OPERATIONS AND SERVICE MANUAL BF MICRO ADHESIVE

OPERATIONS AND SERVICE MANUAL BF MICRO ADHESIVE

ITW Dynatec

An Illinois Tool Works Company

31 Volunteer Drive

Hendersonville, TN 37075 USA

Telephone 615.824.3634

FAX 615.264.5222

OPERATIONS & SERVICE MANUAL #40-44

Revised 12/66

Adhesive Application Solutions · ISO 9001 Certified

OPERATIONS AND SERVICE MANUAL

BF MICRO ADHESIVE APPLICATOR with MICRO OPTIMA MODULE

HOT MELT ADHESIVE APPLICATOR

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

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

GENERAL CONSIDERATIONS

1.

Read and follow these instructions.

Failure to do this could result in severe personal injury or death.

2.

Additional safety instructions and/ or symbols are located throughout this manual. They serve to warn maintenance personnel and operators about potentially hazardous situations.

3.

Inspect the machine for unsafe conditions daily and replace all worn or defective parts.

4.

Keep work area uncluttered and well lit.

5.

All covers and guards must be in place before operating this equipment.

For precautions and definitions of safety symbols, refer to the Safety Chapter of the service manual.

SAFETY INSTRUCTIONS

SERVICING EQUIPMENT

1.

Only trained personnel are to operate and service this equipment.

2.

Never service or clean equipment while it is in motion.

Shut off the equipment and lock out all input power at the source before attempting any maintenance.

3.

Follow the maintenance and service instructions in the manual.

SIGNS

1.

Read and obey all of the warning labels, signs and caution statements on the equipment.

2.

Do not remove or deface any of the warning labels, signs and caution statements on the equipment.

3.

Replace any warning labels, signs and caution statements which have been removed or defaced. Replacements are available from ITW Dynatec.

ADDITIONAL CONSIDERATIONS

1.

To ensure proper operation of the equipment, use specified electrical and/ or air supply sources.

2.

Do not attempt to alter the design of the equipment unless written approval is received from ITW Dynatec.

3.

Keep all manuals readily accessible at all times and refer to it often for the best performance from your equipment.

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page iii

Revised 6/03

TABLE OF CONTENTS

Chapter - Page #

Chapter 1 Safety Precautions

Chapter 2 Description & Specifications

Description

Specifications

Dimensions

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2-1

2-2

2-3

Chapter 3 Installation & Start Up

Handling and Shipping

Service Requirements

Installation Instructions

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3-1

3-1

3-1

Chapter 4 Maintenence

Maintenence Schedule

Adhesive Pressure Relief

Replacement of the Built-in Filter

Module Maintenance

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4-1

4-2

4-2

4-2

Chapter 5 Troubleshooting & Service

In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Resistance of Heater Cartridge or Temperature Sensor

Replacement of the Heater Cartridge or RTD Sensor

Re-Assembly Procedures and General Cautions

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5-1

5-1

5-3

5-3

5-4

5-5

Chapter 6 Component Illustrations & Bills of Material

Model Designation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bill of Materials: Micro Module Service Body Assemblies (120v & 240v) . . . . . . . . . . . . . . . . . .

Component Illustration: Micro Module Service Body Assemblies (120v & 240v) . . . . . . . . . . . . .

6-1

6-2

6-3

Chapter 7 Ordering Guides

Optima Modules

Optima Module Dummy (Blank)

Repair Kits

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

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Service Block Assembly Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7-1

7-2

7-2

Chapter 8 Engineering Drawings & Schematics

DynaControl/ Dynamini

Upgradei

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8-1

8-1

Appendix Air Control FIlter Coalescing Kit for Applicator Heads

Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Drawing for Head Air Control

Component Illustration & Bill of Material

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1

1

2

Page iv

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

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

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 2-1

Revised 8/02

Chapter 2

DESCRIPTION AND SPECIFICATIONS

Description

ITW Dynatec’s BF Micro Applicator is an air-operated, single-nozzle hot melt adhesive applicator assembly with an integrated filter cartridge which prevents particulate matter from obstructing flow through the head. It is used with intermittent pressure and constant pressure hot melt adhesive supply units (ASUs).

Each applicator features one Micro Optima module mounted to a single service block. The module is “optimized” (self-cleaning). It’s nozzle is integrated into the module, making it maintenance free.

