

14

15

16

7

8

9

10

Bill of Materials for Typical Electrical Panel Box Assembly

107715

Item No.

3

4

5

1

2

6

Part Number

Description

Qty.

802102

107625

802626

102328

103377

103378

103439

Mounting Bracket

Bezel

Heat Sink

Panel Box Lock Kit

Wire duct, 1.5” W x 3” H

Wire duct, 2” w x 3”H

Wire Duct Cover, 1.5.”

103438

104387

Wire Duct Cover, 2.25”

Rotary Handle & Shaft

107891 Bracket, Circuit Breaker 1

104387 Mechanical, Operato r, Circuit Breaker 1

3

1

104761

802850

107890

048H384

107993

Circuit Breaker

Panel Box

Insert Panel

SSR Dual 40A, 240VAC

Memory Card Assembly (option)

102326 Cover, Memory Card 1

109770 Pendant Control Assembly (option 1

Continued on pages 6 thru 7.

1

1

1

3--8

1

2

2

1

1

3

3

3

c. 1999

DYNAMELT M ASU Manual #20-36

Optional Pendant Control

16

3

2

1

7

4

15

14

Component Illustrations & BOM’s Page 10-5

Revised 9/00

11

13

3

9

7

10

12

5 6

Page 10-6 Component Illustrations & BOM’s

Revised 3/03 c. 1999

DYNAMELT M ASU Manual #20-36

Bill of Materials for Typical Electrical Panel Box Assembly 107715 (Cont. from pg. 4)

Item No.

40

41

42

43

44

36

37

38

39

45

46

47

48

29

30

31

32

33

34

35

22

23

24

25

26

27

28

17

18

19

20

21

Part Number

Description

Qty.

102762

103183

103184

Terminal Rail

1 Amp Fuse

Fuse Block, Lever Open

Fuse, GDC4, 250VAC

Terminal Rail

Control Processor Board (CPU)

Circuit Breaker, CB,16A,63F,415V,1P,SPCL

109857

103069

103070

104193

10062

105252

107892

105254

103663

105256

106978

Circuit Breaker, CB,20A,63F,415V,1P,SPCL

Ground, Small Dual

Level Control

End Plate for105251

Side Panel Insert

End Plate for105253

Ground BUS

End Stop

Filter, RFI (EMI)

048H383

048E162

Contactor, 90A, 3Pole, 480V, 230VCOIL

Stand-off

110090 Motor Control Interface 1

1

4-8

804713

107033

106395

106111

107440

106147

107438

Ground Block

Motor Choke, RFI/EMI, 30 AC

Motor Speed Control

M4 x 0.7 x 12 Button head

Power Board

Pressure Board

Clutch Board

KBSI Board

2 Amp Fuse

1

1-2

1-2

6-12

107466

107893

107922

108256

107891

Eprom Chip

Ribbon Cable Assm., 15PinM, 9 PinF Serial, 8 conductor crimp-on

Control Assembly

Cable Assembly Bracket

1

1

1

1--2

1

1

1

1

1

1

6

1

4

1

4

1

4

3

1

1

4

2

1

1

22

47

2

23

24

29

21

c. 1999

DYNAMELT M ASU Manual #20-36

43

28

42

44

41

Backside Of Control Panel or Pendant Control

48

46

Drive One

39

38

18

35

34

37

Component Illustrations & BOM’s Page 10-7

Revised 9/02

26

30

17

20

19

25

27

29

31

Drive Two

32

39

22

45

18

36

8

10

40

7

9

33

Page 10-8 Component Illustrations & BOM’s

Revised 9/02 c. 1999

DYNAMELT M ASU Manual 20-36

18

19

20

21

14

15

16

17

22

23

24

25

26

10

11

12

13

8

9

6

7

39

40

41

42

35

36

37

38

31

32

33

34

27

28

29

30

Bill of Materials for DYNAMELT M35 Series Cabinet Assembly

Item No.

Part Number

Description

43

44

45

46

3

4

1

2

5

106769

106770

106771

101842

804749

805042

804532

N02145

078C013

078C017

804526

N01829

078D008

106111

101304

104279

105111

106066

104662

106324

106237

106112

105060

109585

106048

106772

106773

105152

106892

101843

105880

106186

106184

107890

108128

106187

105882

106183

802805

802102

106110

103115

101074

103866

107393

105117

106236

106876

106319

105865

105101

Handle, Side Panel

Panel, Top, Bracket

Access Cover

Rear Cover M35

Manifold Cover

Manifold Cover , Hi Flow Only

Base Plate M70/140

Top Panel M70/140

Heat Barrier, Panel Box, M70

Panel Box

DCL Mounting Bracket

M5 Hex Nut

Swivel Caster

Receptacle

Bracket, Connector Bank, Amphenol

3/8-16 Kep nuts

M4 x 12 BHC Screw

Blank Plate, Dual

Blank Plate, Single

M3 Hex Nut

M5 x 16mm HHC Screw

M6 x 16mm SHC Screw

M6 Flat Washer

M8 Star Washer

M8 x 12mm HHC screw

M8 Hex Nut

Stand-off Option

Lid Assembly

Inner Hinge

Outer Hinge

M3 x 6mm PHLC Screw

M3 Flat washer

M4 x 8 Pan Head Screw

M4 Star Washer

Retaining Clip

M6 Star Washer

M6 Hex Nut

M6 x 16mm HHC Screw

Hinge (Attached to hopper lid)

Lid Hopper

Heat Deflector, M35/70

Collar, Hopper, M35/70

Handle, Hopper, Lid

Front Panel Kit (Option)

Transformer Option

Base Plate Transformer Extention

3/8-16 x 1.25 SHC Screw (Transformer extention hardware)

3/8 Flat washer (Transformer extention hardware)

3/8 Lock Washer (Transformer extention hardware)

Transformer (not Shown)

3/8-16 x 3 HHC Screw (transformer hardware not shown)

3/8-16 Hex Nut (transformer hardware not shown)

4

2

2

4

4

4

6

6

2

2

4

1

4

4

6

8

1

4

4

4 or 8

1

1

1

1

1 or 2

4

16 or 32

0, 1 or 3

0 or 4

0, 4 or 8

4

6

1

1

2

1

1

1

1

4

4

4

4

1

4

Qty.

2

1

4

1

1

c. 1999

DYNAMELT M ASU Manual 20-36

35 34

36

41

38

39

11

40

7

17

18

16 13

19

14

29

29

31

32 33

37

3

Component Illustrations & BOM’s Page 10-9

27

30

29

28

9

20

8

21

22

34

Revised 9/02

35

34

10

2

21

22

34

4

5

25

23

44

45

46

3

42

1

26

15

6

Stand-off Option

Note: without the transformer option the casters attach to the base plate.

With the transformer option the casters attach to the transformer frame. Stand-off option attaches to Base plate only.

43

Component Illustration: DM M35 Cabinet Assembly

15

12

23

24

12

Page 10-10 Component Illustrations & BOM’s

Revised 9/02 c. 1999

DYNAMELT M ASU Manual #20-36

16

17

18

19

12

13

14

15

20

21

22

9

10

11

7

8

5

6

3

4

1

2

Bill of Materials for AC Dual Drive 107943 & AC Single Drive Assembly PN 107942

Item No.

Part Number

Description

Qty.

Dual Qty.

