ITW Dynatec M 70, M 140 Adhesive Supply Unit Operations & Service Manual

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 20-29

Revised 9/15/07

DYNAMELT

®

M SERIES ADHESIVE SUPPLY UNIT

OPERATIONS AND SERVICE MANUAL

Models: DM M70 & M140 PLC

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. 1999

DYNAMELT M70/140 ASU Manual 20-29

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-29

Table of Contents Page iii

Revised 3/01

TABLE OF CONTENTS

Chapter 1 Safety Precautions

Chapter - Page #

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

High Temperatures

High Pressure

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

Eye Protection & Protective Clothing

Safe Installation and Operation

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Treatment for Burns From Hot Melt Adhesives

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

Explosion/ Fire Hazard

Lockout/ Tagout

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1-2

1-2

1-2

1-3

1-1

1-1

1-1

1-1

1-3

1-3

Chapter 2 Description & Specifications

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

Specifications

Dimensions

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Total System Wattage Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Circuit Breaker Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-2

2-4

2-6

2-6

Chapter 3 Installation & Start Up

Placing the DYNAMELT ASU

To Open/ Close Panel Box Door

Installation

Adding Adhesive

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

Dynamelt M70/140: Layout of Pumps & Hopper Temperature Zones . . . . . . . . . . . . . . . . . . . . . . . . . .

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3-1

3-2

3-2

3-4

3-4

3-4

Hose/ Head Electrical & Adhesive Connections (illustration) 3-5

Electrical Connections & Filter Manifold Arrangement, Maximum Hose/ Head Configuration (illus.) 3-5

Adjusting the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Enable (Ready) Thermostat Calibration

Field Installation of Controller Options

Optional Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Start Up and Shut Down Procedures

Storage and Disposal of the Application System

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Installation of the Optional Tach Generator or DC Tracking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3-6

3-8

3-8

3-9

3-10

3-11

3-12

Chapter 4 Controller Set-Up

PLC Logic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Control Functions in General

Defining Temperature Control Terms

Error Indication Alarms

Settings for a Typical Operation

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4-1

4-1

4-2

4-4

4-4

Chapter 5 Programming of Controller

Screens in General

Main Menu Screen

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Use of Main Menu/ System Status Screen

Temperature Menu Screen

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5-1

5-2

5-3

5-4

Page iv Table of Contents

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-29

Setpoint Entry Programming Screen(s)

Adhesive Application Unit’s (ASU’s) Motor Menu Screen

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

Adhesive Pressure Monitoring Screen

Setup Menu Screen

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Seven-Day Scheduler Programming Screen

PanelView Configuration Screen

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Configuration Mode Main Menu Parameter Screens

Helpful Tips for the User

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5-6

5-8

5-10

5-12

5-14

5-16

5-18

5-20

5-21

Chapter 6 Preventive Maintenence

General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Schedule

Replacing the Outlet Filter Basket

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Standard Outlet Filter Manifold (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Optional High Flow Outlet Filter Basket

High Flow Outlet Filter Manifold (illustration)

Hose Fittings

Fasteners

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Filter Shutoff Cleaning or Replacement

Pump Shaft Leak

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Summary of Preventive Manintenance Schedule

Flushing the System

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6-3

6-3

6-4

6-4

6-1

6-1

6-1

6-2

6-4

6-5

6-5

6-5

Chapter 7 Troubleshooting

General Troubleshooting Notes

Pump Enable Thermostat

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High-Temperature Redundant Overtemp Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SLC 500 Power Supply Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SLC Processor Battery

Handling the SLC 500’s Components

Model DM M210 SLC Module Configuration

DeviceNet Communication Modules

DeviceNet Troubleshooting

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Model DM M35 SLC Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model DM M70/140 SLC Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SLC Processor (CPU) Module

Input Modules

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Output & Output/Input Modules

Heater and Sensor Resistance Values

Resistance Tables

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Error Indication Alarm Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Adjustable Adhesive Pressure Relief Valve

Operation of the ASU’s Gear Pump

Troubleshooting the ASU Pump

Gear Pump Troubleshooting Guide

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7-2

7-3

7-4

7-5

7-1

7-2

7-2

7-2

7-6

7-7

7-8

7-10

7-11

7-12

7-13

7-14

7-15

7-23

7-24

7-25

7-26

Chapter 8 Disassembly & Re-assembly Procedures

Disassembly Procedures

To Remove the Access Doors

To Open Junction Boxes

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

8-1

8-1

8-1

8-2

c. 1999

DYNAMELT M ASU Manual 20-29

Table of Contents Page v

Revised 8/02

To Remove Manifold Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove Lower Manifold Cover

Heater Replacement

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

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

To Access the Electrical Components Inside the Panel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Removal

Relay Removal

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SLC 500 Module Removal

To Access the Pump or Motor

Motor Removal

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

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

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

8-2

8-2

8-2

8-3

8-3

8-3

8-3

8-3

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

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Filter Options & Accessories

Pump Options & Accessories

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Return (Re-circulating) Hoses

Pneumatic Clutch

Level Control

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

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

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

Pressure Transducer Assembly

Dual Hopper

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

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

Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

9-2

9-2

9-2

9-3

9-3

9-3

9-4

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 Assemblies

Electrical Panel Box Assembly

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

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

Cabinet Assembly

Drive Assemblies

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

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

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

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

Pump Adapter Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

10-1

10-2

10-6

10-10

10-14

10-16

10-18

10-26

10-28

In addition to the assemblies listed above, this chapter may also contain illustrations for other optional or special assemblies installed on your ASU.

Chapter 11 System Schematics & Engineering Drawings

Hose Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Head Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flow Diagram, Outlet Filter Manifold/ Cross Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Hydraulic Schematic

Grounding Diagram

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

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

11-2

11-3

11-4

11-5

11-6

Page vi Table of Contents

Revised 5/04 c. 1999

DYNAMELT M ASU Manual 20-29

Pump & Zone Configuration

Dynamelt M ASU Schematic

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

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

11-7 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

Optional Pressure Transducer

Optional Pneumatic Clutch

Optional TSHA Pumps

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

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

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

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

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

Appendix 1

Appendix 15

Appendix 29

Appendix 34

Appendix 35

Appendix 39

Appendix 49

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. 1999

DYNAMELT M ASU Manual 20-29

Description & Specifications Page 2-1

Revised 6/99

Chapter 2

DESCRIPTION AND SPECIFICATIONS

Description

The DYNAMELT

Ò

M70 and M140 adhesive supply units (ASU) are computer-controlled hot-melt supply units designed on metric standards. They utilize Allen Bradley SLC (small logic controller)

500 systems and they interface with Allen Bradley’s PanelView touchscreen control panel.

The Dynamelt M Series ASUs are available in three cabinet sizes and offer four hopper sizes. Their microprocessor temperature control closely controls the temperature of hot-melt adhesive for up to

8 hoses and 8 heads. Temperature setpoints are operator-selected for up to 32 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions.

The Dynamelt 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.

The SLC 500 maintains all temperature zone setpoints, alarms and motor parameters, as well as the scheduling parameters. The SLC’s processor (CPU) monitors the electronic circuitry and provides alarms for error conditions. A DeviceNet module provides communication to the ASU’s drives. The

PanelView 600 touchscreen color controller is the operator’s interface to the SLC 500 system.

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.

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

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

The DM140 is also available in a high flow model..

Page 2-2 Description & Specifications

Revised 2/01 c. 2001

DYNAMELT M ASU Manual #20-37

Specifications

Environmental:

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

Ambient service temperature

Noise emission

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

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

-40 ° C to 70°C (-40° F to 158°F)

-7

° C to 50°C (20° F to 122°F)

< 60 dbA at 1 meter (39 inches)

Physical:

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

Number of heads/ hoses see dimensional layouts on following pages

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

1 to 8

Number of return hoses or auxillary zones

Number of hopper temperature zones

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

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

1 to 8

1 to 2

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

Number of (optional) drop-in grids

1 to 4

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

2

Number of standard grids

Gear pumps

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

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

2

Zenith, 2.92 cc/rev standard

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

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

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

Hopper (tank) capacity wrench-secured fluid fittings (#6 JIC)

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

210 kg/ 420 lb

Hopper construction

Filtration

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

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

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

Weight, empty

Adhesive form

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

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

TBD accepts most forms

Electrical:

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

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

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

Minimum supply amperes

Power consumption, hopper

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

see circuit breaker size

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

10,000 watts

Power consumption, 2 drop-in grids

Hopper heater type

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

5,000 watts

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

cast in

Temperature control . . . . . . . . . . . . . . .

microprocessor-based proportional integral derivitive (PID)

Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

100 Ohm Platinum RTD standard

120 Ohm Nickel RTD optional

Electrical connectors

Motor

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

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

durable, latching connectors

1/2 hp, alternating current motor, TEFC*, direct drive,

Maximum current available for each hose or head vertical orientation, right angle gearbox

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

10 ampere

* totally enclosed, fan cooled

c. 1999

DYNAMELT M ASU Manual 20-29

Description & Specifications Page 2-3

Revised 2/04

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

. . . .

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

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

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

up to 68 bar (1000 psi) maximum

Temperature Control:

RTD input board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 zones per board, modular construction

Line speed inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature control zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 to 4

32 maximum with solid state relays

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

Solid state relay input hopper: 10,000 watt hose: 1200 watt applicator head: 1200 watt auxiliary: 2000 watt

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

3-15 VDC

Other:

Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature standby

PanelView 600, color

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

High and low temp alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes

Ready interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequential heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yes yes (hopper, hose, head staged heating)

Sensor open alarm

RS232 and RS485 communications capable

Seven-day scheduler

RPM display

SLC 5/04 CPU 32K

DeviceNet module

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

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

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

High temperature capable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Alarm & system ready outputs (120v) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Standby & E-stop inputs (120v)

Remote On/Off (120v)

CE approval granted

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

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

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

yes yes yes yes yes yes yes yes yes yes yes

Page 2-4 Description & Specifications

Revised 2/04 c. 1999

DYNAMELT M ASU Manual 20-29

F

D

C

G

H

B

D

A

C

I

G

B

DIMENSION

mm inches

DYNAMELT M70 Installation Dimensions

A B C D E F G H I

1002.4 850 1301.6 1622.3 177.8 342.9 838.2 320.68 1,377.7

39.46

33.46

51.24

63.87

7.00

13.5

33 12.625

54.24

E

c. 1999

DYNAMELT M ASU Manual 20-29

Description & Specifications Page 2-5

Revised 2/04

F

H

B

F

D

A

C

I

G

B

DIMENSION

mm inches

DYNAMELT M140 Installation Dimensions

A B C D E F G H I

1506.4 850 1301.6 1622.3 177.8 342.9 838.2 320.68 1377.7

59.31

33.46

51.24

63.87

7.00

13.5

33 12.625

54.24

E

Page 2-6 Description & Specifications

Revised 3/01

Total System Wattage Capacity

Maximum Wattage

Hopper + High Temp Heater

PreMelt

Optional Drop-in Grid

Up to 8 Hose Zones

(1200 w each)

Up to 8 Applicator Zones

(1200 w each)

Up to 8 AUX Zones

(2000 w each)

DYNAMELT MODELS

M70 M140

12,000 w

5000 w

-- --

9600 w

12,000w

5000 w

5000 w

9600 w

9600 w

16,000 w

9600 w

16,000 w

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

c. 1999

DYNAMELT M ASU Manual 20-29

Main Circuit Breaker Determination

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

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

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

c. 1999

DYNAMELT M ASU Manual 20-29

Installation Page 3-1

Revised 3/06

Chapter 3

INSTALLATION

Placing the DYNAMELT M ASU

The DYNAMELT

®

M SERIES ASU stands alone on flat surfaces.

The main electrical power and the serial communication connections come in from below the unit and connect into the circuit breaker.

Hopper Lid

Hose/ Head

Electrical

Connections

Manifold

Cover

Controller Keypad

Main Disconnect

Switch

Panel Box

Keylock

Panel Box

Keylock

Access

Door

Keylock

Panel Box

Dotted line indicates location of Circuit

Breaker within

Panel Box

The DYNAMELT M70/ M140 ASU (model M140 shown)

Page 3-2 Installation

Revised 7/00 c. 1999

DYNAMELT M ASU Manual 20-29

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 switch to “Reset” and then back to

“ON”.

5. Lock the panel box door with the key.

Installation

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

F

O

F

R

E

S

E

T

Lockout Safety

TR

I P

ON

Tab

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

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.

Required Customer Wiring

On the insert within the panel box assembly: a. Connect 3 electrical leads with the appropriate voltage to the main circuit breaker.

b. Connect one electrical lead to the ground (PE) lug.

Main

Circuit

Breaker

Ground

Lug

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

c. 1999

DYNAMELT M ASU Manual 20-29

Installation Page 3-3

Revised 5/07

3.

Optional Customer Interface Wiring

a. The I/O terminals provide for remote monitoring of an alarm condition. A source voltage occurs when any alarm is activated. Alarm terminals are binary (on/off) I/Os and are located on the Allen Bradley rack in the panel box assembly.

Refer to the schematics and layout drawings in Chapter 11 for details.

b. The optional LEVEL CONTOL terminals provide for remote monitoring of level control conditions. Level Control terminals are binary (on/off) I/Os and are located on Allen Bradley module rack in the panel box assembly.

Refer to the schematics and layout drawings in Chapter 11 for details.

c. The LINE SPEED terminals for “Auto” operation of the motor(s) are analog. There are two wires for each terminal (INO+ and INO--) on the Allen Bradley analog input. Polarity must match from wire to terminal (+ to + and -- to --). Line speed varies between 0 and 10VDC.

Refer to the schematics and layout drawings in Chapter 11 for details.

4. The adhesive hoses are connected at the rear of the ASU (see illustration on page 3-5). Remove the manifold cover and the lower manifold cover for access. 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 head/ hoses, hookup head/ hose #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. Refer to the hose and applicator manuals for further details.

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 3-5.

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 are ITW Dynatec factory-calibrated.

Units not using transducers may use either a PSI port or a feed hose port to mount an

(optional) pressure gauge. If all ports are in use, the pressure gauge may be installed in line with a hose.

Page 3-4 Installation

Revised 4/00 c. 1999

DYNAMELT M ASU Manual 20-29

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.

4

2

1

3

PUMP

4

PUMP

3

PUMP

2

PUMP

1

4

DM70 Single Hopper Temperature Zones:

Zone 1 Grid 1 (optional)

Zone 2 Grid 2 (standard)

Zone 3 Hopper (standard)

Zone 4 Primary Filter (standard)

5000w

5000w

10000w

2000w

3 1

2

4

8

6

5

7

PUMP

4

PUMP

3

PUMP

2

PUMP

1

DM70 Dual Hopper Temperature Zones:

Zone 1 Grid 1 (optional)

Zone 2 Grid 2 (standard)

Zone 3 Grid 3 (optional)

Zone 4 Grid 4 (standard)

Zone 5 Hopper 1 (standard)

Zone 6 Hopper 2 (standard)

Zone 7 Pimary Filter 1 (standard)

Zone 8 Primary Filter 2 (standard)

2500w

2500w

2500w

2500w

5000w

5000w

1000w

1000w

2

1

3

4

1

2

4

3

4

PUMP PUMP PUMP PUMP

4 3 2 1

DM140 Single Hopper Temperature Zones:

Zone 1 Grid 1 (optional)

Zone 2 Grid 2 (standard)

Zone 3 Hopper (standard)

Zone 4 Primary Filter (standard)

5000w

5000w

10000w

2000w

8

6

5

7

PUMP

4

PUMP

3

PUMP

2

PUMP

1

DM140 Dual Hopper Temperature Zones:

Zone 1 Grid 1 (optional)

Zone 2 Grid 2 (standard)

Zone 3 Grid 3 (optional)

Zone 4 Grid 4 (standard)

Zone 5 Hopper 1 (standard)

Zone 6 Hopper 2 (standard)

Zone 7 Primary Filter 1 (standard)

Zone 8 Primary Filter 2 (standard)

2500w

2500w

2500w

2500w

5000w

5000w

1000w

1000w

Dynamelt M70/140: Layout of Pumps & Hopper Temperature Zones

(View from Pump Side)

c. 1999

DYNAMELT M ASU Manual 20-29

Filter Nut

Electrical

Connections

F1

#1

A1

Auxiliary

#1

Installation Page 3-5

Revised 8/99

Closeable Cross

Channel

Tamper Proof Screw

Bleed Valve Port

Retainer Plate

Purge Drain

Hose/ Head Electrical and Adhesive Connections

Heater Channel

RTD Sensor Channel

Head/ Hose

Electrical

Connects

Auxiliary

(Return Hose)

Electrical

Connects

F1 F2

A1

A2

A 1 A 2

PSI 1 PSI 2

F 1 F 2

F3

F4

A3

A4

A 3 A 4

PSI 3 PSI 4

F 3 F 4

F5

F6

A5

A6

A 5 A 6

PSI 5 PSI 6

F 5 F 6

F7

F8

A7

A8

A 7 A 8

PSI 7 PSI 8

F 7 F 8

Adhesive supplied by motor/pump #1

Adhesive supplied by motor/pump #2

Adhesive supplied by motor/pump #3

Adhesive supplied by motor/pump #4

Up to Four Filter Blocks with up to 16 Adhesive Ports

Note:

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

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

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

Maximum Head/ Hose Configuration

Page 3-6 Installation

Revised 4/00 c. 1999

DYNAMELT M ASU Manual 20-29

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. Note: it is not necessary to remove the Lower Manifold 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

Jam nut

Adjustment screw

Turning the adjustment screw

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

Turning the adjustment screw

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

c. 1999

DYNAMELT M ASU Manual 20-29

Installation Page 3-7

Revised 8/99

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 3-8 Installation

Revised 11/00 c. 1999

DYNAMELT M ASU Manual 20-29

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.