The Micro Optima module is designed for high speed/ high pressure (above 400 psi) applications where a sharp cutoff is necessary.

The module is opened and closed by air pressure. The rate of adhesive flow from the applicator is determined by the adhesive pressure applied by the ASU’s pump, the size of the nozzle orifice and the characteristics of the adhesive.

The applicator is heated by replaceable cartridge heating elements which are controlled by an integrated RTD sensor and electronic control.

As seen in the illustration below, a module is mounted onto a service block. A piston inside the module is pneumatically triggered by a solenoid air valve, which allows adhesive to flow through a valve within the module.

The heated adhesive supply hose may be connected at the rear of the service block or at the top. A variety of optional 45 and 90 degree fittings allows positioning flexibility.

Adhesive flows from the hose into

Air Inlets

Electrical

Connection

and through the channels within the block to the module. Air pressure opens the adhesive module, allowing adhesive to flow through the nozzle when the valve is open.

Supply

Hose

Inlet

Operating air connections, from the solenoid valve, and electrical connections are made at the top of the service block.

Micro

Optima

Module

Service

Block

Piston

The applicator is configured for ITW

Dynatec’s DynaControl or Dynamini controller. Both 120 and 240 volt configurations are available. The applicator is water-tight for washdown service.

Nozzle

Pressure

Relief Port

Pressure Relief

Plug

Filter

Cap

Filter

Page 2-2

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Specifications

Environmental:

Storage/ shipping temperature

Ambient service temperature

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

-40 °C to 70°C (-40°F to 158°F)

-7

°C to 50°C (20°F to 122°F)

Physical:

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

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

See dimensional layout on following page

Weight (with module)

Mounting

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0.58 kg (1.3 lb.)

Integrated clamp-mount for 1/2” (12 to 13 mm) rod

Material Anodized aluminum with stainless steel screws

Performance:

Temperature range

Warm-up time

Cycle rate

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

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

15 minutes for cold start/ 1 minute for module change only

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

38 °C to 218°C (100°F to 425°F)

5000 cycles/ minute maximum

Adhesive pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 bar maximum (1000 psi maximum)

Air Requirements:

Air pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 to 9.5 bar (70 to 140 psi)

Electrical:

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

Power requirements

120 VAC or 240 VAC/ 1ph/ 50-60 Hz

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

120 VAC: 125 watts or 240 VAC: 125 watts

CE Mark

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yes

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Dimensions

B A

Page 2-3

Revised 8/02

84mm

3.31”

106.3mm

4.16”

12.5mm

.49”

73.5mm

2.89”

22mm

.87”

Page 2-4

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Chapter 3

INSTALLATION & START UP

Page 3-1

Revised 8/02

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

Handling and Shipping

BF Micro applicator head assemblies are packaged within protective cushioning material in a fiber packing carton. This package may be shipped inside another carton along with other individual boxes containing components of the system.

Service Requirements

The applicator assembly consists of a service block assembly and a micro-module assembly.

Incoming electrical power and temperature control is supplied through the flexible cable exiting the adhesive supply hose cuff. The applicator has a circular, plastic connector which mates with the connector attached to this cable.

Incoming (operating) air is supplied through a solenoid valve (not supplied). It must be clean and unlubricated. It is controlled by a four-way solenoid valve and should be separately regulated and maintained at a pressure between 4.8 to 9.5 bar (70 to 140 psi). Air lines from the solenoid valve should be 6.4mm (1/4 inch). Head air inlet ports are 1/8 NPT. The air outlet ports on the solenoid air valve are marked “A” or “1” (open/ ON) and “B” or “2” (closed/ OFF).

Installation Instructions

The ITW Dynatec applicator’s service block has been tested at the factory and is ready for installation and operation. BF Micro applicators require a 4-way solenoid valve for each applicator. The modular applicator has an very high speed capability. To take advantage of this, the solenoid air valve should be located as close to the applicator as possible to keep applicator air lines short.

(Note: air lines and fittings must be capable of withstanding temperatures up to 218 °C (425°F.) ITW

Dynatec supplies Air Control Filter Coalescing Kits (PN 100055) to be used with air-operated applicators (see the Air Control Filter Coalescing Kit Manual in the appendix of this manual).

Applicator control solenoid valves may be controlled by timers or limit switches which sense the position of the package or object to which adhesive is being applied. Switches should be mounted on moveable brackets to provide adjustment for proper location of adhesive application.

cont.