101156

107602

102172

107941

106389

103518

107401

M6-1,0 x 20mm SHC Screw

M8 x 1,25 x 40mm

Coupling, Jaw, .50/.75 Sahft

Motor Bracket

Motor, 1/4 HP, 20:1, AC

Pump (See Your Order For Part Number)

M10 x 30mm SHC Screw

M10 Nut

4

1

4

4

1

1

4

1

8

2

8

8

1

2

4

2

107946

104648

105101

N00688

N00697

107077

104647

N00853

N00692

104649

N06006

103470

106111

103121

104651

Digital RPM Readout Kit (Option)

Encoder bracket

M6--1.0 x 16mm HHC

1/4 Flat Washer

1/4 Spring Lock Washer

Encoder Assembly, DM SBC

Encoder Mount Arm

4-40 x .375 Fil Head Screw

#04 Spring Lock Washer

Encoder Drive Wheel

O-ring, -224

M3-0.5 x 5mm Flat Point Set Screw

M4-0.7 x 12mm Button Head Screw

M4-0.7 Hex Nut

Torsion Spring, .56 OD x .063d

1

2

1

1

1

4

1

1

4

3

2

1

1

2

23

24

25

26

27

28

107945

103435

103436

106071

103121

105865

N00053

N06946

Electric Clutch Kit (Option used in place of Coupling)

Clutch

Power Supply

M4 x 25 mm SHC Screw

M4 x 0.7 Nut

M6 x 1.0 Nut

Terminal Butt, 16-14 GA, Insulation (Not Shown)

Terminal Spade, 22-18 GA, #6, Insulation (Not Shown)

2

2

1

1

1

2

1

1

c. 1999

DYNAMELT ASU M Manual #20-36

Digital RPM

Readout Option

9

22

14

13

15

16

20

21

17

18

19

Digital RPM Readout Option

11

10

12

6

1

3

5

Component Illustrations & BOM’s Page 10-11

Revised 9/02

5

1

5

5

3

or

6

23

Electric Clutch Option in place of coupling

25

28

26

or

4

2

7

8

27

24

Component Illustration: DYNAMELT AC Drive Assembly 107942 & 107943

Page 10-12 Component Illustrations & BOM’s

Revised 3/07 c. 1999

DYNAMELT M ASU Manual All M35 Models

31

32

33

34

27

28

29

30

35

36

37

38

39

Bill of Materials for DYNAMELT M35 Melt & Grid Assemblies.

Item No.

Part Number

Description

18

19

20

21

14

15

16

17

22

23

7

8

9

5

6

3

4

1

2

10

11

12

13

24

25

26

40

41

42

43

44

45

46

47

48

49

036B015

036B013

N07958

106189

105883

105881

L00006

108298

N07370

N00686

N00697

103749

N00210

108827

105885

106001

048J018

107441

107604

N05889

107389

048J015

048J018

108828

104166

104165

104164

103538

N00181

104696

003E023

036B103

106174

104802

107645

N00192

102446

N07416

078A055

084Q465

069X064

012G009

104072

N00754

105968

805216

105149

N00192

108297

N00181

106103

Pump Enable Thermostat, N.O. 1/2 Dia.

Pump Enable Thermostat, N.C. 1/2 Dia.

Temperature Sensor

Hopper Support

Hopper, Assy.

Heater Plate

Spacer

M8 x 30mm HHC Screw

M6 x 30 SHC Screw

Flat Washers, 1/4

Lock Washer, 1/4

Filter Shut-off Plug (used in place of or opposite Filter Shut-off)

O-ring, -912

Junction Box Assembly

Junction Box, Prog-Melt, M70/ 140

Cover, Junction Box,

Bushing, Plastic Cap, 1/2”

Terminal Rail, 11.5”

Block, Terminal

Terminal

M4 x8

1/2 Sealtite Connector

Plastic Bushing

Conduit,1/2”Sealtite,20”

Over Temp. Switch Assembly (Sold as an assembly only)

Insulator, Over Temp Thermostat

Overtemp Reset Thermostat

M4 X 6mm Pan Head

Grid Group

O-ring, -014

Flange

Cover

Temperature Sensor

Sensor Adapter

Cast Heater

5/16 ID Conduit

O-ring

M4-0. 70 x 10mm SHC Screw

M8 x 35mm SHC Screw

10-24 x 3/16 SHS Screw

Filter Block (see your order for part number)

Pump (see your order for part number)

Pump Block Off Assembly

O-ring, #-041

Block-off Plate

M10 x 100 Stud

Level Seal Plug

Filter Shutoff Assembly, Alim, TFE

Grid Block Off Assembly (Option)

Block off Plate

O-ring, #-032

M8 x 20mm HHC Flange Screw

O--ring, #014

Ball Valve Assembly (Option)

50

51

52

105097

107392

072X093

M6 x 30mm SHSet Screw

M8 Nut With Washer

1/2 NPT Level Seal Plug

Qty.

1

1

6

12

6

1

2

1

1

1

1

1

1

18

18

1

1

1’

1

1

1

4

1

2

4

1

1

1

2

1

2

1

22

3

1

1

1

1

1

1

6

2

4

1

1

4

1

1

2

1

1

1

4

1-2

1

c. 1999

DYNAMELT M ASU Manual All M35 Models

Component Illustrations & BOM’s Page 10-13

Revised 3/07

15

46

45

48

47

Grid Block-off Option

30

31

50

44

52

49

5

38

16

22

23

21

43

14

24

25 26

2

3

1

17 18 19 20

10

11

9

6

10 11 8

51

8

7

4

to base plate

42

32

27

12

13

34

40

52

41

51

33

8

11

10

37

28

36

35

29

39

Page 10-14 Component Illustrations & BOM’s

Revised 9/00 c. 1999

DYNAMELT M ASU Manual 20-36

12

13

14

15

16

17

8

9

6

7

10

11

3

4

5

1

2

Bill of Materials for 1.54 cc / Rev. , Single Gear Pump Assembly # 100860

Bill of Materials for 3.2 cc / Rev. , Single Gear Pump Assembly # 100861

Item No.

Description

Part Number

#100860 / #100861

012D079 / 012D077

078I001

101626

069X160

069X061

018X041

100866 / 100867

012D080 / 012D078

018X031

012C020 / 012C019

069X064

078F017

018X041

100865

100908

104775/ 104776

NPN

Drive Shaft

Key, Woodruff

M5 x 12 SHC Screw

Seal Retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Diameter ( See illustration for quantity)

Drive Gear, 1.54 cc/rev

Pump Seal

Shaft Retaining Ring

Bearing Sleeve, Rear Plate

Rear Plate Assembly

M4 x 25 SHC Screw

M10-1.5 x 75mm/ 80mm

M10 Flat Washer

1

2

4

4

4

2

2

2

2

1

1

2-4

4

1

1

1

1

Qty.

c. 1999

DYNAMELT M ASU Manual 20-36

Component Illustrations & BOM’s Page 10-15

Rev. C Eng: JW Revised 9/00

2

9

Pump # 100860 has one bearing in this Shaft

Pump # 100861 has two bearing in this shaft

1

3

4

5

16

17

9

10

Pump # 100861 has two bearing in this Shaft

Pump # 100860 has one bearing in this shaft

7

6

8

12

10

13

11

14

11

15

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

Component Illustration: 1.54 cc / Rev, Single Gear Pump Assembly #100860

Page 10-16 Component Illustrations & BOM’s

Revised 9/00 c. 1999

DYNAMELT M ASU Manual 20-36

Item No.

7

8

9

10

11

12

13

3

4

5

6

1

2

14

15

16

17

Bill of Materials for 4.50 cc / Rev. , Single Gear Pump Assembly # 100862

Part Number

012D072

078I001

101626

069X160

069X061

018X041

100868

012D073

018X031

012C018

069X064

078F017

018X041

100865

100908

104776

NPN

Description

Drive Shaft

Key, Woodruff

M5 x 12 SHC Screw

Seal Retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Diameter

Drive Gear, 4.5 cc/rev

Pump Seal

Shaft Retaining Ring

Bearing Sleeve, Rear Plate

Rear Plate Assembly

M4 x 25 SHC Screw

M10-1.5 x 80mm

M10 Flat washer

Qty.

4

4

1

2

2

2

4

2

1

4

4

1

1

1

1

2

1

c. 1999

DYNAMELT M ASU Manual 20-36

2

9

Component Illustrations & BOM’s Page 10-17

Revised 9/00

1

3

4

5

16

17

9

10

7

6

8

12

10

13

11

14

11

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

15

Component Illustration: 4.50 cc / Rev, Single Gear Pump Assembly #100862

Page 10-18 Component Illustrations & BOM’s

Revised 9/00 c. 1999

DYNAMELT M ASU Manual 20-36

Item No.