Note: The thermostat must be re-calibrated and the controller’s pump enable temperature must be reprogrammed.

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

As an example: the operator desires to lower the preset Pump Ready temperature to 107°C (225°F).

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

2. Open the heater access door after loosening its captive screw.

3. Wait for the hopper temperature to stabilize at 107°C (225°F), then: a. For thermostats with purple & black wire leads or solid tan wire leads: turn the thermostat’s adjustment screw counter-clockwise to increase the temperature (or clockwise to decrease it) until 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 the pump’s motor begins turning. Adjust no further.

4. Close the heater access cover and tighten its captive screw.

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

6. Re-program the controller’s pump enable temperature to 107°C (225°F) (refer to Ch 5).

Field Installation of Controller Options

Customers who choose to modify their adhesive supply unit with ITW Dynatec or Allen-Bradley manufactured options should assure that only qualified technicians perform such installations.

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

c. 1999

DYNAMELT M ASU Manual 20-29

Installation Page 3-9

Revised 10/00

Installation of an 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 motors 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 Allen Bradley analog input card (see panel box layout in

Chapter 11).

3. A. To install a tach generator: i.Verify the tach generator’s voltage polarity and connect it to the analog input card’s terminals per the schematic in Chapter 11.

ii. Verify that the gear pump motor is running at full speed when set to 100% in MANUAL mode (this is normally 180 VDC at the pump motor armature). 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 AllenBradley analog input card per the schematic in Chapter 11.

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.

Page 3-10 Installation

Revised 5/01 c. 1999

DYNAMELT M ASU Manual 20-29

Optional Level Controls

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

Single Point Level Control

The single point level control monitors either a low or a high adhesive level.

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

DO NOT CUT the sensor cable.

Adjustment of the Single Point Level Control:

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

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

LED lights to indicate the presence of adhesive. When the LED goes out, the audible and visible alarms will activate.

Use of Two Level Controls in One Hopper:

Two single point level controls can work together to maintain a range of adhesive in the ASU’s hopper. In this application, one level control’s sensor is mounted at the level of high adhesive and the other is mounted at the low level. Each amplifier requires its own sensitivity adjustment.

Sensor

Connect

1 2 3 4 5 6 min max

S

7 8 9 10 11 12

Sensitivity Adjustment Screw

Yellow LED

Amplifier

Multi-Point Level Control (available on DM M140 only)

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

The multi-point level control has the capability for three separately calibrated outputs. However, for most applications, one output, calibrated with a high and a low level, is sufficient.

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

c. 1999

DYNAMELT M ASU Manual 20-29

Installation Page 3-11

Revised 8/99

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

The following simplified sequence assumes that the PanelView 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 controller keypad, press the Heater Power ON/ OFF button. The display will read

“System Heating”.

4. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the temperatures of the temperature zones to stabilize. Monitor the display until it reads “System Ready”, indicating that all temperature zones are up to ready temperature.

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

a. If Motor is in Auto Program:

i For systems with no clutches installed: Adhesive will begin to pump when the production line begins to operate.

ii. For systems with clutches installed:

Press Motor Menu. Press desired Motor # Setup. Toggle Clutch ON. (If other motors are desired to run, repeat by pressing Return, press a desired Motor # Setup, toggle Clutch

ON, etc.) Adhesive will begin to pump when the production line begins to operate.

b. If Motor is in Manual Program: i. Press Motor Menu.

ii. Press desired Motor # Setup.

iii.Press Manual button.

iv. Enter desired pump speed.

v. If motor is installed with a clutch, toggle Clutch ON.

vi. If other motors are desired to run, press Return, then repeat steps “ii” thru “v”.

v. Adhesive will begin to pump after ready condition is attained.

6. Return the PanelView controller to its Main Menu/ System Status Screen while ASU is operating, to monitor potential alarms.

Shut Down Procedures

If Motor is in Auto Program:

1. a. When the production line stops, the motor(s) will automatically stop, or b. Turn OFF the motor(s) manually by pressing the Motor Menu, press desired Motor # Setup, then press OFF. Repeat for each motor in the system.

2. a. Toggle Heater Power* OFF (on Main Menu), or

cont.

Page 3-12 Installation

Revised 4/00 c. 1999

DYNAMELT M ASU Manual 20-29

b. If all power is to be removed, turn OFF the ASU’s Main Disconnect Switch.

If Motor is in Manual Program:

1. Turn OFF the motor(s) by pressing the Motor Menu, press desired Motor # Setup, then press

OFF. Repeat for each motor in the system.

2. a. Toggle Heater Power* OFF (on Main Menu), or b. If all power is to be removed, turn OFF the ASU’s Main Disconnect Switch.

*Note: If the Seven-Day Scheduler is employed, turn off with Heater Power key only.

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.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Controller Set-Up Page 4-1

Revised 1/99

Chapter 4

CONTROLLER SET-UP

PLC Logic Requirements

IMPORTANT NOTE: To Customers who supply PLCs (programmable logic computers) to operate ITW Dynatec adhesive application systems --

ITW Dynatec’s product warranty is in effect only if the following safeguards are written into the logic of customer-provided PLCs:

WARNING

Any software deviations from the following may cause unsafe conditions, including fire, in the hopper, hoses and applicators.

1. Shorted and open sensors must open the main heater contactors.

2. Shorted and open sensors must stop all pump motors.

3. The under-temperature switch must stop all pump motors.

4. The under-temperature alarms must stop all pump motors.

5. The over-temperature switch must stop all pump motors.

6. The over-temperature switch must open the main heater contactors.

7. The over-temperature alarms must open the main heater contactors.

8. The E-stop and the auxiliary disconnect must stop all pump motors.

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.

Temperature Control Functions in General

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

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

rect temperature conversions between degrees Celsius and Fahrenheit. Other parameters are independently selected values.

Page 4-2 Controller Set-Up

Revised 1/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Defining Temperature Control Terms

Adhesive Temperature Control Range

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

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.

External Reference Percent

The numeric percentage of the parent line’s full speed. Used in the controller’s Auto mode only.

Heater Output Percent

Heater output fluctuates in order to maintain each temperature zone’s setpoint. Heater output is measured as a percentage of the full wattage of each individual heater.

Heating Sequence Priority

A program which allows certain temperature zones (those assigned priority “1”) to begin heating first, before other zones (those assigned priority “2” or “3”) in the system. See also the definition of

“Sequential Heating”.

High/ Low Alarms (BW + / -)

The high/ low alarm setpoints. This is a range (bandwidth) “+” and “-” a zone’s temperature setpoint.

For example, if the temperature setpoint is 200 degrees, and the high/ low alarm setpoint is 10 degrees, then the high alarm equals 210 degrees and the low alarm equals 190 degrees.

Mechanical High-Temperature Protection

A mechanical, redundant thermostat located on the ASU hopper that will turn 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.

Over-Temperature Setpoint

The programmable temperatures that will cause display alarms to occur when those temperatures are exceeded. Power is disconnected, the READY contact opens and the alarm contact closes. If an external alarm has been connected (for example, to a PLC), it will activate. The over-temp setpoint is the upper limit of the ready temperature range of each zone.

Pump Enable Temperature

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

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Controller Set-Up Page 4-3

Revised 1/99

RS232/ RS485 Serial Communication

A bi-directional data transfer connection to a remote computer which enables system parameters to be monitored and/ or controlled from the remote station. The RS485 serial port connection allows remote interface over a much longer distance than the RS232 connection.

RTD Sensors

The standard Dynamelt system uses 100-ohm platinum resistance temperature detector sensors

(RTDs) to read temperatures for all the system’s temperature controls. As an option, the unit can be configured for 120-ohm nickel sensors.

Ready Temperature

The programmable temperature which allows the ASU pump to turn ON. The ready temperature range is a deviation ( ±) from the setpoint. The setpoint minus the deviation is the low limit of the range, and the setpoint plus the deviation is the high limit of the range.

Sequential Heating

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

ON to OFF. Sequential heating is not needed for most applications and can delay total system warm-up time.

Setpoint

A user-selected temperature that has been programmed for each heating zone of the adhesive application system.

Setpoint Limitation

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

Seven-Day Scheduler

A controller feature that provides for the scheduling of OFF and ON times (“events”) for the adhesive application system. It therefore allows the operator to program heating cycles which coincide with the work week’s production schedule. The scheduler also helps conserve electricity and functions as an additional safety feature.

Standby

The system condition where the ASU, hose and head temperatures are maintained at predetermined reduced temperatures. 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.

Page 4-4 Controller Set-Up

Revised 1/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

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.

Trim Percent

The desired ratio of the parent machine’s pump motor speed to the external reference percent as programmed. Used in the controller’s Auto mode only.

Error Indication Alarms

The conditions that will trigger an alarm are:

∙

When a hopper, hose or head has exceeded its selected over-temperature setpoint, which is the setpoint plus its high/low alarm setting, or when it is below its selected undertemperature setpoint, which is the setpoint minus its high/low alarm setting.

∙

When a hopper, hose or head sensor has an open circuit.

∙

When a hopper, hose or head has a heater with a short circuit.

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)

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Chapter 5

PANELVIEW 600

CONTROLLER TOUCHSCREENS

PROGRAMMING MANUAL 10.02

Programming Page 5--1

Revised 10/02

Numeric Entry Keys

TEMPERATURE

MENU

Main Menu

Delete

Enter

F1 thru F10 = used in Configuration Mode Arrow Keys

Controller Screens in General

1. To progress through the controller’s screens, press within the box (key) of a desired description (function) on the touchscreen. For example, as seen above, to go to the “Temperature

Menu”, press within the “Temperature Menu” box located at the upper right corner of the touchscreen.

2. Once a function is selected (active), use the numeric entry keys to program a desired value.

Press the Enter arrow (on the numeric entry keypad) to enter your value.

3. The “Delete” arrow (located below the numeric keypad, see above) also serves as an “escape” key.

4. This chapter describes a typical system. Your ASU may have more or less temperature zones, motor/ pumps, clutches or pressure transducers installed.

5. To go to “PanelView Configuration”, press the left and right arrow keys (lower right of diagram) simultaneously. See pages 18 thru 20 of this chapter for details on Configuration Mode.

6. To close an error screen, touch it.

Page 5--2 Programming

Revised 1/05

Main Menu Screen

System Status Display

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Optional Display for dual hopper ASUs

(not available on DM35)

Numeric Entry Keys

TEMPERATURE

MENU

HENDERSONVILLE, TN

1 @ Temp

SYSTEM HEATING

2 @ Temp

MOTOR

MENU

LOW ALARM ZONE: ##

HIGH ALARM ZONE: ##

HEATER POWER

10:05:28

2/8/2000

WED

ON

SETUP

MENU

Delete

Enter

Arrow Keys

Use of the Main Menu/ System Status Screen

To: Press This

Function Key

Heater Power

Temperature Menu

Motor Menu

Setup Menu

Toggle Heater Power ON or OFF

Go to the Temperature Menu Screen

Go to the Motor Menu Screen

Go to the Setup Menu Screen

Arrow Keys

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DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--3

Revised 10/02

Use of the Main Menu/ System Status Screen,

cont.

Programming Sequence

1. Press Heater Power to turn the Heater (Main) Power ON or OFF.

2. Press Setup Menu to setup the system in Celsius/ BAR or Fahrenheit/ PSI (screen is diagrammed on page 14 of this chapter).

Note: after temperature zone and motor programming is complete, if desired, you may return to this screen to program the Standby and Seven Day Scheduler

3. Press Temperature Menu to choose a temperature zone. Then program or monitor the following temperature functions (see details beginning on page 4 of this chapter): a. Temperature setpoints b. High/ low alarms c. Heater output d. Actual temperature

4. Press Motor Menu to: a. Choose a motor. Then setup or monitor the following functions for each motor: i. Motor ON/ OFF, Manual or Auto iv. External reference percent (Auto mode only) ii. Pump speed v. Minimum pump rpm (Auto mode only) vi. Maximum pump rpm (Auto mode only) iii. Motor rpm b. Monitor adhesive pressure (PSI/ BAR), or c. Turn clutches ON or OFF.

5. Press Setup Menu to program System Standby and/ or Seven-Day Scheduler.

Monitoring

:

1. “System Status Display” describes system status as one of the following: a. System Initializing: seen immediately after a power on, this screen is of short duration. It indicates that the controller is booting up.

b. System OFF c. System Heating: power is ON but zone temperatures have not risen to setpoint.

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

e. High Alarm: a temperature zone has exceeded its high limit.

f. Standby: the system is in a programmed standby state. Display flashes when Standby is active (ON).

g. Remote E Stop: the system has been stopped by a remote emergency stop.

h. Level Low: adhesive level in the hopper is low (used with optional level control only).

i. Level High: adhesive level in the hopper is overfull (used with optional level control only) .

j. OT T’stat Open: hopper temperature has exceeded safety limit (232

°C/ 450°F).

k. DeviceNet Fault: DeviceNet is not connected properly or is faulted (refer to pgs. 7-7 to 7-9).

l. Drive # Fault: the system is not ready until all of the drives are ready. (This fault will clear itself out) m. Pump # Low (or High) Pressure (optional): transducers indicate that #’d pump has high or low pressure, due to a clogged filter, adhesive leak, excessive adhesive flow, etc.

2. Low Alarm Zone or High Alarm Zone: the controller will list, one at a time, the identification number of any zone with a low or high alarm (the identification numbers are assigned on each zone’s Temperature Zone Programming screen). The i.d. numbers on the alarm display disappear as alarms clear.

3. Dual Hopper System Ready indicators: For ASUs with two adhesive hoppers, a display appears when each hopper is at ready temperature.

4. Error Screen: an error will cause this screen to appear. Touch within the error screen and it will disappear.

5. Seven-Day Scheduler’s Time-of-Day Clock: clock must be set for scheduler to function. See

“PanelView Configuration Screen” in this chapter for clock setting instructions.

Page 5--4 Programming

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Temperature Menu Screen

Example of Temperature Menu Screen #1

Selected Zone

Numeric Entry Keys

Z1

Z5

Z9

Z13

Z2

Z6

Z10

Z14

Z3

Z7

Z11

Z15

Z4

Z8

Z12

Z16

HEAD 3

ZONE 9

SP = 350

PV = 305

CV = 100

Z17

Z21

Z18

Z22

F1: PREV F2: NEXT

Z19

Z23

Z20

Z24

Setpoint

Entry

TEMP

SCREEN

# 3

TEMP

SCREEN

# 2

MAIN

Delete Enter

Arrow Keys

Example of Temperature Menu Screen #2: additional temperature zones (if applicable)

Z25 Z26

Z30

Z34

Z38

Z27

Z31

Z45

Z39

Z28

Z32

Z36

Z40

HOSE

3

ZONE 33

Z29

Z33

Z37

SP = 35

PV = 347

CV = 15

Z41

Z45

Z42

Z46

Z43

Z47

Z44

Z48

Setpoint

Entry

F1: PREV F2: NEXT

TEMP

SCREEN

# 3

TEMP

SCREEN

# 1

MAIN

Temperature Menu Screen #3 (not shown): additional termerature zones (if applicable)

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--5

Revised 5/03

Use of the Temperature Menu Screen

To: Press This

Function Key

Z#

Main

Setpoint Entry

F1 or F2

Temp Screen #2 or

Temp Screen #3

Program or monitor this numbered temperature zone

Return to the Main Menu

Go to the Setpoint Entry screen

Go to the Previous or Next numbered zone

Go to the second or third Temperature Menu screen for more zones

(if applicable)

Programming

1. Press “Z1” to go to the first temperature zone screen. See the following two pages for programming instructions.

2. Press each of the zone keys to program each temperature zone in the same manner.

3. Press “Temp Screen #2” or press “Temp Screen #3” to program the zones on the other Temperature Menu screens (if applicable).

Notes:

1. Hoses are numbered according to the hose outlet each is connected to. For example, Hose #3 is the hose connected to the #3 hose outlet.

2. Your PanelView controller may have up to three Temperature Menu screens, depending on the number of temperature zones in your adhesive application system.

Monitoring

1. When selected. each temperature zone is displayed, in the upper right corner of this screen, with its identification number (ie. Zone 1, Zone 2, etc. or Z1, Z2, etc.) in addition to its name (ie. Prog

Melt 2, Hose 3, etc.).

2. When selected, each temperature zone is displayed in the middle, right area of this screen, with its Setpoint (SP), Process Variable (PV) which represents the actual temperature and its Control

Variable (CV) which represents the percentage of heater output.

3. A bar indicator to the right of each zone’s key signifies if the zone is currently ON (heating).

The indicator appears “green” on the PanelView.

For example: Temperature Menu Screen #1, on the previous page, indicates the following zones are ON: Z1, Z4, Z5, Z8, Z11, Z12, Z15, Z16, Z18, Z19, Z22 and Z23.