Page 3-2

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

To Timer or Limit Switch

Purge Button

Air-to-close air line

Electrical Connection

Air Inlet Port

B A

Muffler

Solenoid

(not supplied)

Air-to-open air line

Adhesive Supply Hose

Adhesive Inlet

Micro Optima Module

Nozzle

Pressure relief bleed valve

Pressure Relief Port

Installation Diagram

See the diagram above for location of the components referred to in the following section.

1. The applicator should be supported from brackets that permit lateral and vertical adjustments.

Mount the applicator on a 12mm to 13mm (1/2 inch) rod or bracketry using the clamp provided.

Allow access to the filter. Be sure that the module’s “weep” holes are visible for periodic inspection.

2. Before making the adhesive connection to the applicator, align the adhesive supply hose with its electrical connector oriented in relation to the electrical connector on the top of the applicator.

Connect the swivel fitting of the hot melt hose to the male fitting on the service block. When tightening the hose fitting, hold the hose cuff to prevent the hose core from rotating.

3. Make the electrical connection from the hose to the applicator by connecting the female connector of the hose to the male connector of the applicator.

cont.

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 3-3

Revised 8/02

4. When connecting the air lines to the applicator, the air line which has air pressure to the module when the 4-way solenoid is OFF is the closing air line (marked “B” or “2” on the solenoid air valve). This line connects to the ”close” air fitting on the applicator. The other air line is connected to the “open” air port on the air valve. The “A” (or “1”) air line has pressure when the solenoid is ON (open). This line can be checked by loosening the air line after the system has been pressurized. The air line closest to the module is always the closed/ OFF line.

CAUTION: Do not use lubricating oil with the air supply as applicators are lubricated at the factory and do not require lubrication when used in production. Where oil is present in the air supply, a coalescing filter (Dynatec PN 100055) must be installed between the standard air regulator/ filter and the applicator.

5. It is advisable to check the temperature of the applicator. This can be done through the temperature readout of the adhesive supply unit. Surface temperature may be checked with a separate pyrometer and surface probe or with a dial thermometer. Turn the system power switch

ON. Permit the applicator to warm up at least 15 minutes (1 minute for module change) before reading temperature.

6. Purge the applicator of air and test fluid. Turn the applicator ON electrically and pneumatically.

Allow adhesive and applicator to warm up.

WARNING HIGH PRESSURE

During the purging procedure, hot adhesive and fluid can come out of the head under high pressure. Wear safety glasses, gloves and protective clothing.

WARNING

Use a stable, deep container to collect hot-melt adhesive and/ or fluid.

Place a heat resistant container under the module to collect the material that drains from the applicator. Manually open the solenoid air valve by pushing (with a small screwdriver or other tool) the purge button located on the solenoid coil. Continue to hold in the purge button until all air and fluid have drained and only adhesive flows from the module.

7. Orient the nozzle tip so it points toward the substrate.

Page 3-4

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 4-1

Revised 8/02

Chapter 4

MAINTENENCE

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

The BF Micro Applicator requires no regular maintenance. Wipe the applicator clean of adhesive with a clean cloth while still hot at the end of each shift. Inspect the applicator periodically as outlined in the following table.

Maintenence Schedule

ITEM

Adhesive supply hose fitting connection

CHECK

Inspect for leaks

FREQUENCY

As required

ACTION

Tighten if loose

Air supply connections Inspect for leaks

Module weep holes Inspect for adhesive

As required

As required

Tighten if loose

Replace module

Nozzle performance

Built-in filter

Inspect all nozzles for proper operation

As required

Inspect for cleanliness

Monthly or as required by use

Replace module

Replace filter element

Page 4-2

Revised 9/07

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Adhesive Pressure Relief

WARNING HIGH PRESSURE

During this procedure, hot adhesive can come out of the applicator under high pressure. Wear safety glasses, gloves and protective clothing.

The applicator should be at operating temperature. Turn the ASU’s pump/ motor OFF.

1. Place a heat-resistant container under the module.

Back View

2. With a 5mm hex key (allen wrench), slowly loosen the screw recessed under the service body (do not try to remove it). Stand clear since there may be residual adhesive pressure in the applicator.