13

14

15

16

17

18

19

7

8

9

10

11

12

3

4

5

6

1

2

Bill of Materials for 1.54 cc / Rev. , Dual Gear Pump Assembly # 100863

Part Number

012D083

078I001

101626

069X160

069X061

018X041

100866

012D082

018X031

012C020

069X064

078F017

018X041

100865

101692

NPN

100869

N00198

NPN

Description

Drive Shaft

Key, Woodruff

M5 x 12 SHCS

Seal retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Dia.

Pump Gear, 1.5 cc/Rev

O-ring, -041

Shaft Retaining Ring

Bearing Sleeve, rear Plate

Rear Plate Assembly

M4 x 35 SHCS

M10-1.5 x 85mm SHC Screw

Middle Plate

O-ring, -113

M10 Flat Washer

Qty.

4

1

1

2

2

4

4

3

4

2

1

3

4

1

1

1

1

2

1

c. 1999

DYNAMELT M ASU Manual 20-36

9

2

1

Component Illustrations & BOM’s Page 10-19

Revised 9/00

3

4

5

16

19

9

10

7

6

8

12

10

11

17

18

10

13

11

14

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

15

11

Component Illustration: 1.54 cc / Rev, Dual Gear Pump Assembly #100863

Page 10-20 Component Illustrations & BOM’s

Revised 8/02

2

1

9

3

4

5

16

19

c. 1999

DYNAMELT M ASU Manual 20-28

9

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

7

6

8

12

10

11

17

18

10

13

11

14

10

11

15

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

Bill of Materials for 3.2 cc / Rev. ,

Dual Gear Pump Assembly # 100864

Item No.

Part Number Description

012D088

078I001

101626

069X160

069X061

018X041

100867

012D087

018X031

012C019

069X064

078F017

018X041

100865

101691

NPN

100870

N00198

NPN

Drive Shaft

Key, Woodruff

M5 x 12 SHCS

Seal retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Dia.

Drive Gear, 4.5 cc/Rev

O-ring, -041

Shaft Retaining Ring

Bearing Sleeve, rear Plate

Rear Plate Assembly

M4 x 40 SHCS

M10-1.5 x 85mm

Middle Plate

O-ring, -113

M10 Flat Washer

Qty.

2

4

2

1

3

4

5

4

1

2

4

1

1

1

2

4

1

1

1

c. 1999

DYNAMELT M ASU Manual 20-28

Component Illustrations & BOM’s Page 10-21

8/02

10

5

11

2

1

4

6

3

12

13

8

5

7

Bill of Materials for 10cc Single Gear Pump Assembly # 109690

Item No.

11

12

13

14

7

8

9

10

1

2

3

4

5

6

Part Number

018X031

078F017

078I001

069X061

069X064

100908

101626

109685

109686

109689

109687

109688

069X160

001U002

Description

Ball bearing, 1/8 Dia.

Snap ring, 1/2”

Key Woodruf, #404

Shaft Seal

O-ring, -041

M4-0.7 x 25mm SHC Screw

M5-0.8 x 12mm SHC Screw

Pump Body10cc Rev

Rear Bearing Plate 10cc Rev.

Gear 10cc Rev

Drive Shaft 10cc/ 20cc

Driven shaft, 10cc/20cc

Shaft seal retainer

Dow Corning 112 Lubricant (Not Shown)

9

Qty.

1

2

4

1

1

1

1

6

4

1

1

2

2

Page 10-22 Component Illustrations & BOM’s

Revised 4/05 c. 1999

DYNAMELT M ASU Manual All Models

Bill of Materials for Assorted Pump Adapter Assemblies

Item No.

7

8

5

6

3

4

1

2

20

21

22

17

18

19

12

13

14

15

16

9

10

11

084E428

084E374

084E430

084E434

108875

084E438

084E389

084E432

108874

084E419

012G027

069X064

N01010

069X270

078A618

078C141

069X289

110289

110290

110291

103923

103624

103924

N00181

069X270

102927

Part Number

084E406

012G024

069X058

N00179

069X274

N00190

078C130

NPN

103917

103918

103919

104351

Description

TSHA Pump Adapter Assembly

Pump Adapter

O--Ring #28

O--Ring #12

Seal Dual Pump to Progmelt (not part of this assembly)

O-Ring #24

3/8 Washer, 3/4 OD

M10 x 85mm SHC screw

Zenith Pump (Shown For REf. Only)

THSA .297 cc Single Outlet

THSA .584 cc Single Outlet

THSA 1.168 cc Single Outlet

THSA 2.292 cc Single Outlet

THSA 8.5 cc Single Outlet

THSA 30.0 cc Single Outlet

THSA .584 cc Dual Outlet

THSA 1.168 cc Dual Outlet

THSA 2.292 cc Dual Outlet

Zenith Pump Adapter Assembly

Adapter, Z Pump

O-Ring, #041

O-Ring, #021

O-Ring, #025

Screw, Pump Mounting

7/16 ss Washer, 3/4 OD

Drive Shaft Seal (shown For REf Only)

THSA Pump (Shown for ref. only)

THSA 20 cc Single Outlet

THSA 30 cc Single Outlet

THSA 45 cc Single Outlet

Feinpruef Pump Adapter Assembly

Adapter Plate

O-ring Plate

O-ring, -014

O-ring-025

O-ring, -133

Feinpruef Pump

Feinpruef Pump .3 cc

Feinpruef Pump 1.2 cc

Feinpruef Pump 2.4 cc

Coupling Half (Not Shown, See drive Section)

1

4

2

1

4

1

1

1

Qty.

4

1

2

4

1

1

1

1

1

1

1

4

1

1

c. 1999

DYNAMELT M ASU Manual #20-36

THSA Pump Adapter Assembly 084E406

5

3

4

1

2

8

6

THSA Pump Adapter Assembly 084E419

7

11

16

12

9

10

15

14

13

Feinpruef Pump Adapter Assembly 103923

Component Illustrations & BOM’s Page 10-23

Revised 7/03

21

17

19

18

20

19

22

Page 10-24 Component Illustrations & BOM’s

Revised 3/01 c. 1999

DYNAMELT M ASU Manual #20-36

4

1

Item No.

1

2

3

4

Part Number

072X118

101174

104325

805632

Pressure Gauge Assembly-805641

Description

Fitting, 1/4 NPTM x #6 JIC x 90

Pressure Guage, 1000 PSI

Fitting Adapter, Swivel, 6J x 1/4 MPT

Fitting, 1/4 NPT 1/2-20 Tranducer

3

2

Qty.

1

1

1

1

c. 2000

DYNAMELT M ASU Manual 20-36

Chapter 11

SCHEMATICS &

ENGINEERING DRAWINGS

Drawing:

Hose Schematic, ASU to Applicator

Applicator Head Schematic

Flow Diagram, Outlet Filter Manifold

Typical Hydraulic Schematic

Optional System Status Lights Schematic

Optional Level Control Schematic

Optional Electric Clutch Schematic

Grounding Diagram, CE Mark

Power Wiring Diagram, 240v

Signal Wiring Diagram, 4Hose/4Head, 240v

Power Wiring Diagram, 380v

Instruction Sheet for Pump & Zone Configuration

Special ASU Schematics (if applicable)

Found on:

page 11-2 page 11-3 page 11-4 page 11-5 page 11-5 page 11-6 page 11-7 page 11-8 page 11-9 page 11-10 page 11-12 page 11-13 end of chapter

Schematics Page 11-1

Revised 6/01

Page 11-2 Schematics

Revised 7/07 c. 2000

DYNAMELT M ASU Manual 20-36

HOSE SCHEMATIC PN 101082 REV. G

ASU to Applicator

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-3

Revised 10/00

Notes:

1. ALL WIRE MIL-W-22759/10 OR 12, MINIMUM 600 VOLTS, 260 DEG. C

2. SOLENOID(S) VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION.

3. RTD WILL BE PLATINUM 100 OHM.

HEAD SCHEMATIC PN 103117 REV. B

Page 11-4 Schematics

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36

Function of Outlet Filter Manifold’s Closeable Cross Channel

A Closeable Cross Channel Plug is located inside the Outlet Filter Manifold to prevent adhesive flow between the two outlet filters when a dual pump is in use.