Temperature Zone Limits

1. Model DM35 asu’s have up to 16 zones of temperature zone capability.

2. Model DM70 and DM140 asu’s have up to 32 zones of temperature zone capability.

3. Model DM210 asu’s have up to 46 zones of temperature zone capability.

Page 5--6 Programming

Revised 1/05

Setpoint Entry Programming Screen(s)

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Numeric Entry Keys

ZONE NAME

ZONE (#)

SETPOINT

ACTUAL

ON

HEATER OUTPUT % ###

HENDERSONVILLE, TN

500

### F

400

###.# F

300

ALARM BW + / -##

200

TEMP

SCREEN

ONE

F1: PREV F2: NEXT

PRIORITY #

100

0

Delete Enter

Arrow Keys

For a list of the names/ numbers of the Temperature Zones for your system, see the electrical schematic in Chapter 11 and/ or the last page of this chapter.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--7

Revised 10/02

Use of the Setpoint Entry Programming Screen(s)

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

To: Press This

Function Key

ON/OFF

Setpoint ###

Alarm BW +/- ##

Priority #

F1 or F2

Temp Screen 1 or 2

Toggle zone ON or OFF

Program the zone’s temperature setpoint

Program the zone’s high and low alarm range

Program a heating sequence priority for this zone

Go to the Previous zone or the Next zone on active menu

Return to a Temperature Menu

Programming

1. Toggle to turn the zone ON or OFF.

2. Press Setpoint ### to program the zone’s temperature setpoint: a. Use the numeric keypad to enter desired setpoint value (0-450

°F).

b. Press the Enter arrow to store your desired value.

3. Press Alarm BW +/- ## to program the zone’s high and low alarm value:

Note: The high/ low alarm setpoint is a range (+ and -- the zone’s temperature setpoint).

For example: if the temperature setpoint is 200 degrees, and the high/ low alarm setpoint is

10 degrees, then the high alarm equals 210 degrees and the low alarm equals 190 degrees.

a. Use the numeric keypad to enter desired high/ low alarm range (10-50 °F).

b. Press the Enter arrow to store your desired value.

4. If a heating sequence priority is desired, press Priority #:

Note: Priorities of “1”, “2” or “3” are allowed. A priority “1” programs a zone to begin heating first, before other zones in the system. If no priorities are programmed, the controller will default to “1” for each zone, causing all zones to begin heating simultaneously.

a. Use the numeric keypad to enter desired priority (1 thru 3).

b. Press the Enter arrow to store your desired value.

5. Press Temp Screen 1 (or 2) and repeat programming steps for another temperature zone.

Monitoring

1. “Zone #” (in upper right corner): the number which appears here is the controller’s identification number for this zone. This i.d. number will appear on the Main Menu screen any time the zone has a high or a low alarm.

2. Actual temperature may be viewed as: a. a line item of the display (for example, “Actual 117.5 F”), or b. a graph, located to the right in the display.

3. Heater output is measured as a percent of the full wattage for that heater. Heater output cycles on and off continuously in order to maintain each temperature zone setpoint.

4. Temperature setpoint is displayed as programmed.

5. High/ low temperature alarm is designated “Alarm BW +/- ” and is displayed as programmed.

6. Zones that are OFF will be bypassed when pressing F1 (PREV) or F2 (NEXT).

Page 5--8 Programming

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Adhesive Application Unit’s (ASU) Motor Menu Screen

Numeric Entry Keys

MOTOR 1 MOTOR 2 MOTOR 3 MOTOR 4

SETUP SETUP

0.0

PUMP

RPM

0.0

PUMP

RPM

0.0

PUMP

RPM

0.0

PUMP

RPM

PRES-

SURE

0.0

0.0

MOTOR 5 MOTOR 6

SETUP SETUP

MAIN

Delete

Enter

Arrow Keys

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DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--9

Revised 5/03

Use of the ASU’s Motor Menu Screen

Press This

Function Key

Motor 1 Setup

Motor 2 Setup

Motor 3 Setup

Motor 4 Setup

Motor 5 Setup

Motor 6 Setup

To:

Program or monitor Motor #1

Program or monitor Motor #2 (if applicable)

Program or monitor Motor #3 (if applicable)

Program or monitor Motor #4 (if applicable)

Program or monitor Motor #5 (if applicable)

Program or monitor Motor #6 (if applicable)

Pressure (if applicable) Monitor pressure values of (optional) pressure transducers

Main Return to the Main Menu

Programming

There is a “Motor # Setup” screen for each motor installed on your system.

1. Press Motor 1 Setup to program the first ASU motor. See the following two pages for programming instructions.

2. If more than one motor is installed on your ASU, press each Motor Setup to program each one in the same manner.

Monitoring

1. Actual Pump RPM is displayed for each motor.

2. If pressure transducers are installed on your ASU, press “Pressure” to advance to the Adhesive

Pressure Monitoring screen (see pages 12 & 13 of this chapter).

Motor Limits

1. Model DM35 asu’s may utilize one motor (only).

2. Model DM70 and DM140 asu’s may utilize up to four motors.

3. Model DM210 asu’s may utilize up to six motors.

Page 5--10 Programming

Revised 10/02

Motor Programming Screen

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

MANUAL

OFF

AUTO

ENTER

PUMP

##.#

SPEED

HENDERSONVILLE, TN

PUMP

RPM

##.#

MOTOR 1

PSI

58.4

EXT REF %

###.#

CLUTCH

OFF

MIN PUMP RPM

AUTO MODE

###.#

F1: PREV F2: NEXT

MAX PUMP RPM

AUTO MODE

###.#

RETURN

Numeric Entry Keys

Delete Enter

Arrow Keys

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--11

Revised 10/02

Use of the Motor Programming Screen

To: Press This

Function Key

Manual

OFF

Auto

Enter Pump Speed ##.#

Up & Down Arrows

Min Pump RPM

Max Pump RPM

Clutch (if applicable)

F1 or F2

Return

Choose Manual Mode

Choose Motor OFF

Choose Auto Mode

Program Pump Speed (used in Manual mode only)

Adjust Pump Speed up or down (used in Manual mode only)

Enter desired minimum pump speed (used in Auto mode only)

Enter desired maximum pump speed (used in Auto mode only)

Toggle (optional) clutch ON or OFF

Go to the Previous zone or the Next zone on active menu

Return to the Motor Menu screen

Programming

1. Press Manual, OFF or Auto to choose desired motor mode.

2. If in Manual, press Enter Pump Speed ##.# to program pump speed: a. Use the numeric keypad to enter desired rpm value.

b. Press the Enter arrow to store your desired value.

3. If in Auto: a. Press Min Pump RPM to program minimum pump speed. Enter and store value as above.

At 0 volts, this value will be between 0 and 10 rpm.

b. Press Max Pump RPM to program maximum pump speed. Enter and store value as above.

At 10 volts, this value will be between 0 and 90 rpm, depending on motor installed on ASU.

4. Toggle (optional) Clutch ON or OFF. This key is present only if optional clutch(es) is installed.

Adjustments

To adjust pump motor speed: a. In Manual mode: use the upper set of adjustment arrows to ramp speed up or down.

Monitoring

1. Actual Pump RPM is displayed.

2. Ext Ref % (external reference percent): the percent of the parent line’s full speed. Used in Auto mode only.

3. PSI or BAR is displayed as chosen on Setup Menu. The actual pressure is also displayed.

Page 5--12 Programming

Revised 10/02

Adhesive Pressure Monitoring Screen

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

PRESSURE DISPLAY PSI PSI

PRESSURE #2 0.0 PRESSURE #8 0.0

PRESSURE #3 0.0 PRESSURE #9 0.0

PRESSURE #4 0.0 PRESSURE #10 0.0

PRESSURE #5 0.0

PRESSURE #6 0.0

RETURN

Numeric Entry Keys

Delete Enter

Arrow Keys

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--13

Revised 10/02

Use of the Adhesive Pressure Monitoring Screen

Note: this screen is functional only if optional pressure transducers are installed on your ASU.

Press This

Function Key

To:

Return

This screen is read only.

Return to the Motor Menu screen

Adhesive pressure is displayed as read by the system’s pressure transducers installed on the

ASU’s outlet filter manifold.

Monitoring

Pressure is read as “PSI” or “BAR”; this selection is registered in the box at the top, right of screen. To change selection, go to Setup Menu screen.

Page 5--14 Programming

Revised 10/02

Setup Menu Screen

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

SETUP MENU

TEMPERATURE UNITS

DEGREES F

HENDERSONVILLE, TN

SYSTEM STAND-BY

OFF

--

##

1/10 HRS

### F

SEVEN DAY

SCHEDULER

MAIN

Numeric Entry Keys

Delete

Enter

Arrow Keys

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--15

Revised 5/03

Use of the Setup Menu Screen

Press This

Function Key

To:

Temperature/ Pressure Units Toggle to choose Celsius/ BAR or Fahrenheit/ PSI

OFF/ON Toggle to choose System Standby ON or OFF

## 1/10 HRS

-- ### F or C

Seven Day Scheduler

Main

Program a Standby delay

Program a Standby temperature reduction value

Press to procede to Seven Day Scheduler programming

Return to the Main Menu

Programming

1. Press Temperature/ Pressure Units to choose Celsius/ BAR or Fahrenheit/ PSI.

2. System Standby Programming:

“Standby” is a temperature value by which all temperature zones will lower when Standby mode is activated. For example, if your temperature setpoints are all 300 degrees, and you program a 100 degree Standby, then the Standby temperature of all zones will be 200 degrees. Similarly, if your temperature zones setpoints vary, and you program a 100 degrees Standby, each zone’s Standby temperature will be 100 degrees lower than its setpoint. Standby must be programmed for the length of time before which these lowered temperatures start.

To Program: a. Press ## 1/10 HRS to enter the number of tenths of a hour the system will delay before going into the standby condition (0 - 500). Press Enter.

Examples: A. Programming the number 10 here results in 1 hour delay (10/10 hour = 1).

B. Programming the number 4 here results in 24 minutes delay (4/10 hour = 24).

b. Press -- ### F (or C) to enter the number of degrees below temperature setpoints desired for your standby temperature (0 - 200 degrees). Press Enter.

c. Toggle OFF/ON to turn System Standby ON or OFF. Press Enter.

Notes: When Standby is active (i.e., ON and standing by), all the setpoints on the Temperature

Zone Programming screens will display the reduced standby temperatures after the duration of the standby delay. When standby mode is deactivated, these temperatures will resume their pre-standby values.

Entering a standby time delay of “0” will result in the unit immediately going into standby when

“standby mode” is activated.

3. Press Seven Day Scheduler to program the Scheduler. See the following pages for programming instructions.

Page 5--16 Programming

Revised 3/03 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Seven Day Scheduler Programming Screen

The Seven-Day Scheduler allows the operator to program automatic Turn On or Turn Off events which coincide with his daily production schedule throughout the work week. On or Off events may be programmed for any individual day of the week, or may be programmed for “Everyday” of the week at the same time.

Day-of-Event Display

Hour Keys

Minute Keys

Numeric Entry Keys

EVERYDAY

ON/

OFF

NEXT

SYSTEM ON ## :

SYSTEM OFF ## :

##

##

PREV

SYSTEM ON ## :

##

SYSTEM OFF ## :

13:38:43

13:38:35

09/21/00

THURS

##

RETURN

Delete Enter

Arrow Keys

CPU Clock

Hours: Minutes: Seconds

PanelView Clock

Hours: Minutes: Seconds

Month: Day: Year

Clock Synchronization

The 7-Day Scheduler screen displays two clocks which must be synchronized periodically in order for the scheduler to function properly. These clocks are the PanelView’s clock (which can be reset by following instructions on page 17) and the CPU’s clock (which must be synchronized to be reset).

The clocks are automatically re-synchronized whenever all of the scheduler’s eight days (Monday through Sunday plus Everyday) are turned OFF.

Even when the clocks are in sync, their times may read up to a couple of minutes difference

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--17

Revised 10/02

Use of the Seven Day Scheduler Programming Screen

Press This

Function Key

Next

Prev

To:

Select next day

Select previous day

System ON Hour ## Program a desired turn ON hour

System ON Minute ## Program a desired turn ON minute

System OFF Hour ## Program a desired turn OFF hour

System OFF Minute ## Program a desired turn OFF minute

System ON Hour ## Program a second desired turn ON hour

System ON Minute ## Program a second desired turn ON minute

System OFF Hour ## Program a second desired turn OFF hour

System OFF Minute ## Program a second desired turn OFF minute

ON/OFF

Return

Toggle the Seven Day Scheduler ON or OFF for this day

Return to the Main Menu

Programming

Up to four “events” may be scheduled for each day. An event is a programmed ON or OFF time.

1. Press Next or Prev to choose the first day you desire to schedule.

2. Hours and minutes are programmed in two steps as follows: a. Press the first Hour key, to program a desired ON hour: i. Use the numeric keypad to enter desired time of day (use 24 hour day/ military time).

ii. Press the Enter arrow to store your desired time.

b. Press the first Minute key, to program a desired ON minute: i. Use the numeric keypad to enter desired time of day (use 24 hour day/ military time).

ii. Press the Enter arrow to store your desired time.

c. Press On/ Off to make the Scheduler active or inactive for this day.

3. Repeat steps 1 and 2 until all days and times are programmed as desired.

4. Press Return to return to the Main Menu.

Page 5--18 Programming

Revised 10/02

PanelView Configuration Screen

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DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

CONFIGURATION MODE

MEMORY CARD

COMMUNICATION SETUP

PRESET OPERATION

TERMINAL INFO

SCREEN SETUP

DATE/ TIME

PRINTER SETUP

LANGUE

SPRACHE

LINGUA

LENGUA

LANGUAGE

F8

F2

RUN

MODE

F9

RESET

VIDEO

COMM

LED

FAULT

LED

To Set Seven-Day Scheduler’s Clock

1. Advance to the Configuration Mode screen (seen above) by pressing both the left and right arrow keys simultaneously.

2. On the menu, Scroll down to “DATE/ TIME”. Press Enter.

3. Press F1 and enter the year.

Press F2 and enter the month.

Press F3 and enter the day.

Press F6 and enter the hour.

Press F7 and enter the minute.

Press F8 and enter the second.

4. Press F10 to Exit.

5. Press F2 RUN MODE to return to the hot melt application.

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DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--19

Revised 10/02

Use of the PanelView Configuration Screen

Press This

Function Key

F2

F8

To:

Return to Run Mode (Main Menu)

Select the displayed language

F9 Reset Video

The Configuration Mode screen allows the operator to adjust parameters that pertain to the PanelView controller only. These parameters do not pertain to the hot melt application. The Seven-

Day Scheduler’s clock is set via the Configuration screen.

Among the many adjustable parameters are: screen brightness and backlight, display language, date and time, printer parameters, communications and fault LED, etc.

Use the up and down arrows and the function keys (F1 thru F10) to move through the configuration screens.

To select items on the main Configuration Mode menu (the menu beginning with “Memory

Card” and ending with “Printer Setup”), use the up and down arrows to select an item, then press

Enter to bring up its parameter screen. Follow instructions on each screen to make adjustments or return to the configuration screen. For examples of each of the Configuration Mode Main Menu parameter screens, see the following page.

COMM LED and FAULT LED are read only status monitors.

Press F9 to reset the video. No further adjustment is necessary.

Use F8 to choose a display language (for the Configuration screen only): French, German, Italian, Spanish or English.

Press F2 to return to the Main Menu and the hot melt application.

Page 5--20 Programming

Revised 10/02

Configuration Mode

Main Menu Parameter Screens

Memory Card Screen:

No Card Inserted

APPLICATIONS ON CARD

\ * .PVA

* * * *

F1

F2 Restore from Card

F3 Save to Card

F4 Erase/ Fomat Card

F5 Disconnect Card

Memory

Card

Listing

EXIT

F10

Communication Setup Screen:

DH-485

Max Node:

Node:

Baud:

31

2

19200

F1

F2

F3

Comm

LED

Fault

LED

EXIT

F10

F1

PRESET OPERATIONS

Power-up With:

Key Repeat

Rate

Presets

Last States

F4

0 ms

Key Delay

Rate

F9

400 ms

Restart Unit

And

Load Values

EXIT

F10

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Boot:

Firmware:

Hardware

TERMINAL INFO

V01.06

V04.00

Filename:

Fontfile:

HWCFG KP TS PO.232SS6.0

M50

95993 Bytes Used

149702 Byes Free

EXIT

F10

Screen

Saver

SCREEN SETUP

Normal

Intensity

Off

100

Reset

Video

F9 F1 F2

SCREEN SAVER

Timeout Intensity

10 min.

0

EXIT

F10

F6 F7

DATE/TIME

Year

98

F1

Month

11

F2

Day

5

F3

Hour

15

F6

11/5/1998

Minute

17

F7

Second

40

F8

03:17:40PM

EXIT

F10

PRINTER SETUP

Handshaking

Communication

Parameters

None

No Parity

8 Data Bits

1 Stop Bit

Baud

9600

F1 F3

Top of

Form

F6

F2

Port Mode

Port

Not

Installed

F7

EXIT

F10

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Programming Page 5--21

Revised 10/02

Helpful Tips for the User

∙

When the ASU is turned ON, the controller will detect any unused hose circuits which are turned ON (for example, a hose not plugged in), and will go into alarm. For this reason, all unused temperature zones must be programmed OFF.

∙

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

∙

When the ASU is turned ON, all system heaters go ON unless they have previously been turned OFF.

Page 5--22 Programming

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Chapter 6

PREVENTIVE MAINTENANCE

Preventive Maintenance Page 6-1

Revised 7/99

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

General Cleaning

The DYNAMELT

Ò

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

The molded plastic handles may be cleaned with mineral spirits.