Replacement of the Built-in Filter

Observe the warning and conditions for “Adhesive Pressure

Relief”, see above.

The applicator should be at operating temperature. Turn the

ASU’s pump/ motor OFF.

1. Relieve adhesive pressure as described above.

Pressure Relief

Port

Pressure Relief

Plug Screw

2. Remove the filter cap with an open wrench and remove (and discard) the old filter element. At the base of a new filter element, install an o-ring

(PN N00179). Insert the new filter element into the filter cap.

3. Re-install the filter cap slowly, taking care to seat the cap o-ring without pinching it.

CAUTION: Apply a coat of anti-seize compound onto the threads of the filter cap before re-installing it.

Module Maintenance

Refer to the Optima Module’s User Manual for details on its care.

Filter Cap

Filter

Observe the warning and conditions for “Adhesive Pressure Relief” (see above) before removing or working on modules.

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Chapter 5

TROUBLESHOOTING & SERVICE

Page 5-1

Revised 8/02

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

In General

If failure occurs, first check all the electrical and pneumatic connections. Verify that the main power switch is ON at the ASU. Verify that the pump is ON and the application heads have sufficient air pressure. Verify that the temperature controller is in operation and that the setpoints are correct for the application. Check to see if all components are heating properly.

Troubleshooting Guide

Problem Possible Cause Solution

Module does not open 1. Temperature adjustment 1. Check temperature adjustment.

of head is too low.

2. Inoperative solenoid valve. 2. Push the solenoid’s manual button.

If it opens, the problem is electrical.

No adhesive flowing out of module

1. Filter element is dirty.

1. Replace filter, see instructions in

Ch. 4 Maintenence.

2. Replace module.

2. Module seals (o-rings) are inoperative.

3. ASU’s hopper is empty.

3. Re-fill hopper.

4. Adhesive is too cold.

4. Adjust temperature, see ASU manual.

Hot melt is coming out 1. Module seals are damof the module’s “weep” aged.

holes

1. Replace module, see instructions in this chapter.

cont.

Page 5-2

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Problem

Applicator does not reach operating temperature

Applicator is too hot

Air escapes from module

Possible Cause Solution

1. Hopper temperature set1. Change setpoint, see ASU manual.

point is too low.

2. Inoperative heater cartridge.

2. Check/ replace heater cartridge, see instructions in this chapter.

3. Inoperative temperature 3. Check/ replace sensor, see instrucsensor.

tions in this chapter.

1. Applicator temperature 1. Change setpoint, see ASU manual.

setpoint is too high.

2. Inoperative temperature 2. Check/ replace sensor, see instrucsensor.

tions in this chapter.

1. Piston seal failure.

1. Replace module.

2. O-rings located between 2. Remove module from block (see module and service block are out of position or damaged.

instructions in this chapter: “Replacement of Module”) and replace o-rings.

Application pattern is 1. Adhesive pressure is too 1. a. For units without speed control: erratic low.

increase adhesive pressure at ASU.

b. For units with speed control (tach

follower): adjust pump speed control.

2. Adjust pattern controller.

2. See pattern controller manual for proper adjustment.

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 5-3

Revised 8/02

Replacement of the Module

Turn the ASU OFF. Turn all adhesive and air pressure OFF.

WARNING HIGH PRESSURE

During this procedure, hot adhesive can come out of the applicator under high pressure. Wear safety glasses, gloves and protective clothing.

1. Place a heat-resistant container under the manifold.

2. With a 5mm hex key (allen wrench), slowly loosen loosen the screw recessed under the service body (do not try to remove it). Allow the adhesive to flow out of applicator. Be sure to stand clear since there may be residual adhesive pressure in the applicator.

3. Verify that there is no internal pressure.

4. Remove the module from the service block by removing the two 4mm socket head cap screws on the front of the module with a 3mm hex key screwdriver (allen wrench). Make sure that the three old o-rings located on the back of the module are also removed (the new module will include three new o-rings).

5. Mount the new module using a 3mm hex key on the socket head cap screws.

Testing of Heater Cartridge or Temperature Sensor

1. Turn the ASU OFF and make sure all adhesive air pressure and the pump are turned OFF.

2. Unplug the electrical cable from the adhesive supply hose to expose the pins in the cable.

Note: Pin connectors and pinout numbers vary depending on the control scheme of the applicator.

See Chapter 8 for a pinout diagram.