When a single pump is used, ITW Dynatec removes the Cross Channel Plug.

When changing an ASU from a single to a dual pump, or vice versa, consult ITW Dynatec for complete instructions.

When Cross

Channel Plug is removed, one adhesive outlet must be plugged.

Adhesive

Outlet To

Hose

Adhesive

Outlet To

Hose

Closeable Cross

Channel Plug

FLOW DIAGRAM, OUTLET FILTER MANIFOLD

Check Valve

Adhesive Return Port*

Adhesive In Port*

Cross Channel

Plug is removed thru port on side of manifold.

* The second Adhesive In and Adhesive

Return ports are not shown.

c. 2000

DYNAMELT M ASU Manual 20-36

Transducer

Filter

Basket

Schematics Page 11-5

Revised 10/00

Bypass

Gauge

Pump

Motor

TYPICAL HYDRAULIC SCHEMATIC: Single Pump, Motor, Bypass, Filter, optional Transducer & optional

Pressure Gauge

WIRING DIAGRAM FOR PN 108266 OPTIONAL SYSTEM STATUS LIGHTS

Page 11-6 Schematics

Revised 10/00 c. 2000

DYNAMELT M ASU Manual 20-36

LEVEL CONTROL SCHEMATIC PN 802972 REV. A

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-7

Revised 10/00

SCHEMATIC PN 804370 Rev. A FOR PN 107945 OPTIONAL ELECTRIC CLUCH KIT

Page 11-8 Schematics

Revised 10/01 c. 2000

DYNAMELT M ASU Manual 20-36

GROUNDING DIAGRAM, CE MARK, PN 804704 REV. E

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-9

Revised 6/01

PN 107938 POWER WIRING DIAGRAM, DM35 DCL, 240V

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-11

Revised 7/07

See previous page

PN 107937 DM35 DCL SIGNAL WIRING DIAGRAM, 4HOSE/4 HEAD, 200-240V, Page 2 of 2

Page 11-12 Schematics

Revised 6/01 c. 2000

DYNAMELT M ASU Manual 20-36

PN 107939 POWER WIRING DIAGRAM, DM35 DCL, 380V

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-13

Revised 7/07

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 1 of 3

Page 11-14 Schematics

Revised 7/07 c. 2000

DYNAMELT M ASU Manual 20-36

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 2 of 3

c. 2000

DYNAMELT M ASU Manual 20-36

Schematics Page 11-15

Revised 7/07

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 3 of 3

Page 11-16 Schematics

Revised 12/02 c. 2000

DYNAMELT M ASU Manual 20-36

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

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

DYNATEC/ ZENITH STANDARD ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E427, 084E429, 084E431, 084E433, 084E435, 084E437

Appendix 1

Revised 3/01

Part Number

084E427

084E429

084E431

084E433

084E435

084E437

Material Type/Accuracy

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Nodular Iron

Single/ Standard

Single/ Standard

Dual/ Standard

Single/ Standard

Dual/ Standard

Single/ Standard

Output/Rev Shaft Seal PN

0.29cc

1.17cc

1.17cc

2.92cc

2.92cc

8.5cc

069X251

069X251

069X251

069X251

069X251

069X251

Thoroughly read and understand this entire manual before installation and operation of pump.

Note: The instructions given herein cover the description, installation, operation and maintenance of subject equipment. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.

Manual revised 8/94

Appendix 2

Revised 10/00 c. 2000

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

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccuracies, multiple seal areas and slippage, which required constant calibration, high maintenence and extended downtimes.

Zenith Pumps met the challenge and designed a rotary external gear pump of unique precision and simplicity. Manufacturing techniques were developed to hold tolerances to

.00005”, and an internal pressure relief mechanism assured reliable precision metering. The pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.

For years since, chemical engineers have relied on Zenith to provide precision fluid handling solutions for their most difficult pumping applications. Zenith gear pumps can be found wherever precise, pulseless, repeatable metering of fluids is required.

BENEFITS

High Accuracy

Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and temperature.

High Temperature Capability

Operating temperatures to 450 degrees F (232 degrees C).

Maximum Life

Only three moving parts; components are through-hardened tool and die steels to 56 HRc or better. The bodies are cast nodular iron. Replaceable sleeve bearings for low-cost rebuilds.

High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under pressure by built-in alignment pins.

Minimum Pulsation

Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance.

Precision Construction

Ground and lapped components for close control of operating clearances.

c. 2000

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

Appendix 3

Revised 3/01

SPECIFICATIONS

Pump Type: Rotary external spur gear, single stream.

Rotation: Clockwise

Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.

Temperature: To 450 degrees F (232 degrees C)

OPERATION

All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed gear tooth volumes and is transported around the outer diameter of the gear pocket.

As the gears mesh together, the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate.

Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pressure required. However, when high-viscosity fluids are used, more time is required to fill the tooth volumes. As a result, the inlet pressure must be increased, or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation.

Dynatec/ Zenith pumps rely on the metered fluid for lubrication of internal bearing areas.

The pump should never be allowed to run dry or be allowed to run with non-lubricating fluids such as water. Because of the close clearances in the bearing areas, lack of sufficient lubrication can cause pump seizure or some other catastrophic failure.

Slippage will occur across the faces of the gears from the high-pressure side to the low-pressure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential pressure and pump clearances. Under reasonably stable operating conditions, slippage is repeatable and predictable and pump operation can be adjusted to compensate.

The Standard Accuracy Pumps are designed for high-temperature and high-pressure operation. As such, operating temperatures to 450 degrees F can be achieved.

INSTALLATION

Pumps should be carefully unpacked to make sure that the shipment is complete. If any items are missing or damaged, the freight carrier and Dynatec should be notified immediately.

While the pump is composed of steel, it is a precision instrument. Dropping the pump or hitting with a non-yielding material can cause serious damage to the components. All materials are through-hardened to maximum hardness resulting in brittle material. Treat

cont.

Appendix 4

Revised 10/00 c. 2000

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

them as you would any other precision gauging instrument.

Dynatec/ Zenith pumps are shipped filled with a rust preventive oil. Flush the oil throughly with a cleaning solvent. It may be necessary to disassemble the seal arrangement to remove all traces of the oil, but disassemble only if necessary.

After flushing, the pump should be lubricated internally for start-up purposes. Pour a suitable high-temperature lubricant (silicone oil) into the inlet port. Rotate the metering gears until lubricant appears at the discharge port.

Mount the pump to a block with a flatness of true flat to .0001” convex and a surface finish of

4 to 8 rms to prevent leakage between the pump and block. Mounting bolts should be a Grade

8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize compound such as DAG Dispersion #154. Bolts should be alternatively torqued in even increments up to Dynatec’s recommended limit for the bolt size used. See Table 1 on page 10 for torque values.

The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact Dynatec.

TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.

2. Filters should be installed prior to the pump inlet that filter ideally to half the pump running clearances.

3. Turn pumps by hand before running. Pumps should turn freely.

4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the coupling* and that it is aligned within one degree angular and .005” parallel with the true pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate.)

5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque at room temperature.

6. Make sure fluid is in the pump before starting.

7. Start pump slowly and, if possible, run it with a lubricating fluid.

8. When satisfactory operation is achieved, the pump and system may be gradually brought up to normal process speeds and pressures.

9. If at any time during operation the pump does not appear to be running smoothly, stop the pump immediately to avoid any serious internal damage.

CLEANING, INSPECTION AND REPAIR

REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop the high pressure demanded, the clearance between the metering gears and their housing must be as small as possible, yet large enough to allow adequate lubrication. All parts are machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths of an inch (.0001”/ .0002”). Because of these close running clearances,

cont.

c. 2000

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

Appendix 5

Revised 3/01

these pumps require careful maintenence and handling, especially of component parts. The slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These pumps are precision instruments; you can’t keep them too clean. Please treat them with care, and if it’s at all possible, set aside a separate clean area for pump maintenance.