Preventive Maintenence Schedule

The Dynamelt M ASU requires little maintenance. The hopper is fitted with a coarse screen to prevent large debris from entering the system. Normally this screen does not require cleaning. The

ASU parts that require regular, periodic maintenance are as follows:

Replacing the Outlet Filter Basket

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

Use the following procedure to replace the standard outlet filter.

cont.

WARNING HIGH PRESSURE

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

WARNING

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

Page 6-2 Preventive Maintenance

Revised 3/01 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Adjustment Screw Cap

O-ring PN A69X133

Spring

Spring Clip

Filter Basket

PN 101246/ 40 mesh

PN 101247/ 100 mesh

Flat Surface

O-ring PN 069X275

Filter Plug

Roll Pin in Groove

Roll Pin

Slide in “Locked” Position

Slide in “Open” Position

Outlet Filter Manifold

Purge Set Screw

Purge Drain

Purge Set Screw

Purge Drain

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

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

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

3. Remove the Manifold Access Cover by unscrewing 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. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Preventive Maintenance Page 6-3

Revised 7/99 still pressure in the system. Stop and verify that the motor/ pump is turned OFF and the applicator’s valves are open before proceeding. Then repeat step 5.

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

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

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

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

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

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

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

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

12. Re-tighten the two purge screws.

Retainer

Plate

Screws

Filter Plug

Replacing the Optional High Flow Outlet Filter Basket

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

O-ring

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

Filter

Basket

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

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

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

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

cont.

Outlet

Filter

Manifold

High Flow Filter Manifold

Page 6-4 Preventive Maintenance

Revised 7/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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

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

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

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

10. Restore application system to normal operation.

Hose Fittings

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

Fasteners

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

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

Filter Shutoff Cleaning or Replacement

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

DM70, DM140 and DM210 models have two filter shutoffs.

1. Pump all the adhesive out of the hopper.

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

WARNING HOT SURFACE

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

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

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

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

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

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Preventive Maintenance Page 6-5

Revised 7/99

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

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

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

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

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

Pump Shaft Leak

There is a cutout in the baseplate, directly below the pump shaft(s), which will allow adhesive from a leaking pump to exit the ASU. Inspect the area under the baseplate cutout every month for adhesive. A leaking pump shaft indicates a worn pump seal. See instructions in Chapter 8 for replacement of this seal.

Summary of Preventive Maintenance Schedule

Monthly (or as experience dictates)

1. Inspect outlet filter basket. Replace as required.

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

Every Three Months (or as experience dictates)

1. Check all hose fittings for tightness.

2. Check all fasteners for tightness.

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

Flushing the System

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

WARNING

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

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

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

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

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

cont.

Page 6-6 Preventive Maintenance

Revised 7/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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

4. Add flushing fluid to the hopper and allow approximately fifteen minutes for it to reach hopper temperature. Carefully stir the flushing fluid to mix with any adhesive remaining in the hopper.

5. Slowly increase the pump pressure. Pump about half of the fluid through the hopper, pump and adhesive supply hose into the flushing container.

WARNING

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

6. Reduce the pump speed to zero.

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

”Outlet Filter” section of this chapter.

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

9. Slowly increase motor speed to the pump.

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

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

12. Re-fill the hopper with adhesive. The system is now ready for production.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-1

Revised 8/01

Chapter 7

TROUBLESHOOTING

General Troubleshooting Notes

DANGER

HIGH VOLTAGE

WARNING

HOT SURFACE

Dynamelt systems use electrical power that can be life threatening and hot-melt adhesives that can cause serious burns. Re-read Chapter 1 “Safety Precautions” before performing any troubleshooting or repair procedures. All troubleshooting and repair procedures must be performed by qualified, trained technicians.

CAUTION: The SLC 500 modules are prone to damage from static electrical charges during handling. Read “Handling Printed CIrcuit Boards” on page 7-3 before handling or attempting service on the ASU’s modules.

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.

High & Low Alarm Zone Messages:

PanelView’s Main Menu lists the identification numbers of zones with either high or low temperature alarms as they occur.

Low Alarms: At startup, all zones will show a low alarm until adhesive temperatures have reached their Ready setpoints. When Ready temperatures have been met, the alarms will automatically clear from the controller’s display.

High Alarms: The controller will automatically turn OFF any temperature zone which registers a high alarm. High alarms indicate either: 1.) a zone which is over its high temperature limit, 2.) a short circuit, or 3.) an open circuit. To correct a high alarm, refer to the troubleshooting guide in this chapter. After correction, the operator must return to the Main Menu and toggle Heater Power ON.

The controller will then clear the alarm and scan the system for other alarms.

Drive 1,2,...etc. Fault or DeviceNet Fault Messages:

PanelView’s Main Menu System Status indicator may specify a faulted drive or a faulted Device-

Net. In most instances, these faults will automatically clear in (up to) 30 seconds. If they do not automatically clear, turn the ASUs power Off, then ON again at the circuit breaker. Observe the DeviceNet module, it may indicate a numbered fault. If so, refer to the AB DeviceNet manual to clear.

Hose/ Applicator Troubleshooting Tip

Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU. If the malfunction goes with the applicator and hose, the problem will usually be in the applicator or hose that was moved. If the malfunction does not move with the applicator and hose, the problem is probably in the ASU.

Page 7-2 Troubleshooting

Revised 9/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

High-Temperature Redundant Overtemp Thermostat

The Dynamelt M Series ASU includes a mechanical (redundant) overtemp thermostat that acts as a safety back-up. 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 heater access door (see Chapter 8). To reset: turn

OFF the ASU’s main power switch, push the center of the thermostat’s insulator, then 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 132 °C (270°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 needs.

To access the pump enable thermostat, follow the instructions given in Chapter 8. To calibrate the thermostat, refer to instructions in Chapter 3.

SLC 500 Power Supply Fuse

An AGC-3 fuse, located inside the SLC’s power supply, is intended to guard against fire hazard due to a short circuit. See illustration on page 7-4 for location. If all of the LEDs on the power supply and SLC 500 modules (inside the panel box) are unlit, this indicates an inoperative fuse.

DANGER HIGH VOLTAGE

Before attempting fuse replacement, all power must be removed from the SLC

500 power supply. Note: the exposed pin on the 3-pin jumper (located directly below the fuse) is electrically live. Contact with the pin may cause injury.

SLC Processor Battery

Inside the SLC processor module is a replaceable lithium battery. When the battery gets low, a red

LED will illuminate on the module (for LED location see illustration on page 7-10).

To replace the battery:

Important Note: A capacitor provides at least 30 minutes of battery backup while the battery is disconnected. Data in RAM is not lost if battery is replaced within 30 minutes.

DANGER HIGH VOLTAGE

Do not remove the processor from the SLC 500 chassis until all power is removed from the SLC 500 power supply.

1. Remove all power from the SLC power supply.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-3

Revised 1/99

2. Remove the processor from the chassis by pressing the retainer clips at both the top and bottom of the module before sliding it out.

CAUTION: Do not expose the processor to areas that may hold an electrostatic charge.

See the following section “Handling the SLC 500’s Components”.

3. Unplug the battery connector from the socket and remove the battery.

4. Remove the battery from the retaining clips. Insert the new battery into the clips.

5. Plug the new battery’s connector into the socket.

6. Re-insert the module into the SLC 500 chassis. Restore power to the power supply.

Handling the SLC 500’s Components

The Dynamelt ASU and controller utilize several components and modules which are extremely sensitive to electrostatic charges. When working near or with these components, the following procedures must be followed to avoid damage to them.

DANGER HIGH VOLTAGE

Before unplugging connectors from a component, ground yourself to the

ASU by touching any available unpainted cool metal surface, mounting screws, etc. This will avoid electrical discharge to the components when you are removing and replacing connectors.

CAUTION: The Allen Bradley modules 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 the component by its edges only. Don’t grip a component across its surface.

3. When removed from the ASU, each component must be individually packaged inside a metallized, static drain envelope. Do not place the removed component on a table, counter, etc. until it has first been placed in or on a static drain envelope.

4. When handing a component to another person, touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the component to him.

5. When unwrapping a component from its static drain envelope, place the envelope on a grounded, nonmetallic surface.

6. To cushion components for shipment, use only static-drain bags or packaging. Do not use foam peanuts or bubble pack not known to be static draining.

The following pages detail the SLC 500 modules.

Page 7-4 Troubleshooting

Revised 9/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Model DM M35: AllenBradley SLC Module Configuration

Illustrated below is the maximum module configuration for a fully loaded Model 35 ASU.

AGC3/250v/3a

0 1 2 3 4 5 6 7 8 9 10 11 12

Jumper

SLC

POWER

SUPPLY

3

4

1

2

5

Terminals:

1. Pwr Out +24VDC

2. Pwr Out Com

3. 120/240 VAC

4. VAC Neutral

5. Chasis Ground

Layout of Components DM M35 SLC Modules

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-5

Revised 4/02

Model DM M70/140: AllenBradley SLC Module Configuration

Illustrated below is the maximum module configuration for a fully loaded Model 70 or 140 ASU.

For SLC Power Supply’s fuse size and terminal definitions, see page 7-4.

Jumper

SLC

POWER

SUPPLY

3

4

1

2

5

0 1 2 3 4 5 6 7 8 9 10 11 12

Layout of Components DM M70/140 SLC Modules

Page 7-6 Troubleshooting

Revised 9/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Model DM M210: AllenBradley SLC Module Configuration

Illustrated below is the maximum module configuration for a fully loaded Model 210 ASU.

For SLC Power Supply’s fuse size and terminal definitions, see page 7-4.

0 1 2 3 4 5 6 7 8 9 10 11 12

Jumper

SLC

POWER

SUPPLY

3

4

1

2

5

0 1 2 3 4 5 6 7 8 9 10 11 12

Jumper

SLC

POWER

SUPPLY

3

4

1

2

5

Layout of Components DM M210 SLC Modules

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-7

Revised 1/99

DeviceNet Communications Module

The SLC 500 system utilizes DeviceNet to communicate with the ASU’s drives. DeviceNet operates via two modules: the scanner module which is a card on the SLC 500 rack, and the DeviceNet module(s) which is mounted on the drives.

The illustrations below provide a brief description of the LEDs and connections. For more detail, refer to the Allen Bradley DeviceNet manual.

Green = scanner module is ON

DeviceNet

STATUS

MODULE NET

ADDRESS/ERROR

Green = network is ON

Refer to troubleshooting guide on the following pages to interpret display

Red = unrecoverable fault

Flashing Red = I/O connection timed out

Green = DeviceNet is ON and allocated to a master

Flashing Green = DeviceNet is ON but not allocated to a master

Red = drive is faulted

DeviceNet

COMM

FAULT

READY

Green = drive is ON

Terminals (left to right):

Black wire

Green wire

Scanner wire

White wire

Red wire

Scanner Module Layout

DeviceNet Module Layout

Page 7-8 Troubleshooting

Revised 9/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

DeviceNet,

cont.

Troubleshooting with the Scanner’s Error Code Display

The Scanner Module displays an “Address/ Error” code that is interpreted as follows:

Code # Problem

0-63 Normal operation. The numeric display matches the scanner’s node address on the

DeviceNet network.

70 Scanner failed Duplicate Node Address check.

71

72

73

74

75

76

77

78

79

80

Correction

Do nothing.

Scanner is in IDLE mode.

Change the scanner channel address to another available one. The node address you selected is already in use on that channel.

Illegal data in scan list table (node number alternately flashes).

Slave device stopped copmmunicating

(node number alternately flashes).

Device ID does not match scan list table entry (node number alternately flashes).

Data overrun on port detected.

Reconfigure the scan list table and remove any illegal data.

Inspect the field devices and verify connections.

Enter a matching scan list device ID.

Modify your configuration and check for invalid data.

No network traffic at all has been detected.

No direct network traffic for scanner detected.

Verify connections.

None. The scanner hears other network communication.

Data size returned does not match scan lists entry (node number alternately flashes).

Reconfigure your module and change the addressing.

Slave device in scan list table does not exist (node number alternately flashes).

Add the device to the network, or delete the scan list entry for that device.

Scanner has failed to transmit a message.

Make sure that your module is connected to a valid network.

Check for disconnected cables.

None.

cont.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-9

Revised 1/99

Troubleshooting with the Scanner’s Error Code Display

,

cont.

Code # Problem Correction

81

82

83

84

85

88

90

91

92

95

97

98

99

Scanner is in FAULT mode.

Error detected in sequence of fragmented

I/O messages from device (node number alternately flashes).

Slave device is returning error responses when scanner attempts fo communicate with it (node number alternately flashes).

Scanner is initializing the DeviceNet channel.

Data size returned is bigger than expected.

None. This code clears itself once scanner attempts to initialize all slave devices on the channel.

Check accuracy of scan list table entry.

Check slave device configuration.

None.

This is not an error. At powerup and reset, the module dislays all 14 segments of the node address and status display LEDs.

User has disabled communication port.

Bus-off condition detected on comm port.

Scanner is detecting communication errors.

Reconfigure your module.

Check DeviceNet connections and physical media integrity. Check system for failed slave devices or other possible sources of network interference.

No network power detected on comm port.

Provide network power. Make sure that scanner drop cable is providing network power to scanner comm port.

Application FLASH update in progress.

Scanner halted by user command.

Unrecoverable firmware failure.

Unrecoverable firmware failure.

None.

Check scan list table entry for slave device to make sure that input and output data lengths are correct. Check slave device configuration.

Check accuracy of scan list table entry.

Check slave device configuration.

None. Do not disconnect the module while application FLASH is in progress. You will lose any existing data in the scanner’s memory.

None.

Service or replace your module.

Service or replace your module.

Page 7-10 Troubleshooting

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

SLC Processor (CPU) Module

The SLC 500 Processor operates as the system’s CPU.

A keyswitch selects one of the module’s three modes: Run Mode, Remote Mode or Programming

Mode. To operate the adhesive application system through the PanelView controller, select Run

Mode. To connect to a programming device (laptop, remote PLC, etc.) select Remote Mode. Select

Programming Mode to lockout (disable) all ASU and programming functions.

Force (see illustration) is used during Setup or Toubleshooting. It is a warning that a device has been turned on when the ASU is not ready.

The illustration below provides a brief description of the LEDs on this module. For more detail, refer to the Allen Bradley manual.

Green = Run Mode is ON

Red = CPU is faulted

Red = CPU’s battery backup is low

SLC 5/xx CPU

RUN

FLT

BATT

FORCE

DH +

RS232

RUN REM PROG

Green = a device has been forced ON when not ready

Green = a PLC is in use

Green = PanelView is in use

RUN = Run Mode

REM = Remote Mode

PROG = Programming Mode

SLC Processor (CPU) Module Layout

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-11

Revised 10/02

Input Modules

The SLC 500 utilizes RTD, Analog and 115 VAC Input modules.

Pressure transducers and/ or line speed inputs are wired into the Analog Input module(s).

The system’s RTDs are wired into the RTD Input module(s). Each temperature zone in the ASU system utilizes an RTD to measure temperature. Each RTD is wired into a terminal of a RTD Input module. One RTD Input module can accomodate up to four RTDs (channels).

The 115 VAC Input modules accomodates items such as the overtemp and pump enable thermostats and temperature zones.

A green light on the module means that it is ON (inputting).

The illustrations below provide a brief description of the LEDs on these modules. For more detail, refer to the Allen Bradley manual.

INPUT INPUT

CHANNEL

STATUS

MODULE

0 4

1 5

2

3 7

6

RTD/resistance

CHANNEL

STATUS

0

1

MODULE STATUS

2

3

RTD/resistance

INPUT

0 4

1 5

2 6

3 7

115 VAC

INPUT

CHANNEL STATUS

0 2 4 6

1 3 5 7

MODULE

STATUS

ANALOG

INPUT

POWER

ANALOG

8-Input Module 4-Input Module

RTD Input Module Layouts

115 VAC Input

Module Layout

Analog Input Module Layouts

Page 7-12 Troubleshooting

Revised 10/02 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Output Modules

On the Output modules, each temperature zone has a red LED. The LEDs illuminate when the zone’s heater comes on (ie, is outputting).

On the Relay Output module (shown below to the left), the top eight outputs are used by ITW Dynatec for 115 VAC. The bottom eight outputs may be used by the customer for either AC or DC.

The DC Source Output modules are used for the ASUs solid state relays.

The illustrations below provide a brief description of the LEDs on these modules. For more detail, refer to the Allen Bradley manual.

OUTPUT

0 4 8 12

1 5 9 13

2 6 10 14

3 7 11 15

RELAY

OUTPUT INPUT

2

3

0 4

1 5

2

3

0 4

1 5

RELAY 115 VAC

OUTPUT

.0/0 to 15 .1/0 to 15

0 4 8 12 16 20 24 28

1 5 9 13 17 21 25 29

2 6 10 14 18 22 26 30

3 7 11 15 19 23 27 31

DC SOURCE

OUTPUT

0 4 8 12

1 5 9 13

2 6 10 14

3 7 11 15

DC SOURCE

Output Module Layouts

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-13

Revised 5/02

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.

Page 7-14 Troubleshooting

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

°

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

12

16

24

4

6

8

10

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

3

4

5

6

1

2

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

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-15

Revised 1/99

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 a

PCB, the PCB must be replaced.

DANGER HIGH VOLTAGE

Some of the procedures in the following Troubleshooting Guide require potentially dangerous electricity to be present. Only qualified service personnel should perform these procedures.