Testing Resistance of the Heater Cartridge

a. The resistance value (Ohms) of the applicator’s 125 watt heater cartridge is 122.9-106.2 Ohms

(120v) or 492.1-425.0 Ohms (240v).

b. For DynaControl or Dynamini: With an ohmmeter, contact pins 7 and 8 and measure heater resistance.

c. A heater cartridge that tests outside of the above noted range must be replaced. Replacement instructions follow in this chapter.

Page 5-4

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Testing Resistance of the RTD Temperature Sensor

a. The resistance value (Ohms) of your temperature sensor depends on the temperature of the sensor at the time it is being tested. At 25 °C (77°F), the resistance of a PT 100 (Platinum) sensor should be 110 Ohms.

b. For DynaControl/Dynamini: With an ohmmeter, contact pins 5 and 6 and measure sensor resistance.

c. A tolerance range of ± 10% is allowed. A sensor that tests outside of this range must be replaced. Replacement instructions follow in this chapter.

Replacement of Heater Cartridge or Sensor

RTD Sensor

Heater Cartridge

Ground Wire

Pin Connector*

Set

Screw

RTD Sensor

Ground Wire

& Screw

Heater

Cartridge

(in a verticle port)

Heater/ RTD Sensor Replacement Diagram

RTD Sensor

2 Set Screws

(directly behind heater in this view)

Ground Wire

& Screw

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 5-5

Revised 8/02

1. Disconnect power to the ASU and make sure all adhesive air pressure and pumps are turned OFF.

2. Loosen the two screws in the cable anchor and withdraw anchor from the service block body.

3. Disconnect the ground wire screw.

4. Remove the two set screws in the bottom of the back of the service body. Note: It may be necessary to apply heat in order to break the thread sealant.

5. Pull the cable assembly out of the service block.

6. Loosen the set screw in the cable anchor and remove the cable assembly from the anchor.

Re-assembly

1. Re-assemble the cable assembly to the cable anchor. Re-attach the ground wire to the service block body. Insert the heater and sensor into their respective holes in the service block body and carefully insert the anchor and cable assembly into the body.

2. Tighten the two cable anchor screws.

3. Re-assemble and tighten the two set screws in the back of the service body. If a water-tight seal is desired, re-apply thread sealant (Loctite 242 or equal) to the set screws.

Re-Assembly Procedures and General Cautions

Unless noted, head re-assembly is simply the reverse sequence of the disassembly procedures. However, the following “cautions” should be followed (whenever they apply) for proper re-assembly:

CAUTION: In general, all O-RINGS AND SEALS must be replaced whenever hot-melt equipment is re-assembled. All new o-rings must be lubricated with o-ring lube (PN N07588).

CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the pump air supply and on the outlet filter manifold. Apply thread sealant (PN

N02892) whenever tapered pipe threaded parts are re-assembled.

CAUTION: SOME FITTINGS used for adhesive on hot melt equipment have straight threads and o-ring seals. Use of thread sealant is not necessary with these parts, but the o-ring seals should be clean and lubricated. Tighten straight-threaded parts and fittings until their shoulders are firmly seated.

Excessive torque may damage straight-threaded parts and the use of power wrenches is not recommended.

CAUTION: HOT-MELT RESIDUE must be cleaned from parts before they are re-assembled, particularly from threaded parts. As a precaution against adhesive residue preventing proper re-assembly, threaded parts must always be re-tightened at operating temperature.

Page 5-6

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 6-1

Revised 8/02

Chapter 6

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.

The following pages provide exploded-view reference drawings to assist users of the applicator to identify parts and aid in servicing the equipment.

BF Micro Applicator Model Designation Guide

BF Micro Applicator

B F X X X X X X X X X

0 2 2 1 M 1 D 1 S

Service Block Length/ # of Modules:

0221 = 22mm/ 1 module

Z 2 N 2

3

4

5

6

Module Type

M = Micro Optima

Z = No Module

7

8

9

Options:

S = Standard (water-resistant)

Applicator Voltage:

1 = 120 AC

2 = 240 AC

Control Scheme:

D = DynaControl

P = Dynapro or Dynaplus

M = MTC or CompuVision

E = ETCRO

N = Upgrade

0

Module Size/ ref. #:

1 = 7020/ #1

2 = 7021/ #2

3 = 7022/ #3

4 = 7023/ #4

5 = 7024/ #5

6 = 7025/ #6

7 = 7026/ #7

8 = 7027/ #8

9 = 7028/ #9

0 = 7029/ #10

Page 6-2

Revised 4/05

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

6

7

8

4

5

Item No.