To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to the pump size and the degree of polymer contamination and should be determined by trial. Note: Careful control of he furnace temperature (700 degrees F max.) and atmosphere is critical. Should the temperature exceed the original tempering temperature, the steel hardness will draw back and the dimensional stability of the pump may be upset.

Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.

The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization process usually takes between 3 and 12 hours, depending on the polymer type, temperature, pump size and furnace load.

CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.

After gradually cooling to room temperature, the pump should be thoroughly flushed in a clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer ash.

If present, always replace the carbon seal plate after pump burnout. If the pump was performing satisfactorily when removed from service and still turns freely after burnout, pressure test it and add a high-temperature lubricant to prepare it for return to service. To store for future use, simply add a rust preventative oil.

It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum. By noting the performance of a pump immediately before removing it from service and correlating the performance to measured component wear, the user can establish the maximum wear limits for the pump’s critical components. Further, he can predict the service life of the pump and schedule his down-time accordingly.

As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for complete rehabilitation as necessary. This procedure may be desirable if only a few pumps are involved. If a large number of pumps are to be maintained at the user’s plant, it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing, gauging and assembly techniques involved in producting the pumps.

Please contact Dynatec (at 1-800-538-9540) for further information on these items.

Appendix 6

Revised 10/00 c. 2000

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

STANDARD ACCURACY PUMP DISASSEMBLY

If pumps are to be disassembled on a regular basis, we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate

“clean” area for assembly, testing and storing of rebuilt pumps.

If maintenence is required due to low delivery or seizure, the following procedure is recommended for disassembly.

NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.

Refer to assembly drawing (located in the back of this manual) for your correct pump type.

1. Remove the seal arrangement.

2. Remove all binder screws.

3. Remove pins (10) and arbor (5) with an arbor press in the direction which disengages the press fit in the shortest distance.

NOTE: Dowels and arbors for the standard accuracy pumps are press fit in the gear/ rear plate.

4. Separate the plates by pry slots that are available in the pump. Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart.

5. After disassembly, clean all components in a non-destructive solvent.

6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang parts together.

7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and faces of the gears may be hand blocked on 600 grit paper and any nicks, burrs or sharp edges can be lightly removed with a honing stone. Be careful not to round off the edges of the gear teeth while lapping.

CAUTION: Since the thickness relationship between the metering gears and the gear/ rear plate is critical to metering performance, and the gear/ rear plate is non-wearing on its sides, lapping these components is not necessary and should not be done under any circumstances.

Place a layer of 600 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 1) approximately five times until a smooth finish appears. Turning in a circular fashion, or other non-uniform motion, may cause the ground holes to lose their perpendicularity to the faces.

Always use clean, lint-free rags and compressed air to clean components. Paper towels are not acceptable; they may leave small pieces of paper and dust on the components. Use chemical brushes to clean between gear teeth, bores and reliefs.

8. Replace sleeve bearings as necessary and hone in the plate to the original new part specifications.

9. After each resurfacing, carefully gauge the area between the inlet and discharge ports at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical part of the plate. Scoring or wear marks here will allow increased slippage from the

cont.

c. 2000

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

Appendix 7

Revised 3/01

high-pressure discharge port section across the throat to the lower inlet port, reducing efficiency. Therefore, carefully gauge this area for flatness after each resurfacing.

10. After all components are “hospital clean”, the pump is ready for assembly.

Figure 1

STANDARD ACCURACY PUMP RE-ASSEMBLY

NOTE: During and between each re-assembly step, manually turn the metering gears to ensure that they are free turning. If binding occurs at any time, determine the cause and correct it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned, the pieces will fit easily into place and the pump will turn freely. Re-assemble as follows:

1. After all worn parts have been re-finished or replaced, all parts should be throughly cleaned in a solvent and dried.

2. Using the driven gear (5) as an up-righting fixture, carefully locate the arbor (7) over its press-fit hole in the gear/ rear plate. Smoothly drive the arbor into its hole with the help of an appropriate arbor press.

3. Place the gear/ rear plate (1) with the arbor in position in a soft-jaw vise or holding fixture.

4. Slip together the driving metering gear (6), drive shaft (4), key (8) and retaining rings

(21). Position in the front of the gear/ rear plate.

5. Place the driven metering gear on its arbor and carefully mesh with the drive metering gear.

6. NOTE: Repeat steps 3 through 5 for four-gear pumps.

7. Position the front side plate (3).

8. Rotate the gears to ensure free rotation.

9. Press the roll pins (41) into place.

10. Lubricate the binder screws (23) with DAG dispersion #154 or a similar heat resistant lubricant and install. Torque the screws in even increments to the manufacturer’s recommended limit. It is especially important to rotate the gears frequently during this operation.

11. Re-assemble the seal arrangement, making sure the sealing surfaces are perfectly clean and free of scratches, nicks or burrs. When a carbon seal plate is used, always use a new carbon seal that has been lightly polished on 600 grit paper. When using a carbon seal, the coupling housing screws (27) should be torqued to the manufacturer’s recommended limit.

For pumps with a compensation packing seal, be sure all old packing is removed

cont.

Appendix 8

Revised 10/00 c. 2000

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

from the packing housing.

12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or worn. Worn shafts will result in premature seal leakage and should be replaced.

13. Inspect lip seals for wear, cracks and abrasions. Replace if needed.

14. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-O-

Lubricate or an equivalent silicone-based oil.

tion.

15. Install lip seals (15) into seal housing (9) as shown.

16. Tighten seal housing screws (22) in a cross pattern to 60 lbs./in. Check for free rota-

SCREW TORQUE VALUES (Standard Alloy Steel)*

Screw Size & Thread

(UNC Alloy Steel)

Torque (Lubricated Threads)

Lbs.-in.

Nxm Lbs.-ft.

#10-24 (w/ carbon seal gasket)

#10-24 (w/o carbon seal gasket)

#12-24

1/4-20

5/16-18

3/8-16

7/16-14

into aluminum block (hopper)

[50]

[64]

[120]

[150]

[305]

[360]

[480]

5.7

[4.2]

7.2

[5.3]

13.6

[10]

16.9

[12.5]

33.9

[25]

40.6

[30]

54.2

[40]

Table 1

*In critical applications where control of bolt preload is important, the torque-tension relation should be determined by experimenting on the actual parts involved (including thread lubricants). At elevated temperatures, it is often desirable to reduce screw stress because of deformation (creep) under sustained loading. Screws constructed of type H-11 high-temperature alloy steel provide extremely high creep resistance.

c. 2000

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

Appendix 9

Revised 3/01

TROUBLESHOOTING GUIDE

Trouble

Pump will not turn.

Probable Cause

1. Low pump temperature.

Remedy

Check temperature sensor and control loop for proper setting/ operation.

Allow sufficient heat-up time.

2. Drive malfunction.

Verify drive is powered.

Check to assure all alarm circuits are clear.

Check drive motor current and speed settings.

Check all drive couplings.

3. Process conditions changed.

Check process conditions for proper melt temperature, pressures, viscosities and materials.

4. Entrained particle.

Return pump to ITW Dynatec for repair.

5. Possible internal damages.

Return pump to ITW Dynatec for repair.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Return pump to ITW Dynatec for repair.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 1. Worn gear(s).

2. Worn bearings.

Return pump to ITW Dynatec.

for repair.

Return pump to ITW Dynatec.

for repair.

3. Process conditions changed.

Consult factory for clearance recommended on new process conditions.

* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.

Appendix 10

Revised 10/00 c. 2000

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

c. 2000

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

Appendix 11

Revised 3/01

Appendix 12

Revised 10/00 c. 2000

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

c. 2000

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

Appendix 13

Revised 3/01

Appendix 14

Revised 10/00 c. 2000

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

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

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

DYNATEC/ ZENITH HIGH ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E428, 084E430, 084E432, 084E434, 084E436

Appendix 15

Revised 3/01

Part Number

084E428

084E430

084E432

084E434

084E436

Material

Tool Steel

Tool Steel

Tool Steel

Tool Steel

Tool Steel

Type/Accuracy

Single/ High

Single/ High

Dual/ High

Single/ High

Dual/ High

Output/Rev Shaft Seal PN

0.297cc

1.168cc

1.168cc

2.920cc

2.920cc

069X251

069X251

069X251

069X251

069X251

Thoroughly read and understand this entire manual before installation and operation of pump.