Problem

Hopper (tank)

Overtemp

Hopper Sensor

Possible Cause Solution

1. Setpoints have been programmed without enough deviation.

2. Disconnection between an RTD module and the rack.

3. Hopper sensor inoperative.

1. Re-program setpoints, allowing a larger deviation between the high and low limits.

2. Verify that all modules are properly inserted in their sockets on the module rack.

3. Replace hopper sensor if resistance does not comply with the resistance table in this chapter.

4. Hopper control solid state relay inoperative.

4. 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

Page 7-16 Troubleshooting

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Problem

Hopper Sensor Open

Possible Cause Solution

1. Sensor cable has become unplugged from RTD module.

1. Verify that hopper sensor cable is properly connected on the RTD module.

2. Disconnection between

RTD module and the rack.

3. Inoperative hopper sensor.

2. Verify that all RTD modules are properly inserted in their sockets on the module rack.

3. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

Hopper Sensor

Hopper Sensor Short

1. Pinched sensor lead wire.

2. Inoperative hopper sensor.

1. 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 RTD module. Repair or replace any damaged wire.

2. Replace hopper sensor if resistance does not comply with resistance table in this chapter.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-17

Revised 1/99

Problem

Hopper Heater Open

Possible Cause Solution

Hopper

Sensor

Thermostat

Hopper

Heater Wire

1.Disconnection in hopper heater circuit.

2. Hopper circuit breaker tripped.

3. Open hopper heater element.

1. Inspect hopper heater wiring for proper connections.

2. 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.

3. At the terminal rail, use an ohmmeter to measure resistance as follows:

Model M35: across H3A and H3B,

Models 70/140: across H5A and H5B,

Model 210: across H7A and H7B.

See the resistance table in this chapter for normal resistance values.

Infinitely high reisistance values indicate an open heating element which must be replaced.

Hopper Circuit Breaker

(Optional) Drop-in

Grid Overtemp

Grid Sensor

H3A etc. Terminals

3000w

Thermostat

1750w

1. Setpoints have been programmed without enough deviation.

2. Disconnection between the RTD module and the rack.

3. Grid sensor inoperative.

4. Grid control solid state relay inoperative.

1. Re-program setpoints, allowing a larger deviation between the high and low limits.

2. Verify that all modules are properly inserted in their sockets on the module rack.

3. 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.

4. 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.

cont.

Page 7-18 Troubleshooting

Revised 7/00

Problem

(Optional) Drop-In

Grid Sensor Open

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Possible Cause

1. Sensor cable has become unplugged from RTD module.

2. Disconnection between

RTD module and the rack.

3. Drop-in grid sensor inoperative.

Solution

Then, when Temperature Zone is OFF, use a VOM AC voltmeter to verify that

240 volts are not present at the heater terminal.

1. Verify that grid sensor cable is properly connected to its RTD module.

2. Verify that all modules are properly inserted in their sockets on the module rack

3. Replace sensor if resistance does not comply with the resistance table in this chapter

(Optional) Drop-in

Grid Sensor Short

1. Pinched sensor lead wire.

2. Drop-in grid sensor inoperative.

3. RTD module is inoperative.

1. 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 RTD module. Repair or replace any damaged wire.

2. Replace sensor if resistance does not comply with the resistance table in this chapter

3. Replace RTD module.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-19

Revised 7/00

Problem Possible Cause Solution

(Optional) Drop-in

Grid Heater Open

3000w

Grid Sensor

H3A etc. Terminals

Thermostat

1750w

1. Disconnection in grid’s heater circuit.

2. Drop-in grid circuit breaker tripped.

3. Open drop-in grid heater element.

4. RTD module is inoperative.

1. Inspect grid’s heater wiring for proper connections.

2. 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.

3. 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: H3A & N (380v)

H3A & H3B (240v)

For 4th grid: H4A & N (380v)

H4A & H4B (240v)

For 5th grid: H5A & N (380v)

H5A & H5B (240v)

For 6th grid: H6A & N (380v)

H6A & H6B (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.

4. Replace RTD module.

Page 7-20 Troubleshooting

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Problem Possible Cause Solution

Hose/ Head

(No.) Overtemp

A 1

F 1

A 2

F 2

Sensor

Heater

Plug

Sensor &

Heater

Hose/ Head (No.)

Sensor Open

A 3

F 3

A 4

F 4

Note: DMM 70/ 140/ 210 arrangement shown above. For DMM 35, see Chapter 3.

1. Hose/ Head setpoints incorrectly programmed.

1. Re-program setpoints to allow a larger deviation.

2. Inoperative head/ hose dual solid state relay.

2. Refer to the schematic in Chapter 11 to locate the correct head/ hose relay. Use a clamp-on ammeter to monitor head/ hose current. If current does not cycle on and off, then the relay has failed and must be replaced.

3. Disconnection between

RTD module and the rack.

3. Verify that all modules are properly inserted in their sockets on the module rack.

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.

1. Disconnection between hose and ASU.

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 DC output module 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 DC output module.

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).

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-21

Revised 1/99

Problem

A 1

F 1

A 2

F 2

A 3

F 3

A 4

F 4

Note: DMM 70/ 140/ 210 arrangement shown above. For DMM 35, see Chapter 3.

Possible Cause Solution

2. Hose sensor harness unplugged from RTD module.

2. Verify that effected hose is properly connected to heater on the RTD module. Replace or repair damaged hose harness as necessary.

3. Disconnection between

RTD module and the rack.

3. Verify that all modules are properly inserted in their sockets on the module rack.

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 RTD module 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 RTD module 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.

Page 7-22 Troubleshooting

Revised 10/99

Problem

Hose/ Head (No.)

Heater Open

Sensor

Heater

Plug

Sensor &

Heater

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Possible Cause

1. Disconnection between hose/ head and ASU.

2. Disconnection between cartridge heater and cable assembly inside head.

3. Inoperative hose/ head circuit breaker.

4. Open hose/ head heater element.

5. Open wiring inside ASU.

Solution

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. Visually inspect wiring inside head.

Verify that cartridge heater leads are properly connected in the service block area.

3. 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.

4. 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.

5. 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.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-23

Revised 1/99

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.

Check Valve return to hopper from pump

Adhesive flow through filter block to hose

Check Valve

Spring

Pressure

Relief

Valve return to hopper from pump to hose

Adhesive flow through filter block to hose

Pressure

Relief

Valve

Filter

Basket to hose

Operation of the Adjustable Adhesive Pressure Relief Valve

Page 7-24 Troubleshooting

Revised 7/00 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Operation of the ASU’s Gear Pump

Manual or Automatic Pump Operation

Choose “Manual”, “OFF” or “Auto” gear pump operation from the Motor Programming screen on the PanelView keypad. When the Dynamelt’s pump is to be operated manually (that is, without a line following signal), the manual mode is used to control pump speed (and adhesive output). For the gear pump to be operated in the automatic mode, a tach generator, or equivalent (attached to the parent conveyor line) must be provided and the following set-up procedure should be performed:

1. The tach generator or the signal isolator must be adjusted so that the voltage from the speed controller is 0 to10 VDC (but not more than +10 VDC when the conveyor is at maximum speed). This voltage is measured at either the analog input card, typically at TB2 on I00100 and I00101 (for a tach generator) or at terminals 9 (+) and 10 (-) of the signal isolator board.

2. The “Auto” 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 auto mode by setting maximum and minimum pump speed (rpm) values on the controller’s keypad. MAX pump speed will be the true motor speed at 10 volts input. This value cannot exceed 100%.

To make this motor speed adjustment, follow the programming instructions in Chapter 5.

Pump Operation

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 from the Motor Programming screen 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, loosen the locknut and turn the allen screw clockwise to increase pressure or counterclockwise to decrease pressure. The relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-25

Revised 1/99

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.

Page 7-26 Troubleshooting

Revised 10/00 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

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 in the system can run independently (or dependently) and may have its own operating parameters. Therefore, each motor should be troubleshot independently.

Problem

Pump doesn’t operate in “Manual” mode.

Possible Cause

1. Motor on/off is off at the controller keypad.

2. Hopper temperature is below ready setpoint.

Solution

1. Check keypad setting.

3. No incoming electrical power.

4. 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.

5. Inoperative SLC 160 drive.

6. Low temp alarm.

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.

4. Check condition of the remote switch

(the hand-held applicator).

7. Drive circuit breaker tripped.

5. If the drive is inoperative it must be replaced.

6. Verify that ASU is warmed up and that hopper temperature is above the factoryset pump enable temperature.

7. Refer to schematic (Ch. 11) to locate circuit breaker. With an ommeter, verify that the drive input is not shorted.

If it is shorted, replace the drive.

Reset the breaker, if it trips again, replace the breaker.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Troubleshooting Page 7-27

Revised 1/99

Problem

Pump doesn’t operate in “Auto” mode, hopper is at ready conditon.

Possible Cause

1. Parent machine is not running.

Solution

1. Check parent machine.

2. “Auto” motor is set at zero (at controller keypad).

2. Re-program motor.

3. No incoming line following signal.

4. Low temp alarm.

3. Check for presence of 0 to 10 VDC control signal at analog input card.

If signal is not present, check ASU wiring connections and tachometer drive connections. If control signal is present there, the problem is within the ASU.

4. Verify that ASU is warmed up and that hopper temperature is above the factoryset pump enable temperature.

Pump runs but there is no adhesive output.

1. ASU is out of adhesive.

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.

Page 7-28 Troubleshooting

Revised 1/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Problem

Low or inconsistent adhesive output.

Filter Basket

Possible Cause

1. Pump filter clogged.

2. Adhesive used is too viscous.

3. Clogged hose.

4. Clogged applicators.

5. The fixed pressure relief valve is opening.

6. Inoperative lower o-ring in filter plug is allowing pressure to escape.

Solution

1. Remove and inspect filter basket and filter shutoff.

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.

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.

Filter

Shutoff

Adhesive leak at pump shaft seal.

Seal Assembly

Rear Plate

O-ring

1. Pump seal is incorrectly positioned inside the seal and bearing assembly.

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 the rear plate o-ring groove that could damage a new o-ring.

Adhesive leak at pumpto-hopper interface.

1. Pump assembly screws are missing or loose.

2. Helicoil insert pulled out of hopper.

1. Verify that all four pump screws are tightly assembled to the hopper.

2. Remove pump and inspect bottom of hopper. Repair or replace hopper as necessary.

c. 1999

DYNAMELT M ASU Manual 20-29

Disassembly & Re-assembly Page 8-1

Revised 6/01

Chapter 8

DISASSEMBLY & RE-ASSEMBLY PROCEDURES

Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All disassembly and repair procedures must be performed by qualified, trained technicians.

Disassembly Procedures

Note: Use the exploded-view drawings referenced with each procedure in conjunction with the instructions outlined in this chapter. Read the “cautions” on page 8-5 before re-assembling the ASU.

To Remove the Access Doors

There are two access doors, one on either side of the ASU. Use the key to unlock the door, then lift it off, being careful not to pull off the ground wire attached. Remove the ground wire and re-attach when the door is re-installed. These doors allow access to: the motor, pump, junction boxes, (optional) drop-in grids, filter shutoffs and (optional) ball valves.

To Open Junction Boxes

There are two junction boxes, one on either side of the hopper(s). A junction box cover is removed by two screws at the bottom of the box. Within the juction boxes are thermostats, heater terminals and the hopper sensor. See also the detailed illustration on the following page.

Access

Door

Keylock

Panel Box

Assembly

Filter Shutoff Assembly

Ball Valve Assembly

(option)

Access

Door

Filter

Shutoff

Assembly

Rear

Cover

Ball

Valve

Over-Temp Reset

Thermostat

(for dual hopper)

Pump Enable

Thermostat

(for dual hopper)

Manifold

Cover

Junction Box

Over-Temp Reset

Thermostat

Pump Enable

Thermostat

Filter Manifold

Page 8-2 Disassembly & Re-assembly

Revised 3/01 c. 1999

DYNAMELT M ASU Manual 20-29

Junction

Box cover

Hopper

Junction

Box

Cutouts for conduit connectors for filter manifold heater and sensor.

Over Temp

Reset

Thermostat

Cutouts for drop-in grid assembly

Filter Shutoff

Junction Box

Hopper Sensor

Port

Heater

Terminals

Side View

Pump Enable-

Thermostat Port

Sensor or Thermostat Replacement

Remove the junction box cover.

a.

Over-Temperature Thermostat Replacement:

Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper.

b.

Pump Enable Thermostat Replacement:

Disconnect two wires from the terminal strip and slide the thermostat out.

c.

RTD Sensor Replacement:

Disconnect two wires from the terminal strip and slide the sensor out.

To Remove the Manifold Cover

Unscrew its captive screw and slide cover off. Cover allows access to the hose connections on the filter manifold, outlet filters, heaters and the pressure relief.

Heater Replacement

The heaters are located underneath the hopper.

Remove the access door. Use a hex head socket wrench to remove the six heater plate bolts.

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.

c. 1999

DYNAMELT M ASU Manual 20-29

Disassembly & Re-assembly Page 8-3

Revised 2/00

To Remove Rear Cover

No customer replaceable components are behind the rear cover. To remove: remove the two access doors in order to access and remove the five screws which hold the rear cover in place. Two screws are located in the upper corners of the rear cover. Three screws are located across the bottom of the cover.

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

Remove the access door. Remove the screws on the drop-in grid’s junction box cover in order to remove the cover. Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter.

To Access Electrical Components inside the Panel Box

DANGER HIGH VOLTAGE

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

Verify again that the main power is OFF. On the outside of the panel box, use the main disconnect switch to open the panel box door (see Chapter 3 for instructions on opening door).

a.

Fuse Removal:

Transformer fuses are located on the upper terminal rail (item #18 on page

10-7).

b.

Relay Removal:

1. The solid state relays (item #14 on page 10-5) are located on the right-hand side of the inside of the panel box, behind the heat sinks(s). Two screws hold each relay. They also plug into a connector.

2. Drive relays (one relay per drive) are located on the terminal rail (item #31 on page 7).

Push the lever located below these relays to release them from the rail.

c.

SLC 500 Module Removal:

Open the door of the selected module to expose the wires and terminals within. Disconnect wires from all terminals. Press and hold the two module retainer clips simultaneously (located at the top back and bottom back of each module), then gently pull the module straight out of its slot on the rack. To re-install module: align the module’s circuit board to the rack’s card guide and slide the module in until both the top and bottom retainer clips engage.

Page 8-4 Disassembly & Re-assembly

Revised 3/01 c. 1999

DYNAMELT M ASU Manual 20-29

To Access the Pump or Motor

DANGER HOT SURFACE & HIGH VOLTAGE

If the pump is not operable but the heating system will function, raise the temperature of the application system to the operating temperature to aid in the pump disassembly process. Otherwise, a heat gun or other controlled heating method is recommended to melt hardened hot melt material. Never use a torch or an open flame on any of the components of the application system. Once the system is up to temperature, disconnect all incoming power before proceeding.

Remove access door(s) using the key, being careful not to pull off the ground wire attached. Turn

OFF the filter shutoff valve by turning it to its closed “0” position.

a.

Motor Removal:

Open the motor junction box cover (2 screws). Inside the junction box, disconnect the wires leading to the motor. On the outside of the junction box, unscrew the hex nut conduit fitting. Slide the wires through the conduit fitting. Remove the four bolts which attach the motor to the gear box. Lift the motor up and out of the ASU.

For re-assembly: torque should be approximately 1.8 Nm (16 foot/lbs) at room temperature.

With hopper at 177

°C (350°F), the maximum allowable torque on screws is 4.1 Nm (36 foot/lbs).

Motor

Access

Door

Gear

Box

Motor

Junction

Box

c. 1999

DYNAMELT M ASU Manual 20-29

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 5/02

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 “cautions” 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 8/99 c. 1999

DYNAMELT M ASU Manual 20-29

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Chapter 9

AVAILABLE OPTIONS & ACCESSORIES

Options & Accessories Page 9-1

Revised 6/03

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 804467/ 805942

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. Pressure transducers are monitored via pressure readouts through the controller. See Appendix for manufacturer’s manual.

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).

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

cont.

Page 9-2 Options & Accessories

Revised 9/07 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

PN 084E376: 1.752 cc/rev single, high accuracy gear pump

PN 084E428: 0.297 cc/rev single, high accuracy gear pump

PN 084E430: 1.168 cc/rev single, high accuracy gear pump

PN 084E434: 2.920 cc/rev single, high accuracy gear pump

Dual Pumps:

Note: all dual pumps require PN 102049, see below.

PN 100863: 1.54 cc/rev dual, standard accuracy gear pump

PN 100864: 3.18 cc/rev dual, standard accuracy gear pump

PN 084E389: 0.584 cc/rev dual, high accuracy gear pump

PN 084E432: 1.168 cc/rev dual, high accuracy gear pump

PN 108874: 2.920 cc/rev dual, high accuracy gear pump

Hi-Flow Pumps:

PN 110289: 20cc/rev single, gear pump, TSHA

PN 110290: 30cc/rev single, gear pump, TSHA

PN 110291: 45cc/rev single, gear pump, TSHA

Feinpruf Pumps

Often preferred by the European market where they are readily available.

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

Return (re-circulating) Hoses

Available on all models. Use of return hoses allows higher adhesive pressures from the head to the substrate because the head is “overfed” adhesive. The overflow adhesive is re-circulated to the hopper.

Pneumatic Clutch PN 106877

A clutch is available to relieve adhesive pressure quickly in applications where there are periods of time when adhesive is not being applied.