1

2

3

9

10

11

16

17

18

19

20

12

13

14

15

21

22

23

24

Part Number

109954

109700

N00175

109701

109745

N00093

109702

106853

109707

N00182

109742

109708

110065

106857

103405

108362

109747

109746

106374

109710

N01702

111987

109840

110182

109883

109748

108700

BF Micro Applicator Service Block Assemblies: 109740 (120V) &109741 (240v)

110066 (240v Ni120)

28

29

30

25

26

27

L13533

N02028

N02212

100978

103053

N00175

109706

Description

Service Body Assembly, With Pressure Relief Plug

Insulator, Mount

O-ring,-008, Viton

Base, Mount, Micro Head

M4 x 0.7 x 20mm, SHC Screw, SST

Fitting, Straight Male Adapter, 1/8 NPT x .25T, Brass

Clamp, Mount, Micro Head

M6 x 1 x 25mm SHC Screw, SST

Anchor, Cable, Micro Head

O-ring, -015, 75 Duro Viton

Cable Assembly,120vac (Service Block Assembly 109740)

Cable Assembly, 240vac (Service Block Assembly 109741)

Cable Assembly, 240vac (Service Block Assembly 110066)

M3 x 0.5 x 5mm Flat Point Set Screw, SST

Screw, SHC, M3 x 0.5 x 6mm, Black Oxide

Lock Washer, External Tooth, M3

M3 x 0.5 x 14mm, SHC Screw, SST

M4 x 0.7 x 4mm, Flatpoint Set Screw, SST

Adhesive/ sealant, Loctite 242

Fitting, Male Adapter, #6 SAE 37° x #4 ST Thd ORS

O-ring, -904, 75 Duro Viton

Filter Assembly, Applicator, 200 mesh

Filter Cap, Micro Head

Label, Info, Micro Head

Label, Warning, Micro Head

M2.5 x 0.45 x 6mm SST Socket Flat Head Screw

Lube, TFE (Not Shown)

Anti-Seize Compound (Not Shown)

Tube, Aluminum, .25 OD x .035 wall x 8.0, Lg.

CAPLUG, Red Poly, T-1-X

CAPLUG, Red Poly, T-6

Tag, QAC (Not Shown)

Tag Oil Free (Not Shown)

Optima Micro Module (See Ordering Guide)

O-ring, -008 (shown for ref. only)

O-ring,-15mm x 1,8mm

Qty.

2

1

2

1

1

1

1

4

1

4

1

2

1

1

2

1

1

1

1

1

1

2

1

1

1

2

2

1

1

3

1

1

1

Bill of Materials

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

26

25

6

8

7

5

4

28

17

16

2

29

1

22

24

Assembled Front View

15

13

14

3

10

9

12

15

18

19

20

30

27

21

11

Page 6-3

Revised 3/05

23

BF Micro Applicator Service Block Assemblies: 109740 (120V) & 109741 (240v)

Page 6-4

Revised 6/03

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Page 7-1

Revised 12/06

Chapter 7

ORDERING GUIDES

Micro Optima Modules

Modules are listed in order of increasing adhesive flow. The diameter of the module orifice is not shown because this is not the only flow control variable incorporated into module design. For assistance in module selsection, contact your ITW Dynatec representation or visit our website at

Module Part Number

7020

7021

7022

7023

7024

7025

7026

7027

7028

7029

Filters

Reference #

No. 1

No. 2

No. 3

No. 4

No. 5

No. 6

No. 7

No. 8

No. 9

No. 10

The standard filter for the Micro Optima is the 200 mesh filter.

Module Part Number

7020

7021

7022

7023

7024

7025

7026

7027

7028

7029

Filter Assembly PN

109711

111987

Filter

200 mesh

200 mesh

200 mesh

200 mesh

100 mesh

100 mesh

100 mesh

100 mesh

100 mesh

50 mesh

Filter

100 mesh

200 mesh

Filter Part Number

111987

111987

111987

111987

109711

109711

109711

109711

109711 n.a.