Note: The instructions given herein cover the description, installation, operation and maintenance of subject equipment. Dynatec and Zenith reserve the right to make engineering refinements that may not be reflected in this bulletin.

Manual revised 8/94

Appendix 16

Revised 10/00 c. 2000

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

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccuracies, multiple seal areas and slippage, which required constant calibration, high maintenence and extended downtimes.

Zenith Pumps met the challenge and designed a rotary external gear pump of unique precision and simplicity. Manufacturing techniques were developed to hold tolerances to

.00005”, and an internal pressure relief mechanism assured reliable precision metering. The pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.

For years since, chemical engineers have relied on Zenith to provide precision fluid handling solutions for their most difficult pumping applications. Zenith gear pumps can be found wherever precise, pulseless, repeatable metering of fluids is required.

BENEFITS

High Accuracy

Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and temperature.

High Temperature Capability

Operating temperatures to 550 degrees F (288 degrees C).

Maximum Life

Only three moving parts; components are through-hardened tool and die steels to 62 HRc or better. Replaceable sleeve bearings for low-cost rebuilds.

High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under pressure by built-in alignment dowels.

Minimum Pulsation

Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance.

Precision Construction

Ground and lapped components for close control of operating clearances.

c. 2000

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

Appendix 17

Revised 3/01

SPECIFICATIONS

Pump Type: Rotary external spur gear, single stream.

Rotation: Clockwise

Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.

Temperature: To 550 degrees F (288 degrees C)

DESIGN

Dynatec/ Zenith High Accuracy Metering Pumps consist of two gears rotating in mesh within a closely fitted housing that is comprised of three plates. The center gear plate fits closely around the outside diameter of the metering gears. The front and rear plates sandwich the center plate and restrict axial movement of the gears. Power is transmitted to the gears by the drive shaft which is a through shaft. Shaft sealing is accomplished with a high temperature cup seal.

High-accuracy pumps are precision instruments requiring skilled and careful maintenence.

Constructed of high-quality tool and die steels such as AISI D2, M2, M4 and CPM-M4, or other high-performance alloys, they are tempered after heat treatment to hardnesses ranging from HRc 58 to HRc 64. Since the thermal expansion rates for all three steels are almost identical and are otherwise entirely compatible, it is possible to combine them so as to take advantage of their best qualities in the most economical way.

The Type D2 tool steel is often selected for the side and center plates as it offers good abrasion resistance and it is the most economical of the three steels we most commonly use.

Type D2 will also provide a higher degree of corrosion resistance than M2 or M4.

The portion of the side plate subject to the most wear is the shaft bearing hole, which has an easily replaceable, inexpensive sleeve bearing that can be made of the extremely wear resistant Type M4 tool steel. Types M2 and CPM-M4 steels are commonly used for the metering gears, drive shaft and universal seal coupling, due to their superior torsional strength and abrasion resistance for these items that are the most critical to proper metering performance.

OPERATION

All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed gear tooth volumes and is transported around the outer diameter of the gear pocket.

As the gears mesh together, the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate.

cont.

Appendix 18

Revised 10/00 c. 2000

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

Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pressure required. However, when high-viscosity fluids are used, more time is required to fill the tooth volumes. As a result, the inlet pressure must be increased, or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation.

Dynatec/ Zenith pumps rely on the metered fluid for lubrication of internal bearing areas. The pump should never be allowed to run dry or be allowed to run with non-lubricating fluids such as water. Because of the close clearances in the bearing areas, lack of sufficient lubrication can cause pump seizure or some other catastrophic failure.

Slippage will occur across the faces of the gears from the high-pressure side to the low-pressure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential pressure and pump clearances. Under reasonably stable operating conditions, slippage is repeatable and predictable and pump operation can be adjusted to compensate.

The High Accuracy Pumps are designed for high-temperature and high-pressure operation.

As such, operating temperatures to 550 degrees F can be achieved.

INSTALLATION

Pumps should be carefully unpacked to make sure that the shipment is complete. If any items are missing or damaged, the freight carrier and Dynatec should be notified immediately.

While the pump is composed of steel, it is a precision instrument. Dropping the pump or hitting with a non-yielding material can cause serious damage to the components. All materials are through-hardened to maximum hardness resulting in brittle material. Treat them as you would any other precision gauging instrument.

Dynatec/ Zenith pumps are shipped filled with a rust preventive oil. Flush the oil throughly with a cleaning solvent. It may be necessary to disassemble the seal arrangement to remove all traces of the oil, but disassemble only if necessary.

After flushing, the pump should be lubricated internally for start-up purposes. Pour a suitable high-temperature lubricant (silicone oil) into the inlet port. Rotate the metering gears until lubricant appears at the discharge port.

Mount the pump to a block with a flatness of true flat to .0001” convex and a surface finish of

4 to 8 rms to prevent leakage between the pump and block. Mounting bolts should be a Grade

8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize compound such as DAG Dispersion #154. Bolts should be alternatively torqued in even increments up to Dynatec’s recommended limit for the bolt size used. See Table 1 on page 26 for torque values.

The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact ITW Dynatec.

cont.

c. 2000

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

Appendix 19

Revised 3/01

TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.

2. Filters should be installed prior to the pump inlet that filter ideally to half the pump running clearances.

3. Turn pumps by hand before running. Pumps should turn freely.

4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the coupling* and that it is aligned within one degree angular and .005” parallel with the true pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate.)

5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque at room temperature.

6. Make sure fluid is in the pump before starting.

7. Start pump slowly and, if possible, run it with a lubricating fluid.

8. When satisfactory operation is achieved, the pump and system may be gradually brought up to normal process speeds and pressures.

9. If at any time during operation the pump does not appear to be running smoothly, stop the pump immediately to avoid any serious internal damage.

CLEANING, INSPECTION AND REPAIR

REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop the high pressure demanded, the clearance between the metering gears and their housing must be as small as possible, yet large enough to allow adequate lubrication. All parts are machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths of an inch (.0001”/ .0002”). Because of these close running clearances, these pumps require careful maintenence and handling, especially of component parts. The slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These pumps are precision instruments; you can’t keep them too clean. Please treat them with care, and if it’s at all possible, set aside a separate clean area for pump maintenance.

To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to the pump size and the degree of polymer contamination and should be determined by trial. Note: Careful control of he furnace temperature (950 degrees F max.) and atmosphere is critical. Should the temperature exceed the original tempering temperature, the steel hardness will draw back and the dimensional stability of the pump may be upset.

Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.

The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization process usually takes between 3 and 12 hours, depending on the polymer type, temperature, pump size and furnace load.

cont.

Appendix 20

Revised 10/00 c. 2000

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

CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.

After gradually cooling to room temperature, the pump should be thoroughly flushed in a clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer ash.

If present, always replace the carbon seal plate after pump burnout. If the pump was performing satisfactorily when removed from service and still turns freely after burnout, pressure test it and add a high-temperature lubricant to prepare it for return to service. To store for future use, simply add a rust preventative oil.

It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum. By noting the performance of a pump immediately before removing it from service and correlating the performance to measured component wear, the user can establish the maximum wear limits for the pump’s critical components. Further, he can predict the service life of the pump and schedule his down-time accordingly.

As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for complete rehabilitation as necessary. This procedure may be desirable if only a few pumps are involved. If a large number of pumps are to be maintained at the user’s plant, it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing, gauging and assembly techniques involved in producting the pumps.

Please contact Dynatec (at 1-800-538-9540) for further information on these items.

HIGH ACCURACY PUMP DISASSEMBLY

If pumps are to be disassembled on a regular basis, we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate

“clean” area for assembly, testing and storing of rebuilt pumps.

If maintenence is required due to low delivery or seizure, the following procedure is recommended for disassembly.

NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.

Refer to assembly drawing (located in the back of this manual) for your correct pump type.