Level Control Options

Single-Point Level Control Kit: PN 810237 (DMM140 & DMM210 only)

Multi-Point Level Control Assembly: PN 084Q210 (DMM140 & DMM210 only)

Level control devices inform the operator, via a message on the controller, that the hopper’s adhesive level is low. They may also be wired to stop production, turn on an alarm light or signal, or signal a PLC.

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Options & Accessories Page 9-3

Revised 5/07

Pressure Transducer Assembly: PN 801122

A pressure transducer is an electronic probe that allows the melted adhesive’s pressure to be processed by the ASU’s control system. They are used to monitor system operating pressures and their limits. They troubleshoot clogged nozzles and filters.

Dual Hopper

Available on DM M70, M140 and M210. The adhesive hopper on the dual hopper models is divided into two separate chambers to allow the application of two different adhesives simultaneously. Each chamber is an independent temperature zone, allowing them to operate at different adhesive temperatures.

High Flow ASUs: PN 106696 = DM140/ PN 106697 = DM210

These ASUs are available as DM M140 or M210 units for applications requiring a pump rate up to

2,625 cc/min per pump. The high flow models are equipped with high flow grid groups, including high flow hoppers, filter shutoff assemblies, filter manifolds and filter baskets.

Controller Options

On PLC-controlled models, ITW Dynatec supplies an Allen-Bradley SLC 500 system, including their DeviceNet communication module and 160 drive(s).

As an option to the SLC system, Allen-Bradley’s Control Logix systems are offered for customers who desire more universal communications. Among the communication modules available for Control Logix ASUs are DeviceNet, EtherNet and ControlNet. Drives available are either the 160 or

PowerFlex.

SLC 5/04 CPU 64K

SLC 5/05 CPU 32K with Ethernet

The above listed Allen Bradley SLC 500 CPU options are available for systems which require additonal memory and/ or networking capability than supplied by the standard SLC.

Control Logix CPU Models

The Control Logix-controlled system’s communication modules and electronic drives are chosen to meet the specific needs of individual customers. Call your Dynatec sales representative to discuss your options.

Pressure Display

The pressure display option enables the controller to read and display adhesive pressure (PSI or

BAR) in the ASU’s outlet filter manifold. A pressure reading device (transducer or gauge) is mounted on the outlet filter manifold.

Line Speed Tracking

This option allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage input. One of the following devices must be installed:

PN 015D050 Tach Generator: a mechanically operated device which produces a reference voltage that allows the ASU’s gear pump to track a parent machine’s production line speed.

PN N06642 Signal Isolator: a device which conditions a parent machine’s production line’s DC speed reference voltage to allow the ASU’s gear pump to track line speed.

Remote HMI Interface

An option that allows controller monitoring and adjustments from a customer-provided programmable logic controller (PLC) or a remote location.

Page 9-4 Options & Accessories

Revised 10/04 c. 1999

DYNAMELT M ASU Manual 20-29

Recommended Service Parts List

Category

Electrical:

O-rings:

Filters:

Misc:

Part No.

103184

036B103

N07958

104166

036B015

102411

105261

048H384

036A077

036A170

036A079

102149

036A077

801680

802101

802110

801684

801688

802111

802693

802694

802711

802109

804914

ACG-3

1747-BA

Description

Fuse GDC4 (terminal rail)

RTD Sensor, PT

RTD Sensor, PT

Over-Temp Thermostat & Insulator Assy.

Pump Enable Thermostat

Boot, Insulator

Relay, 120v

Solid State Relay, Dual

Heater, 2000w

Heater, 500w (for 1 filter block)

Heater, 1000w (for 2 filter blocks)

Heater, 1500w (for 3 filter blocks)

Heater, 2000w (for 4 filter blocks)

Printed Circuit Board, SLC 5/04

Printed Circuit Board, SLC DeviceNet

Power Supply, AB

Module, RTD

Module, I/O

Module, DN, 160 Drive

Module, SLC, Analog, 8 Input

Module, SLC, DC, 32 Output

Power Supply, 15VDC, 40w

Drive, AB 160, 240 VAC, 3P, 1HP

Drive, AB 160, 480 VAC, 1HP

Fuse, SLC Power Supply (locally available)

Battery, SLC Processor (locally available from AB)

N00181

A69X133

N00185

N00187

069X275

N00199

103770

103771

N00192

N00173

807729

069X061

O-ring 014 (outlet filter/ manifold)

O-ring 124 (outlet filter/ manifold)

O-ring 018 (outlet filter/ manifold)

O-ring 020 (outlet filter/ manifold)

O-ring 122 (outlet filter/ manifold)

O-ring 114 (outlet filter/ manifold)

O-ring 5-005 (outlet filter/ manifold)

O-ring 5-254 (outlet filter/ manifold)

O-ring 032

O-ring 006

Pump Shaft Seal (Zenith/ TSHA pump models)

Pump Shaft Seal (optional ITW Dynatec pumps)

069X289 Pump Shaft Seal (Hi Flow pump models) see IBOM Pump Adapter O-rings

101247

101246

006C156

109482

105968

105967

Filter Basket, 100 mesh

Filter Basket, 40 mesh (optional)

High Flow Filter Basket (optional)

Filter Basket, 200 mesh (optional)

Filter Shutoff Assembly, Right

Filter Shutoff Assembly, Left

N07588

L15653

001U002

102717

108012

Lubricant, O-ring

Kit, Flushing Fluid, 1 gallon

Hi-Temp Lubricant, tube

Check Valve (pressure relief)

Filter/ Pressure Relief Plug Assembly

16 + 6 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

2 per manifold

4

2

2 per pump

2 per pump

2 per pump

1 of each per pump

2 per manifold

2 per manifold

2 per manifold

2 per manifold

1

1

1

1

2

1

1

Qty.

1

1

1

1

1

1

2

1

1

2

2

16

1

1

3

2

1

1

1

1

1

1

1

1

1

1

c. 1999

DYNAMELT M ASU Manual 20-29

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.

Because of the similiarities of the Model M70 and M140 ASUs, both are diagrammed on each illustration. When a part number is not identical, both models’ part numbers are given with a note to distinguish between the two models.

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 8/06 c. 1999

DYNAMELT ASU Manual

Part Number

048D142

N00220

048J022

806206

104733

006G112

078A005

N04458

N00838

N00839

078A164

N07790

078A337

078A379

078D027

078C005

N00185

003D105

006B043

809533

806182

807796

807797

807798

807800

807799

806188

006G064

006G078

012G001

012G010

048D141

078C021

101833

807188

N00754

N00755

807179

036A079

036B013

106174

N07958

807543

807542

N00817

Item No.

34

35

36

37

38

39

40

27

28

29

30

23

24

25

26

31

32

33

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

3

4

1

2

5

6

Hi Vol. Filter & Pressure Relief Assembly # 809534

Description

O-ring, #018

Heater Plate

Heat Isolator

Block, Filter

Filter Nut

Large Filter Basket (20 Mesh, Option)

Large Filter Basket (40 Mesh, Option)

Large Filter Basket (80 Mesh, Option)

Large Filter Basket (120 Mesh, Option)

Large Filter Basket (100 Mesh, Option)

Filter Retainer Plate

Block, Pressure Relief

Spring, Pressure Relief

Relief Piston

Pressure Relief Screw

Junction Box

Cover

Snap-In Hole Plug

3/8” St, Conduit Fitting

O-Ring #333

1/2 NPT Level Seal Plug

Cap, Adjustment Screw

10-24 x 1/2 SHCS

1/4 Dowel Pin

3/8-16 x 1 1/4SHCS

3/8-16 x 1 3/4 SHCS

10-24 x 1/2 HHSMS

3/8-16 x 4 1/4 SHCS

3/8-16 x 5 1/2 SHCS

1/4-20 x 4 1/2 SHCS

3/4-16 Jam Nut

Flat Washer, #8 SAE

Flat Washer, .88 x 1.0 x .13

10-32 Tamper Proof Screw

Plug, Drain

Level Seal Plug, 1/4

3/8-18 NPT Level Seal Plug

Heater Control Section

Heater, 5/8 x 10, 240v,1000w

T’Stat, Cartridge, N.C., 1/2 Dia.

Sensor Adapter

Temperature Sensor

Hi Volume Filter Nut Cover Assembly (Option)

Cover Plate

1/4-20 x 1.25 SHC Screw

Qty.

2

4

4

6

1

4

8

4

4

4

4

2

1

2

1

1

2

1

2

2

2

2

2

2

2

2

2

2

1

2

6

1

3

1

2

1

2

4

1

2

2

1

1

1

4

c. 1999

DYNAMELT M ASU Manual All Models

40

39

21

5

13

16

7

19

28

12

23

14

37

36

35

6

20

22

Component Illustrations & BOM’s Page 10-5

Revised 8/05

8

18

27

11

9

10

1

22

1

1

3

34

24

25

29

15

31

30

17

32

Optional

33

32

4

32

26

Note: The junction box can be mounted either side of the filter block depending on the application set-up.

Component Illustration:Hi Vol. Filter & Pressure Relief Assembly # 809534

2

Page 10-6 Component Illustrations & BOM’s

Revised 8/99 c. 1999

DYNAMELT M ASU Manual #20-29

Bill of Materials for Typical Electrical Panel Box Assembly

802704

Item No.

3

4

5

1

2

8

9

6

7

10

11

12

13

14

Part Number

802710

802626

102329

103377

103378

103438

103438

104382

104383

104384

104767

802657

802658

048H384

Description

Allen Bradley Panel View Kit (Color)

Heat Sink

Panel Box Lock Kit

Wire duct, 1.5” W x 3” H

Wire duct, 2” W x 3” H

Wire Duct Cover, 2.25”

Wire Duct Cover, 1.5”

Rotary Handle

Shaft, 8”

Mechanical, Operator, Circuit Breaker

Circuit Breaker,175A, 3P, 240V, ED Series

Panel Box

Insert Panel

SSR Dual 40A, 240VAC

Continued on pages 6 thru 7.

Qty.

1

1

1

1

1

1

16

2

3

1

2

3

3

3

c. 1999

DYNAMELT M ASU Manual #20-29

8

Component Illustrations & BOM’s Page 10-7

Revised 11/00

1

12

14

2

3

9

10

11

6

5

4 7

13

Page 10-8 Component Illustrations & BOM’s

Revised 8/99 c. 1999

DYNAMELT M ASU Manual #20-29

Bill of Materials for Typical Electrical Panel Box Assembly 802704 (Cont. from pg. 4)

Part Number

105261

105263

801684

801688

802100

802101

802109

802110

802111

802599

802693

802694

802695

802711

802697

102286

102956

103099

105288

105288

TBD

104391

104392

105251

105252

105253

105254

105255

105256

105260

048F159

103063

103183

103184

103425

103819

104207

Item No.

38

39

40

41

42

34

35

36

37

27

28

29

30

31

32

33

48

49

50

51

43

44

45

46

47

20

21

22

23

24

25

26

15

16

17

18

19

Description

Terminal Rail, 14”

Circuit Breaker, 15A, 60F, 240V, 1P

Fuse Block, Lever Open

Fuse, GDC4, 250VAC

Terminal Rail, 22”

Transformer

Circuit Breaker, 15A, 60F, 240V, 2P

Circuit Breaker, 20A, DP

Circuit Breaker, 30A, DP

Terminal Block, Dual, 10A

End Plate for105251

Terminal Block Single, 20A

End Plate for105253

Terminal Block, Ground

End Stop

Distribution Block

Relay, 120v w socket

Contactor, 3P, 600V, 120V

Module, RTD,1746-NR4

Module, I.O., 12

PCB, SLC

PCB, SLC, Device Net

Drive, AB, 160, 240v, 3P, 1HP

Power Supply, AB,

Module, AB, DN, 160 Dr

Filter, 160 Drive, 240v, 3P

Module, SLC, Analog, 8 Input

Module, SLC, DC, 32 Output

Rack, 13 Slot

Power Supply, 15VDC, 40w

Rack, 4 Slot

Harness, Aux, Head (not shown)

Harness, Hose, Head 8’ (not shown)

Harness, Dual SSR to Dynacontrol (not shown)

Harness, Aux Head 18’ (not shown)

Harness, Hose/ Head 18’ (not shown)

Ground

Qty.

1

4

1

1

2

1

8

1

4

4

1

1

4

1

4

4

16

4

1

1

1

6

1

67

9

12

5

1

8

4

3

3

1

6

2

1

1

c. 1999

DYNAMELT M ASU Manual #20-29

20

16

19

21

22

23

38

35

36

33

41

34

42

43

38

39

45

29

25

24

18

17

26

28

31

15

37

40

Component Illustrations & BOM’s Page 10-9

Revised 6/99

11

10

9

51

24

25

26

27

28

19

44

32

30

Page 10-10 Component Illustrations & BOM’s

Revised 10/07 c. 1999

DYNAMELT M ASU Manual All M70--140 Models

Bill of Materials for DYNAMELT M70 Series Cabinet Assembly (Base Unit 106045)

Item No.

Part Number

Description

Qty.

078C008

106111

101304

104279

105111

106048

105117

106236

106876

106319

105865

106772

106773

105152

106892

105101

101843

105880

105886

105978

107890

108128

105891

105882

105975

802657

802102

106110

009E006

009E009

101074

103866

103516

106770

106771

101842

106769

806399

808682

106321

108297

808778

810716

805026

18

19

20

21

22

14

15

16

17

10

11

12

13

8

9

6

7

3

4

1

2

5

35

36

37

38

31

32

33

34

27

28

29

30

23

24

25

26

39

40

41

42

43

44

Handle, Side Panel

Panel, Top, Bracket

Access Cover

Rear Cover M70

Manifold Cover

Manifold Cover, Hi Flow Only

Base Plate M70/140

Top Panel M70/140

Heat Barrier, Panel Box, M70

Panel Box

Mounting Bracket

M5 Hex Nut

Swivel Caster

Rigid Caster

Receptacle

Bracket, Connector Bank, Amphenol

M8 HHC screw

M8 Star Washer

5/16 Flat Washer

M4 x 12 BHC Screw

Blank Plate, Dual

Blank Plate, Single

M3 Hex Nut

Lid Assembly

M4 x 8 Pan Head Screw

M4 Star Washer

Retaining Clip

M6 Star Washer

M6 Hex Nut

Inner Hinge

Outer Hinge

M3 x 6mm PHLC Screw

M3 Flat Washer

M6 x 16mm HHC Screw

Hinge, Hopper lid

Heat Deflector,

Collar, Hopper

Handle, Hopper, Lid

Lid Hopper

Lid (with level cnt. mnt.) (807141 Lvl Cnt Assm.) (option)

Optional ASU Leg Assembly 5.5”

Washer, Flat, M8, 9 x 17 x 1.6

M8-1.25 x 20mm, HH Ser Fl

Leg, Machine Support, 5.5”

Lid Blank (option for one split hopper)

No Filter Cover Plate (option for one split hopper)

1

1

1

1

2

1

6

2

1

12

12

4

2

6

4

2

2

4

4

4

4

16 or 64

0, 1 or 7

0 or 4

4

4

8

1

0, 4 or 16

2

2

2

1

8

1

1

1

1

2

1

4

1

2

1

c. 1999

DYNAMELT M ASU Manual All M70--140 Models

9

10

2

30

43

30

28

31

30

Component Illustrations & BOM’s Page 10-11

Revised 12/03

38

37

33

34

27

26

32

36

11

35

29

33

25 24 23

7

22

15

14

19

21 20

3

8

3

4

44

6

39

42

40

41

18 17

16

12

13

Component Illustration: DM M70 Cabinet Assembly

5

Page 10-12 Component Illustrations & BOM’s

Revised 12/04 c. 1999

DYNAMELT M ASU Manual 20-29

Bill of Materials for DYNAMELT M140 Series Cabinet Assembly 106046

Item No.

Part Number

Description

Qty.

106321

106111

101304

104279

105111

106048

105117

106236

106876

106319

105865

106772

106773

105152

106892

101843

105880

105887

105979

107890

108128

105891

105882

105976

101853

802657

802665

802755

105101

107390

009E006

009E009

101074

103866

108296

106770

106771

101842

106769

806399

37

38

39

33

34

35

36

29

30

31

32

25

26

27

28

16

17

18

19

12

13

14

15

20

21

22

23

24

8

9

6

7

10

11

3

4

1

2

5

Handle, Side Panel

Panel, Top, Bracket

Access Cover, M140

Rear Cover, M140

Manifold Cover

Manifold Cover, Hi Flow Only

Base Plate M70/140

Top Panel, M70/140

Heat Barrier, Panel Box, M140

Lower Manifold Cover

Panel Box

Mounting Bracket, PV600

Mounting Bracket, PV550

M6 x 16mm SHC Screw

M6 Hex Nut

Swivel Caster

Rigid Caster

Receptacle

Bracket, Connector Bank, Amphenol

M8 HHC screw

M8 Star Washer

5/16 Flat Washer

M4 x 12 BHC Screw

Blank Plate, Dual

Blank Plate, Single

M3 Hex Nut

Lid Assembly

M4 x 8 Pan Head Screw

M4 Star Washer

Retaining Clip

M6 Star Washer

M6 Hex Nut

Inner Hinge

Outer Hinge

M3 x 6mm PHLC Screw

M3 Flat Washer

Hinge, Hopper Lid

Heat Deflector

Collar, Hopper

Handle, Hopper, Lid

Lid Hopper

Lid (with level cnt. mnt.) (807141 Lvl Cnt Assm.) (option)

2

1

6

6

2

2

4

4

16 or 64

0, 1 or 7

0 or 4

0, 4 or 16

4

2

2

4

1

1

1

1

4

4

4

4

2

8

8

2

1

4

1

1

1

2

1

1

2

1

4

1

2

10

c. 1999

DYNAMELT M ASU Manual 20-29

11

2

32

32

7

8

30

39

33

32

31

13

Component Illustrations & BOM’s Page 10-13

Revised 11/03

38

34

35

37

12

28

29

36

27 26 25

34

3

24

17

16

21

23

22

4

1

3

5

6

20 19 18

14

15

Component Illustration: DM M140 Cabinet Assembly

Page 10-14 Component Illustrations & BOM’s

Revised 12/04 c. 1999

DYNAMELT M ASU Manual #20-29

072X004

106877

N00099

N02745

N07677

N08236

110504

110503

N00093

N00753

101692

106198

106319

N00732

N00933

N00687

106342

078A183

106341

808916

030A014

048J184

104663

106714

106658

108018

106661

106662

109226

106754

106659

107602

105060

801679

106324

21

22

23

24

17

18

19

20

25

26

27

28

29

10

11

12

13

14

15

16

8

9

6

7

30

31

32

33

34

35

Bill of Materials for DYNAMELT M70/ 140 AC Drive Assembly 106660 Front

106663 Rear, Special

Item No.