Filter 10-pack

CF6001

CF6001

CF6001

CF6001

CF6002

CF6002

CF6002

CF6002

CF6002

CF6004

Page 7-2

Revised 5/07

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

Repair Kits

TBD

Optional Solenoids

PN 113314 kit for Festo, 24v solenoid is offered with standard fittings, tubing and cable for one- or two-port Micro applicators. The Festo solenoid is more compact than conventional MAC solenoids.

PN 113682 kit for Festo, 24v solenoid is offered with standard fittings, tubing and cable for DY

2002-8 and DPC2 timers. The Festo solenoid is more compact than conventional MAC solenoids.

PN 113350 Festo, 24v, four-way solenoid only. This valve is contained in both of the above kits.

Service Block Assembly Recommended Service Parts List

Part Number Description Qty. per Service Block

N00175

N00182

N01702

108700

see list on pg. 7-1

O-ring, -008

O-ring, -019

O-ring, -904

TFE Lube, 0.25 oz.

Filter

Heaters and RTD Sensors are located in the Cable Assemblies, choose one of the following:

109742

or

109708

or

110065

Cable Assembly, 120v

Cable Assembly, 240v (Pt100)

Cable Assembly, 240v (Ni120)

1

1

1

1

1

2

14

1

ITW Dynatec c. 2002

BF MICRO OPTIMA APPLICATOR Manual #40-44

Chapter 8

ENGINEERING DRAWINGS & SCHEMATICS

Page 8-1

Revised 6/03

Pin Connectors & Electrical Schematics

Note: Pin connectors are viewed from the exposed end. Pins not shown on schematics are not used.

DynaControl/Dynamini Uses PN N07958 RTD Sensor, Pt100

7

6

8

5

1

4

3

2

Heater

RTD Sensor

Ground

7

8

5

6

9

Upgrade Uses PN N07864 RTD Sensor, Ni120

1

2

3

4

5

Heater

RTD Sensor

Ground

Page 8-2

Revised 8/02

ITW Dynatec c. 2002

BF MICRO APPLICATOR Manual #40-44

ITW Dynatec

An Illinois Tool Works Company

Adhesive Application Solutions

Dynatec PN 100055

Page 1 of 2 pages

Appendix PN 100055 Air Control Filter Coalescing Kit for Applicator Heads

ITW Dynatec applicator heads require compressed air for needle actuation. Air Control Filter Coaslescing Kits (PN 100055) are available to provide filter regulators, tubing and fittings for one or more applicator heads.

In addition to the kit, a solenoid valve with voltage that matches the output voltage of the electrical control device must be selected for the application. Use the following chart to select an appropriate solenoid valve:

Part No.

Voltage Application

100054

100383

100421

100422

24 VDC

24 VDC

120 VAC

240 VAC

Air Control Filter Coalescing Kit Installation Notes

Single-port head

Multi-port head

Single or multi-port head

Single or multi-port head

1) Compressed air for applicator head operation should be clean, dry and oil free.

2) Operation of more than two applicator heads by one kit may require additional lines, teefittings and solenoid valves not supplied in one kit.

3) To provide identical operation of more than one head, air line circuits from solenoid valves to heads should be the same length and contain similar fittings.

4) To minimize applicator response time, minimize length of the air line circuits from the solenoid valve(s).

Pneumatic Drawing for Head Air Control

OFF

ON

3 2

5

1

4

c. ITW Dynatec 1994

All Rights Reserved

}

Electrical Signal for

Head Control

Issued 1/96

Supersedes 8/95

Dynatec PN 100055

Page 2 of 2 pages

Component Illustration: PN 100055 Air Control Filter Coalescing Kit

2

Air Lines to Head are to be cut 3.5 - 4.0 inches long

4

5

7

8

7

1

3

1

7

to additional solenoid valve assemblies

6

Item No.

7

8

5

6

3

4

1

2

Part Number

N06438

N00318

100380

N04264

N06504

N06430

N04531

Issued 2/00

Supersedes 3/97

Description

Nylon Tubing, .250 Dia.

Cable Tie, .09 x 3.62 Lg

Filter Assembly

Solenoid Valve Assembly

Cable Tie Anchor

Push-in Union Tee Fitting

Male Connect Fitting

1/4 Treet T, Brass

Qty.

3

1

3

1

1

1

10 ’

10

c. ITW Dynatec 1994

All Rights Reserved

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