1. Remove the seal arrangement.

2. Remove all binder screws.

3. Remove dowels (10) and arbor (5) with an arbor press in the direction which disengages the press fit in the shortest distance.

NOTE: Dowels and arbors for the high accuracy pumps are press fit in the rear front plate (1) and slip fit in the center (2) and side plates (3).

cont.

c. 2000

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

Appendix 21

Revised 3/01

4. Separate the plates by pry slots. Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart.

5. After disassembly, clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning. Alternative, non-destructive cleaning methods such as water jet or solvents are also acceptable.

6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang parts together.

7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and faces of the gears may be hand blocked on 400/600 grit paper and any nicks, burrs or sharp edges can be lightly removed with a honing stone. Be careful not to round off the edges of the gear teeth while lapping.

CAUTION: Since the thickness relationship between the metering gears and the center plate is critical to metering performance, and the center plate is non-wearing on its sides, lapping these components is not necessary and should not be done under any circumstances.

Place a layer of 400 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 1) approximately ten times until a smooth finish appears. Turning in a circular fashion, or other non-uniform motion, may cause the ground holes to lose their perpendicularity to the faces.

Always use clean, lint-free rags and compressed air to clean components. Paper towels are not acceptable; they may leave small pieces of paper and dust on the components. Use chemical brushes to clean between gear teeth, bores and reliefs.

8. Replace sleeve bearings as necessary and hone in the plate to the original new part specifications.

9. After each resurfacing, carefully gauge the area between the inlet and discharge ports at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical part of the plate. Scoring or wear marks here will allow increased slippage from the highpressure discharge port section across the throat to the lower inlet port, reducing efficiency.

Therefore, carefully gauge this area for flatness after each resurfacing.

10. After all components are “hospital clean”, the pump is ready for assembly.

Figure 1

Appendix 22

Revised 10/00 c. 2000

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

HIGH ACCURACY PUMP RE-ASSEMBLY

NOTE: During and between each re-assembly step, manually turn the metering gears to ensure that they are free turning. If binding occurs at any time, determine the cause and correct it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned, the pieces will fit easily into place and the pump will turn freely. Re-assemble as follows:

1. After all worn parts have been re-finished or replaced, all parts should be throughly cleaned in a solvent and dried.

2. Using the driven gear (7) as an up-righting fixture, carefully locate the arbor (5) over its press-fit hole with the help of an appropriate arbor press.

3. Place the rear side plate (3) with the arbor in position in a soft-jaw vise or holding fixture.

4. Slip together the driving metering gear (6), drive shaft (4), key (8) and retaining ring.

Position in the front of the side plate by installing the drive shaft through the bearing (49).

gear.

5. Place the driven metering gear on its arbor and carefully mesh with the drive metering

6. Carefully lower the center plate (2) over the gears.

NOTE: Repeat steps 5 and 6 for four-gear pumps, placing the middle plate between gear plates.

7. Position the front side plate (1).

8. Rotate the gears to ensure free rotation.

9. Press the dowels (10) into place moving in the direction of the shortest press distance.

(Usually from the rear side of the pump.)

10. Lubricate the binder screws (47, 48) with DAG dispersion #154 or a similar heat resistant lubricant and install. Torque the screws in even increments to the manufacturer’s recommended limit. It is especially important to rotate the gears frequently during this operation.

11. Re-assemble the seal arrangement, making sure the sealing surfaces are perfectly clean and free of scratches, nicks or burrs. When a carbon seal plate is used, always use a new carbon seal that has been lightly polished on 400/600 grit paper. When using a carbon seal, the coupling housing screws (27) should be torqued to the manufacturer’s recommended limit. For pumps with a compensation packing seal, be sure all old packing is removed from the packing housing.

12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or worn. Worn shafts will result in premature seal leakage and should be replaced.

13. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-O-

Lubricate or an equivalent silicone-based oil.

14. Install lip seals into seal housing (22) as shown.

15. Tighten seal housing screws to 60 lbs./in. Check for rotation.

c. 2000

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

Appendix 23

Revised 3/01

SCREW TORQUE VALUES (Standard Alloy Steel)*

Screw Size & Thread

(UNC Alloy Steel)

#10-24 (w/ carbon seal gasket)

#10-24 (w/o carbon seal gasket)

#12-24

1/4-20

5/16-18

3/8-16

7/16-14

into aluminum block (hopper)

Torque (Lubricated Threads)

Lbs.-in.

[50]

[64]

[120]

[150]

[305]

[360]

[480]

Nxm Lbs.-ft.

5.7

[4.2]

7.2

[5.3]

13.6

[10]

16.9

[12.5]

33.9

[25]

40.6

[30]

54.2

[40]

Table 1

*In critical applications where control of bolt preload is important, the torque-tension relation should be determined by experimenting on the actual parts involved (including thread lubricants). At elevated temperatures, it is often desirable to reduce screw stress because of deformation (creep) under sustained loading. Screws constructed of type H-11 high-temperature alloy steel provide extremely high creep resistance.

TROUBLESHOOTING GUIDE

Trouble

Pump will not turn.

Probable Cause

1. Low pump temperature.

Remedy

Check temperature sensor and control loop for proper setting/ operation.

Allow sufficient heat-up time.

2. Drive malfunction.

Verify drive is powered.

Check to assure all alarm circuits are clear.

Check drive motor current and speed settings.

Check all drive couplings.

3. Process conditions changed.

Check process conditions for proper melt temperature, pressures, viscosities and materials.

4. Entrained particle.

Return pump to ITW

Dynatec for repair.

cont.

Appendix 24

Revised 10/00 c. 2000

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

TROUBLESHOOTING GUIDE,

continued

Trouble Probable Cause Remedy

5. Possible internal damages.

Return pump to ITW Dynatec for repair.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Return pump to ITW Dynatec for repair.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 1. Worn gear(s).

Return pump to ITW Dynatec for repair.

2. Worn bearings.

Return pump to ITW Dynatec for repair.

3. Process conditions changed.

Consult factory for clearance recommended on new process conditions.

* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.

c. 2000

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

Appendix 25

Revised 3/01

Appendix 26

Revised 10/00 c. 2000

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

c. 2000

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

Appendix 27

Revised 3/01

Appendix 28

Revised 10/00 c. 2000

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

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 2000

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

ZENITH MELT SPINNING PUMPS MANUAL

Covers ITW Dynatec part numbers:

084E374 0.584cc, single pump

084E376 1.752cc, single pump

084E388 0.297cc, dual pump

084E389 0.58cc, dual pump

084E411* 20cc, single, high flow

084E412* 30cc, single, high flow

084E413* 45cc, single, high flow

*available on models DM 70/140/210 only

Appendix 29

Revised 3/01

Pump PNs 084E374 thru 084E389 use PN 069X251 pump shaft seal.

Pump PNs 084E411 thru 084E413 use PN 069X289 pump shaft seal.

Appendix 30

Revised 10/00 c. 2000

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

c. 2000

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

Appendix 31

Revised 3/01

Appendix 32

Revised 10/00 c. 2000

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

c. 2000

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

Appendix 33

Revised 3/01

HIGH ACCURANCY PUMP PERFORMANCE

100

90

80

70

60

50

40

30

20

084E387

.160 cc/rev

084E388

084E428

.297 cc/rev

084E374

084E389

.584 cc/rev

10

.01

.02

.05

VOLUMETRIC EFFICIENCY FACTOR

D

P

m

N

.10

.2

.5

D

P = DIFFERENTIAL PRESSURE (PSI) m

= APPARENT VISCOSITY (CENTIPOISES)

N = RPM

1.0

084E434

084E436

2.92 cc/rev

084E376

1.752 cc/rev

084E430

084E432

1.168 cc/rev

c. 2000

DYNAMELT M ASU Manual 20-36

PN 800225 Pressure Transducer

(used in PN 800260 Pressure Transducer Assy.)

Appendix 35

Revised 10/00

(page 1 of 2 pg. pasteup of PN 800225)

Note: Transducers installed on

ITW Dynatec ASUs have been factory calibrated.

cont.

Appendix 36

Revised 10/00 c.2000

DYNAMELT M ASU Manual 20-36

c. 2000

DYNAMELT M ASU Manual 20-36

Appendix 37

Revised 10/00

Appendix 38

Revised 10/00 c.2000

DYNAMELT M ASU Manual 20-36

c. 2000

DYNAMELT M ASU Manual 20-36

TOOL-STEEL HIGH ACCURACY GEAR PUMPS

USER’S GUIDE

Appendix 39

Revised 4/06

Pump #

108863

108864

108865

108866

108867

108868

108869

108870

108871

108872

108873

108874

108875

110290

110291

Identifier

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

TSHA*

Displacement

0.160 cc rev.

0.160 cc rev.

0.297 cc rev.

0.297 cc rev.

0.584 cc rev.

0.584 cc rev.

1.168 cc rev.

1.168 cc rev.

1.752 cc rev.

2.920 cc rev.

4.500 cc rev.

2.920 cc rev.

8.500 cc rev.

30.0 cc rev.

45.0 cc rev.

Type

single dual single dual single dual single dual single single dual dual single single single

# Gears

2

4

4

2

4

2

2

2

2

4

2

4

2

4

2

# Plates

3

5

5

3

5

3

3

3

3

5

3

5

3

5

3

Shaft Seal #

807729

807729

807729

807729

807729

807729

807729

807729

807729

807729

807729

807729

808680

808680

808680

* Tool Steel, High Accuracy

Customer should read and thoroughly understand this manual before installation and operation of pump.

If necessary, any Dynatec pump requiring maintenance can be returned to the factory for complete repair and overhaul. Please contact our Rebuild

Department for further details.

Appendix 40

Revised 3/05 c.2000

DYNAMELT M ASU Manual 20-36

Description

ITW Dynatec’s metering gearpumps are manufactured to precise tolerances. To retain their high performance, these pumps must be carefully installed and maintained. These pumps are CE (Declaration of Conformity) rated.

Health & Safety

Dismantling

Internal components are precisely machined and have sharp edges and corners. These features are essential to the accurate metering performance. Particular care must be exercised when handling these components.

Cleaning

Cleaning fluids and methods are subject to strict Health and Safety regulations. Avoid contact with skin, do not inhale fumes and protect eyes.

Operation

Pump outlet pressure and speed limits are dependant on fluid viscosity and throughput. Pump inlet pressure is an important feature for lubrication and fluid homogeneity. Materials for pump construction are important for corrosion and wear resistance. Consult ITW Dynatec for detailed applications. Normally the pumps are single or dual output. Typical speed ranges are 10-90 rev/ min.

Flushing

To avoid contamination of process fluid, the pump should be flushed out to remove test oil. Precaution must also be taken to flush out pumps at plant shutdown, since congealed fluid can cause seizure.

Filtration

Unless fluid purity can be guaranteed (especially from metal fragments), filtration must be installed before pump inlet, to avoid damage to pump internals.

Note: The following guide is for general purposes only. Due allowance must be made for any special features.

Installation

Ensure pump is free from protective packing materials and rotates freely.

Pump Drive

Drive alignment is very important. Ensure backlash is 0.1mm (0.004”) to avoid shock or radial load. In the event of driveshaft connection, two flexible components must be incorporated into each driveshaft to allow for misalignment. These flexible components must have the capacity to distort over the misalignment range while ensuring that any radial load is minimal. Do not allow

c. 2000

DYNAMELT M ASU Manual 20-36

Appendix 41

Revised 4/06

shaft to put end thrust on the pump.

Rotation

Ensure drive rotates in correct direction (generally counter-clockwise at the pump drive spindle).

The pump must be checked for smooth operation by hand.

Fixing and Lubrication

The pump must be fixed securely to maintain position and alignment. When secured by lubricated bolts, torque them evenly to the suggested torque (see Maintenance).

Start drive and bring up to speed slowly. Flush with process fluid.

Note: motor baseplate assemblies should be pre-checked in case the drive alignment has been disturbed.

Gland Leakage

If oil seal is fitted, there should not be any fluid leakage.

Problem-finding Chart

Problem

LEAKAGE

Screws not tight

Seal scratched or worn

Remedy

Re-torque

Replace seal

FLOW RATE ERROR

Gear worn on diameter or width

Return to ITW Dynatec

Gear teeth damage Return to ITW Dynatec

Plates worn, scratched or not Return to ITW Dynatec flat

Low inlet pressure (cavitation) Check process

High outlet pressure (slippage) Check process

Appendix 42

Revised 3/05 c.2000

DYNAMELT M ASU Manual 20-36

Cleaning

Before removal from machine, the pump should be rotated for a short period (with inlet supply shut off) to discharge process fluid. Care should be taken, when removing and stripping the pump, to allow for any residual fluid. Pump components can be solvent or ultrasonically cleaned by immersion, using a compartmentalized wire baset. Dry in air. Stubborn residues may be removed with a brass wire brush. Avoid burnishing the sharp edges of gear and gear races.

Fluid immersion in rust inhibitor is advised. If components are to be stored for some time, they should be lightly smeared with oil.

Maintenance

Tightening Torque

for High Tensile ISO 12.9 Lubricated Bolts (300°C max)

Bolt Size & Qty.

M5 (4)

M10, 12 (4)

M10, 12 (4)

Bolt Location

retainer cap mounting bolts mounting bolts

Torque Nm/ Ft.lbs.

7.1/ 5.2

41/ 30 at ambient temperature

24/ 18 at production temperature

Notes: If mounting bolts are torqued at production temperature, they should be re-torqued (to 41

Nm/30 Ft lb.) when machine is at ambient temperature.

1 Nm = 8.85 in/lbs. Torques given above are for Metric and UNF threads. Multiply by 0.8 for

UNC and BSF threads.Multiply by 0.8 for BSVV threads (multiply by 0.67 for stainless steel)

ITW Dynatec frequently provides special features at their customer’s request. Please consult with

ITW Dynatec, quoting job and pump references, if questions arise.

c. 2000

DYNAMELT M ASU Manual 20-36

Appendix 43

Revised 4/06

Reconditioning

Should reconditioning (overhauling) become necessary, return the pump to ITW Dynatec.

Pump Shaft Seal Replacement

The ITW Part Number for all Standard Tool Steel High Accuracy Pump Shaft Seals (8.5cc and smaller) is PN 807729.

DANGER HOT SURFACE & HIGH VOLTAGE

If the pump is not operable but the heating system will function, raise the temperature of the application system to the operating temperature to aid in the pump disassembly process. Otherwise, a heat gun or other controlled heating method is recommended to melt hardened hot melt material. Never use a torch or an open flame on any of the components of the application system. Once the system is up to temperature, disconnect all incoming power before proceeding.

Pump Shaft Seal (O-ring) Replacement:

In most cases, the pump does not have to be removed from the ASU in order to replace the shaft seal.

1. Disconnect the drive coupling so that the pump may be accessed.

2. Remove the four screws in the pump “cap” and remove the cap.

3. Within the cap is the pump shaft seal. Remove the old seal.

4. Clean all pump parts, paying particular attention to the pump shaft seal groove.

Pump

Shaft

5. Lightly lubricate the shaft seal before inserting it in the shaft seal groove.

6. Before re-assembling, wrap a small piece of paper around the shaft so that the shaft’s woodruff key seat does not damage the new seal.

7. Re-assemble. Remove paper.

8. Re-tighten four screws.

9. Re-connect drive coupling.

10. Return ASU to operation and check pump for leaks.

Cap

Appendix 44

Revised 3/05 c.2000

DYNAMELT M ASU Manual 20-36

Rebuild Kit for 8.5cc TSHA Pump, PN 111939

The rebuild kit for the PN 108875 8.5cc TSHA pump consists of the following parts:

PN

111699

111699

111701

111702

111704

Description Qty.

Drive Shaft

Idler Shaft

Bushing, Front Plate 1

Bushing, Back Plate

Dowel

1

1

1

2

PN

111707

111709

807729

111705

078I001

Description

Retaining Ring

Screw, 10-24

Pump Shaft Seal

Key

Key, Woodruff

Qty.

1

1

1

4

1

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