Part Number

Description

3

4

5

1

2

106874

106875

Coupling Half, Pump Side (Option, not part of this assembly)

Coupling Center (Option, not part of this assembly)

Drive Assembly, M70/ M140/ M210

M6‘--1,0 x 25mm

Coupling, Half, Motor Side

Shaft, Gearbox, 20:1 (Front Drive Assembly 106660)

Shaft, Gearbox, 20:1 (Front Drive Assem. 106660,4.5cc pump)

Shaft (Rear Drive Assembly 106663)

Gear Box, 20:1

Key, 1/4 Sq. x.75

Ring Clip

Motor Mounting Bracket

Bolt M8 x 40mm HHC, Ser Fl, Screw

Nut

Motor, AC, 3P, 240v, 1HP, K256

Flat Washer, M6

External Tooth Lock Washer, M6

5/16-18 x 3/4 SHC Screw

5/16 Lock Washer

5/16 Flat Washer

Adapter Plate

3/8-16 x 1 HHC Screw‘

M8-1.25 x 40mm SH Set Screw

Optional Pneumatic Clutch Assembly

Solenoid, 120V, 3--way

Cord Grip, 1/8 --1/4

1/8 Hex Nipple

Clutch Kit, 56C, In line

Fitting, Elbow, 90deg., Brass

Muffler, Pneumatic Exhaust, 1/8 NPT

Tubing, TFE, .25 OD x .125 ID cable, 18ga, 3C, SV

Optional Clutch Air Manifold Assembly

Air manifold

Fitting, 1/4 tube x 1/8 NPT

1/8 NPT Level Seal Plug

M4-0.7 x 35mm SHC Screw

Lockwasher, 4mm

Qty.

1

1

1

1

4

1

1

2

1

1

3

2

2

1

1

1

1

1

1

4

1

4’

10’

1

8

8

8

4

8

1

4

1

4

1

7

4

To Melt

Section

c. 1999

DYNAMELT ASU M Manual #20-29

20

13

6

1

2

4

8

5

7

8

26

Component Illustrations & BOM’s Page 10-15

Revised 12/03

36 35

33 32

To Heat

Barrier

Panel

25

30

24

33

34

28

23

3

27

29

15

14

16

17

18

10

11

12

21

9

19

106660 Front 106663 Rear to Base Plate

Component Illustration: DYNAMELT AC Drive Assembly 106660 &106663

Page 10-16 Component Illustrations & BOM’s

Revised 8/07 c. 1999

DYNAMELT M ASU Manual All M70--140 Models

Single 106040, M140 Single High Flow 106694 and M140 Dual 106039 Melt & Grid Assemblies.

Item No.

Part Number

Description

26

27

28

29

30

31

22

23

24

25

18

19

20

21

12

13

14

15

8

9

10

11

16

17

5

6

7

3

4

1

2

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

106103

N00834

N00754

105967

105968

804464

804465

805216

105149

N00192

108297

N00181

105097

069X274

811278

N00181

N007081

104696

003E023

N07958

106174

104802

048J048

NN00192

069X285

102446

N07429

078A055

084Q465

069X064

012G009

036B015

N07958

105999

105883

105884

105889

105890

106620

105881

105135

108297

107602

N00686

N00697

072X093

N00210

105885

106001

078C021

048J018

048F125

048F136

048F137

048F021

048F069

107751

N06883

107645/ 107646

048J088

108829/ 108830

104166

104165

104164

103538

Pump Enable Thermostat

Temperature Sensor

Hopper Support

Hopper, Weldment, Dual, M70 (106037)

Hopper, Weldment, Dual, M140 (106039)

Hopper, Weldment, M70, Single (106038)

Hopper, Weldment, M140, Single (106040)

Hopper, Weldment, M140, Single, High Flow (106694)

Heater Plate, M70/ 140

Spacer

M8 x-1.25 x 20mm HHC Screw

M8 x 40 HHC Screw

Flat Washers, 1/4

Lock Washer, 1/4

Filter Shut-off plug (fits in place of or opposite Filter shut-off)

O-ring, -912 (fits in place of or opposite Filter shut-off)

Filter Block Assembly (See Your order for part Number and Qty.)

Ball Valve Assembly (Option)

Junction Box Assembly

Junction Box, Prog-Melt, M70/ 140

Cover, Junction Box,

Flat Washer, .88X1.0X.13

Bushing, Plastic Cap, 1/2”

Terminal Rail, 11.5” (one of each)

Block, Terminal 35 Amp

Cover End

Ground Terminal

End Clamp

5/16 Conduit Fitting

Jam Nut

5/16 Conduit, 12 /25” (one for each conduit fitting)

1/2” Sealtite Connector

1/2”Sealtite Conduit, 36” / 1/2”Sealtite Conduit, 40” (opposite side)

Over Temp. Switch Assembly (Sold as an assembly only)

Insulator, Over Temp Thermostat

Overtemp Reset Thermostat

M4 X 6mm Pan Head

Grid Group

O-ring, -014

O-ring, (-014 Kalrez)

Flange

Cover

Temperature Sensor

Sensor Adapter

Cast Heater

1/4 ID Conduit

O-ring, -032

O-ring, -032 (kalrez)

M4-0. 70 x 10mm SHC Screw

M8-1.25 x 35mm SHC Screw

10-24 x 3/16 SHS Screw

Pump Block-off Assembly (option)

O-ring, #-041

Block-off Plate

3/8-16 x 1.25 SHC Screw

1/4 Level Seal Plug

Filter Shutoff Assembly (Left)

Filter Shutoff Assembly (Right)

Filter Shutoff Assembly (Left) (HI-Temp Option)

Filter Shutoff Assembly (Right) (HI-Temp Option)

Grid Block Off Assembly

Block off Plate

O-ring, #-032

M8 x 20mm HHC Flange Screw

O-ring, -#014

M6 x 30mm SH Set Screw

Seal Dual Pump to Prog melt (not Shown)

Grid Support As needed

4

4

2

1

4

1-2

1

1

1

1

1

4

2

1

1

8

2

2

2

1

2

4’

2--4

2--4

4

2

2

2

2

2

8--16

8--16

2

2

4

6

2

6

2

2

1ea

2

2

2

44

1

1

2

2

Qty.

2

12

12

24

48

48

2-4

2-4

1

1

2

1

4

2

2

4

c. 1999

DYNAMELT M ASU Manual All M70--140 Models

43

55

54

37

44

36

53

52

or

45

41

19

31

21

20

30

28

27

56

50

14

15

48

47

46

18

17

32

33 34

27

28

29

2

1

8

20

22 23

24

25 26

12

13

11

12 13 10

9

12 13 10

3

to base plate

49

Component Illustrations & BOM’s Page 10-17

Revised 8/06

35

40

58

38

39

51

42

5

17

4

1

2

32

33 34

9

3

12

11

13

16

Note the dual progmelt for the

M70 is identical to the dual

M140 with a shorter hopper.

7

12 13 10

6

Note the Single progmelt for the

M70/ M140 is identical to the dual with only one melting compartment.

Page 10-18 Component Illustrations & BOM’s

Revised 9/01 c. 1999

DYNAMELT M ASU Manual 20-29

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 20-29

Component Illustrations & BOM’s Page 10-19

Revised 9/01

2

9

Pump # 100860 has one bearing in this Shaft

Pump # 100861 has two bearing in this shaft

1

3

4

5

16

17

9

10

Pump # 100861 has two bearing in this Shaft

Pump # 100860 has one bearing in this shaft

7

6

8

12

10

13

11

14

11

15

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

Component Illustration: 1.54 cc / Rev, Single Gear Pump Assembly #100860

Page 10-20 Component Illustrations & BOM’s

Revised 9/01 c. 1999

DYNAMELT M ASU Manual 20-29

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 20-29

2

9

Component Illustrations & BOM’s Page 10-21

Revised 9/01

16

1

3

4

5

17

9

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104042 M10-1.5 x 100 All Thread

7

6

8

12

10

13

11

14

15

11

Component Illustration: 4.50 cc / Rev, Single Gear Pump Assembly #100862

Page 10-22 Component Illustrations & BOM’s

Revised 9/01 c. 1999

DYNAMELT M ASU Manual 20-29

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 20-29

9

2

1

Component Illustrations & BOM’s Page 10-23

9/01

3

4

5

16

19

9

10

7

6

8

12

10

11

17

18

10

13

11

14

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

15

11

Component Illustration: 1.54 cc / Rev, Dual Gear Pump Assembly #100863

Page 10-24 Component Illustrations & BOM’s

Revised 8/02

2

1

9

3

4

5

16

19

c. 1999

DYNAMELT M ASU Manual 20-29

9

10

In some cases the pumps are mounted with the following hardware:

104158 M10 Flange Nut

104073 M10-1.5 x 105 All Thread

7

6

8

12

10

11

17

18

10

13

11

14

10

11

15

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

Bill of Materials for 3.2 cc / Rev. ,

Dual Gear Pump Assembly # 100864

Item No.

Part Number Description

012D088

078I001

101626

069X160

069X061

018X041

100867

012D087

018X031

012C019

069X064

078F017

018X041

100865

101691

NPN

100870

N00198

NPN

Drive Shaft

Key, Woodruff

M5 x 12 SHCS

Seal retainer & Bearing Housing

Lip Seal

Bearing Sleeve

Front Plate Assembly

Driven Gear Shaft

Ball, 1/8” Dia.

Drive Gear, 4.5 cc/Rev

O-ring, -041

Shaft Retaining Ring

Bearing Sleeve, rear Plate

Rear Plate Assembly

M4 x 40 SHCS

M10-1.5 x 85mm

Middle Plate

O-ring, -113

M10 Flat Washer

Qty.

2

4

2

1

3

4

5

4

1

2

4

1

1

1

2

4

1

1

1

c. 1999

DYNAMELT M ASU Manual #20-37

Component Illustrations & BOM’s Page 10-25

8/02

10

5

11

2

1

4

6

3

12

13

8

5

7

Bill of Materials for 10cc Single Gear Pump Assembly # 109690

Item No.

11

12

13

14

7

8

9

10

1

2

3

4

5

6

Part Number

018X031

078F017

078I001

069X061

069X064

100908

101626

109685

109686

109689

109687

109688

069X160

001U002

Description

Ball bearing, 1/8 Dia.

Snap ring, 1/2”

Key Woodruf, #404

Shaft Seal

O-ring, -041

M4-0.7 x 25mm SHC Screw

M5-0.8 x 12mm SHC Screw

Pump Body10cc Rev

Rear Bearing Plate 10cc Rev.

Gear 10cc Rev

Drive Shaft 10cc/ 20cc

Driven shaft, 10cc/20cc

Shaft seal retainer

Dow Corning 112 Lubricant (Not Shown)

9

Qty.

1

2

4

1

1

1

1

6

4

1

1

2

2

Page 10-26 Component Illustrations & BOM’s

Revised 7/03 c. 1999

DYNAMELT M ASU Manual #20-29

Bill of Materials for Assorted Pump Adapter Assemblies

Item No.

7

8

5

6

3

4

1

2

20

21

22

17

18

19

12

13

14

15

16

9

10

11

084E428

084E374

084E430

084E434

108875

084E438

084E389

084E432

108874

084E419

012G027

069X064

069X230

069X270

078A618

078C141

069X289

084E411

084E412

084E413

103923

103624

103924

N00181

069X270

102927

Part Number

084E406

012G024

069X058

N00179

069X274

N00190

078C130

NPN

103917

103918

103919

104351

Description

TSHA Pump Adapter Assembly

Pump Adapter

O--Ring #28

O--Ring #12

Seal Dual Pump to Progmelt (not part of this assembly)

O-Ring #24

3/8 Washer, 3/4 OD

M10 x 85mm SHC screw

Zenith Pump

THSA .297 cc Single Outlet

THSA .584 cc Single Outlet

THSA 1.168 cc Single Outlet

THSA 2.292 cc Single Outlet

THSA 8.5 cc Single Outlet

THSA 30.0 cc Single Outlet

THSA .584 cc Dual Outlet

THSA 1.168 cc Dual Outlet

THSA 2.292 cc Dual Outlet

Zenith Pump Adapter Assembly

Adapter, Z Pump

O-Ring, #041

O-Ring, #021

O-Ring, #025

Screw, Pump Mounting

7/16 ss Washer, 3/4 OD

Drive Shaft Seal

THSA Pump

THSA 20 cc Single Outlet

THSA 30 cc Single Outlet

THSA 45 cc Single Outlet

Feinpruef Pump Adapter Assembly

Adapter Plate

O-ring Plate

O-ring, -014

O-ring-025

O-ring, -133

Feinpruef Pump

Feinpruef Pump .3 cc

Feinpruef Pump 1.2 cc

Feinpruef Pump 2.4 cc

Coupling Half (Not Shown, See drive Section)

1

1

1

1

4

1

2

4

1

1

1

4

1

1

Qty.

1

4

2

1

4

1

1

1

c. 1999

DYNAMELT M ASU Manual #20-29

THSA Pump Adapter Assembly 084E406

5

3

4

1

2

8

6

THSA Pump Adapter Assembly 084E419

7

11

16

12

9

10

15

14

13

Feinpruef Pump Adapter Assembly 103923

Component Illustrations & BOM’s Page 10-27

Revised 7/03

21

17

19

18

20

19

22

Page 10-28 Component Illustrations & BOM’s

Revised 9/01

5

2

4

1

3 or

3

6

Item No.

1

2

5

6

3

4

Part Number

806883

101174

104325

805632

102987

N00104

Pressure Gauge Assembly-805641

Description

Fitting, 1/4 NPTM x #6 JIC x 90

Pressure Guage, 1000 PSI

Fitting Adapter, Swivel, 6J x 1/4 MPT

Fitting, 1/4 NPT 1/2-20 Tranducer

Insulator

Fitting, 1/4 NPTM x #6, ST

c. 1999

DYNAMELT M ASU Manual #20-29

2

Qty.

1

1

1

1

1

1

5

4

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Chapter 11

SCHEMATICS &

ENGINEERING DRAWINGS

Drawing:

Hose Schematic, ASU to Applicator

Applicator Head Schematic

Flow Diagram, Outlet Filter Manifold

Typical Hydraulic Schematic

Grounding Diagram, CE Mark

Pump & Zone Configuration

ASU Schematics

Found on:

page 11-2 page 11-3 page 11-4 page 11-5

Page 11-6

Page 11-7 end of chapter

Schematics Page 11-1

Revised 12/02

Page 11-2 Schematics

Revised 7/07 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

HOSE SCHEMATIC PN 101082 REV. G

ASU to Applicator

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Schematics Page 11-3

Revised 1/01

HEAD SCHEMATIC PN 103117 REV. B

HEAD SCHEMATIC PN 103117 REV. B

Page 11-4 Schematics

Revised 5/00 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Schematics Page 11-5

Revised 5/00

Transducer

Filter

Basket

Bypass

Gauge

Pump

Motor

TYPICAL HYDRAULIC SCHEMATIC: Single Pump, Motor, Bypass, Filter, optional Transducer & optional

Pressure Gauge

Page 11-6 Schematics

Revised 10/01 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

GROUNDING DIAGRAM, CE MARK, PN 804704 REV. E

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Schematics Page 11-7

Revised 7/07

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 1 of 3

Page 11-8 Schematics

Revised 7/07 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 2 of 3

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Schematics Page 11-9

Revised 7/07

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 3 of 3

Page 11-10 Schematics

Revised 10/01 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

APPENDIX

DYNATEC/ ZENITH STANDARD ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E427, 084E429, 084E431, 084E433, 084E435, 084E437

Appendix 1

Revised 10/99

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 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccuracies, multiple seal areas and slippage, which required constant calibration, high maintenence and extended downtimes.

Zenith Pumps met the challenge and designed a rotary external gear pump of unique precision and simplicity. Manufacturing techniques were developed to hold tolerances to

.00005”, and an internal pressure relief mechanism assured reliable precision metering. The pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.

For years since, chemical engineers have relied on Zenith to provide precision fluid handling solutions for their most difficult pumping applications. Zenith gear pumps can be found wherever precise, pulseless, repeatable metering of fluids is required.

BENEFITS

High Accuracy

Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and temperature.

High Temperature Capability

Operating temperatures to 450 degrees F (232 degrees C).

Maximum Life

Only three moving parts; components are through-hardened tool and die steels to 56 HRc or better. The bodies are cast nodular iron. Replaceable sleeve bearings for low-cost rebuilds.

High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under pressure by built-in alignment pins.

Minimum Pulsation

Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance.

Precision Construction

Ground and lapped components for close control of operating clearances.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 3

Revised 10/99

SPECIFICATIONS

Pump Type: Rotary external spur gear, single stream.

Rotation: Clockwise

Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.

Temperature: To 450 degrees F (232 degrees C)

OPERATION

All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed gear tooth volumes and is transported around the outer diameter of the gear pocket.

As the gears mesh together, the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate.

Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pressure required. However, when high-viscosity fluids are used, more time is required to fill the tooth volumes. As a result, the inlet pressure must be increased, or the gears must rotate at a slower speed to ensure complete volume filling and to prevent cavitation.

Dynatec/ Zenith pumps rely on the metered fluid for lubrication of internal bearing areas.

The pump should never be allowed to run dry or be allowed to run with non-lubricating fluids such as water. Because of the close clearances in the bearing areas, lack of sufficient lubrication can cause pump seizure or some other catastrophic failure.

Slippage will occur across the faces of the gears from the high-pressure side to the low-pressure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential pressure and pump clearances. Under reasonably stable operating conditions, slippage is repeatable and predictable and pump operation can be adjusted to compensate.

The Standard Accuracy Pumps are designed for high-temperature and high-pressure operation. As such, operating temperatures to 450 degrees F can be achieved.

INSTALLATION

Pumps should be carefully unpacked to make sure that the shipment is complete. If any items are missing or damaged, the freight carrier and Dynatec should be notified immediately.

While the pump is composed of steel, it is a precision instrument. Dropping the pump or hitting with a non-yielding material can cause serious damage to the components. All materials are through-hardened to maximum hardness resulting in brittle material. Treat

cont.

Appendix 4

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

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 8 for torque values.

The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact Dynatec.

TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.

2. Filters should be installed prior to the pump inlet that filter ideally to half the pump running clearances.

3. Turn pumps by hand before running. Pumps should turn freely.

4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the coupling* and that it is aligned within one degree angular and .005” parallel with the true pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate.)

5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque at room temperature.

6. Make sure fluid is in the pump before starting.

7. Start pump slowly and, if possible, run it with a lubricating fluid.

8. When satisfactory operation is achieved, the pump and system may be gradually brought up to normal process speeds and pressures.

9. If at any time during operation the pump does not appear to be running smoothly, stop the pump immediately to avoid any serious internal damage.

CLEANING, INSPECTION AND REPAIR

REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop the high pressure demanded, the clearance between the metering gears and their housing must be as small as possible, yet large enough to allow adequate lubrication. All parts are machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths of an inch (.0001”/ .0002”). Because of these close running clearances,

cont.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 5

Revised 10/99

these pumps require careful maintenence and handling, especially of component parts. The slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These pumps are precision instruments; you can’t keep them too clean. Please treat them with care, and if it’s at all possible, set aside a separate clean area for pump maintenance.

To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to the pump size and the degree of polymer contamination and should be determined by trial. Note: Careful control of he furnace temperature (700 degrees F max.) and atmosphere is critical. Should the temperature exceed the original tempering temperature, the steel hardness will draw back and the dimensional stability of the pump may be upset.

Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.

The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization process usually takes between 3 and 12 hours, depending on the polymer type, temperature, pump size and furnace load.

CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.

After gradually cooling to room temperature, the pump should be thoroughly flushed in a clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer ash.

If present, always replace the carbon seal plate after pump burnout. If the pump was performing satisfactorily when removed from service and still turns freely after burnout, pressure test it and add a high-temperature lubricant to prepare it for return to service. To store for future use, simply add a rust preventative oil.

It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum. By noting the performance of a pump immediately before removing it from service and correlating the performance to measured component wear, the user can establish the maximum wear limits for the pump’s critical components. Further, he can predict the service life of the pump and schedule his down-time accordingly.

As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for complete rehabilitation as necessary. This procedure may be desirable if only a few pumps are involved. If a large number of pumps are to be maintained at the user’s plant, it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing, gauging and assembly techniques involved in producting the pumps.

Please contact Dynatec (at 1-800-538-9540) for further information on these items.

Appendix 6

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

STANDARD ACCURACY PUMP DISASSEMBLY

If pumps are to be disassembled on a regular basis, we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate

“clean” area for assembly, testing and storing of rebuilt pumps.

If maintenence is required due to low delivery or seizure, the following procedure is recommended for disassembly.

NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.

Refer to assembly drawing (located in the back of this manual) for your correct pump type.

1. Remove the seal arrangement.

2. Remove all binder screws.

3. Remove pins (10) and arbor (5) with an arbor press in the direction which disengages the press fit in the shortest distance.

NOTE: Dowels and arbors for the standard accuracy pumps are press fit in the gear/ rear

plate.

4. Separate the plates by pry slots that are available in the pump. Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart.

5. After disassembly, clean all components in a non-destructive solvent.

6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang parts together.

7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and faces of the gears may be hand blocked on 600 grit paper and any nicks, burrs or sharp edges can be lightly removed with a honing stone. Be careful not to round off the edges of the gear teeth while lapping.

CAUTION: Since the thickness relationship between the metering gears and the gear/

rear plate is critical to metering performance, and the gear/ rear plate is non-wearing on its sides, lapping these components is not necessary and should not be done under any circumstances.

Place a layer of 600 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 1) approximately five times until a smooth finish appears. Turning in a circular fashion, or other non-uniform motion, may cause the ground holes to lose their perpendicularity to the faces.

Always use clean, lint-free rags and compressed air to clean components. Paper towels are not acceptable; they may leave small pieces of paper and dust on the components. Use chemical brushes to clean between gear teeth, bores and reliefs.

8. Replace sleeve bearings as necessary and hone in the plate to the original new part specifications.

9. After each resurfacing, carefully gauge the area between the inlet and discharge ports at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical part of the plate. Scoring or wear marks here will allow increased slippage from the

cont.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 7

Revised 10/99

high-pressure discharge port section across the throat to the lower inlet port, reducing efficiency. Therefore, carefully gauge this area for flatness after each resurfacing.

10. After all components are “hospital clean”, the pump is ready for assembly.

Figure 1

STANDARD ACCURACY PUMP RE-ASSEMBLY

NOTE: During and between each re-assembly step, manually turn the metering gears to en-

sure 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 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

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. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 9

Revised 10/99

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.

Disassemble and clean pump; replace any damaged parts.

5. Possible internal damages.

Disassemble and clean pump; replace any damaged parts. Consult factory.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Replace seal plate and coupling if necessary.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 1. Worn gear(s).

2. Worn bearings.

Replace worn gear(s).

Replace worn bearings.

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 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

(this page is a paste up)

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 11

Revised 10/99

Appendix 12

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 13

Revised 10/99

Appendix 14

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

DYNATEC/ ZENITH HIGH ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL

PN 084E428, 084E430, 084E432, 084E434, 084E436

Appendix 15

Revised 10/99

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 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

INTRODUCTION

In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise, pulseless, repeatable flow and assure better quality control. The options then were the same as those in the chemical process industry today: diaphragm, lobe, coarse gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccuracies, multiple seal areas and slippage, which required constant calibration, high maintenence and extended downtimes.

Zenith Pumps met the challenge and designed a rotary external gear pump of unique precision and simplicity. Manufacturing techniques were developed to hold tolerances to

.00005”, and an internal pressure relief mechanism assured reliable precision metering. The pump’s simple design of only three moving parts - two metering gears and a drive shaft provided long life and easy maintenance.

For years since, chemical engineers have relied on Zenith to provide precision fluid handling solutions for their most difficult pumping applications. Zenith gear pumps can be found wherever precise, pulseless, repeatable metering of fluids is required.

BENEFITS

High Accuracy

Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and temperature.

High Temperature Capability

Operating temperatures to 550 degrees F (288 degrees C).

Maximum Life

Only three moving parts; components are through-hardened tool and die steels to 62 HRc or better. Replaceable sleeve bearings for low-cost rebuilds.

High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under pressure by built-in alignment dowels.

Minimum Pulsation

Unique design offers virtually pulseless flow without valves or flexible elements to hinder performance.

Precision Construction

Ground and lapped components for close control of operating clearances.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 17

Revised 10/99

SPECIFICATIONS

Pump Type: Rotary external spur gear, single stream.

Rotation: Clockwise

Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.

Temperature: To 550 degrees F (288 degrees C)

DESIGN

Dynatec/ Zenith High Accuracy Metering Pumps consist of two gears rotating in mesh within a closely fitted housing that is comprised of three plates. The center gear plate fits closely around the outside diameter of the metering gears. The front and rear plates sandwich the center plate and restrict axial movement of the gears. Power is transmitted to the gears by the drive shaft which is a through shaft. Shaft sealing is accomplished with a high temperature cup seal.

High-accuracy pumps are precision instruments requiring skilled and careful maintenence.

Constructed of high-quality tool and die steels such as AISI D2, M2, M4 and CPM-M4, or other high-performance alloys, they are tempered after heat treatment to hardnesses ranging from HRc 58 to HRc 64. Since the thermal expansion rates for all three steels are almost identical and are otherwise entirely compatible, it is possible to combine them so as to take advantage of their best qualities in the most economical way.

The Type D2 tool steel is often selected for the side and center plates as it offers good abrasion resistance and it is the most economical of the three steels we most commonly use.

Type D2 will also provide a higher degree of corrosion resistance than M2 or M4.

The portion of the side plate subject to the most wear is the shaft bearing hole, which has an easily replaceable, inexpensive sleeve bearing that can be made of the extremely wear resistant Type M4 tool steel. Types M2 and CPM-M4 steels are commonly used for the metering gears, drive shaft and universal seal coupling, due to their superior torsional strength and abrasion resistance for these items that are the most critical to proper metering performance.

OPERATION

All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the exposed gear tooth volumes and is transported around the outer diameter of the gear pocket.

As the gears mesh together, the fluid is displaced in a very precise amount out through the discharge port that is drilled alongside the inlet port in the rear plate.

cont.

Appendix 18

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

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 23 for torque values.

The following is a brief “standard” installation procedure. For any special applications, considerations or simply to ask our advice, please contact Dynatec.

cont.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 19

Revised 10/99

TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.

2. Filters should be installed prior to the pump inlet that filter ideally to half the pump running clearances.

3. Turn pumps by hand before running. Pumps should turn freely.

4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the coupling* and that it is aligned within one degree angular and .005” parallel with the true pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the internal operating pressure of the pump to force it forward and effect a seal against the carbon or metal seal plate.)

5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque at room temperature.

6. Make sure fluid is in the pump before starting.

7. Start pump slowly and, if possible, run it with a lubricating fluid.

8. When satisfactory operation is achieved, the pump and system may be gradually brought up to normal process speeds and pressures.

9. If at any time during operation the pump does not appear to be running smoothly, stop the pump immediately to avoid any serious internal damage.

CLEANING, INSPECTION AND REPAIR

REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to develop the high pressure demanded, the clearance between the metering gears and their housing must be as small as possible, yet large enough to allow adequate lubrication. All parts are machined to extreme accuracy; critical dimensions are held between one and two ten-thousanths of an inch (.0001”/ .0002”). Because of these close running clearances, these pumps require careful maintenence and handling, especially of component parts. The slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These pumps are precision instruments; you can’t keep them too clean. Please treat them with care, and if it’s at all possible, set aside a separate clean area for pump maintenance.

To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temperature will be related to the pump size and the degree of polymer contamination and should be determined by trial. Note: Careful control of he furnace temperature (950 degrees F max.) and atmosphere is critical. Should the temperature exceed the original tempering temperature, the steel hardness will draw back and the dimensional stability of the pump may be upset.

Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.

The bath shold be heated to a temperature that is sufficient to carburize the polymer. The carburization process usually takes between 3 and 12 hours, depending on the polymer type, temperature, pump size and furnace load.

cont.

Appendix 20

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.

After gradually cooling to room temperature, the pump should be thoroughly flushed in a clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer ash.

If present, always replace the carbon seal plate after pump burnout. If the pump was performing satisfactorily when removed from service and still turns freely after burnout, pressure test it and add a high-temperature lubricant to prepare it for return to service. To store for future use, simply add a rust preventative oil.

It is recommended that pump users institute a program of dimensional inspection of critical parts in order to keep maintenence and operting costs at a minimum. By noting the performance of a pump immediately before removing it from service and correlating the performance to measured component wear, the user can establish the maximum wear limits for the pump’s critical components. Further, he can predict the service life of the pump and schedule his down-time accordingly.

As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for complete rehabilitation as necessary. This procedure may be desirable if only a few pumps are involved. If a large number of pumps are to be maintained at the user’s plant, it may be worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view the manufacturing, gauging and assembly techniques involved in producting the pumps.

Please contact Dynatec (at 1-800-538-9540) for further information on these items.

HIGH ACCURACY PUMP DISASSEMBLY

If pumps are to be disassembled on a regular basis, we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate

“clean” area for assembly, testing and storing of rebuilt pumps.

If maintenence is required due to low delivery or seizure, the following procedure is recommended for disassembly.

NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.

Refer to assembly drawing (located in the back of this manual) for your correct pump type.

1. Remove the seal arrangement.

2. Remove all binder screws.

3. Remove dowels (10) and arbor (5) with an arbor press in the direction which disengages the press fit in the shortest distance.

NOTE: Dowels and arbors for the high accuracy pumps are press fit in the rear front plate (1)

and slip fit in the center (2) and side plates (3).

cont.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 21

Revised 10/99

4. Separate the plates by pry slots. Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart.

5. After disassembly, clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning. Alternative, non-destructive cleaning methods such as water jet or solvents are also acceptable.

6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang parts together.

7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and faces of the gears may be hand blocked on 400/600 grit paper and any nicks, burrs or sharp edges can be lightly removed with a honing stone. Be careful not to round off the edges of the gear teeth while lapping.

CAUTION: Since the thickness relationship between the metering gears and the center

plate is critical to metering performance, and the center plate is non-wearing on its sides, lapping these components is not necessary and should not be done under any circumstances.

Place a layer of 400 Grit Emery Cloth on a lapping block or plate-a granite flat is suitable. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Figure 1) approximately ten times until a smooth finish appears. Turning in a circular fashion, or other non-uniform motion, may cause the ground holes to lose their perpendicularity to the faces.

Always use clean, lint-free rags and compressed air to clean components. Paper towels are not acceptable; they may leave small pieces of paper and dust on the components. Use chemical brushes to clean between gear teeth, bores and reliefs.

8. Replace sleeve bearings as necessary and hone in the plate to the original new part specifications.

9. After each resurfacing, carefully gauge the area between the inlet and discharge ports at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical part of the plate. Scoring or wear marks here will allow increased slippage from the highpressure discharge port section across the throat to the lower inlet port, reducing efficiency.

Therefore, carefully gauge this area for flatness after each resurfacing.

10. After all components are “hospital clean”, the pump is ready for assembly.

Figure 1

Appendix 22

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

HIGH ACCURACY PUMP RE-ASSEMBLY

NOTE: During and between each re-assembly step, manually turn the metering gears to en-

sure that they are free turning. If binding occurs at any time, determine the cause and correct 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. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 23

Revised 10/99

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.

Disassemble and clean pump; replace any damaged parts.

cont.

Appendix 24

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

TROUBLESHOOTING GUIDE,

continued

Trouble Probable Cause Remedy

5. Possible internal damages.

Disassemble and clean pump; replace any damaged parts. Consult factory.

Excessive seal assembly leakage

1. Worn seal plate.

2. Insufficient inlet pressure.

3. Worn lip seal.*

Replace seal plate and coupling if necessary.

Increase inlet pressure.

Replace lip seal.

Reduced pump efficiency 1. Worn gear(s).

Replace worn gear(s).

2. Worn bearings.

Replace worn bearings.

3. Process conditions changed.

Consult factory for clearance recommended on new process conditions.

* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 25

Revised 10/99

Appendix 26

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 27

Revised 10/99

Appendix 28

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 29

Revised 10/99

Appendix 30

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 31

Revised 10/99

Appendix 32

Revised 10/99 c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-28, 20-29 and 20-30

Appendix 33

Revised 10/99

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. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 39

Revised 12/99

Appendix 40

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 41

Revised 12/99

Appendix 42

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 43

Revised 12/99

Appendix 44

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 45

Revised 12/99

Appendix 46

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 47

Revised 12/99

Appendix 48

Revised 12/99 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

TOOL-STEEL HIGH ACCURACY GEAR PUMPS

USER’S GUIDE

Appendix 49

Revised 4/06

Pump #

108863

108864

108865

108866

108867

108868

108869

108870

108871

108872

108873

108874

108875

110289

110290

110291

Identifier

TSHA*

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.

20.0 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 single

# Gears

2

4

4

2

4

2

2

2

2

2

4

2

4

2

4

2

# Plates

3

5

5

3

5

3

3

3

3

3

5

3

5

3

5

3

Shaft Seal #

807729

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 50

Revised 5/04 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 51

Revised 5/04

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 52

Revised 5/04 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

Appendix 53

Revised 5/04

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 54

Revised 3/05 c. 1999

DYNAMELT M ASU Manual 20-29 and 20-30

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

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions