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Dynamelt M35 DCL - Astro Packaging, Inc.

1. 1 10 8 7 mm 4 Ovik 9779 tme uo XAV CB12 pie VCIH EE gciH 4 213 77 H12 L 8n 9 87 16 CB10 22 7 Hio H 297 8 9 WHT BRN lt A es LE JP Xnv COPS 498 C wa 21 A 4 pel T 21 27 ll sr 21 97 Jeli 3509 215 H9 d
2. CUSTOMER INPUT X SPEED INTERFACE RPM l N06642 ENCODER Ber T 5 y WHT 4 GRAY 9 106391 CABLE 55 MOTOR INTERFACE TO MOTOR SPEED 2 SET BOTH J1 amp J2 TO M2 o GREY gt x 4 m 9 ORA xo 8m GREY 5 MOTOR SPEED 2 scr us sv d oa p2 CONTROL BOARD EMI RFI f x e al 5 106595 gl CIL aw CHOKE SAL 11 M i EMI RFI gt m FILTER A 8c T J Sm 07 I MOTOR CONTROL 3 1 4 HP 240 L INTERFACE BOARD 41 ED gt 2 5 AC MOTOR
3. P remelt No Setpoint Tolerance Offset On Off P rogmelt No Setpoint Tolerance Offset On Off Filterblock No Setpoint Tolerance Offset On Off Hose No Setpoint Tolerance Offset On Off Head No Setpoint Tolerance Offset On Off Aux Zone No Setpoint Tolerance Offset On Off 1 12 50 450 5 50 0 50 ON OFF Pressure No Min P ressure Max Pressure 1 12 0 1500 0 1500 Pump No Mode Manual Automatic Min Automatic Max 1 6 Manu Auto S top 0 100 096 0 100 096 0 100 0 Text No Customer Name Temp 1 48 20 characters Pumps 49 54 Press 55 66 Line Commands page 2 of 2 S ystem 1 Setback Premelt Setback Progmelt Setback Filterblock Setback Hose Setback Head Setback Aux Zone S ystem 2 Setback General Setpoint Heat up Sequence Elect Head Hold C F Spare Limitation 0 1 2 Temp 0 F 1 S ystem 3 Power On Heater Power On Motor Keypad Lock Keypad Lock Mo Configuration Lock Configuration Lock 1 1 Start 1 1 Start Temp Settings 0 Settings O Page 1 BitO Bit7 Page 2 BitO Bit7 free 1 locked free 1 locked 1 lock 1 Sock System 4 PI Loop Premelt PI Loop Progmelt Pl Loop Filterblo PI Loop Hose Pl Loop Head PI Loop Aux Zone High I Low P High l Low P High I Low P 1 Low P High I Low P High l Low P System 5 Gear Ratio
4. 100 F 425 F Dynatec Dynacontrol EtherNet IP Data Table pee 2 Adhesive Application Systems Dynacontrol to PLC Version V5 15M Word Address Function Zone Name Valid Range Pressure Channel 1 Pressure Channel 2 Pressure Channel 3 Pressure Channel 4 Pressure Channel 5 Pressure Channel 6 0 to 1500 PSI Pressure Channel 7 requires digital pressure readout option Pressure Channel 8 Pressure Channel 9 Pressure Channel 10 Pressure Channel 11 Pressure Channel 12 Actual Temp Premelt 1 Actual Temp Premelt 2 Actual Temp Premelt 3 Actual Temp Premelt 4 Actual Temp Premelt 5 Actual Temp Premelt 6 Actual Temp Progmelt 1 Actual Temp Progmelt 2 Actual Temp Progmelt 3 Actual Temp Filterblock 1 Actual Temp Filterblock 2 Actual Temp Filterblock 3 Actual Temp Hose 1 Actual Temp Hose 2 Actual Temp Hose 3 Actual Temp Hose 4 Actual Temp Hose 5 Actual Temp Hose 6 Actual Temp Hose 7 Actual Temp Hose 8 Actual Temp Hose 9 Actual Temp Hose 10 Actual Temp Hose 11 Actual Temp Hose 12 Actual Temp Head 1 Actual Temp Head 2 Actual Temp Head 3 Actual Temp Head 4 Actual Temp Head 5 Actual Temp Head 6 Actual Temp Head 7 Actual Temp Head 8 Actual Temp
5. pi EEL LT Mamtenanceeo EL mE tt Femperature H Metering EN Pump PNs 084E 374 thru 084E 389 use PN 069X 251 pump shaft seal Pump PNs 084 411 thru 084E 413 use PN 069X 289 pump shaft seal Appendix 30 Revised 10 00 iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 This maintenance manual is as specific as possible but please remember that there are many varieties of Zenith pumps in service If you have any questions about specific parts and their orientation always refer to the drawings and parts lists for your exact pump by type If you still have questions refer them to us at the factory 1 Introduction Zenith Spinning Purnps are precision instruments requiring skilled and careful maintenance Constructed of high quality tool and die steefs such as AIS types D 2 M2 and M 4 or other high performance alloys they are tempered after heat treatment to hardnesses ranging from Rockwell Sale 58 to 64 Zenith Pump may be constructed from any one or any combination of these steels since their coeffi cients of thermal expansion are almost identical Zenith Metering Pumps consist of two or more gears housed within center and side plates Power is transmitted to the g
6. 3 07 NW 90d 6 3NOZ LAW jNOZ LIAW 90 61 3NOZ LISW 3NOZ v v MH MIN C HIN dW d dWfd 00 3NOZ 35018493113 bv 3NOZ 520 883L1l4 o o S 3NOZ NW 90Nd 61 3NOZ NAW 90d INOZ LIAN 90Md 6 3NOZ 90ud 3NOZ IIN 90ud Ml C MIN L 015 Ot L OZN 9u07 sdung xooj qj9y 4 bojg 10 uonpunb C ssaddoy jong j suaddoy eui ueewjeq LOISIAIP y sejpoipu 0 601 910 SALON ANOZ MOOI8YSL IIS JNOZ LIAW 9044 i C l dl iL 1 02 M201883Ll1lJ 3304 3 5 L dWnd Ge PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 2 of 3 Revised 7 07 Schematics Page 11 15 T Dynatec c 2000 DYNAMELT M ASU Manual 20 36 je Zone Configuration for Premelt PREM PREMELT 1 ZONE 2 2 PREM PREMELT 1 ZONE PREMELT 2 ZONE 2 NOTES M70 140 2 Pl ELTS M210 5 S PREMELT 1 ZONE 2 PREMELT 2 ZONE 18 M70 140 4 PREMELTS PREMELT 1 ZONE 1 PREMELT 2 ZONE 17
7. 2 8 5 Re assembly Procedures amp Cautions 8 5 Chapter 9 Available Options amp Accessories Pressure Gauge ier id edie aida ete d v prp ve aa 9 1 Pre PSI and Post PSI Transducers 9 1 Pop ATEENA 9 1 High Temperature Heater Groups 9 1 Filter Options amp Accessories tu uere ee EU e ee 9 1 Level Contool S mre teer eee tae eed Seine othe ue tene re ran te e ash C ete eee 9 1 Pump Options Accessories e rw Lue cH P deb pes 9 2 Gear Motor Options i inse ev ES p bd hae A PEE RU Wu EIE PIU E ee hdd ge os 9 2 Returf R circ lating y HOSES ose quce ed qu ah quce e tee 9 3 El ctric Clutch RE Lec oc FERE AID 9 3 9 3 Recommended Service Parts Last eiu Ron eum E pei E a Sie te 9 5 Chapter 10 Component Illustrations amp Bills of Material Chapter Format nne et CD ue eR edepol ive cues 10 1 Pressure Relief amp High Temperature Fllter Block Assembly 10 2 Typical Electrical P
8. Electrical 103184 Fuse GDC4 terminal rail 0481016 Fuse KTK 15 terminal rail 102762 Fuse 1 amp motor control interface board 108566 Fuse T6 3AL 5x20 fast boards 036B103 RTD Sensor PT 104166 Over Temp Thermostat amp Insulator Assy 036B015 Pump Enable Thermostat 102411 Boot Insulator 048H384 Solid State Relay Dual 036A170 Heater 500w for 1 filter block 036A079 Heater 1000w for 2 filter blocks 109857 CPU Printed Circuit Board V5 108256 Control Assy w PCB 107440 48 Zone Power I O PC Board 106149 Auxiliary RTD PC Board optional 106395 Motor Speed Control AC Drive Board 110090 Motor Control Interface PC Board 107438 Optional Clutch PC Board 106147 Optional Pressure PC Board RP RRP RP RRP ORR PRP amp N00181 O ring 014 outlet filter manifold 8 6 per manifold A69X133 O ring 124 outlet filter manifold 2 per manifold N00185 O ring 018 outlet filter manifold 2 per manifold N00187 O ring 020 outlet filter manifold 2 per manifold 069X275 O ring 122 outlet filter manifold 2 per manifold N00199 O ring 114 outlet filter manifold 2 per manifold 103770 O ring 5 005 outlet filter manifold 2 per manifold 103771 O ring 5 254 outlet filter manifold 2 per manifold 807729 Pump Shaft Seal Zenith TSHA pump models 2 per pump 069X061 Pump Shaft Seal optional ITW Dynatec pumps 2 per pump see Pump Adapter O rings 1 of ea per pump Fi
9. 2 5 Definition of ASU Code uolo A RI ee Ie ae He ee HG ee eA 2 6 Chapter 3 Installation amp Start Up Placing the DYNAMELT ASU conden Sis At eek CEA SOA A pre 3 1 To Open Close Panel Box Door 3 2 Installation card oho Reade cane P I ME d Uber Qe d 3 2 User Connections ina meae shah eta a aan Tad aude Xd add a een Wad 3 3 Printed Circuit Board Location Diagram 2 3 4 Hose Head Electrical amp Adhesive Connections 3 6 Electrical Connections amp Filter Manifold Arrangement Maximum Hose Head Configuration illus 3 6 Adding Adhesive sies ea t e Shad deny dee dean Pre ua 3 7 Changing the Adhesive Formula 7 2 2 3 7 Field Installation of Controller Options 3 7 Adjusting the Pressure Relief 1 3 8 Pump Enable Ready Thermostat Calibration 3 10 Calibration of the Optional Voltage Tachometer 3 11 Installation of the Optional Tach Generator or DC Tracking Signal 3 12 Calibration of the Optional Tach Generator or D
10. 5 26 Chapter 6 Preventive Maintenence General Cleaning eo epu ere QE ier I eet qud T do ERE 6 1 Preventive Maintenance Schedule 6 1 Outlet FIET 6 1 Outlet Filter Manifold illustration 0 6 2 Hose Eittings or beLC NE E tI IL INS 6 3 Fasteners ite Ne OA 6 3 Filter Shutoff Cleaning or 6 3 Pump Shafi Leak nm 6 4 Summary of Preventive Manintenance 6 4 Flushing the System 0 eet eC RD AW E a Boe 6 5 Chapter 7 Troubleshooting General Troubleshooting Notes scsi ocala 7 1 Preliminary Checks RR e eh exa eere ie eie e eed 7 1 Error Messages ox sv v pce 7 1 Hose Applicator Troubleshooting 2 2 7 1 Motor Speed Control PC Board Re set 7 1 High Temperature Redundant Overtemp Thermostat 7 2 Pump Enable Thermostat eere e eh rer eg ph e eee eeu ene 7 2 Lithium Battery PC
11. 4 or 8 lor2 16 or 32 0 10r3 0 0 4 0 40r 8 A gt gt gt He 1999 Component Illustrations 8 BOM s Page 10 9 DYNAMELT M ASU Manual 20 36 Revised 9 02 Note without the transformer option the casters attach to the base plate With the transformer option the casters attach to the transformer frame S tand off option attaches to Base plate only Page 10 10 Component Illustrations amp BOM s Revised 9 02 T Dynatec 1999 DYNAMELT M ASU Manual 20 36 Bill of Materials for AC Dual Drive 107943 amp AC Single Drive Assembly PN 107942 Item No gt WN 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Part Number 101156 107602 102172 107941 106389 103518 107401 107946 104648 105101 N 00688 N 00697 107077 104647 N 00853 N 00692 104649 N 06006 103470 106111 103121 104651 107945 103435 103436 106071 103121 105865 N 00053 N 06946 Description M 6 1 0 x 20mm SHC Screw M 8 x 1 25 x 40mm Coupling Jaw 50 75 Sahft M otor B racket M otor 1 4 HP 20 1 AC Pump See Y our Order For Part Number M 10 x 30mm SHC Screw M 10 Nut Digital RPM Readout K it O ption Encoder bracket M 6 1 0 x 16mm HHC 1 4 Flat Washer 1 4 Spring Lock Washer Encoder Assembly DM SBC Encoder M ount A rm 4 40 x 375 Fil Head Screw 04 Spring Lock Washer Encoder Dr
12. Models 9100 0104 0102 0103 Modeis 0410 0141 0412 0413 Models 0126 0121 0122 0123 As with ony of electronic or mechanical instrument the 151 Melt Pressure Tronsducer will perform os required if proper attention is green to proven and well estobished handling are provided ond when followed will ensure that the tronsducer will provide the service and perfomance amp expected of this type of instrument Electrical Checklist PROCEDURE Wiring shown Coble Connection Use six wire shielded cables as provided by ISL or equivalent With the extuder ot operaling fernperature ond no presse applied transducer Adjust the zero conto until readout 200 Push the calibration button ond Odjust spon gos unti readout ot 80 of ful range Calibration Calibration Certificate Range 0 1 500 FSI Rcak 1 200 PSI Balance 0 5 foll scale Full Scale Sensitivity 3 320 Excitation Vollage 10 volts recommended 12 volts moximun INDUSTRIAL SENSORS INCORPORATED Telephone 617 725 5249 Fox 617 729 1639 Mechanical Mounting Checklis PROCEDURE Prolecfive Cop on Remove only when ready to instol Sensing tronsducer Diaphrogm Mochined Hole Snouid be s shown Exirude Transducer threads with Never Preparation Seez by Bostik o CSA by feipro Transducer locate in less thon 140 ombent Housing temp Transducer C
13. PREMELT 5 ZONE 2 PREMELT 4 ZONE 18 Indicates the division line between the two hoppers if Dual hoppers are installed PREMELT 2 ZONE 18 3 PREMELT 1 ZONE 2 ZONE 34 M210 6 PREMELTS PREMELT 1 ZONE 1 PREMELT 2 ZONE 17 PREMELT 5 ZONE 55 PREMELT 4 ZONE 2 PREMELT 5 ZONE 18 PREMELT 6 ZONE 34 PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp ZONE CONFIGURATION Page 3 of 3 Page 11 16 Schematics iTV Dynatec c 2000 Revised 12 02 DYNAMELT M ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 2000 Appendix 1 DYNAMELT ASU Manual 20 36 20 37 20 38 Revised 3 01 DYNATEC ZENITH STANDARD ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL PN 084E 427 084E 429 084E 431 084E 433 084E 435 084E 437 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 427 Nodular Iron Single Standard 069X251 084E 429 Nodular Iron Single Standard 069X251 084E 431 Nodular Iron Dual Standard 069X251 084E 433 Nodular Iron Single Standard 069X251 084E 435 Nodular Iron Dual Standard 069X251 084E 437 Nodular Iron Single Standard 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
14. CAPACITY CHAR SESS DISS OOOO O 2502 OUTLET PORT 2 HOLES 469 NON STD 40 DEPTH ata SENT 813 INLET PORT FRONT VIEW 2 HOLES 20 7 REAR VIEW REF HPD 5966 HPB 6074 NOTES PUMPS TO BE SHIPPED WITH 4X MOUNTING BOLTS EACH 378 UNC X J 25 ITEMS 52 AND 4X WAGHERS ITEHS 53 pem 1 VARIOUS CC REV Appendix 27 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec c 2000 ONIINDON 803 z90 X 6t Z X 89940 SHILI SUSHSVM v ONY CG 58211 GO X ONQ 98 HOY3 51708 v daddIHS 38 OL SdHfld GLO9 dH 996G UdH 434 M3IA M3IA 3015 iS ET 30H 1708 LNOYS Liz S30H Z oss 300H 1708 9NIINDON 2907 3308000 E NER 009 1 0 1 9 1808 137400 PS RD PIX Yum N IN h 931vNAU A1I A LIOY dV2 U 3 OMddY 31vO ROISIAIY Appendix 28 iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 2000 Appendix 29 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 ZENITH MELT SPINNING PUMPS MANUAL Covers ITW Dynatec part numbers 084 374 0845276 84E387 O84E388 AHAHAHAHA Ext
15. Dynatec Adhesive Application Systems Word Address Function Local Access Temps Dynacontrol EtherNet IP Data Table OUT Area PLC to Dynacontrol Zone Name all temp zones Local Access Pumps all pumps Date 08 11 05 Page 5 of 5 Version V5 15M Valid Range setto 1 enables setpoint changes on keypad to 0 enables setpoint changes via EtherNet IP Premelts On Off Progmelts On Off Each zone is Filterblocks On Off represented by the Hoses On Off corresponding bit in Heads On Off these words Aux Zones On Off BitO to Bit 5 to Bit2 BitO to Bit2 each bit 1 zone enabled BitO to Bit11 BitO to Bit11 BitO to Bit11 Controller ON OFF set to 0 to switch off set to 1 to switch on Standby ON OFF set to o for normal mode set to 1 for standby mode Identification Word DM M 68 has to be set to validate communication ITW Dynatec c 2000 Programming Page 5 1 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Chapter 5 PROGRAMMING INSTRUCTIONS FOR DynaControl CONTROLLER WITH EXPANDED KEYPAD V 5 00c amp UP Controller Safety Consideration Never open the control panel without switching off the main disconnect switch to ensure that it is disconnected from its power source i DANGER HIGH VOLTAGE The printed circuit boards should always be carefully
16. S 617 1 iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 PN 105729 Electric Clutch Important Please read these instructions carefully before installing operating or servicing your Stearns clutch brake or clutch brake Failure to comply with these instructions could cause injury to personnel and or damage to property if the brake is installed or operated incorrectly For definition of limited warranty liability contact Rexnord Corporation Stearns Division 120 North Broadway Milwaukee Wisconsin 53202 414 272 1100 Caution 1 Servicing shall be in compliance with applicable local safety codes including Occupational Safety and Health Act OSHA All wiring and electrical connections must comply with the National Electric Code NEC and local electric codes in effect 2 To prevent an electrical hazard disconnect power source before working on the clutch brake or clutch brake If power disconnect point is out of sight lock disconnect in the off position and tag to prevent accidental application of power 3 Be careful when touching the exterior of an operating unit Allow sufficient time to cool before disassembly Surface may be hot enough to be painful or cause injury General Description The CCC Clutch Clutch Couplings are designed to be assembled on adjacent shafts It transmits rotational motion when energized by coupling these shafts together Through an electromagnetic force the drive hub will attract
17. Sum a S x ra x 1 EE S mz z ul ul m 5 SHSH IE gt QUE PAA 5 ER T aa ag ET 579 9 2 T7155 ings 0 85 io zo go jz s e zo zo loo End RE SE gt zon L2 x 2 N INPUT POWER PE L1 o 240 VOLT 3 PHASE PN 107938 POWER WIRING DIAGRAM DM35 DCL 240V
18. e e e e e e e a 1 OQ t A t NY C Part Number 012D083 0781001 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 amp 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 FN e A Ne WO WO RP e AA me iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 19 DYNAMELT M ASU Manual 20 36 Revised 9 00 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread Component Illustration 1 54 cc Rev Dual Gear Pump Assembly 100863 Page 10 20 Component Illustrations amp BOM s T Dynatec c 1999 Revised 8 02 DYNAMELT M ASU Manual 20 28 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104073 M10 1 5 x 105 All Thread Bill of Materials for 3 2 cc Rev Dual Gear Pump Assembly 100864 Item No Part Number Description Qty 1 012D088 Drive Shaft 1 2 0781001 K ey Woodruff 1 3 101626 M5x12SHCS 4 4 069X 160 Seal retainer amp Bearing Housing 1 5 069X 061 Lip Seal 1 6
19. DUAL STREAM HOD METERING PUMP STAINLESS STEEL _ TOOLSTEELS Appendix 13 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec 2000 9331 ADVI 5733187001 20 ONY ZY 51 114315 SS3 NIV1S 20 ARN JV M TRA A DE SNId 7108 HO4 SINOK O3 IIS G HOLVA 55 9313 31ON g 015 ISNY N N V V NOILOSS SE ZZZINS SY ASN KAN GLS ISNV NON 22255 ANAKAN HAZ ALY SS NI 1 961 6 6 0020089 NEA d d3o XO Xov d 9 38vu9 Wey 59517 SPSL dy HOIH 601 MOHININ 118 NAOHS NOILYOQ AY INWY Loyd Hoi3e A38 22 iuvd ALIJYdYI IJLYNAOZALI Appendix 14 iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions iTV Dynatec 2000 Appendix 15 DYNAMELT ASU Manual 20 36 20 37 20 38 Revised 3 01 DYNATEC ZENITH HIGH ACCURACY GEAR PUMPS INSTALLATION CARE amp MAINTENANCE MANUAL 084 428 084E 430 084E 432 084E 434 084E 436 Pare Number material Type Accuracy Output Rev Shaft Seal PN 084E 428 Tool Steel Single High 0 297cc 069X251 084E430 Tool Steel Single High 1 168cc 069X251 084E432 Tool Steel Dual High 1 168cc 069
20. Local Access PUMP OUT word 63 does not have to be set 2 Automatic Mode the pump speed is controlled via a 0 to 10V signal connected to the hot melt machine In order to activate this mode the OUT word 50 for pump 1 must be set to 65 ASCII A The pump speed which follows the line speed can be read in IN word 134 for pump 1 This value shows 0 146 resolution 3 Stop Mode The pump is stopped 4 Bus Mode the pump speed is controlled via OUT word 56 for pump 1 Out word 50 for pump 1 must be set to 66 ASCII B On the keypad of the hot melt machine the pump speed can be fine tuned by using the min and max scaling similar to the Automatic Mode The speed setting must be transmitted in increments of 0 1 0 to 1000 0 0 to 100 0 Adhesive Level Indication Word 142 143 142 single hopper 142 amp 143 dual hopper shows the state of the optional adhesive level control A 0 indicates the level is and a 1 indicates a low level situation This signal is an instantaneous non latched indication In order to avoid local low level indications which have to be reset on the keypad the low level detection should be disabled in the customer set up menu of the Dynamelt M hot melt unit Zone Status Indication The status of all temperature zones can be read in IN word 146 to 175 This information is bit wise coded and organized in zone type Examples IN word 146 00036 0000 0000 0000 0000 0011 premel
21. Page 10 24 Component Illustrations amp BOM s Revised 3 01 Item No Part Number 072X118 101174 104325 805632 Pressure Gauge Assembly 805641 Description Fitting 1 4 NPTM x 6 JIC x 90 Pressure Guage 1000 PSI Fitting Adapter Swivel 6J x 1 4 MPT Fitting 1 4 NPT 1 2 20 Tranducer TWDynatec 1999 DYNAMELT ASU Manual 20 36 iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 Chapter 11 SCHEMATICS amp ENGINEERING DRAWINGS Drawing Hose Schematic ASU to A pplicator A pplicator H ead Schematic Flow Diagram Outlet Filter M anifold Typical Hydraulic Schematic Optional System Status Lights Schematic Optional Level Control Schematic Optional Electric Clutch Schematic Grounding Diagram CE M ark Power Wiring Diagram 240v Signal Wiring Diagram 4H ose 4H ead 240v Power Wiring Diagram 380v Instruction Sheet for Pump amp Zone Configuration Special ASU Schematics if applicable Schematics Page 11 1 Found on page 11 2 page 11 3 page 11 4 page 11 5 page 11 5 page 11 6 page 11 7 page 11 8 page 11 9 page 11 10 page 11 12 page 11 13 end of chapter Revised 6 01 Page 11 2 Schematics T Dynatec 2000 Revised 7 07 DYNAMELT M ASU Manual 20 36 WHT AW 1 RED 20 1 TRIGGER WHT BLK 20 AWG 2 2 TRIGGER WHT BLU 20 AWG 5 5 HEAD SENSOR WHT YEL 20 AWG 6 6 HEAD SENSOR RED 18 AWG E 7 HEAD HEATER ORANGE 18 AWG 8 8 HEAD HEATER PT1
22. Then increase motor speed in smaller increments 1 to 596 until adhesive flow returns to the desired amount Note Thisistheoptimum pointof operation for the motor pump and pressure relief It will also facili tate the best system performance and reduce wear on these components The application system is now adjusted for normal operation 14 Re tighten the two purge screws and re install the access cover Page 3 10 Installation iTV Dynatec 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 Pump Enable Ready Thermostat Calibration The Pump Enable Ready Thermostat is preset to 132 C 270 F unless the customer has specified a different preset temperature on his original ASU order Generally the pump enable thermostat is set approximately 30 50 F lower than the application setpoint If a different temperature is de sired use the following procedure to re calibrate the thermostat CAUTION DO NOT set the pump enable thermostat lower than the softening point of your adhesive or pump damage may result As an example the operator desires to lower the preset Pump Ready temperature to 107 C 225 1 Atthe controller keypad set the hopper temperature setpoint to the temperature at which you want the pump to start i e 107 C 225 Hopper 2 Usethe key to unlock the side door then remove it being carefull not to pull out the ground wire attached 3 Wait for the hopper temperature to stabili
23. LARM ama S A 10 JS4 CONNECTOR 107440 20 X WHT RED USE 3 amp 4 FOR HOPPER 2 x x CONNECTIONS DYNAMELT PUR WIRING DIAGRAM FOR PN 108266 OPTIONAL SYSTEM STATUS LIGHTS Page 11 6 Schematics iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 CO M P N ug CJ gt e d SiS pr 7 47 493 DES CA A OM W x U 7 i N CC M NO Ax F CO gt lt Go 2 OO e C CHD x9 X NE e fa JAJE MAW X fX S J L LEVEL CONTROL SCHEMATIC PN 802972 REV A iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 MER SUPPLIED CONTACTS TO ACTIVATE CLUTCH 1 RED XK 120 VO f CABLE ELE z CLUTCH AN1 BLK CUSTOMER SUPPLIED CONTACTS TO ACTIVATE CLUTCH 2 o RED 2 120 VOLT f CABLE ELECTRIC U CLUTCH AN1 DES Pd CUSTOMER SUPPLIED CONTACTS TO ACTIVATE CLUTCH 3 o o ag RED Nie cs ind 7 1 CUSTOMER SUPPLIED CONTACTS TO ACTIVATE CLUTCH 4 n H EE RED CABLE ANT BLK d CUSTOMER SUPPLIED CONTACTS TO ACTIVATE CLUTCH 5 o o RED CLS JO CABLE ELECTRIC 4 CLUTCH ANI Ey CUSTOMER SUPPLIED C
24. and Dynatec Melter O The input output tags consist of 180 80 words each Dynatec Melter 15 the configuration tag not used Dynatec Melter I is the data coming from the Dynatec hot melt unit Dynatec Melter O holds the data going to the hot melt unit The definitions of the data tags are explained on the last pages of this section 15ITW Dynatec c 2005 Page 4 15 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Revised 8 05 6 Importing Controller Tags The CD ROM that is provided with the EtherNet IP option contains a pre defined controller tag table In order to save time this table may be imported In the RSLogix5000 go offline Select Tools Import Tags Select the Dynatec Controller Tags DMM CSV from the CD ROM Click Import If the import was successful the Report Window in the lower part of the screen should indicate 242 imported tags Go online again Go back to the controller tag screen and verify the tags Details on the Communication General Information The In and Out data table Controller Tags contain all parameters for a maximum equipped hot melt machine In most of the cases only parts of the parameters are needed The temperature zones are logically organized first all premelt zones progmelt zones hopper then filter blocks up to the auxiliary zones The number of actually available zones depends on the type of machine Setting LocalAccessTemps to 1 allows t
25. x 106148 214 d CUSTOMER INPUT n LINE SPEED INTERFACE RPM A N06642 7 ENCODER U 2 2 g S p m a WHT 106891 CABLE ASSY MOTOR INTERFACE TO MOTOR SPEED SET BOTH J1 amp J2 TO M1 d GREY o OFA HIDE L baee MOTOR SPEED c Sv d p2 CONTROL BOARD my x 77 5 5r 7 N 106595 op M 2 6 x 5 ur BLK gt J EMI RFI Y D FILTER BLU 4 1 RED d motor contro 5 7 1 4 HP 240v 2 INTERFACE BOARD LE Xon gt gt S d 5 AC MOTOR d 106148 x CAE A mh L1 ri N 2 E PRESSURE TRANSDUCERS 108184 MEMORY CARD i READER 4 CHANNEL PRESSURE PCB f DISPLAY amp 101675 106147 d EYPAD 4 o Lr E N C t Pe C E NOTE SEE MANUAL FOR PUMP CONFIGUATION 88 88 929 929 88 29 929 Fe 79 4 X eo aie gie le cde a CUSTOMER PRESSURE gt z 805114 2 ALARM CONTACTS p E cj m gt 5 UD 4 0 CPU BOARD 2 TO X14 TO XS BLU 18 6 1 0 w B8 41 10 2 RID HOSE 1 BLU 18 5 i a EXPANSION 9 GRY_ J1 9 1 A X11 8 BLU 2 1 1 aui 2 TEMP TO X7 12 BLU J7 6 x6 d amp MS 6 xo BLU yy 37 5 oe y A X9 x ay PROGMELT 11 X5 xD X4 _ In 5 10 W B 407 10 4 BLU 228 2 HOSE 4 11 7 3 9 J L2 N J ar PREMELT2 12 5 3 BLU J6
26. GearRatio Mo GearRatio Mo GearRatio Motor Gear Ratio Motor Gear Ratio Motor tor 1 tor 2 tor 3 4 5 6 S ystem 6 Rpm Displayn Pump Clutches Level Control Bar PSI Pressure Sensor Active Recipe 0 1 BitO Bit5 Bit7 0 1 0 51 1 type 1 4 System 7 Zone Premelt 1 Zone Premelt 2 Zone Premelt Zone Premelt 4 Zone Premelt 5 Zone Premelt 6 System 8 Zone Zone Progmelt Zone Progmelt Zone Progmelt Zone Progmelt Zones Progmelt Progmelt 1 2 3 4 5 6 System 9 Zone Filterblo 1 Zone Filterblo 2 Zone Filterblo 3 Zone Filterblo 4 Zones Filterblo 5 Zone Filterblo 6 System 10 Zone Hose 1 Zone Hose 2 Zone Hose 3 Zone Hose 4 Zone Hose 5 Zone Hose 6 System 11 Zone Hose 7 Zone Hose 8 Zone Hose 9 Zone Hose 10 Zone Hose 11 Zone Hose 12 S ystem 12 Zone Head 1 Zone Head 2 Zone Head 3 Zone Head 4 Zone Head 5 Zone Head 6 5 ystem 13 Zone Head 7 Zone Head 8 Zone Head 9 Zone Head 10 Zone Head 11 Zone Head 12 System 14 Zone Aux Zo 1 Zone Aux Zo 2 Zone Aux Zo 3 Zone Aux Zo 4 Zone Aux Zo 5 Zone Aux Zo 6 System 15 Zone Aux Zo 7 Zone Aux Zo 8 Zone Aux Zo 9 Zone Aux Zo 10 Zone Aux Zo 11 Zone Aux Zo 12 System 16 Motor Pump 1 Motor Pump 2 Motor P ump 3 Motor Pump 4 Motor Pump 5 Motor Pump 6 i TV Dynatec 2000 Preventive Maintenance Page 6 1 DYNAMELT M ASU Manual 20 28 and 20 36 Revised 9 00 Chapter 6 PREVENTIVE MAINTENANCE Note
27. 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 P P P P P P P P P P Feinpruf Gear Pumps Feinpruf pumps are commonly used in the European marketplace Gear Pump Repair Kit PN 103151 Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps Description Description N00198 O ring 069X064 O ring 018X031 Bearing 078F017 Ring Clip 069X061 Seal 0781001 Key Woodruff Gear Motor Options Lenze DC Motors PN 103843 These European 1 4 hp motors are equipped with tachometer feedback and a closed loop control They are required for the Actual Digital RPM Readout option DC Motors PN 101418 These 1 4 hp American motors are rated at 83 rpm 180v i TV Dynatec 2000 Options amp Accessories Page 9 3 DYNAMELT M ASU Manual 20 36 Revised 9 01 Return re circulating Hoses Available on all models U se 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 hop per Electric Clutch PN 105729 Clutch Kit PN 107945 An electric clutch is available for the Dynamelt M 35 ASU A clutch relieves adhesive pressure quickly in applications where there are periods of
28. 13 6 10 1 4 20 150 16 9 12 5 5 16 18 305 33 9 25 3 8 16 into aluminum 360 40 6 30 7 16 14 block hopper 480 54 2 40 Table 1 n 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 itis 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 Probable Cause Remedy Pump will not turn 1 Low pump temperature 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 tempera ture pressures viscosities and materials 4 Entrained particle Return pump to ITW D ynatec for repair cont Appendix 24 iTW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 TROUBLESHOOTING GUIDE continued Trouble Probable C ause 5 Possible internal damages Excessive seal 1 Worn seal plate assembly leakage 2 Insufficient inlet pressure 3 Worn lip seal Reduced pump effic
29. 5 e Cleaning 1 clean melt spinning pumps place them in a suitable furnace and gradually heat in an inert atmosphere for the initia hour to prevent flashing of the polymer Time at temperature will be related to pump size and degree of polymer contamination and should be determined by trial NOTE Careful control of the furnace temperature and atmosphere is critical Should the temperature exceed the original tempering lemperature the steel hardness may draw back and the dimensional stability of the pump may be upset Consult Table for proper tempering temperature Rockwell AISI Tempered At Hardness D 2 Ohio Air Die 8509 50 58 60 M 2 1050 566 C 61 64 M 4 Neatro 1050 F 556 C 61 64 Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath The bath should be heated to a temperature that is sufficient to carburize ihe polymer The carburization process usually takes between 3 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 2 After gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent Again it is usually necessary to disassemble only the seal arrange ment to remove polymer ash 3 Always replace the carbon seal plate after pump burnout the pump was performing satisfactorily when removed from service and
30. 7 2 Handling Printed Circuit Boards 1 7 3 CPU Printed Circuit Board amp Layout Illustration 7 4 Display CPU Printed Circuit Board amp Layout Illustration 7 5 Motor Control Interface Printed Circuit Board amp Layout Illustration 7 6 Motor Speed Control Printed Circuit Board amp Layout Illustration 7 7 48 Zone Power Printed Circuit Board amp Layout 7 9 Optional Clutch Printed Circuit Board amp Layout Illustration 7 10 Optional RS232 485 Printed Circuit Board amp Layout 7 10 Optional Pressure PST Printed Circuit Board amp Layout Illustration 7 11 Heater and Sensor Resistance 2 7 12 Resistance Tables Gente dee Db e ED eae Puce els e e 7 13 Error Indication Alarm Troubleshooting 7 14 Adjustable Adhesive Pressure Relief Valve 7 22 Operation of the ASU s Gear 222 7 23 Troubleshooting the ASU Pump 0 22 2 2 7 2
31. CPU 1 23 103069 Circuit Breaker CB 16A 63F 415V 1P SPCL 22 24 103070 Circuit Breaker CB 20A 63F 415V 1P SPCL 2 25 104193 Ground Small D ual 1 26 10062 L evel Control 4 27 105252 End Plate for105251 1 28 107892 Side Panel Insert 1 29 105254 End Plate for105253 6 30 103663 Ground BUS 1 31 105256 End Stop 4 32 106978 Filter RFI EMI 1 33 048H 383 Contactor 90A 3Pole 480V 230V COIL 1 34 048 162 Stand off 4 8 35 110090 M otor Control Interface 1 36 804713 Ground Block 1 37 107033 otor Choke RFI EMI 30 AC 1 2 38 106395 M otor Speed Control 1 2 39 106111 M 4 x 0 7 x 12 Button head 6 12 40 107440 Power Board 1 41 106147 Pressure Board 1 42 107438 Clutch Board 1 43 KBSI Board 1 2 44 107466 2 Amp Fuse 1 45 107893 Eprom Chip 1 46 107922 Ribbon Cable ssm 15PinM 9 PinF Serial 8 conductor crimp on 1 47 108256 Control A ssembly 1 48 107891 Cable A ssembly Bracket 1 Revised 9 02 Component Illustrations amp BOM s Page 10 7 DYNAMELT M ASU Manual 20 36 iTVW Dynatec 1999 Backside Of Control Panel Page 10 8 Component Illustrations amp BOM s Revised 9 02 iTV Dynatec 1999 DYNAMELT ASU Manual 20 36 Bill of Materials for DYNAMELT M35 Series Cabinet Assembly Item No Part Number 101843 105880 106186 106184 107890 108128 106187 105882 106183 802805 802102 106110 103115 101074 103866 107393 106111 101304 104279 105111 106066 104662 106324 106237 106112 105060 10
32. CPU of the microprocessor temperature control Cold Start When the ASU resets itself to default setting due to either a malfunction or to a deliberately initiated cold start procedure When the ASU is turned ON via the Main Power Disconnect Switch Default Settings The factory set programmable system values that will be in effect if the user does not enter new val ues The controller will revert to its defaults whenever it is reset The DynaControl controller s de faults are listed in this chapter Error Indication Alarms Alarms which indicate that the programmed over temperature values have been exceeded for one or more hopper hose or head zones Alarms may also indicate an open or short circuited sensor Mechanical High Temperature Protection A mechanical redundant thermostat located on the hopper which turns OFF the system at 232 C 450 F Microprocessor based Proportional Temperature Control The built in control system that controls monitors and displays all system temperature values cont Page 4 2 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Over Temperature Setpoint The programmable temperatures that will cause alarms blinking up and down display arrows to occur when those temperatures are exceeded Power is not disconnected the READY contact opens and the alarm contact opens If an external alarm has been connected it will activate The over temp setpoint is th
33. Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance procedures must be performed by qualified trained technicians General Cleaning The DY NAM ELT 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 T he hopper is fitted with a coarse screen to pre vent large debris from entering the system Normally this screen does not require cleaning The ASU parts that require regular periodic maintenance are as follows Outlet Filter The outlet filter should be replaced monthly during the first few months of operation After you gain experience with your system you can determine how often you need to replace it The outlet filter is located on the outlet filter manifold on the hose connection panel of the ASU See illustra tion of the outlet filter on page 6 2 Use the following procedure to replace the outlet filter cont WARNING HIGH PRESSURE Turn the motor OFF and trigger the applicators to relieve adhesive pressure before performing any outlet filter maintenance WARNING Avoid splashing hot adhesive
34. Return String STAX 0322s 9443 1l i is ETX zone 1 is not used 0 zone 2 amp 3 heating but below setpoint window 2 zone 4 heating and ready 3 zone5 amp 6 waiting due to heat up sequence 1 zone 7 amp 8 sensor attached 7 D D D D cont Dynatec desve Application Sysrems Parameter opcode Syntax DynaControl Version V5M Serial Protocol Return String Function Option 0x41 zz n dddd ACK NAK write temperature setpoints C 10 to 232 will switch to Celsius 1 zone multiple zones 0x46 F zz n dddd ACK NAK write temperature setpoints F 50 to 450 will switch to Fahrenheit 1 zone multiple zones 0x61 a 77 n dddd read temperature setpoints 1 zone all zones 0x64 d 77 dddd n dddd read actual temperature 1999 open sensor 0999 shorted sensor 1 zone all zones 0x42 B zz n dd ACK NAK write temperature tolerance window 5 to 50 degree 1 zone multiple zones 0x62 b 77 dd n dd read temperature tolerance window 1 zone all zones 0x43 C zz n dddd ACK NAK write pump speed setpoint 0 0 to 100 0 1 pump multiple pumps 0x63 c 77 dddd n dddd read pump speed setpoint 0 0 to 100 0 1 pump all pumps 0x65 e 77 dddd n dddd read actual pump speed 0 0 to 150 0 Rpm 1 pump all pumps 0x6c l 77
35. Setpoint 325F tab tab 325 tab The DynaControl list screen indicates the commands in abbreviated form A after the command on the D ynaControl list screen indicates a wrong parameter indicates unknown command or syntax error If downloading system info using the System command the controller does not check for validity of the parameters Upload Instructions The upload function will send an ASCII file to the external PC PL C The file contains all zone related information The size of the file depends on the number of zones pumps and pressure transducers The data format is similar to the download file Example PREME 1 41035 5 PUMP 2 M 850 100 900 Premelt 1 setpoint 410 tolerance 35 offset 5 zone is ON Pump 2 manual mode with 85 0 min speed for automatic 10 0 max speed 90 0 Customer zone names will be indicated with TXT TE fortemperature zones TXT PU for Pumps TXT PR for Pressure transducers 1 DynaControl must be connected to a PC via a Null M odem Cable 2 Start terminal program on PC 3 Start PC Link on DynaControl Function 5 on Service Page 2 4 f necessary select Configuration and change baudrate then re enter Function 5 5 A ddress setting is not used 6 Start Capture Textfile at terminal program 7 Press SAVE F2 8 Stop and close file on terminal program 9 Press RETURN to exit service mode Line Commands page 1 of 2
36. 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 iTV Dynatec c 2000 Revised 3 01 DYNAMELT M ASU Manual 20 28 and 20 36 Adjustment Screw Cap O ring PN A69X133 N Filter Plug Spring Filter Basket gt 101246 40 mesh PN 101247 100 mesh Roll Pin in Groove A lt Roll Pin lt Slide in Locked Position Outlet Filter Manifold Purge Set Screw Purge Drain 3 Purge Set Screw Purge Drain Outlet Filter Manifold located at the Hose Connection Panel 1 The system should be at operating temperature before starting this procedure 2 Before proceeding verify that the motor s is turned OFF and the applicators have been triggered to relieve pressure 3 Remove the M anifold 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 A dhesive will drain into the container 5 Wearing insulated gloves push down on the adjustment screw cap with sufficient force to release the slide W hile holding the cap down p
37. Worn seal plate assembly leakage 2 Insufficient inlet pressure 3 Worn lip seal Reduced pump efficiency 1 Worn gear s 2 Worn bearings 3 Process conditions changed Appendix 9 Revised 3 01 Remedy Check temperature sensor and control loop for proper setting operation Allow sufficient heat up time Verify drive is powered Check to assure all alarm circuits are clear Check drive motor current and speed settings Check all drive couplings Check process conditions for proper melt tempera ture pressures viscosities and materials Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Increase inlet pressure Replace lip seal Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair 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 iTW Dynatec 2000 DYNAMELT ASU Manual 20 36 20 37 20 38 Appendix 10 Revised 10 00 658 4219919698323 2508 OUTLET PORT 2509 OUTLET PORT 1 031 406 MOUNTING SCREW HOLE 2 HOLES BOLT HOLES 813 INLET PORT NOTES sETCH PART NUMBER amp DISPLACEMENT AT LOCATION SHOWN WITH MINIMUM 125 HIGH CHARCTERS UDE FOUR SCREWS ITEMS 52 GRADE 8 amp BLACK OXIDED 3 25 LONG AND FOUR WASHERS ITEMS 5
38. ZONE CONFIGURATION Page 1 of 3 T Dynatec 2000 DYNAMELT M ASU Manual 20 36 Page 11 14 Schematics Revised 7 07 9 3NOZ A004311 3Noz o1883113 v 3NOZ A009414 3NOZ NAN 908d 61 3NOZ NAW 90d 2 3NOZ LIAN 903d 9 MLN S ML v MIN C HL E anale dnd 9 3NOZ 901883Il4 02 3NOZ 5900 1883lT1J 3NOZ 520 18M3L I3 3NOZ LIAW 90 6 3NOZ LIAW 3NOZ 113 90d G al V HIN MIN C MIN HL S dNnd dWAd 02 3NOZ 0018M3ll4 3NOZ OZ 3NOZ 3NOZ S 3 07 90d 6l 3NOZ NAW 90d 3 07 LI3N 903d 61 3NOZ jNOZ 90Md v HIN MIN C 7 MIN XIN C Hl L ML 00 3 07 MOO 8M3l IJ Y 3NOZ 3507843113 04 3NOZ MOOTEYSL TS v 3NOZ 520 TESLA 3 07 90d 61 3NOZ LIAW 3NOZ LIAW 90d 61 3NOZ 13N jNOZ LISW 90Md MIN C SIN HL dNnd dnd XIN C MIN lL al dWNd lt 0 JNOZ MOO 1883l1lJ 0 3NOZ 201833LlllJ Y 3NOZ 590 833L1l3
39. a L3 CB 78 en 8 18 3 779 ET gia Tuy 2L 7X H128 CB12 m VCIH 16 25 47 HA 1 87 8 87 16 CB10 22 T i 0210 215 15A VOIH EX g01H 164 22 i lt lt EBH lt lt 95 amp Hd 6 11 6 21 j 86H Gag cae 1 uc eH 4 6 g sp SSH Js 16A C 1 9 8 01 r RARS LS om cq 979 C O S Q 21 d Dope 2 88H 16A 8 7 16 CB6 2 25 4405 Dad 86 2 a 16 You 16 C87 n a 46 Q vat H pef VIR 024505 HH LL Lier Zi sr OOOO OOOO E E i VSH 985 CB5 LU cast LI Qv3H 2L Saad HS H 9st 1 0 8 17 16A PN D Sof Tu ven IN 50Hd acu mo qe dASIH HAB 213 L Y 22 2 2 16 16A n 212 iig cul er 16A vig 1131389 of 5e 20 CHI ZISNSSg 2 20 2u 7 pia YZH CLR 16 16A oO gt oe m gt
40. depending on the lubricity of the solution and the differential pressure in the application Another cause of low through put is slippage across the sides of the gears from the high pressure discharge section to the lower pressure inlet section when thin fluids are metered against a substantial differential pressure This slippage is dependent on three factors viscosity of the material speed of the and the differential pressure Therefore even though the clearance between the gears and their housing may be as little as 00025 high slippage may still occur from high to low pressure ports if viscosity is low and pressure high 3 Preparing Your Zenith Pump for Use Assembly itea vin Acetone o MEK Since Zenith Pumps are precise instruments their assembly requires detailed attention to every step 1 Zenith Pumps are shipped filled with a rust preventative oil Flush the oil out thoroughly with a cleaning solvent may be necessary to disassemble the seal arrangement to remove all traces of the oil but disassemble only if necessary 2 After flushing the pump should be lubricated internally Pour a suitable high temperature lubricant into the inlet port Rotate the metering gears until the lubricant ap pears at the discharge port 3 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 pre vent leakage between the pump and the block Make sure mounting bol
41. e e E L 1 2 o5l 111 gt o gt 9 4 n PN 107939 POWER WIRING DIAGRAM DM35 DCL 380V 95 nN gt o Zone Configuration for Hose Head Aux 9 5 pr 8 w Q 5 8 Hose Head 6 9 Head p Head Aux E 10 Aux Aux Hose Hose Hose Head Head 4 Head Aux Aux Aux Hose Hose Head Head Aux Aux Hose 27 Hose Head 28 Head Aux 29 Aux Hose 10 Head Aux NOTES There are no odd hose numbers in the predefined defaults If for example 5 hoses are installed the default has to be loaded for 6 If necessary remove hose 6 manually from the zone table 2 dide Aux Indicates the division line between the two hoppers if Dual hoppers 5 are installed These zone numbers are independent from number of pumps and premelt grids TV Dynatec c 2000 DYNAMELT M ASU Manual 20 36 PN 108534 Rev C INSTRUCTION SHEET FOR PUMP amp
42. heat up ready 4 low temp 5 high temp 62 sensor short circuit 72 sensor open 4 System mode 0 SetbackOn Off Bit1 Heat up sequence yes no Bit2 Scheduler active yes no Bit3 controller On Off 77 zone number 01 to max or 00 for all zones dddd four digit data dd two digit data d one digit data or character 13ITW Dynatec 2005 Page 4 13 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Revised 8 05 PN 112224 M Series DynaControl EtherNet IP Adapter Option V1 06 General This optional adapter provides an EtherNet IP connection for Dynamelt M Series hot melt ASUs This connection makes it possible to monitor and control the basic functions of the hot melt unit from a remote PLC or PC This adapter uses an ODVA approved module In order to fully operate the Dynamelt M must be equipped with firmware rev V5 15M or later Basic Features 10 100 Mbit s DHCP BootP Access to basic process parameters Local and remote access Watchdog signal 4 14 ITW Dynatec c 2005 Revised 8 05 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Installing the EtherNet IP Adapter in a ControlLogix5000 System These installation steps assume that RSLogix5000 and ControlLogix5000 with an EtherNet IP module bridge 1756 ENBT or similar are set up and working properly 1 Connect the Dynatec Hot melt unit ASU to the Ethernet network using a standard RJ45 cable 2 Start RsLogix5000 with a new or
43. most critical part of the plate Scoring or wear marks here will allow increased slippage from the 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 Appendix 32 Revised 10 00 7 Reassembly NOTE During and between each reassembly step manually tura the metering gears to ensure that they are free turning 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 reassembling or turning a Zenith Pump H property aligned the pieces will fit easily into place and the pump will turn freely Reassemble the pump as follows 1 After all worn parts have been refinished or replaced all parts should be thoroughly cleaned in a solvent and dried 2 Using the driven gear as an uprighling fixture carefully locate the arbor over its press fit hole in either the front or rear plate Smoothly drive the arbor into its hole with the help of an appropriate arbor press 3 Piace the front side plate with the arbor in position in a softjaw vise or holding fixture 4 Siip together the driving melering gear drive shaft and key Position in the front of the side plate by installing the drive shaft through the hearing 5 Place the driven metering on its arbor and careful ly mesh with the d
44. 018X 041 Bearing Sleeve 2 7 100867 Front Plate ssembly 1 8 0120087 Driven Gear Shaft 1 9 018X 031 Ball 1 8 Dia 5 10 012C019 Drive Gear 4 5 cc R ev 4 11 069 064 O ring 041 3 12 078F017 Shaft Retaining Ring 4 13 018X 041 Bearing Sleeve rear Plate 2 14 100865 Rear Plate Assembly 1 15 101691 4 405 5 2 16 NPN M 10 1 5 x 85mm 4 17 100870 M iddle Plate 1 18 N 00198 O ring 113 2 19 NPN M 10 Flat Washer 4 iTV Dynatec c 1999 Component Illustrations amp BOM s Page 10 21 DYNAMELT M ASU Manual 20 28 8 02 Bill of Materials for 10cc Single Gear Pump Assembly 109690 Item No Part Number Description Qty 1 018X031 Ball bearing 1 8 Dia 6 078F 017 Snap ring 1 2 4 3 0781001 Key Woodruf 404 1 4 069X061 Shaft Seal 1 5 069X064 O ring 041 2 6 100908 M4 0 7 x 25mm SHC Screw 2 7 101626 M5 0 8 x 12mm SHC Screw 4 8 109685 Pump 10 Rev 1 9 109686 Rear Bearing Plate 10cc Rev 1 10 109689 Gear 10cc Rev 2 11 109687 Drive Shaft 10cc 20cc 1 12 109688 Driven shaft 10cc 20cc 1 13 069X160 S haft seal retainer 1 14 0010002 Dow Corning 112 Lubricant Not Shown Page 10 22 Component Illustrations amp BOM s Revised 4 05 TWDynatec 1999 DYNAMELT ASU Manual All Models Bill of Materials for Assorted Pump Adapter Assemblies Item No tn FR WN 10 11 12 13 14 15 16 17 18 19 20 21 22 Part Number 084 406 0126024 069 058 N00179 069X274 N00190 078C130 NPN 084
45. 11 5 11 5 11 5 Resistance Ohms for each Drop in Grid Heater 23 23 23 Nominal Hopper Heater Resistance in Ohms of Filter Manifolds M70 140 on ASU 115 2 115 2 51 6 51 6 not available 38 4 not available 28 8 not available not available not available not available Nominal Filter Manifold Heater optional Resistance in Ohms Page 7 14 Troubleshooting iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Error Indication Alarm Troubleshooting Guide The operation of error indication alarms is described in Chapter 4 When checking for correct equipment operation in the following guide be aware that all heaters will go off immediately after an error indication alarm occurs if the operator takes no action With the exception of the fuses there are no user replaceable parts on the printed circuit boards If there is a non fuse failure on any of the PCBs the PCB must be replaced DANGER HIGH VOLTAGE Some of the procedures in the following Troubleshooting Guide require poten tially dangerous electricity to be present Only qualified service personnel should perform these procedures Hopper tank 1 Setpoints have been 1 setpoints allowing a Overtemp programmed without larger deviation between the high enough deviation and low limits 2 Hopper sensor 2 Replace hopper sensor if resistance inoperative does not comply with the resistance table in this chapter 3 Hop
46. 38 Revised 11 01 Use of the Main Scheduler Screen Function Press 1 to manually activate or deactivate Standby Press Press F4 to return to the M ain Scheduler screen N ote use of this key will override a programmed Standby Press 2 to program the time of day and date of year clock Press F1 or F2 to change a selected item press F3 to select another item Press Press F4 to return to the M ain Scheduler screen Press 3 to program the 7 Day Scheduler See programming details and screen on following page Press 4 to select an active recipe 1 4 Use F1 F2 to select recipe 1 2 3 or 4 Press F3 to Con firm Press F4 to return to the M ain Scheduler screen U p to four separate setpoint recipes programs can be programmed and stored in the controller though only one recipe is active at any given time Setpoints may differ from one recipe to another When switching between recipes the new recipe s setpoints take over so there may be error alarms if the new recipe s unused temperature zones are turned on The program recipes are referred to as Recipe 1 Recipe 2 Recipe 3 and Recipe 4 To create a Recipe advance to the M ain Scheduler Screen and press 4 Use F1 or F2 to choose a recipe number for this example say 2 Press to confirm Press F4 then press F4 again to go to the A ctual Temperatures Screen Program all controller setpoints and functions as outlined on page 5 4 When all programming is completed Recip
47. 6 2 BLU BLU J6 5 Sp ALARM PREMELT 7 105062 OPT 6 45 6 CUSTOME E ma POWER MEE d e Tux 4 w 8 45 6 2 5 CON AC S 1 8 m HOSE 3 451 E E Ar 7 GRY 43 5 2 6 3 BLY s E 6 BLU 13 10 2 sE ANTA a 5 NIMM HOSE 2 BLU 24 5 AUX 2 ry JF5 F X E Hs 4 w 8 42 6 L AUX 1 POWER BOARD 3 ces CUSTOMER P Hs 07440 2 BLU e 41 8 EE do do 11 A SYSTEM READY O a CONTACTS 9 1 131 P e 1 o S EO HT 3 sur 454 Li O mi gi 108186 D 9 H 543 3 H 5 nO L1 M z ON m FN em M 35 SBE SYSTEM 5 Y GND E Ds pa _ 3i 1 5 9 Es eR SIGNAL WIRING DIAGRAM i E 8 2 sg 29 RI Part No 107438 8 xf bo BO Es 200 240 50 50 60 HZ ECT ay E t 50 5s 4 HOSE 4HEAD z3 JF2 2 9 107397 REV A 2 OPTIONAL COMPONENTS ARE gt PYNATRO 805116 IN DOTTED LINES L2 N 2000 Schematics 11 11 DYNAMELT M ASU Manual 20 36 Revised 7 07 See previous page PN 107937 DM35 DCL SIGNAL WIRING DIAGRAM 4HOSE 4 HEAD 200 240V Page 2 of 2 Page 11 12 Schematics iTWDynatec 2000 Revised 6 01 DYNAMELT M ASU Manual 20 36
48. CAUTION Printed circuit boards PCBs should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is notavailable frequently touch a bare metal part of the ASU unpainted frame mounting screw etc to safely discharge any electrostatic buildup on your body 2 Handle a PCB by its edges only Don t grip a PCB across its surface 3 When removed from the ASU each PCB must be individually packaged inside a metallized static drain envelope Do not place the removed PCB on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the PCB to him 5 When unwrapping a PCB from its static drain envelope place the envelope on a grounded nonmetallic surface 6 To cushion PCBs for shipment use only static drain bubble pack Do not use foam peanuts or bubble pack not known to be static draining The following pages detail the Dynamelt M Series PCBs Page 7 4 Troubleshooting ITW Dynatec c 2000 Revised 10 07 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 CPU Printed Circuit Board The CPU board contains the controller s CPU chip built into the board and optional 7 Day Scheduler chip It also contains the optional Memory Card Reader interface and ribbon cable connection The CPU chip can only be reprogrammed at ITW Dynatec
49. Configuration and change baudrate than re enter Function 5 5 A ddress setting is not used 6 Press LOAD F1 7 Send ASCII file on terminal program 8 DynaControl screen should list all received lines 9 Press RETURN to exit service mode 10 Customer zone text command Text requires the zone number temperatures 1 48 pumps 49 54 pressure 55 66 Download File Format The downloaded A SCII text is line oriented Pages 29 and 30 show all possible line commands Each line starts with and the command following a number of parameters depending on the command E ach parameter must be separated with a horizontal tab char 091 A tab character must be placed after the last parameter in each line Examples 1 Downloading data for the first filterblock zone Filterblock tab 1 tab 325 tab 30 tab 0 tab ON tab This will set the first filterblock to a setpoint of 325 degrees tolerance 30 no offset zone is switched ON 2 Text tab 50 tab Pump 1 Factory Side This will program the customer pump name for motor 2 which could be pump 1 with the string Pump 1 Factory Side cont Page 5 27 Programming ITW Dynatec c 2000 Revised 10 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Important Note the last command in the download file must be End Notes The command lines may be arranged in random order M aximum file length is 5000bytes Each data field may have a comment text tab
50. Cutouts for drop in grid assembly Filter S hutoff Pump Enable Heater Thermostat P ort Terminals Side View Hopper Sensor Port Junction Box Sensor or Thermostat Replacement Remove the junction box cover a Over Temperature Thermostat Replacement Remove the two screws and slip the terminals and the hopper ground wire off of the thermostat before removing the thermostat from the base of the hopper b Pump Enable Thermostat Replacement Disconnect two wires from the terminal strip and slide the thermostat out C RTD Sensor Replacement Disconnect two wires from the terminal strip and slide the sensor out To Remove the Manifold Cover Unscrew its captive screw and slide cover up and off Cover allows access to the hose connections on the filter manifold outlet filters heaters and the pressure relief Heater Replacement One heater is located in the heater plate underneath the hopper Remove the access door Use a hex head socket wrench to remove the six heater plate bolts through the holes drilled in the base plate Disconnect the heater wires Slide the old heater plate out Connect heater wires to new plate Slide new plate in place and fasten with the six bolts One cartridge heater is located under the filter manifold At the rear of the ASU remove the filter manifold cover Remove the cover located at the end of the heater retainer plate 4 screws Disconnect heater wires from the terminal rail
51. D efaults Press 1 to toggle the heaters On or Off Press 2 to toggle the pumps On or Off Press 3 to toggle the external inputs On or Off Note if you select heaters Off the controller will remind you at power on to press F1 to turn the heaters On Page 5 20 Programming ITW Dynatec c 2000 Revised 12 02 DYNAMELT M ASU Manual 50 13 20 36 20 37 20 38 Service Functions Screens Page 2 cont Press 3 to program Factory Defaults CAUTION Factory Default programming is not essential If done improperly it can cause re pro gramming of setpoints to be necessary If you are satisfied with your ASU s setup you may leave Factory Defaults unprogrammed Upon entering this screen the ASU Type model of your melter will be displayed Use this screen to program the quantity of hoses quantity of premelt grids and quantity of pumps installed on your ASU if desired It is o k to leave these items unchanged or with selected Scroll F1 to the line you wish to amend ie hose premelt pump Press Change F 2 repeatedly to view the list of possibilities for this line Press Change until your desired quantity is displayed Repeat until all lines are programmed Then Scroll F1 to Configure EU US Press Change F2 to toggle between EU Setup or US Setup for setpoints and parameters if required Press Load F3 Then press Confirm F1 Press Return F4 to return to menu Choosing EU or US reloads all factory setpoint
52. Dynatec c 2000 Installation Page 3 15 DYNAMELT M ASU Manual 20 36 Revised 4 06 Typical Start Up and Shut Down of the DYNAMELT M Application System The following simplified sequence assumes that the DynaControl Controller has been pro grammed Start Up Procedures 1 Fill the ASU s hopper with clean hot melt adhesive to within a couple of centimeters inches of the top of the hopper Close the hopper lid immediately to prevent contaminants from falling in Cover your bulk supply of adhesive to prevent contaminants also 2 Switch ON the Main Disconnect the circuit breaker located on the panel box 3 At the DynaControl keypad press the controller s F1 button if prompted to do so 4 Allow adequate time approximately 20 30 min for the adhesive to melt and the temperatures of the temperature zones to stabilize Monitor the System Status display to see when Heat Up changes to Ready Undertemp arrows will blink until the temperature zones are up to ready temperature 5 When temperatures are ready the pump and motor are enabled to pump adhesive At the pump screen Select Auto or Manual Mode Select desired pump press Enter a If Pump is in Auto Mode Adhesive will begin to pump when the production line begins to operate b If Pump is in Manual Mode 1 Press Manual F1 Press Enter ii Enter desired speed value Press Enter iii Scroll to select next pump if applicable Repeat steps i thru iii until all pumps are
53. ETX Address Setting Each telegram sent to the D ynaControl contains the slave address D ynaControl is only responding if the received address matches the programmable address Examples Controller address 2 37 1 Write temperature setpoints Zone 3 250 F Zone 4 280 F Zone 5 300 Zone 6 350 F but temporarily not in use EOT 3 7 F 0 3 0 2 5 0 0 2 8 0 0 3 0 0 1 3 5 0 ENQ 37 3 250 280 300 350 Off note adding 1000 to the setpoint will deactivate this zone 2 R ead actual temperatures EOT 3 7 d 0 0 ENQ 37 00 note zone number 00 will request information of all available zones ITW Dynatec c 2000 Controller Setup Page 4 11 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 7 01 Return String 517 0 2 3 5 0 2 4 4 1 9 0 90 2 3 5 zonelis235 zone 2 is 244 F zone 3 has no sensor attached Note 1999 indicates open sensor 0999 indicates sensor short circuit 3 R ead actual pump speed 0 3 7 0 0 0 request the speed of all pumps Return String 5 0 8 5 0 0 6 6 4 gt System has 2 pumps 1 85 0R pm 2 66 4R pm 4 R ead System Status EOT 3 7 f ENQ Return String STX F z46hex Bit wise 0 16 05 04 05 1 11 00 Always No setback normal mode Controller is on Enable thermostat closed Hopper not empty No low temper _ No high temper heady 5 R ead status of all temperature zones EOT 3 7 1 0 0 ENQ
54. H14B 240v For 5th grid H25A amp N 380v H25A amp H25B 240v For 6th grid H26A amp 380v See the resistance table in this chapter for normal resistance values Infinitely high reisistance values indicate an open heating element which must be replaced i TV Dynatec 2000 Troubleshooting Page 7 19 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 ose Head 1 Hose Head setpoints No Overtemp incorrectly programmed 1 setpoints to allow a larger deviation 2 or shorted hose head triac or dual solid state relay 2 Refer to the schematic in Chapter 11 to locate the correct head hose triac or relay Use a clamp on ammeter to mon itor hose head current If current does not cycle on and off then the triac or relay has failed and must be replaced Note Vertical configuration is for DM 35 only Larger ASUs are arranged horizontally 3 Disconnection between th 3 Verify that all PCBs are properly 2 Power PCB s and the CPU mounted inside the panel box A board s flat cables 4 Hose Head sensor circuit 4 a Visually examine socket connect inoperative ion where hose head attaches to ASU Verify that pins are properly seated If pins or plug housing are damaged repair or replace hose If socket is damaged repair or replace harness b If hose to A SU plug and socket are okay hose may have intermittent short o
55. Make sure fluid is in the pump before starting 7 Start pump slowly and if possible run it with a lubricating fluid 8 W hen satisfactory operation is achieved the pump and system may be gradually brought up to normal process speeds and pressures 9 f 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 REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op 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 ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances these pumps require careful maintenence and handling especially of component parts T he slightest burr nick or particle of foreign matter can cause scoring or even seizure These pumps are precision in struments you can t keep them too clean Please treat them with care and if it s at all pos sible set aside a separate clean area for pump maintenance To clean High A ccuracy M etering 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 temper ature will be related to the pump size and the d
56. a When a hopper hose head or auxiliary zone has exceeded its selected over temperature setpoint which is the setpoint plus its high low alarm setting or when it is below its selected under temperature setpoint which is the setpoint minus its high low alarm setting In these cases heater power will not be switched off b When a hopper hose head or auxiliary zone sensor has an open circuit In this case heater power will be switched off Blinking up arrow indicates overtemp Blinking down arrow indicates undertemp 7 2 3104 SYM DEF 2 3 SYSTEM Alarm Actuals F Premelt Progmelt Filterblock Hose 273 251 Head HOLD a p Aux Zone Pump MANU TOP STOP 96 HOLD 10LD HOLD b SETPOINTS 0 gt ABC 123 ITV Dynatec indicates no sensor open circuit ITW Dynatec 2000 Controller Setup Page 4 5 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 11 02 Error Alarms Message Window The display of a message window as illustrated below signifies an error alarm T he operator s re sponse to an error alarm is to press F4 and to troubleshoot If a sensor error alarm or an overtemperature alarm occurs during operation the controller will switch off internal power to the heaters and an appropriate error alarm display will appear Pressing the F4 function key acknowledges the error If several zones display alarms each must be acknowledged by pressing F4 The alarm dis
57. an alarm or message Copy copy word s to a clipboard Paste paste copied words into text j j CLR Line clear entire line Setpoint Programming Screen Programming entry 1 2 3 numeric only A B C alpha only SN Function keys Fl 2 3 4 Dashed line indicates Progmelts are linked models M70 140 210 only For illustrations of the screens of the Dual Hopper SUs see pages 5 28 amp 29 SYSTEM Ready Tue 3 36PM Press Enter and Select Mode Actual RPM Set Min Max optional display Pump Mode RPM tach generator required 1 MANU 2 AUTO 5 0 5 0 80 0 RUN 87 3 STOP User chosen INFO RIGHT PUMP Mtr 1 Lock this screen is locked from further Function key gt MANUAL AUTOMATIC STOP RETURN programming Manual Automatic or Stop pump modes Restart pump F1 All Stop stop all pumps T Dynatec Pump Programming Screen Page 5 4 Programming ITW Dynatec c 2000 Revised 4 06 DYNAMELT M ASU Manual 50 13 20 36 20 37 20 38 Basic Programming Sequence Quick Reference Follow the screen by screen steps outlined in the remainder of this chapter for complete setup and programming instructions Thereafter use this page as a quick reference Press Turn Controller On x2 6 Language Selection x1 8 Temperature Scale Selection Actual Temperatures To Program Setpoints To Program Pump Motor s aa To Program O
58. 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 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 amp Protective Clothing WARNING EYE PROTECTION REQUIRED q PROTECTIVE CLOTHING REQUIRED It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment Wear safety glasses with side shields which conform to ANSI 787 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
59. at the Zentih factory to view the manufacturing gauging and assembly techniques involved in producting the pumps Please contact D ynatec at 1 800 538 9540 for further information on these items Appendix 6 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 STANDARD ACCURACY PUMP DISASSEMBLY If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with all the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt pumps If maintenence is required due to low delivery or seizure the following procedure is recom mended for disassembly NOTE Be sure to note the location and orientation of all parts to ensure correct re assembl y 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
60. circuit Repair or replace ASU hose head harness or other ASU wiring as necessary Page 7 22 Troubleshooting iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Adjustable Adhesive Pressure Relief Valve D ynamelt pumps are outfitted with a high pressure relief valve located on the outlet filter manifold 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 W hen 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 W hen 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 Open Relieved In the drawing below the pressure relief valve is In this drawing pressure has exceeded the setting closed of the valve causing itto open and discharge adhesive to the hopper Adjustment Screw Cap Check Valve Check Valve i Pr r Spring Relief x return Pressure return Valve to Relief to hopper Valve hopper fT Filter from
61. configured at the dip switches on the Dis play CPU PCB High amp Low Alarm Outputs 4High 4Low 3High 3Low 2High 2Low 1High 1Low 200009000 000000090 Jumpers for High Low Alarms Normally Open default no alarm no continuity Normally Closed no alarm has continuity 1 m oO 2 Flat cable to CPU PCB Transducer 1 gt Green LED Board logic power is OK Layout of Components on Pressure Board Page 7 12 Troubleshooting ITW Dynatec c 2000 Revised 5 02 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Heater and Sensor Resistance Values The resistance values given in the four tables on the following page will aid in troubleshooting when a sensor or heater malfunction is suspected The Temperature Sensor Resistance table gives values for various temperatures If you know the approximate temperature of the suspected sensor you can check to see if the sensor resistance approximates the value given in the table by unplug ging 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 R esistance table gives the heater resistance for hoses A suspected hose heater problem can be qui
62. costs at a minimum noting the perfor mance of a pump immediately before removing it from service and correlating the perfor mance 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 D ynatec for com plete 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 D ynatec 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 recom mended for disassembly NOTE sure to note the location and orientation of all parts to ensure correct re assembl y Refer to assembly drawing located in the back of this manual for your correct pump type 1 Remove
63. existing project Set to Offline mode 3 Add the EtherNet IP Adapter to the PLC Configuration Start by right clicking the EtherNet IP module bridge in the configuration Select New Module Select Generic Ethernet Module Press OK 4 Songur the EtherNet IP Adapter Enter the name of the module for example Dynatec_Melter If you desire to import the controller tags provided on the CD ROM the module name must be exactly Dynatec_Melter See step 6 following Set Comm Format to Data INT since all data are 16 bit words Set Connection Parameter Assembly Instance to 100 for Input and 150 for Output Set Size for 180 input 80 output 16 bit Set the Configuration Instance to 1 but the size to 0 since this instance is not supported Set the IP Address to 192 168 23 180 For more details about IP Address see the following section Changing the IP Address Press Next gt Onnext dialog select Requested Packet Interval 100ms not Inhibit Module Press Finish gt gt On the main screen you should see the ETHERNET MODULE under the I O Configuration Select Go Online from the Communications menu Select Download in the next window Confirm the Download 5 Checking the Tags After successful configuration of the EtherNet IP Adapter it is possible to access the input output data There are three Controller Tags Dynatec Melter C Dynatec Melter
64. factory default of 100 A djusting the MIN 96 value corresponds to the pump speed when the parent line is stopped 0 0 volts at the 0 and 10 terminals most applications the factory default M IN 0 is used Page 3 14 Installation iTV Dynatec 2000 Revised 11 02 DYNAMELT M ASU Manual 20 36 Level Control Capacitive Sensor with Amp The level control device informs the A SU s operator via a Level Low message on the Dyna Control controller s System Status display that the A SU s hopper adhesive level is low When the alarm activates press C to reset it You then have five minutes to refill the hopper before the alarm reactivates and the A SU s pumps stop The capacitive sensor is mounted in the hopper The sensor cable is plugged into the amplifier DO NOT CUT the sensor cable Adjustment of the PN N08122 Level Control To adjust the adhesive level control s sensitivity access the control s amplifier located inside the panel box assembly On the amplifier diagrammed below is a sensitivity adjustment screw Turn the screw clockwise to increase sensitivity or counter clockwise to decrease The yellow LED lights to indicate the presence of adhesive W hen the LED goes out the alarm will acti vate OQ OOOOO OOOOOO0 1 2 3 4 5 6 Sensor an lt Sensitivity Adjustment S crew Connect min _ max Q Yellow LED 7 8 9 10 11 12 OOOOOO Amplifier ITW
65. head 2 auxilliary 240v Quantity of each Type of Pump PB 806457 1 drive 2 hose 2 head 2 auxilliary 380v PC 806458 2 drive 4 hose 4 head 4 auxilliary 240v PD 806459 2 drive 4 hose 4 head 4 auxilliary 380v GAS 100860 Dynatec 1 54cc single GBS 100861 Dynatec 3 18cc single GCS 100862 Dynatec 4 5cc single GAD 100863 Dynatec 1 54cc dual GBD 100864 Dynatec 3 18cc dual Gode PN Options ZLS 084E372 Zenith 0 160 single D Digital Pressure Readout 205 084 428 Zenith 0 297cc single 107945 Electric Clutch Kit ZES 084E374 Zenith 0 584cc single Filter Selection ZFS 084E430 Zenith 1 168 single 101246 40 mesh outlet filter ZGS 084E434 Zenith 2 92cc single 101247 100 mesh outlet filter Standard SHS 108875 S amp P 8 5cc single 106273 150 mesh outlet filter 805641 Analog Pressure Gauge Kit 06642 Signal Isolator 802886 One Point Level Control Assy 107643 Remote Display Kit 108475 RS232 485 Communication 108313 Digital RPM Readout 108425 Handgun Trigger Kit 106103 Drain Valve ZLD 084E387 Zenith 0 160cc dual ZDD 084E388 Zenith 0 297cc dual ZED 084E 389 Zenith 0 584cc dual ZFD 084E432 Zenith 1 168 dual SGD 108874 S amp P 2 92cc dual SPC Special Pump see sales order lt Ao iTV Dynatec 2000 Installation Page 3 1 DYNAMELT M ASU Manual 20 36 Revised 4 01 Chapter 3 INSTALLATION Placing the DYNAMELT M ASU The DY SERIES ASU can stand alone on flat surfaces T he mai
66. input W hen operated as the standard feature a 0 10v signal from a PLC or a similar line speed output device is utilized However it may also be operated utilizing one of the following optional devices PN 0150050 Tach Generator a mechanically operated device which produces a reference voltage that allows the A SU s gear pump to track a parent machine s production line speed PN N06642 Signal Isolator a device which conditions a parent machine s production line s DC Speed reference voltage to allow the ASU s gear pump to track line speed Page 9 4 Options amp Accessories T Dynatec c 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 Serial Communication PC Link Remote Interface PN 108475 Bi directional data transfer to a remote computer is available for the controller The ASU s standard RS232 serial port connection allows remote interface up to 50 meters from the DynaControl con troller The RS485 serial port connection offers remote interface over a much longer distance Either connection enables all system parameters to be monitored and or controlled from the remote sta tion Ethernet IP Adapter Kit PN 112224 This kit adapts the DMM ASU for an Ethernet network so that all system parameters can be trans mitted and received allowing full remote operation of the ASU 2000 Options amp Accessories Page 9 5 DYNAMELT M ASU Manual 20 36 Revised 10 05 Recommended Service Parts List Penno
67. interlock ed TR CER CR end Rt d yes A oe HEU dal S M cce ri yes Sequential heating yes hopper hose head staged heating Sensor open alarm ts ease p Fat REN E CRM NDS and yes RS232 and RS485 communications capable yes Line Speed Tracking us sse 9 Pad ad Red CEA AN AA CA RC DR TA yes Seyc day seheduler 22255 de dex ies user t iuter ipio E yes CE approval granted ig desee abeat Ee yes Page 2 4 Description amp Specifications iTV Dynatec c 2000 Revised 11 02 DYNAMELT M ASU Manual 20 36 863 60 560 800 10 1346 2 177 8 336 55 558 80 228 60 782 32 878 107 2 inches 34 00 22 05 31 5 53 00 7 00 13 25 22 00 9 00 30 80 34 57 4 22 DYNAMELT M35 DCL Installation Dimensions i TV Dynatec 2000 Description amp Specifications Page 2 5 Revised 10 00 DYNAMELT M ASU Manual 20 36 Total System Wattage Capacity e Up to 4 Hose Zones 4800 w 1200 w each Up to 4 Applicator Zones 4800 w 1200 w each Up to 4 AUX Zones 8000 w 2000 w each Maximum System Wattage 28 600 w Main Circuit Breaker Determination M ain circuit breakers vary depending on each unit s system configuration ITW D y
68. it uses the glue as a lubricant Stop and troubleshoot Troubleshooting Page 7 25 iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Gear Pump Troubleshooting Guide WARNING SURFACE amp 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 v and use proper tools for handling hot melt components Note Each motor and M otor Interface PCB in the system can run independently or dependent y Each Motor Interface may have its own operating parameters Therefore each motor and Motor Interface P CB should be troubleshot independently Pump doesn toperate 1 Motor On Off is OFF at 1 Check keypad setting in M anual mode the controller keypad power light doesn t light 2 Hopper temperature is 2 Pump cannot operate until hopper has ON OFF Led below ready setpoint reached ready condition Verify that hopper has reached ready e program Y hopper operating setpoint and ready setpoint if necessary 3 No incoming electrical 3 Check to see if ASU temperature power control is operating If not check for presence of incoming supply voltage Pump doesn t operate 1 M anual motorissetat 1 motor in M anual mode zero at the keypad power lightis ON hopper is at ready condition 2 1f pump On Off is being 2 C
69. 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 Atthe 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 A SU and remove the access cover 4 Position a heat resistant container below the manifold With a hex key screwdriver allen wrench slowly loosen the manifold s two purge set screws do not attempt to remove them Allow adhesive and pressure to escape out of the manifold A dhesive 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 itis 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 P Screw Turning the adjustment screw counterclockwise opens the outlet and decreases the j i pressure to the hose nut gt eod and increases the pressure to the hose Tuming the adjustment screw Adjustment screw clockwise closes the outlet i TwDynatec 2000 Installation Page 3 9 DYNAMELT M ASU Manual 20 36 Revise
70. message on the D ynaControl s readout that the hopper s adhesive level is low It may also be wired to stop production turn on an alarm light or signal or signal a PLC Baseplate Standoff PN 109585 W hen casters are not desired on the A SU baseplate standoffs may be used to make the unit station ary The standoff features a flange on its bottom to allow spot welding and itis open in the center to allow bolt through mounting Page 9 2 Options amp Accessories T Dynatec c 2000 Revised 9 07 DYNAMELT M ASU Manual 20 36 Pump Options and Accessories Gear Pumps For higher tolerances and precision several gear pumps are available for the Dynamelt Gear pumps give better service for continuous applications or applications which require more control over the vol ume of adhesive pumped Gear pumps available are Single Pumps N 100860 1 54 cc rev single standard accuracy gear pump N 100861 3 2 cc rev single standard accuracy gear pump N 100862 4 5 cc rev single standard accuracy gear pump N 109690 10 cc rev single standard accuracy gear pump N 108875 8 5 cc rev single high accuracy gear pump N 084E374 0 584 cc rev single high accuracy gear pump 084E376 1 752 cc rev single high accuracy gear pump 084E428 0 297 cc rev single high accuracy gear pump 084 430 1 168 cc rev single high accuracy gear pump N 084E434 2 920 cc rev single high accuracy gear pump Dual Pumps Note all dual pumps require PN 102049 see below
71. not ready temp 5 Verify that ASU is warmed up and that eratures are too low hopper temperature is above the low temperature thermostat Pump runs butthereis 1 ASU is out of adhesive 1 A dd adhesive to hopper no adhesive output 2 f pump has been serviced 2 Check pump wiring to schematic and leads reversed pump will run with no output Low or inconsistent 1 Filter s clogged 1 and inspect filter basket adhesive output and primary filter 2 Adhesive used is too 2 Verify that system components are viscous at appropriate temperatures and that the selected adhesive is correct for the application Filter Basket 3 Clogged hose 3 Inspect hose for kinks or internal plugs of debris or char Clean or replace hoses as necessary 4 Clogged applicators 4 nspect applicators for plugged nozzles or filters Clean or repair applicators as necessary iTV Dynatec 2000 Troubleshooting Page 7 27 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 5 The fixed pressure relief 5 When fully closed clockwise and valve is opening all applicators are off adhesive pressure should be around 34 bar 500 psi If itis significantly less the pressure relief valve should be replaced 6 Inoperative lower o ring 6 Replace o ring Follow diagram and in filter plug is allowing instructions in Chapter 6 for Outlet pressure to escape Filter to locate the o ring Adhesive leak atpum
72. on th hub to act as a stop for the armature to prevent an excessive air between the armature and rotor face The armature has Since on its inside diameter which mate with splines on the hub The armature is spaced the driven hub so it can Move laterally the face of the drive hub or rotor Rotor and armature Normally the wear rate will be the same on n botti surfaces It is recommended that both elements be changed at the same time Due to the metal to metat contact of rotor and armature grooves will occur in armature face during normal service life _ Repairs When the wear between the armature and friction face the rotor exceeds 3 32 or at the time the clutch fails to engage the following parts are to be replaced Armature Rotor assembly Other parts which are to be replaced when they become worn or malfunction CM Ball bearings ues Magnet and coil assembly Splined driven hub Troubleshooting for industrial Type Clutches Note if DC voltage is measured without the coil being connected misleadingly high reading results due to capacitor in the arc Suppression network used with the rectifier A Overheating coll burned out or loss of torque 1 Check ambient temperature ts it above Consult factory for assistance 2 Check thermal capacity of unit versus actual heat dissipation requirements See Catalog 500 for specification
73. on the polymer type temperature pump size and furnace load CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning A fter gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent t 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 perform ing 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 perfor mance of a pump immediately before removing it from service and correlating the perfor mance 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 D ynatec for com plete 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
74. only if clutches are installed on your ASU It is reached by Pressing F2 Clutches on the Pump Screen seen on pre vious pages The number of clutches on the ASU will equal the number of motors For DM 35 thereis a maximum of two pumps clutches For DM 70 140 there is a maximum of four pumps clutches For DM 210 thereis a maximum of six pumps clutches SYSTEM Ready Tue 3 36 PM L e Press Enter and Select Mode Switch Clutches ON OFF with button 1 SYME AECI 2ST Pump Clutch 1 Pump Clutch 2 Pump Clutch 3 i Pump Clutch 4 Pump Clutch 4 Pump Clutch 6 TUV WXY RE START STOP ALL RETURN i 2 F3 F4 0 gt 123 Turn Clutch ON OFF using numeric keys 1 thru 6 ITW Dynatec c 2000 Programming Page 5 13 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Optional Clutch Programming Screen Press This To Function Key Re start F2 Turn ON all clutches at once Stop Turn OFF all clutches Return F4 Return to the Pump Screen Programming 1 To turn individual clutches On or Off toggle individually on the numeric keypad Monitoring 1 On Off status of each clutch is indicated Optional Pressure PSI BAR Programming Screens The two Pressure Programming screens are active only if pressure transducers sensors are installed on your ASU They are reached by Pressing F3 Pressure on the A ctual Temperatures Screen The number of pressure
75. reinforced safety shoes Safe Installation and Operation To avoid possible failure of hoses make sure all hoses are routed to avoid kinking tight radius turns 8 or less and abrasive contact Hot melt hoses should not have prolonged contact with heat absorbing surfaces such as cold floors or metal troughs These heat absorbing surfaces can alter adhesive flow and cause incorrect calibration Hoses should never be covered with materials that prevent heat dissipation such as insulation or sheathing Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections Do not use adhesive that is dirty or that may be chemically contaminated Doing so can cause system clogging and pump damage When adhesive hand held applicators or other movable applicators are used never point them at yourself or at any other person Never leave a hand held applicator s trigger unlocked when not actually in use Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until the adhesive s temperature is within the operating range Severe damage could result to internal parts and seals Treatment for Burns From Hot Melt Adhesives Burns ca
76. removed DO NOT handle the boards except by their edges Read the section on PCBs in Chapter 7 of this manual for further cautions Software Version You can determine the software version of your controller by noting it when it comes up on the Help Screen or on the display at startup ITW Dynatec M Control V 5 00c Current Software Version Page 5 2 Programming ITW Dynatec c 2000 Revised 12 02 DYNAMELT M ASU Manual 50 13 20 36 20 37 20 38 Display amp Keypad Reference Scheduler Key Standby System Status Day Date Clock Ready Scheduler Active Indicator 7 Day Scheduler Heat up Program Recipes Alarm Day of Week Standby Time of Day Service Key On Off Key amp LED Hs rg SYSTEM Alarm 9 Tue 3 36 L e5 D Actuals F Next Page Press Premelt gt SYM ABC DEF Progmelt 1 2 3 Filterblock Hose Head HOLD HOLD HOLD Aux Zone JKL MNO 4 5 6 Pump PRS TUV WXY 7 8 9 E 0 gt ABC 123 e or Symbol use to enter Enter RPM if optional actual a space colon dash 0 toggle from nu RPM readout is installed dot Q or Z into meric 1 2 3 to alpha text Continued A B C entry lt gt Display amp Function Keypad Numeric Actual Temps Screen shown as example Keypad current software version SYSTEM Alarm N Tue 3 36PM Program gt 5 M C ontrol V5 00
77. s factory The Low Level relay is fixed at normally open The High Low Alarm relay is fixed at normally closed During normal operation the two red indicator lights are always ON Triac control for Hopper Head Hose 1 amp 2 PC PLC Serial Channel EPROM not removable or programmable by user Connect to Operator AG XB iL uud Battery Panel PCB Relay outputs LEDs 182 alarm contacts x1 L 384 low level contacts A Optional Scheduler chip Dynatec factory use Flat nnect t 4 at cable connect to 0 switches Auxiliary PCB or Relay Output PCB Flat cable connect to optional motor board Flat cable connect to optional Memory Card Reader Terminal connections 1 Program Select 1 1 2 Input 2 4 6 8 12V 3 Low Level Detect Input 5 External Setback Input 7 Program Select 2 3 4 Input 9 amp 10 Ground 0000000000 Flat cable connect cutout to Power PCB Sensor Inputs for Head Hose 3 amp 4 Sensor Inputs for Head Hose 5 amp 6 and Aux 1 2 amp 3 Sensor Inputs for P dd e Hopper amp Head Hose 1 amp 2 Sensor Input for channel 16 Layout of Components on CPU Board ITW Dynatec c 2000 Troubleshooting Page 7 5 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 06 Display CPU Printed Circuit Board The Display CPU PCB contains the controller s CPU modul
78. s temperature Press 7 to program Sequential Heating Scroll to choose one of the three selections No sequence First all hopper zones or Hold electric head Press Confirm F3 Sequential heating allows you to choose the heating order of the temperature zones so that zones requiring more time to heat up to temperature can be programmed to begin heating before others In the case of the Hold Electric Head selection programming of a reduced temperature for ten minutes allows for the stabilization of the electric valves A No sequence designation means that all temperature zones will begin to heat immediately after the ASU is powered on b Firstall hopper zones means that the hose head auxiliary zones do not begin heating until all hopper zones have reached the low limit of their setpoints Zones which are switched OFF are not applicable c Hold Electric Heads at xxx F for 10 minutes applies to systems utilizing electric applicators only After choosing this selection and programming the temperature to the softening point of your adhesive see your adhesive manufacturer the controller holds all electric heads at the oper ator selected temperature for ten minutes before releasing them to operating setpoint The controller s default heating sequence for the D ynamelt ASU is first all hopper zones This al lows the larger mass of adhesive in the hopper to begin heating immediately Press 8 to program Temperature Scale
79. strength and abrasion resistance for these items that are the most critical to proper metering performance OPERATION All Dynatec Zenith High A ccuracy 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 ex posed 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 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 Since these pumps are not self priming a flooded suction is usually the minimum inlet pres sure 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 D ynatec Zenith pumps rely on the metered fluid for lubrication of internal bearing areas pump should never be allowed to run dry or be allowed to run with non lubricating fluids Such as water B ecause of the close clearances in the bearing areas lack of sufficient lubrica tion 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 pres sure
80. system They are used to monitor system operating pressures and their limits The Pre PSI transducer measures adhesive pressure in the filter manifold before the filter basket The Post PSI transducer measures the pressure after the filter basket By comparing the two readings the operator can determine if the filter basket is clogged Drop in Grids PN 104802 The drop in grid is an extra heated grid s which is installed near the bottom of the A SU s hopper The additional grid s allows faster melting of adhesive for applications requiring higher melt rates and higher volumes of adhesive W hen installed the drop in grid becomes an auxiliary temperature zone on the controller High Temperature Heater Groups M ore 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 D ynamelt is a 100 mesh filter PN 101247 Level Control PN N08122 This device informs the operator via a
81. that operators using adhesives with extraordinarily high or low melting points can tailor the low temp setting to their production s needs To access the pump enable thermostat follow the instructions given in Chapter 8 Refer to Chapter 3 for instructions on calibration of this thermostat Lithium Battery on CPU PCB The CPU Printed Circuit Board contains a lithium battery which serves no function in the Dynamelt M Series controller configuration Lithium Battery on Display CPU PCB The Display CPU Board contains a lithium battery The normal life of this battery is about ten years W hen the battery needs replacement the scheduler s clock does not function but other con troller features remain intact Return the board to ITW Dynatec for battery replacement ITW Dynatec c 2000 Troubleshooting Page 7 3 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Handling Printed Circuit Boards PCBs The Dynamelt ASU and D ynaControl controller utilize several printed circuit boards PCBs These boards are extremely sensitive to electrostatic charges W hen working near or with any PCBs the following procedures must be followed to avoid damage to them DANGER HIGH VOLTAGE Before unplugging connectors from the I O PCBs ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the PCB assembly when you are remov ing and replacing connectors
82. the armature and the driving torque developed between these components effectively couples the shafts together This torque or power flow is developed whether the driving force is on the driven hub or on the drive hub assembly Our standard terms are used to help identify the parts for descriptive purposes only Installation The magnet and rotor assembly are mounted on one shaft normally the drive shaft Be certain that the key is in place in the keyway and push the assembly on the shaft until the end of the shaft is flush or nearly flush with the counter bore in the rotor face Do not have shaft extend beyond the counter bore in the rotor face The splined driven hub with armature is mounted on the adjacent shaft Maintain the air gap per Table A between the rotor and armature open magnet armature gap Proper positioning can be checked by this air gap with the de energized Setting the initial starting gap near 010 will provide for slightly longer life from the clutch with spring release Fasten restraining bracket in a manner that prevents the magnet body from rotating Caution Do not overtighten the bracket as this preloads the bearing Electrical Connection s The voltage to be applied is determined by the rating shown on the nameplate common way to provide control voltage for a unit is to use a full wave rectifier control Connection diagrams provided with these rectifiers will depict the proper electrical connecti
83. the filter 10 Lower the filter basket and the filter plug back into the filter cavity 11 Position the two flat surfaces at the top of the filter plug parallel to the movement of the slide The slide will not return to its operating locked position unless these flat surfaces are aligned properly If necessary twist the plug to align 12 Re tighten the two purge screws Hose Fittings All hose fittings should be checked for tightness after every three months of operation Fasteners A fter 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 M elt amp Grid Assembly for location of the filter shutoff assem bly 1 Pump all the adhesive out of the hopper 2 Lower the temperature of the application system to the adhesive s softening point cont Page 6 4 Preventive Maintenance iTV Dynatec c 2000 Revised 3 01 DYNAMELT M ASU Manual 20 28 and 20 36 WARNING HOT SURFACE The ASU will still be hotfor this procedure Use insulated gloves and protective clothing when removing the filter shutoff 3 Open the two access doors located at the sides of the ASU Do not pull out the ground wires attached The filter shutoff assembly is located on the side of the hopper 4 Wearing gloves use a wrench to unscrew the filter shutoff nut and
84. the value in the first row then press Enter The Standby Temperature is a reduction in temperature by which all the temperature zones will be reduced in a standby condition F or example if the hopper setpoint is 275 and you program a 100 degree standby temperature the controller will reduce the hopper temperature to 175 Numerical ly the controller will accept any standby temperature within the range of 30 C and 150 C 30 F and 150 F Press 3 to program Standby Time Delay and Sleep M ode Enter a numeric value for the time delay Press Enter Toggle press F1 or F2 to Sleep M ode Enter a numeric value for Sleep M ode Delay Press Enter Press Return F4 The Standby Time Delay allows programming of a delay from the time the external standby ter minals for connection see Chapter 3 are connected until the ASU enters its standby mode The time delay selected must be in the range from 0 00 which represents an immediate entry into standby i e no delay to 18 0 hours The Sleep Mode may be activated only during Standby It becomes activated after a programmed length of time 0 1 to 18 0 hours During Sleep M ode all heaters are turned OFF and the motors are stopped The display reads F 1 to Start Heating when in Sleep Mode To disable the Sleep M ode press Disable F 3 Standby and Sleep M ode work together For example if you program a Standby of 1 hour and a Sleep M ode of 3 hours the ASU enters Standby o
85. time when adhesive is not being applied DynaControl Options Pendant Control Panel PN 107643 The pendant control option gives the DynaControl keypad mobility via a 9 meter 30 ft 6 meter 20 ft or 3 meter 10 ft cable The Pendant Control Panel replaces the standard display panel Pressure Display PN 108388 The pressure board option enables the controller to read and display adhesive pressure PSI values in the outlet filter manifold The option consists of a PSI printed circuit board which is used with a pressure reading device transducer or gauge mounted on the filter manifold Actual Digital RPM Readout PN 107946 This option provides a controller readout for actual motor or pump revolutions per minute N o addi tional programming is necessary Installation on an encoder is required System Status Lights PN 104280 Remote monitoring of system status is made easier with this tri color light The stack light is mounted on a 6 x 6 box which is itself mounted on a stand with a 10 cable Wired into the con troller the lights illuminate to indicate Power On Ready and Alarm An audible signal ac companies the Alarm light The alarm may be wired to indicate either high low temperature low adhesive level or open short sensor Line Speed Tracking Options Line speed tracking is a standard feature of the M Series ASUs which allows the speed of the motor and ASU to follow the speed of a production line via a reference voltage
86. to 122 F Noise emission 60 dbA at 1 meter 39 inches Physical DIMENSIONS eos croce e EFE Eqs see dimensional layouts on following pages Number of heads 5 1 to 4 heads hoses Number of return hoses or auxillany zones 104 Number of hopper temperature zones 2 or 3 add 1 for optional drop in grid NUMDEr OF PUMPS ber p DU aS hen es Gea lor 2 Number of standard drop in gridS sre cid ha tines bean exi ide 1 Number of optional drop in 0105 suit eo E SOR Re e EO eae ie ve Dre ee REPRE ER EN 1 Gear PUMPS cn ases oe e an ERU e Eb EE UE HUP Ears 2 92 cc rev standard Enclosure cssc vasis er ue ere ER styled durable metal dust and splatter resistant Hose connections universal 15 pin A mphenol connectors at asu wrench secured fluid fittings 6 JIC Hopper roto etti aea Nod RE eoe 35 77 lb Hopper 5 machined welded aluminum Teflon impregnated Filtration end eua iore ad ave pet hopper bottom screen large pleated pump outlet filter Weight of base unit empty tbd Adhesive form e catre e ia payer med e ah La quer ear E icd que
87. to 8 Adhesive Ports Note Always connect Auxiliary Return Hose 1 A1 to Auxiliary Electrical Connect 1 A1 Feed Hose 1 F 1 to F eed Electrical Connect 1 F 1 etc as described on page 3 3 511 PSI2 Fl F2 O O OOOO Adhesive supplied Adhesive supplied by motor pump 1 by motor pump 2 Up to Two Filter Blocks with up to 8 Adhesive Ports Dynamelt M35 Electrical Connection and Filter Manifold Arrangement for Maximum Head Hose Configuration iTV Dynatec 2000 Installation Page 3 7 DYNAMELT M ASU Manual 20 36 Revised 11 01 Adding Adhesive Theadhesivelevel in the melt tank should be maintained at 13mm to 100mm 1 2 to 4 from the top of the hopper W here applications demand a high output volume of adhesive add small amounts of adhe sive frequently A dding large amounts of adhesive to an almost empty hopper will lower the tempera ture 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 haveto beflushed if thetwo formulations areincompatible See Chapter 6 of this manual forthe proper flushing procedure W hen in doubt about adhesive compatibility flush your system Field Installation of Controller Options Customers who choose to modify their adhesive supply unit with ITW D ynatec manufactured options should assure that on
88. to en sure that they are free turning If binding occurs at any time determine the cause and correct itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component N ever use force re assembling or turning a D ynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely R e 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 fix ture 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 5 Placethe driven metering gear on its arbor and carefully mesh with the drive metering gear 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 d
89. two or three presses of a key to distinguish between the letters Press Enter after each desired letter or number is in place b press the 0 zero key to toggle from letters to numbers press the SYM key to enter a space colon dash dot 0 2 or other special characters d press F 1 to toggle from upper to lower case e you cannot back up If an error is made press Enter repeatidly to advance through the name loop until you reach the point for correction and re write as desired f press CLR LINE to clear an entire line g you may COPY F2 PASTE F3 and then modify to save time when names are similar h press F4 to advance to the next motor or zone to be named To program Customer Zone N ames Press F1 to program Temperature zones F2 to program Pumps or F3 to program Pressure Transducers Scroll to the first item to be named Press Enter to allow naming Using the A Ipha N umeric keypad and following the rules given above spell out name as desired Press F1 F2 or to select another item to name Repeat until all items are named as desired Press F4 again to Return to Service Page 2 screen Press 2 to program Power On Configuration This function gives the user the choice of having the heaters and pumps come on or remain off whenever the ASU is powered on USA default is both On European default is Heaters On Pumps Off Note programming here overrides programming made at the next Service Function Function 3 Factory
90. 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Hopper H eater O pen 1 Disconnection in hopper 1 Inspect hopper heater wiring for heater circuit proper connections 2 Disconnection between 2 Verify that all connections are properly Power and CPU madeon the CPU 3 Hopper circuit breaker 3 Refer to the schematic in Chapter 11 tripped to locate the hopper circuit breaker If itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit to ground in the hopper heater TH POPE circuit This will be limited to between eater Wire Ries the hopper control relay and the hopper heater 4 Open hopper heater 4 Atthe terminal rail use an ohmmeter element to measure resistance across H3A and 380v or across H3A and H3B P 240v See the resistance table Hopper Circuit Breaker in this chapter for normal resistance values Infinitely high reisistance values indicate an open heating element which must be replaced NOTE A DM 70 140 models If the ASU has a second heater measure may have up to two hopper this heater s resistance across H 15A and heaters 380v or across H 15A and 15B 240v as outlined above NOTE B DM 210 models If theASU has a second heater see Note may have up to three hopper If the ASU has third heater measure heaters this heater s resistance across H27A and N 380v or across H27A and H27B 240v as outl
91. 00 RTD SENSO BLUE 20 AWG Lh 9 HOSE SENSOR R BLUE 20 10 HOSE SENSOR BLACK 18 AWG 11 HOSE HEATER LIS WHITE 18 AWG 120V APPLICATOR END Rew ER WIRE YELLOW 18 AWG 200V ASU END VIOLET 18 AWG 240V T T GREEN YELLOW 16 AWG L GROUND HOSE CORE NOT GROUND ES 1 ALL WIRING 15 ROUTED THROUGH THE HOSE p WIRE SIZES SHOWN ARE FOR NO 6 AND NO 8 HOSES UP TO 24 FT IN LENGTH FOR LARGER DIAMETER AND LONGER HOSES HEATER LEAD WIRES ARE 16 AWG OTHER WIRE SIZES AND COLORS MAY BE CHANGED IN SPECIAL HOSES PER CUSTOMER REQUEST HOSE SCHEMATIC PN 101082 REV G ASU to Applicator i TV Dynatec 2000 Schematics Page 11 3 DYNAMELT M ASU Manual 20 36 Revised 10 00 PLUG HEAD 7 BROWN 22 BROWN 22 GND GRN YEL 18 5005 ACTIVATES HEAD Notes 1 ALL WIRE MIL W 22759 10 OR 12 MINIMUM 600 VOLTS 260 DEG C 2 SOLENOID S VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION 3 RTD WILL BE PLATINUM 100 OHM HEAD SCHEMATIC PN 103117 REV B Page 11 4 Schematics iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 Function of OutletFilter Manifold s Closeable Cross Channel A Closeable Cross Channel Plug is located inside the Outlet Filter M anifold to prevent adhesive flow between the two outlet filters when a du
92. 0001 convex and a surface finish of 4 to 8 rms to prevent leakage between the pump and block M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to D ynatec s recommended limit for the bolt size used See Table 1 on page 26 for torque values The following is a brief standard installation procedure For any special applications con siderations or simply to ask our advice please contact ITW D ynatec cont iTV Dynatec 2000 Appendix 19 DYNAMELT ASU Manual 20 36 20 37 20 38 Revised 3 01 TO PREPARE THE PUMP FOR USE 1 Always flush out the plumbing system before connecting the pump 2 Filters should be installed prior to the pump inlet that filter ideally to half the pump run ning 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 D ynatec recommended torque at room temperature 6
93. 042 M10 1 5 x 100 All Thread Component Illustration 1 54 cc Rev Single Gear Pump Assembly 100860 Page 10 16 Component Illustrations amp BOM s Revised 9 00 T Dynatec c 1999 DYNAMELT M ASU Manual 20 36 Bill of Materials for 4 50 cc Rev Single Gear Pump Assembly 100862 Item No RA W Ne e e me Be a NA nA FB W NY Part Number 012D072 0781001 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 amp 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 4 x 25 SHC Screw M10 1 5 x 80mm M10 Flat washer Qty KR A N e N A N N A e e N e e iTV Dynatec c 1999 Component Illustrations 8 BOM s Page 10 17 DYNAMELT M ASU Manual 20 36 Revised 9 00 In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104042 M10 1 5 x 100 Thread Component Illustration 4 50 cc Rev Single Gear Pump Assembly 100862 Page 10 18 Component Illustrations amp BOM s Revised 9 00 TW Dynatec 1999 DYNAMELT ASU Manual 20 36 Bill of Materials for 1 54 cc Rev Dual Gear Pump Assembly 100863 Item No UU NO
94. 2 Go to the pumps programming screen Pressure F3 Go to the pressure screen Help F4 Go to the Help screen Service Go to the first of the three service screens Scheduler Go the the M ain Scheduler screen ITW Dynatec c 2000 Programming Page 5 7 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Actual Temperatures Screen cont Programming Sequence details on following pages 1 Press Setpoints After programming all of your temperature setpoints return to the A ctual Tem peratures Screen 2 Press Pumps A fter programming all pumps and optional clutch es return to the Tem peratures Screen 3 Press Pressure if optional pressure transducers are installed on ASU A fter setting limits for all pressure transducers return to the A ctual Temperatures Screen 4 Press Scheduler K ey to program the following functions Standby Time amp Date Clock 7 D ay Scheduler and or Program Recipes 5 Press Help to view the Help screen illustrated on page 5 2 Monitoring 1 System Status display describes system status as one of the following a System Heat up power is ON but zone temperatures have not risen to setpoint range b System Ready all zones have reached setpoint temperatures c Alarm a temperature zone is out of its setpoint tolerance range A n overtemp alarm is indi cated by an upwards arrow next to a temperature A n undertemp alarm is indicated by a down wards arrow next to a temp
95. 2 Component Illustrations amp BOM s ITW Dynatec c 1999 Revised 08 06 DYNAMELT M ASU Manual All Models Bill of Materials for Pressure Relief amp 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 102710 Filter Block Top Assembly 1 1 N00181 O ring 014 6 2 N00185 O ring 018 2 3 N00753 1 8 NPT Level Seal Plug 1 4 N00187 O ring 020 2 5 N00754 1 4 NPT Level Seal Plug 3 6 103626 3 8 BSPP Plug 2 7 102712 Filter Block Insulator Plate 1 8 102717 Check Valve 655 Cart 1 way 2 9 NPN 8 1 25 x 90 SHC Screw 6 10 803173 1 2 BSPP Plug 803984 06 804155 08 803142 12 hose fitting 2 108928 Manifold Sub Assembly 1 11 112667 O ring 124 2 12 78 282 0 x 1 8 Drive Screw 6 13 N02969 Pin Spring 125 x 1 2 14 105099 8 x 25 SHC Screw 2 15 N07429 8 1 25 x 30mm 6 16 006G112 Cap Adjustment Screw 2 17 012 002 Pressure Relief Spring 2 18 109244 Pressure Relief Adjustment Screw 2 19 109245 Bullet Hi Pressure 2 20 112666 O ring 122 2 21 104733 Plug Pressure Transducer 1 2 20 4 22 078D027 3 4 16 Jam Nut 2 23 101246 Filter Basket 40 Mesh 2 24 102711 Filter Block 1 25 102713 Filter Block Heater Retainer Plate 1 26 102714 Pressure Relief Filter Plug 2 27 102715 Filter Plug Retainer Slide 2 28 N04349 Pin Spring 250 x 875 2 29 102716 Slide Housing Frame 1 30 102718 Filter
96. 20 38 Motor Control Interface Printed Circuit Board For each motor on the A SU there is a M otor Control Interface PCB and a M otor Speed Control PCB TheM otor Control Interface PCB diagrammed below connects directly to the CPU PCB The M otor Speed Control PCB diagrammed on the following page connects via a spade connector to the M otor Control Interface PCB Up to two motor s pcbs may be connected to one CPU PCB Each M otor Control Interface PCB s jumpers should be set as follows the J1 and J 2 jumpers should always be set in the M 1 position diagrammed below for motor 1 3 and 5 For motor 2 4 and 6 jumpers 1 and 2 are set in the M 2 position opposite from those diagrammed below The M S selection jumper must be set in the M position The 3 jumper is always set as shown below MAX speed adjusting pot This pot adjusts the maximum output voltage of the motor speed con trol board It is factory preset to full pump motor rpm 10096 Normally this pot does not need ad justment Turning clockwise increases the voltage To verify adjustment set the motor to manual mode and to 100 speed Then adjust the pot to desired maximum speed 2 596 NOTE Do not attempt to use the MAX pot adjustment to trim the line speed to a given value Proper automatic line speed following is accomplished with correct motor programming into the controller see Chapter 5 ENCODER connections the optional Digital RPM Readout s enc
97. 3 FOR MOUNTING GUERA e 2242217 lt 6 F STO 25535 SECTION A A 3 85 Ed CAPACITY CC REV AFTER ASS Y MATCH 2 DRILLED HOLES FOR ROLL PINS AR WTC IAT Oe I MRE site APR im Appendix 11 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec c 2000 79891 EE Ties s 5u3108YH2 HOIH 921 NMOHS NOIIVOO 1Y 1N3432V 14510 9 U3QMTN Luvd 13 SALON SNId 7108 304 Sg 0H Gi T1180 amp HOLY A SSV H3liV LIINI 6 310N 24768 sg 18084 137100 1804 131100 d Y Y 11335 BLON 335 la 59 07 12 AY 2 015 ISNV NON OWN iG eeva veo E gt 22 mm ALIOYavO 331VN Q MLI eo 626661 9 5 29 4 iTW Dynatec c 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 12 Revised 10 00 ITW DYNATEC PART CAPACITY CC REV 2 250 ROLL PIN 813 INLET PORT BOLT HOLES NOTES ETCH PART NUMBER amp DISPLACEMENT DE A P 553 Y E eer SANZ STD E ce 4 M N IE M BASANAN SECTION A A 404 WOODRUFF KEYWAY NON ANSI STD AFTER ASS Y MATCH 2 ORILL HOLES FOR ROLL PINS ANG
98. 4 Gear Pump Troubleshooting Guide 7 25 Page vi Table of Contents TW Dynatec 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 Chapter 8 Disassembly amp Re assembly Procedures Disassembly Procedures AA cR CRY OR a RD Re 8 1 To Removeithe Access Doors eri be bbb Re Ce ee od RUE Pap Re ERI n ERR E A e 8 1 To Op n the Junction Box Riv piu Rl RR RR RI PC Rid Rp WE ae 8 1 Sensor or Thermostat Replacement 1 4 8 2 To Remove the Manifold Cover wc ccc vi ebb eee ede eee eb bee re ER E REA Fee iy de 8 2 ot ON AA Sh ete da eee eee ian 8 2 To Access the RTD Sensor in the Optional Drop in Grid 8 2 To Access the Electrical Components Inside the Panel Box 8 3 FuseiReplacement att latent coat entes ti eet pieni 8 3 Printed Circuit Board Replacement 4 8 3 To Access the Pump or Motor ARER Soe epo Ree e 8 4 Motor Removal cuc uer ERREUR E i ene ee A 8 4 Pump Removal Rit aged ole Mea els NE Ma ep de 8 5 Pump Seal O ring Replacement
99. 9585 106048 106772 106773 105152 106892 105117 106236 106876 106319 105865 105101 106769 106770 106771 101842 804749 805042 804532 02145 078 013 078 017 804526 01829 0780008 Description Handle Side Panel Panel Top B racket A ccess Cover Rear Cover M 35 M anifold Cover Manifold Cover Hi Flow Only Base Plate M 70 140 Top Panel M 70 140 Heat Barrier Panel Box M 70 Panel Box DCL Mounting Bracket M5 Hex Nut Swivel Caster Receptacle Bracket Connector Bank Amphenol 3 8 16 K ep nuts M4x 12 BHC Screw Blank Plate Dual Blank Plate Single M 3 Hex Nut M5 x 16mm HHC Screw M 6 x 16mm SHC Screw M 6 Flat Washer M 8 Star Washer M8 x 12mm HHC screw M8 Hex Nut Stand off Option Lid Assembly Inner Hinge Outer Hinge M3 x 6mm PHLC Screw M3 Flat washer M 4 x 8 Pan Head Screw M 4 Star Washer Retaining Clip M 6 Star Washer M 6 Hex Nut M 6 x 16mm HHC Screw Hinge Attached to hopper lid Lid Hopper Heat D eflector M 35 70 Collar Hopper M 35 70 Handle Hopper Lid Front Panel K it Option Transformer O ption Base Plate Transformer Extention 3 8 16 x 1 25 SHC Screw Transformer extention hardware 3 8 Flat washer Transformer extention hardware 3 8 Lock Washer Transformer extention hardware Transformer not Shown 3 8 16 x 3 HHC Screw transformer hardware not shown 3 8 16 H ex Nut transformer hardware not shown Qty pL HP 4
100. C Tracking Signal 3 13 Level Control Capacitive Sensor with Amp 3 14 Typical Start Up and Shut Down Procedures 3 15 Storage and Disposal of the Application 1 3 16 Chapter 4 DynaControl Controller Set Up Temperature Control Functions in General 2 4 1 Defining DynaControl Temperature Control Terms 4 1 Eiror Indication and Alarins ER De Tv P e GRO RR Aa 4 4 Optional System Status 1 48 4 6 Settings for a Typical Operation 4 6 System Values that are Factory Programmed not customer accessible 4 7 Customer Programmable Values Preset at the Factory 4 7 Page iv Table of Contents T Dynatec 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 Default Settings of the DynaControl Controller 1 4 8 Helpful Tips for the User RE RU RE E Rt RE Rc 4 9 Serial Protocol i e here e dH ace GE ea eh a dee ad ac d eed 4 10 EtherNet IP Adapter Option tee ECHO E E
101. DS 4 13 Chapter 5 Programming of DynaControl Controller Controller Safety 2 5 1 SOLtWal Version e 5 eret m PRU DH meer QU PM PI HERMES nME i 5 1 Display amp Keypad 2 52 Basic Programming Sequence Quick 5 4 Controller Setup otro DIN eR epe ERRORI RC ed Dee ge eR Sees ES 5 5 the Controll r On adeb Wa RES sadn tad datas 5 5 Language S lection sa Mb E aaa Boas 5 5 Temperature Scale Selection 5 5 Actual Temperatures Screen sese begeben etm epe ehem et pe ms 5 6 Use of the Actual Temperatures Screen 5 6 Programming Sequence 1 2 5 7 Monitorings p 5 7 S tpoints Programming Screen 22 ssec do a soda da 5 8 Use of the Setpoints Programming 5 5 9 Programming rr eie mi e iR MER PHP 5 9 Monitoring bain tie ah lah D CR E ec 5 9 Motor Programing Screen eet Ret EN Behe in erent once RR e n 5 10 Use of the Motor Pr
102. E428 084E374 084E430 084E434 108875 084E438 084E389 084E432 108874 084 419 0126027 069 064 N01010 069X270 078A618 078C141 069X289 110289 110290 110291 103923 103624 103924 N00181 069X270 102927 103917 103918 103919 104351 Description TSHA Pump Adapter Assembly Pump Adapter O Ring 28 O Ring 12 Seal Dual Pump to Progmelt not part of this assembly O Ring 24 3 8 Washer 3 4 OD M10 x 85mm SHC screw Zenith Pump Shown For REf Only THSA 297 cc Single Outlet THSA 584 cc Single Outlet THSA 1 168 cc Single Outlet THSA 2 292 cc Single Outlet THSA 8 5 cc Single Outlet THSA 30 0 cc Single Outlet THSA 584 cc Dual Outlet THSA 1 168 cc Dual Outlet THSA 2 292 cc Dual Outlet Zenith Pump Adapter Assembly Adapter Z Pump O Ring 041 O Ring 021 O Ring 025 Screw Pump Mounting 7 16 ss Washer 3 4 OD Drive Shaft Seal shown For REf Only THSA Pump Shown for ref only THSA 20 cc Single Outlet THSA 30 cc Single Outlet THSA 45 cc Single Outlet Feinpruef Pump Adapter Assembly Adapter Plate O ring Plate O ring 014 O ring 025 O ring 133 Feinpruef Pump Feinpruef Pump 3 cc Feinpruef Pump 1 2 cc Feinpruef Pump 2 4 cc Coupling Half Not Shown See drive Section Qty RRP NR m A A N RP RP PR m e FRPP TwDynatec c 1999 Component Illustrations amp BOM s Page 10 23 DYNAMELT M ASU Manual 20 36 Revised 7 03 THSA Pump Adapter Assembly 084E 406
103. Head 9 Actual Temp Head 10 Actual Temp Head 11 Actual Temp Head 12 Actual Temp Auxiliary 1 Actual Temp Auxiliary 2 Actual Temp Auxiliary 3 Actual Temp Auxiliary 4 Actual Temp Auxiliary 5 Actual Temp Auxiliary 6 Actual Temp Auxiliary 7 Actual Temp Auxiliary 8 0 to 500 F 1999 open sensor 999 shorted sensor Date 08 11 05 Page 3 of 5 Dynacontrol EtherNet IP Data Table IN Area Dynacontrol to PLC Dynatec Adhesive Application Systems Version V5 15M Word Address Valid Range Function Zone Name Actual Temp Auxiliary 9 Actual Temp Auxiliary 10 Actual Temp Auxiliary 11 Actual Temp Auxiliary 12 Actual Pump Speed 1 Actual Pump Speed 2 Actual Pump Speed 3 Actual Pump Speed 4 Actual Pump Speed 5 Actual Pump Speed 6 010 1500 0 0 to 150 0 RPM requires RPM readout option Line Speed 1 Line Speed 2 Line Speed 3 Line Speed 4 Line Speed 5 Line Speed 6 0 1000 0 to 100 0 0 to 10V Controller ON OFF 0 Controller is OFF 1 Controller is ON Standby ON OFF 0 Normal Mode 1 Standby is active Adhes Level Status 1 Adhes Level Status 2 0 Level is OK 1 Levelislow requires level control option Premelts On Off Progmelt
104. ITW Dynatec ITW Dynatec GmbH OPERATIONS amp SERVICE MANUAL An Illinois Tool Works Company Industiestrasse 28 31 Volunteer Drive D 40822 Mettmann Germany Manual 20 36 Hendersonville TN 37075 USA Telephone 49 2104 915 0 Revised 9 15 07 Telephone 615 824 3634 FAX 49 210 2104 915 111 FAX 615 264 5222 ITW Dynatec K K Daiwashinagawa Bldg 7 15 Konan 3 Chome Minata Ku Tokoyo 108 Japan iTwDynatec GERE M Adhesive Application Solutions ISO 9001 Certified w Hide E DYNAMELT M SERIES ADHESIVE SUPPLY UNIT OPERATIONS AND SERVICE MANUAL Model DM M35 DCL Software V5 11M and up with Expanded DynaControl For an online copy of this manual go to www itwdynatec com manuals htm IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT It is the customer s responsibility to have all operators and service personnel read and understand this information Contact your ITW Dynatec customer service representative for additional copies NOTICE Please be sure to include the serial number of your application system each time you order replacement parts and or supplies This will enable us to send you the correct items that you need ITW Dynatec Service Parts Direct Dial 1 800 538 9540 ITW Dynatec Technical Service Direct Dial 1 800 654 6711 Moving Forward Through Technology Page ii iTWDynatec c 2000 Revised 12 04 DYNAMELT M35 DCL ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company iTWD
105. In 170 to 175 If any word does not equal 0 an alarm 18 present Changing the IP Address The EtherNet IP Adapter will be factory set to 192 168 23 180 but the DHCP BOOTP function is enabled That means the module will request a new IP address after power up If this request is not serviced the old IP address will be valid There are several ways to change the IP address In any case a PC must be connected to the module either directly via crossover cable or via hub switch to the network with the module Configuration Program Anybus IPconfig On the EtherNet IP support disc you will find a configuration tool to change the IP Address Start the Anybus IPconfig installation program Follow the instructions on the screen Once the configuration tool is running press the scan button to search for any Dynatec EtherNet IP modules If a module is detected it will show up in the window Double clicking on it will allow changing the settings for this Module 4 18 ITW Dynatec c 2005 Revised 8 05 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Using the Configuration File The file ethcfg cfg can be used to change the IP address This method is possible only if the actual IP address is known e g the factory set 192 168 23 180 See also section Configuration File OpenaFTP connection to the module e g Windows Explorer FTP 192 168 23 180 Locate the ethcfg cfg Copy this file to a folder on your PC Open the file with
106. L 8 MOUNTING PLATE GRN YEL 6AWG c as os CREW 2 E aee gt 2A SCREW 5 SCREW 285 L z 2 M TOP PLATE GRN YEL M38 14AWG 8 CABINET GRN YEL 6AWG 3 70 140 210 12AWG m Se SCREW SCREW 6 DOOR LEFT GRN YEL 12AWG SCREW amp X DOOR RIGHT GRN YEL 12AWG SCREW E o 4 HOPPER COLLAR GRN YEL 14AWG DYNACONTROL POWER BONRDGRN YEL 14AWG gt 5 SCREW lt gt g gt 4 HOPPER COLLAR GRN YEL S 5 SCREW 2 DYNACONTROL MTR BD CRN YEL 2 o SCREW HOPPER COLLAR GRN YEL 14AWG E DYNACONTROL MTR IF BD GRN YEL f V es M m m SCREW 55 m 8 4 JUNCTION BOX COVER GRN YEL 14AWG 5 5 u HEATSINK 1 GRN YEL 14AWG M E SCREW JUNCTION BOX COVER CRN YEL 14AWG 45 s HEATSINK 2 GRN YEL 14AWG 5 SCREW W amp SCREW 2 SIDE PLATE LEFT GRN YEL 14AWG 5 e Se HEATSINK 5 GRN YEL 14AWG SCREW SCREW lt lt zc SCREW S SIDE PLATE RIGHT GRN YEL 5 ee OPERATOR PANEL GRN YEL 14AWG SCREW 239 S ss PAg 8 yoror GRN YEL 16AWC C SCREW HT COVER 1 GRN YEL 14AWG PI HOSE HEAD 1 7012 GRN YEL 16AWG lt E 4 E HOPPER LEFT TANG E PI AUXLARY 1 TO 12 GRN YEL 16AWG NA E AL m y LEVEL P
107. Loosen the heat er retainer plate and slide the cartridge heater out To Access the RTD Sensor in the Optional Drop in Grid Remove the access door Remove the screws on the drop in grid s junction box cover in order to remove the cover Disconnect the sensor from the terminal strip inside the junction box and slide the sensor out of its adapter TV Dynatec c 2000 Disassembly amp Re assembly Page 8 3 DYNAMELT M ASU Manual 20 36 Revised 4 06 To Access Electrical Components inside the Panel Box Verify again that the main power is OFF On the outside of the panel box use the main discon nect switch to open panel box door see Chapter 3 for instructions for opening door a Fuse Replacement Fuses are located in the upper right corner of the inside of the panel box assembly The following printed circuit boards are fused Motor Control Interface Power I O and the optional Clutch board b Printed Circuit Board Replacement Reference the section entitled Handling Printed Cir cuit Boards in Chapter 7 The PCBs are located in the panel box assembly Refer to detailed lay out in Chapter 3 The PCBs snap into and out of their standoffs To remove place your fingertips under one corner of the PCB and pull out firmly from the standoff Repeat for each corner of the PCB Note aside from fuses and the Lithium battery on the M Series CPU PCB see Chapter 7 there are no replaceable parts on the PCBs Page 8 4 Disassembly amp Re assem
108. ONTACTS TO ACTIVATE CLUTCH 6 CL6 QUA t CABLE ANT 7 NOTE 1 TERMINALS AND ARE IN PANE ERMINALS THRU CL6 ARE ADDED CLUTCH DANE ROY Cl AN BOX NE CLUTC OPERATE WITHOUT CUSTOMER SUPPLIED ON JUMPER SECURE Cl ROTATE Schematics Page 11 7 Revised 10 00 MOTOR CLUTCH MOTOR 2 LUTCH MOTOR 4 CLUTC SCHEMATIC PN 804370 Rev A FOR PN 107945 OPTIONAL ELECTRIC CLUCH KIT Page 11 8 Schematics iTWDynatec c 2000 Revised 10 01 DYNAMELT M ASU Manual 20 36 CONDUCTOR SIZE BOTTOM PLATE ACCORDING TO BACKBONE SIZE TABLE WIRE MUST o RUN CONTINUOUS z8 o 28 t G 2814 4 IND 9 at SIDE PLATE LEFT GRN YEL 14AWG zm GND BOTTOM PLATE GRN YEL N zo U 8 9 E SCBRBEM STUD 6 is SCREW z STUD 2193 amp 2 2a M SIDE PLATE RIGHT GRN YE
109. Place a layer of 400 Grit Emery Cloth on a lapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 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 U se 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 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 P 0 Appendix 22 iTVW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 HIGH ACCURACY PUMP RE ASSEMBLY NOTE During and between each re assembly step manually turn the metering gears
110. Program directly on the menu screen by pressing 8 key to choose between Centigrade or Fahrenheit Press R eturn F4 Press 49 to Change Security Lock for Service Page 1 Enter your access code Press Enter Scroll 1 F2 to select desired function Press to Lock or Unlock function from programming e peat for each desired function To Change Y our A ccess Code Scroll F1 or F2 to select Change A ccess Code Enter your de Sired new access code Press Enter to Confirm Press Return F4 Press Service ey to advance to Service Page 2 ITW Dynatec c 2000 Programming Page 5 19 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 11 01 Service Functions Screens cont Service Page 2 Programming of the Service Functions on this screen is similar to the programming of Page 1 SYSTEM Ready Tue 3 36PM Service Page 2 Press 3 for Next Page Customer Zone Names PowerOn Configuration Factory Defaults Keypad Locking PC Link Language LCD Contrast System Logbook OY Ui 4 UJ NJ F2 Change Security Lock RETURN Function Press 1 to program Customer Zone Names This function allows the programmer to enter his de sired name for each temperature zone pump and optional pressure transducer This up to 20 character name will be the name displayed in the controller s Info Lines Program following these rules a use the Alpha Numeric keypad to enter letters and numbers When entering letters use one
111. Pull Clip 2 31 102719 Filter Preload Wave Spring 2 32 103770 O ring 5 005 2 33 103771 O ring 5 254 2 103571 Heater Control Section 240v 1 block 103572 Heater Control Section 240v 2 block 103573 Heater Control Section 240v 3 block 103574 Heater Control Section 240v 4 block 34 036A170 Heater 5 8 x 5 240v 500w used with 1 Filter Block Assembly 1 036A079 Heater 5 8 x 10 240v 1000w used with 2 Filter Block Assemblies 1 102149 Heater 5 8 x 15 240v 1500w used with 3 Filter Block Assemblies 1 036A077 Heater 5 8 x 20 240v 2000w Used with 4 Filter Block Assemblies 1 35 036E032 Sensor Adapter 1 36 036B103 Temperature Sensor 1 37 107754 Cover Hi Temp Sensor amp Heater Section 1 38 107645 Conduit 10 1 39 106156 M4 x 6mm SHSS 1 40 104163 M6 x 25mm SHC Screw 2 41 101833 10 32 x 1 2 Tamper Proof screw 2 42 104852 M10 x 12 cone Relief Set Screw 2 43 N00199 O ring 114 2 44 107751 Conduit Fitting located in junction box 1 45 N06883 Jam Nut located in junction box 1 46 103570 M5x8x 6 CUD SH Set Screw 1 Note These items are included in 108012 Plug Assembly Revised 6 03 Component Illustrations amp BOM s Page 10 3 DYNAMELT M ASU Manual All Models T Dynatec c 1999 N o o o lt o E a Component Illustration Filter amp Pressure Relief Assembly 102710 Page 10 4 Component Illustrations amp BOM s TW Dynate
112. ROBE GRN YEL tawe Z JUNCTION BOX 1 GRN YEL 12 ANG ha SCREW z MA D HT COVER 2 GRN YEL 14AWG JUNCTION BOX 2 GRN YEL 12AWG S gt gt rLroommrrio M4 HT COVER 3 GRN YEL 14AWG nS 55S 9952073 4 SCREW 399 9998 z 587 592 5 8522 4 HOPPER GRN YEL 12ANG mMALZoL eg eN e OXO SCREW E Pear TI Re ofs 4 Y LEVEL PROBE GRN YEL 250 14ANG 2 9555 S585 c g eV SCREW v E z 4 8 E a 8 GROUNDING DIAGRAM CE MARK PN 804704 REV E ITW Dynatec 2000 DYNAMELT M ASU Manual 20 36 Schematics Page 11 9 Revised 6 01 JF A JSS Ha 2
113. SU Manual 20 36 20 37 and 20 38 MIN adjusting pot This pot adjusts the minimum speed of the pump motor when it is enabled The pot is factory preset to exactly zero RPM when the speed setting is 0 0096 full scale Turning clockwise increases the minimum RPM above zero RPM when the motor is enabled This adjust ment can be utilized to creep the motor also referred to as auto preload so that positive adhe sive pressure is always maintained in the system ITW Dynatec c 2000 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 48 Zone Power Printed Circuit Board Troubleshooting Page 7 9 Revised 9 01 The 48 Zone Power PCB has the capacity to monitor adhesive temperatures for multiple hoses ap plicators hoppers and auxillary zones The LEDs for each temperature zone 1 through 48 illustrated below will flash on and off as their heaters output to maintain setpoint temperature The Power On and Hopper LEDs will light contin uously once the hopper s are up to temperature The settings of theJP1 and JP2 jumpers correspond to the number of hoppers on the ASU For ASU with one hopper both jumpers must be set to position 1 2 shown For two hoppers JP1 must be set at 1 2 and J P2 must be set at 2 3 JumperJP1 1 amp 2 1 hopper 2 amp 3 3 hoppers Jumper J P 2 1 amp 2 1 hopper 2 amp 3 2 hoppers Low temperature High temperature Connect to thermostats for thermostats for CPU lat Connect to Connect to Hoppe
114. Setpoint A programmable temperature that has been selected for hopper hoses applicators or auxiliary Zones Setpoint Limitation This is a universal maximum temperature for all zones The programmer cannot program a tem perature setpoint higher than the setpoint limitation System Logbook This is the controller s record keeping function It contains the D ynaControl s list of the last 1 000 controller events its Data Logger which records the last 1000 lines of selected actual tem peratures and a counter which records the system s elapsed hours Temperature Zone Enable The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not ever appear on the controller s display and heating is switched OFF Temperature Zone Offset D ue to the separation between the heaters and sensors in some systems the controller can be pro grammed to display a temperature for a zone which is different from the sensor s actual tempera ture The temperture zone offset mathematically corrects for these temperature differences E ach zone may have an individual offset Page 4 4 Controller Setup ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Error Indication amp Alarms Error Indication Blinking Up and Down Arrows The following illustration shows the display screen when one or more error indication conditions occur The conditions that will trigger an error indication are
115. T his 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 iTV Dynatec 2000 Appendix 7 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 high pressure discharge port section across the throat to the lower inlet port reducing effi ciency Therefore carefully gauge this area for flatness after each resurfacing 10 After all components are hospital clean the pump is ready for assembly o Figure 1 2 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 itimmediately A tiny nick burr or foreign particle can extensively damage a valuable pump component N ever use force in re assembling or turning a D ynatec pump If properly aligned the pieces will fit easily into place and the pump will turn freely e 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
116. VE 3215 1706 914 11704 DiW 0067 431511 TW NO LND NIH 82v 0 BE O0 Y X W3NIV13M 7935 saor 1 42076 5NIJVJQ 1015 A3 33046005 0051 ATQOE 9150 32494 2 331N3 NAHL 4 90 nihi lt See s 532 14 2 13404 IK ALON 33S S210H 052 xe DNIAV20 A HW3 SV uoneoyddy eas 0061 0051 9 tidy u g 0073700 T 6663730 262290 6963780 9863920 1953700 483990 9263790 62 3760 PLEIFOO CZU3Y90 2463700 984 spom poi HOU UY ABYHS 30N3H343U 55099 SANNA HLEN3Z iTWDynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 34 Revised 10 00 VOLUMETRIC EFFICIENCY 100 80 70 50 30 20 10 HIGH ACCURANCY PUMP PERFORMANCE O84E 434 MERIT T 084E436 084E376 1 752 cc rev O84E 430 084E 432 1 168 4 388 O84E 428 297 cc rev O84E 387 160 cc rev 084E 374 389 584 cc rev 01 02 05 10 2 gt 1 0 VOLUMETRIC EFFICIENCY FACTOR TUN A P DIFFERENTIAL PRESSURE PSI U VISCOSITY CENTIPOISES iTV Dynatec 2000 DYNAMELT ASU Manual 20 36 Appendix 35 Revised 10 00 Pressure Transducer 800225 Model 0101 1 5T 1 5 18 EN INSTRUCTION MANUAL
117. X251 084E 434 Tool Steel Single High 2 920cc 069X251 084E436 Tool Steel Dual High 2 920cc 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 D ynatec and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 16 iTVW Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw pumps Each had problems with pulsation flow inaccura cies 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 preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering 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 e
118. access code in order to advance to calibration Return F4 Return to the A ctual Temperatures Screen Scroll UporDown FlorF2 Select each sensor transducer Hi lt gt F3 Select the screen s high or low column Bar PSI F1 Choose pressure scale Calibrat F2 Calibrate all transducers Programming 1 The names of the pressure transducers shown on the preceeding page as PreFilter Pump 1 etc are programmed at Service Page 2 Function 1 see page 5 19 2 On Pressure Screen 1 press Pr Limits F2 to advance to Pressure Screen 2 Use the Scroll keys to select a Low or High limit for the first pressure transducer sensor to be programmed Use the numeric keypad to enter your desired value Press Enter R epeat until all desired pressure transducers are programmed with Low and High pressure limits Use 1 lt gt to move be tween columns as necessary 3 Press Return F4 to return to Pressure Screen 1 Press Setup F3 On the first message screen enter your four digit access code On the second message screen enter the maximum 51 val ue of the pressure transducer s installed on your ASU 4 Press Bar PSI F1 to choose display in Bar or PSI 5 Press Calibrat F2 to calibrate all the pressure transducers installed The controller will ask System depressurized press Confirm F3 Note Before confirming verify that all transducers are at 0 pressure Pumps must be turned OFF and time allowed for sys
119. al pump is in use When a single pump is used ITW D ynatec 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 D Check Valve 2 Adhesive In Port Adhesive Return Port When Cross Channel Plug is removed one adhesive outlet must be plugged 2225 7 22 Cross Channel Plug is removed thru port on side of manifold 2 Closeable Cross x Channel Plug 4C Tj Adhesive Outlet To 4 Hose Adhesive Outlet To Hose The second Adhesive In and Adhesive FLOW DIAGRAM OUTLET FILTER MANIFOLD Return ports are not shown iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 Schematics Page 11 5 Revised 10 00 Filter Basket TYPICAL HYDRAULIC SCHEMATIC Single Pump Motor Bypass Filter optional Transducer amp optional Pressure Gauge M SYSTEM PANEL BO PN 108266 240 VOLT POWER STACK POLE LIGHT SCHEMATIC FOR VERSION 5 M SYSTEMS BLK EN c7 X1 CONNECTOR Bik N Z lax ON PCB 106093 CPU FIA MS A 2 CR L2 N USE CPU 1 FOR HOPPER 1 git BU N USE CPU 3 FOR HOPPER 1 y 15 2 GRN YE E RG C ao wi eH 4 10 VY Md UE BI 20 RD LARM 7 2 UDIBLE
120. alf 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 A ctuate each of the heads until all the flushing fluid is removed and a steady stream of new adhesive flows cont Page 6 6 Preventive Maintenance iTW Dynatec 2000 Revised 3 01 DYNAMELT M ASU Manual 20 28 and 20 36 11 Re adjust the pump speed for the desired flow 12 Re fill the hopper with adhesive The system is now ready for production ITW Dynatec c 2000 Troubleshooting Page 7 1 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes DANGER WARNING HIGH VOLTAGE 25 7 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 trou bleshooting or repair procedures All troubleshooting and repair procedures must be per formed by qualified trained technicians CAUTION Printed circuit boards PCBs are prone to damage from static electrical charges during han
121. an and ready to use pump an oven at operating temperature This avoids thermal shock and saves valuable beating time 4 Startup 1 Ensure that the pump is free turning and lubricated Engage the outer drive shaft carefully making sure that it iTV Dynatec 2000 DYNAMELT ASU Manual 20 36 20 37 20 38 does not bottom in the slot of the coupling and thal it is aligned within 1 angular and 005 parallel with the true pump drive axis The coupling is the rotating member of the seal and depends on the internal operating pressure of Ue pump to force it forward and affect a seal against the carbon or melal seal plate In pumps with a through shaft and compression packing seal the pump to driver axis may shift unevenly due to pump healing expansion Jo remedy this we recom mend connecting the pump driver to the pump shaft with a double universa joint arrangement This type of joint will prevent bending loads from being transmitted to the pump shaft when misaligned This greatly reduces the possibility of premature shaft failure due to fatigue To prevent seizure be sure to apply adequate high temperature lubrication to the universal joints 2 After startup take up gradually and evenly on the pack ing gland screws until slight weepage Occurs 3 Be sure to follow up closely throughout the running in period of the packing unti the seal is thoroughly seated Do not completely seat the packing in one adjustment
122. and Zenith reserve the right to make engi neering refinements that may not be reflected in this bulletin M anual revised 8 94 Appendix 2 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 INTRODUCTION In 1926 Zenith Pumps was appoached by the synthetic fiber industry to design a pump to provide a precise pulseless repeatable flow and assure better quality control The options then were the same as those in the chemical process industry today diaphragm lobe coarse gear piston plunger and screw pumps Each had problems with pulsation flow inaccura cies 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 preci sion and simplicity M anufacturing techniques were developed to hold tolerances to 00005 and an internal pressure relief mechanism assured reliable precision metering 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 han dling 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 pressur
123. and air dry Be careful not to bang parts together 7 Inspect all parts for nicks burrs score marks and other signs of wear 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 notto round off the edges of the gear teeth while lapping CAUTION Sincethe 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 circum stances Place a layer of 600 Grit Emery Cloth on a lapping block or plate a granite flat is suit able A pply light pressure to the component and turn it in a figure 8 fashion as shown in Fig ure 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 U se 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
124. anel Box 10 4 Cabinet Assembly ret cb be Bre Re puer eig a Rack pei 10 8 Drive Assemblies 4 5 re Si ket ctl scs ipt eU o ed 10 10 Melt amp Grid Assemblies i ua uc eaa a ues e ea ee acit 10 12 Gear Pumps e tee oue ve eee 10 14 Pump Adapter Assemblies ek eee ek be Rx ee e ee e 10 22 Pressure Gauge sobrie wer baste i epe e eDim meg Ee reete idu 10 24 In addition to the assemblies listed above this chapter may also contain illustrations for other optional assemblies ordered with your ASU ITW Dynatec c 2000 Table of Contents Page vii DYNAMELT M ASU Manual 20 36 Revised 4 06 Chapter 11 System Schematics amp Engineering Drawings Hose Schematic all models ES PRIUS ker eeu UM 11 2 Head Schematic all 8 11 3 Flow Diagram Outlet Filter Manifold Cross Channel 11 4 Typical Hydraulic Schematic Rer pU Re Db RD ec eee Re TR 11 5 Optional System Status 8 2 11 5 Optional Level Control penetret re vd enr eR ps 11 6 Optonal Electric Clutch mee ee mee cer eme case a he 11 7 GroundingDiagra
125. any text editor Change the IP address Save the file using the same name Copy the file back to the module Re cycle power on the module hot melt unit Note Ifthe configuration file ethcfg cfg is not found the module will automatically activate a DHCP BOOTP request Using the BootP Server Function The BOOTP Server comes with the RSLinx Tools of the Rockwell Automation Software or can be downloaded as a stand alone application Version V2 3 2 or newer allows to change the IP address of the EtherNet IP module Note The EtherNet IP module only requests an IP address assignment for approx 30 sec If this request is not serviced within this time by entering the desired IP address in the relation list the module s power hot melt machine must be re cycled 19ITW Dynatec 2005 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Diagnostic LED s TwDynatec Adhesive Application Systems Net Stat Cie Active Mod Stat Be Link 1 Net Stat Network Status Page 4 19 Revised 8 05 PN 112224 EtherNet IP Adapter MAC Addr Flashing Green No connections State Summar Description Steady Off No power or no IP The module has no power or no IP address has address been assigned Steady Green Connected The module has at least one established EtherNet IP connection There are no EtherNet IP connections established to the module Flashing Red Connection Timeout One or m
126. bly iTV Dynatec c 2000 Revised 9 00 DYNAMELT M ASU Manual 20 36 To Access the Pump or Motor DANGER HOT SURFACE amp HIGH VOLTAGE If the pump is notoperable but the heating system will function raise the temperature of the application system to the operating temperature to aid in the pump disassembly process Otherwise a heat gun or other controlled heating method is recommended to melt hardened hot melt material Never use a torch or an open flame on any of the components of the application system Once the system is up to temperature disconnect all incoming power before proceeding Remove access door s using the key being careful not to pull off the ground wires attached Turn OFF the filter shutoff valve by turning itto its closed 0 position Motor Removal Disconnect the wires leading to the motor U nscrew the hex nut on the cord grip Slide the wires through the fitting Remove the four bolts which attach the motor to the mounting bracket Slide the motor out of the ASU For re assembly torque should be approximately 1 8 16 foot Ibs at room temperature With hopper at 177 C 3509 the maximum allowable torque on screws is 4 1 Nm 36 foot Ibs Panel Box Assembly I Tv Dynatec c 2000 Disassembly amp Re assembly Page 8 5 DYNAMELT M ASU Manual 20 36 Revised 4 01 b Pump Removal Verify that the filter shutoff is in its closed 0 position Loosen motor adapter plate screws and slide adapter plate wit
127. c 1 2 orP4 Flashing C indicates optional serial commu nication PC Link is ON Press Enter to activate or confirm 1 23 Enter a numeric value with 0 9 keys ABC Enter a letter on the alpha numeric This item or this screen is locked This item is factory setup only lt gt Press button C to see more zones Factory Setup can be HELP Screen F4 on Actual Temperatures Screen modified by ITW Dynatec s technicians only ITW Dynatec c 2000 Programming Page 5 3 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Display Reference cont Condition of Pump Enable Thermostat Black box item is selected for programming Screen continues press C to view SYSTEM Alarm Lo Tue 3 36 System Status Line SETPOINTS F Next Page Press C Temperature Premelt HOLD In priority queue Progmelt 7 299 waiting for release Filterblock l R Zone Status Zone Names Over temp Hose Under temp Head mE 0ff Aux Zone no sensor Zo this is the controller s identifica tion for each zone INFO UPPER PREMELT GRID Information lines Set 300 F Act 300 F Tol 30 F Function keys Scroll Up Down or Right Return to last screen Go to Pressure screen Go to Pump screen Toggle On Off All in category AB C abc letter case T Dynatec Clear
128. c c 1999 Revised 9 02 DYNAMELT M ASU Manual 20 36 Bill of Materials for Typical Electrical Panel Box Assembly 107715 Item No Part Number Description Qty 1 802102 Mounting Bracket 1 2 107625 Bezel 1 3 802626 Heat Sink 2 4 102328 Panel Box Lock Kit 2 5 103377 Wire duct 1 5 W x 3 H 3 103378 Wire duct 2 w x 3 H 3 6 103439 Wire Duct Cover 1 5 3 103438 Wire Duct Cover 2 25 3 104387 Rotary Handle amp Shaft 1 8 107891 Bracket Circuit Breaker 1 9 104387 Mechanical Operatof Circuit Breaker 1 10 104761 Circuit Breaker 1 11 802850 Panel Box 1 12 107890 Insert Panel 1 13 048H384 SSR Dual 40A 240VAC 3 8 14 107993 Memory Card Assembly option 1 15 102326 Cover Memory Card 1 16 109770 Pendant Control Assembly option 1 Continued on pages 6 thru 7 Revised 9 00 Component Illustrations amp BOM s Page 10 5 DYNAMELT M ASU Manual 20 36 iTW Dynatec 1999 o G 79 c S Page 10 6 Component Illustrations amp BOM s 1999 Revised 3 03 DYNAMELT M ASU Manual 20 36 Bill of Materials for Typical Electrical Panel Box Assembly 107715 Cont from pg 4 Item No Part Number Description 17 Terminal Rail 1 18 102762 1 4 19 103183 Fuse Block Lever Open 4 20 103184 Fuse GDC4 250VAC 3 21 Terminal Rail 1 22 109857 Control Processor Board
129. cabinet to remove any debris remaining after heat cleaning Wash components in an ultrasonic cleaning tank and air dry 6 Inspect all parts for nicks burrs score marks and other signs of wear plates and sides of the gears may be hand blocked on 400 600 grit paper and any nicks burrs or sharp edges can be lightly removed with an Arkansas stone CAUTION Since the thickness relationship between the metering gears and center plate is critical to metering performance and the center plate is non wearing on its sides lapping these components not necessary and should not be done under any circumstances T To keep maintenance costs to a minimum the following procedure is recommended A Measure used parts and compare their dimensions with new part standards This will provide you with precise information on the wear of the pump parts and aid in maximizing the useful life of each component Replace worn gears shafts bearings and center plates Side and middle plates may be refinished by grinding and or lapping them to remove wear markings and return them to flatness within 0001 convex and surface finish of 4 to 8 rms 8 Replace the 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
130. cated 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 amp Re assembly iTV Dynatec c 2000 Revised 9 00 DYNAMELT M ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions i TV Dynatec 2000 Options amp Accessories Page 9 1 DYNAMELT M ASU Manual 20 36 Revised 7 02 Chapter 9 AVAILABLE OPTIONS amp ACCESSORIES Pressure Gauge Assembly PN 805641 A n optional analog pressure gauge can be mounted on the outlet filter manifold Reading the adhe Sive 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 amp Post PSI Transducers PN 800225 Transducer Assembly PN 108825 A pressure transducer is an electronic probe that allows the melted adhesive s pressure to be pro cessed by the ASU s control
131. cation system before starting any installation procedures 1 Disconnect and lockout input power to the application system 2 Open the panel box and locate the M otor Control Interface Board see layout illustrtion in Chapter 7 The device will be connected to the 0 and 10 terminals on X3 3 A To install a tach generator i If when facing the shaft on the tach generator the rotation of the shaft is clockwise connect the black lead wire to the 0 terminal and connect the white lead wire to 10 or ii If when facing the shaft on the tach generator the rotation of the shaft is counter clockwise connect the black lead wire to the 10 and connect the white lead wireto 0 iii Verify that the gear pump motor is running at full speed when set to 100 in MANUAL mode T he output of the tach generator can be adjusted depending on the application but it must be at least 10 V DC to obtain full adhesive gear pump speed Note under no conditions will the motor ever run faster than this speed 100 Manual B To install a similar DC tracking device not a tach generator Connect the DC tracking voltage signals to the terminals so that the negative lead is connected to 0 and the positive lead is connected to 10 Note the tracking voltage must be at least 0 10 VDC but not more than 0 25 VDC 4 Close the ASU s panel box door 5 Re connect input power and restore the application system to normal operation Procede
132. ckly isolated by measuring hose heater resistance and comparing itto the correct resistance for your hose length and voltage as shown The Nominal H ead H eater Resistance table gives values for several different head wattages A suspected head heater problem can be isolated by measuring head heater resistance and comparing itto the resistance for the appropriate wattage of your system The Nominal 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 M anifold Heater Resistance table gives heater resistance for the heater located in the optional filter manifold pressure relief block The heater inside the manifold varies depend ing on the number of filter manifolds mounted on the A SU therefore resistance varies also iTV Dynatec 2000 Troubleshooting Page 7 13 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Temperature Resistance Hose Length Resistance F C in Ohms Meters Feet in Ohms 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 Nominal Head Heater Resistance N ote Resistance is measured at ambient temperature 20 C 68 F Temperature Sensor Resistance 0 00385 PT 100 RTD mm Qty Hopper Heaters 1 2 3 Max Drop in Grids 2 4 6 Resistance Ohms for each Hopper Heater
133. ct D ynatec 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 run ning 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 itis 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 D ynatec 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 W hen 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 REMEM BER Dynatec Zenith metering pumps are made for exacting duty In order to devel op the high pressure demanded the clearance between the metering gears and their housing must be as small as possible yet large enough t
134. d 4 01 6 Atthe 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 1 CAUTION Approach desired pressure with caution DO NOT TURN THE ADJ USTMENT 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 itin 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 1096 until the adhesive flow begins to decrease Note Though the speed of the motor is reduced there will beno changein theamount of adhesiveflow 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
135. d am pm in dividually 7 Repeat steps 1 through 6 for each event desired 8 Press F4 to return to M ain Scheduler screen ITW Dynatec c 2000 Programming Page 5 26 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 10 01 Up Downloading Instructions Controller to Remote PC PC Link The U pload Download functions are used to transfer system information and data from or to the D ynaControl To do this the DynaControl must be connected to an external PC or PLC via a se rial cable The data format is an ASCII text with TA B delimited data This text can be created with standard word processing programs or spreadsheet applications and up or downloaded via terminal programs B oth functions are on demand functions i e they must be started on the D ynaControl keypad Hardware Hookup Remove the controller mounting bracket from the ASU via four screws accessed from inside the panel box assembly U sing a standard serial extension cable M ale F emale DB 9 if necessary utilize a DB25 to DB9 adapter connect either of the D ynaControl controller s serial ports on the Display CPU PCB see illustration on page 7 5 to the remote computer s COM 1 or COM 2 Download Instructions Download Transfer data from an external PC to DynaControl 1 DynaControl must be connected to a PC via a Null M odem Cable 2 Start the terminal program on PC 3 Start PC Link on DynaControl Function 5 on Service Page 2 4 f necessary select
136. d e 232 C 450 F iiie teens doe oec PECES a Poele Aa etica p Gl owe 500 to 50 000 centipoise Warm up time full Hoppers Aso cu dro a e ie ee D a DOR e IR err approximately 0 5 hour Typical adhesive melt rate depends on adhesive used 18 65 kg hr 40 143 Ib hr Adhesive press te reor e cd gd up to 68 bar 1000 psi maximum DynaControl Temperature Control Controller power board 48 zones modular construction DIS Play Ty De cR DS e Lee ou Ub So o ries Dau eS graphic liquid crystal Temperature control zones 35 16 maximum with solid state relays Power output 2a corde Pace RUE pac Dd d bat adt Ce del eed bate a RUP Re hopper 5000 watt hose 1200 applicator head 1200 watt auxiliary 2000 watt Sold State Seld ee ee ace ota Re 3 15 VDC Eine Speed Inputs Qupd veu Pu Dog tee Qut cou uuu sro Sow 1to2 Other Display languages English French German Spanish Swedish Italian Japanese Portugese and Dutch Operator Interface iu eoo up a ses Re Fat ao e d multi zone liquid crystal display with alpha numeric keyboard and function keys Temperature Standby 24 ad XC Oe Re A SR oe ORO Xo CAR EA yes High and low temp alarms 2555 a Ae See ton oer e au CE Sos tee yes
137. d force it firmly and evenly to the bottom of the packing housing Tap it firmly into place 15 Rotate the drive shalt by hand alter each ring is installed to aid seating the packing Continue to install the rings in this manner umi the proper number of packings have been installed 6 Firmly compress the packing by alternating and evenly tightening up the gland screws then hack off Ye turn Be sure to adjust the gland evenly 8 Some Causes of Pump Failure Problem Cause Seizure foreign particle b mounting block not flat C uneven heating d lack of lubrication interference fit of moving parts Excessive Slippage worn gears thickness and out reduced pump side reduced diameter corners etficiency of teeth not square b worn center plate c side plates scored at throat amp side plates not flat Seal Leakage pieni or scratched coupling or te b drive shaft bottaming in slot of coup ng drive shaft misatigned minor seal leak o weep is not abnormal and may be desirable for tubricating the seal surfaces 9 Rehabilitation Pumps may be returned to an authorized repair facility for rehabilitation repaired pumps must pass the same strict standards as new ones 10 Factory Visit pumps are to be maintained at your plant it can be very worthwtile to have key maintenance people spend a day at the Zenith factory to view manufacturing gauging and assembly tech
138. dddd n dddd read line speed input 0 0 to 100 0 1 pump all pumps 0x67 g 72 dddd n dddd read pressure transducer 0 0 to 150 0BAR 0 to 1500PSI 2000 open transd 1 transducer all transd 0x50 P zz n dddd ACK NAK write pressure alarm value 0 0 to 150 0BAR 0 to 1500PSI 1 transd multiple transd 0x70 p 22 n dddd read pressure alarm value 0 0 to 150 0BAR 0 to 1500PSI 1 transducer all transd 0 4 M zz n d ACK NAK write pump mode S Stop M Manual A Automatic 1 pump multiple pumps Ox6d m 77 n d read pump mode S Stop M Manual A Automatic 1 pump all pumps 0x66 f n a sys data 1 read system status 1 see note 1 0x6a j n a sys data 2 read system status 2 see note 2 0x69 i 77 n d read status of temperature zone see note 3 1 zone all zones 0x48 H d ACK Set system mode see note 4 0x52 R d ACK NAK set active program number 1 to 4 0x72 d read active program number 1 to 4 4 L n a ACK NAK reset error message 1 System status Bit0 Setback active Bit1 Controller on Bit2 Enable thermostat active Bit3 Low Level Bit4 Low Temp Bit5 High Temp Bit6 always 1 2 System status Bit0 scheduler avtive Bit6 always 1 8 Zone status O off 1 wait 2
139. dling Read Handling Printed Clrcuit Boards in this chapter before handling or attempting service on Dynamelt s PCBs The Dynamelt s DynaControl includes malfunction self diagnostics alerts and error indication alarms The error indication alarms the alarms displayed on the D ynaControl readout are triggered whenever there is a sensor failure and whenever there is an over temperature condition opera tion of the error indication alarms is described in Chapter 4 of this manual Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 TheASU is supplied with power 3 TheASU is supplied with pneumatic air 4 Pneumatic and electrical connections are correct 5 Adhesive is in the hopper Error Messages See Ch 4 for complete instructions on Error Alarms and M essages Sensor Failure on Zone temperature zone has an open or shorted sensor Overtemperature on Zone temperature zone has exceeded setpoint limitation Communication Error indicates a serious problem which requires service by Dynatec Hopper Overtemp hopper temperatures have exceeded their thermostat s setting Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the A SU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunct
140. e 2 is created Press 5 to activate or deactivate the 7 Day Scheduler Press F4 to return to the M ain Scheduler screen Press 4 to return to the A ctual Temperatures Screen Shortcuts 1 To activate or de activate the Scheduler from the the A ctual Temperatures Screen M ain M enu toggle by pressing and holding the Service wrench K ey for five seconds 2 To activate or de activate Standby from the the A ctual Temperatures Screen M ain M enu toggle by pressing and holding the Scheduler clock K ey for five seconds Page 5 24 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Programming of 7 Day Scheduler 7 Day Scheduler The Seven D Scheduler allows the operator to program main power ON and OFF times which coincide with his daily production schedule throughout the work week U p to ten events may be scheduled A n event is a specific day and time or every day atthe same time AnASU which has an active seven day scheduler should be turned ON at the main power switch It should not be turned off by the main power switch while the scheduler is active To turn the ASU OFF temporarily overriding the scheduler use the D ynaControl On Off keypad icon In the event of a power outage or a manually switched main power ON an active scheduler over rides the Power On Heater Start parameter That is if the scheduler is in Switch ON at the time of a power ON the heaters will be tu
141. e scheduler battery serial ports and op tional connections It is located directly behind the controller s display panel within its mounting bracket or within the remote pendant assembly option if applicable When downloading software updates use the download serial port seen at the lower right of the il lustration While downloading the J1 jumper is moved temporarily to its 1 position To configure the number of optional pressure transducers on an ASU use the dip switches shown below beneath the expansion board and the following chart There are four transducers per PSI PCB and a maximum of three PSI PCBs per ASU Note PSI not available on APS models of PSI PCBs Connect to opt Expansion Board for Serial Commu On the RS Com board both the J1 and J2 jumpers must be in upper position for 485 and both in lower position for 232 nication CAUTION FOR Dip Switches to configure PO ECON of opt PSI PCBs only Optional RS232 Serial Connect Optional RS485 Serial Con NECT ONLY switches 1 amp 2 are used use for PLC PC Link nect use for PLC PC Link or APS model Scheduler SS Download NN Reset NS L _ 22 2 00000 1 Ci 2990909 0000 Software Download Port Connect to CPU PCB Layout of Components on Display CPU PCB Page 7 6 Troubleshooting ITW Dynatec c 2000 Revised 1 03 DYNAMELT M ASU Manual 20 36 20 37 and
142. e viscosity and temperature High Temperature C apability Operating temperatures to 450 degrees F 232 degrees C Maximum L ife 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 M aximum 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 iTV Dynatec 2000 Appendix 3 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating 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 ex posed 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 Si
143. e 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 in let 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 Pre caution 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 spe cial 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
144. e 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 tempera ture 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 2 M 4 and M 4 or other high performance alloys they are tempered after heat treatment to hardnesses ranging from HRc 58 to HRc 64 Sincethe thermal expansion rates for all three steels are almost identical and are otherwise entirely compatible itis possible to combine them so as to take advantage of their best qualities in the most economical way TheType D2 tool steel is often selected for the side and center plates as it offers good abra sion 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 M 2 or M 4 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 resist ant Type M 4 tool steel Types M 2 and CPM M 4 steels are commonly used for the metering gears drive shaft and universal seal coupling due to their superior torsional
145. e upper limit of the ready temperature range of each zone PC Link Also referred to as remote I O interface this is a DynaControl controller option that allows monitor ing and programming from a customer provided PLC programmable logic controller or a PC per sonal computer P I Loop A temperature control loop which bases heater output proportional P to the difference betweeen setpoint and actual temperature and combines it mathematically with a time I integral factor Power I O PCBs The Power I O printed circuit board PCB provides control signals to and monitoring signals from all the temperature zones in the ASU s system The ASU s hopper hoses and applicators are con trolled by the Power I O PCB Pump Enable Temperature The pump enable temperature protects the pump pump shaft motor and motor control board from damage by not allowing the pump to activate until a low limit the programmed pump enable tem perature is achieved RTD Sensors The standard Dynamelt system uses 100 ohm platinum resistance temperature detector sensors for all temperature controls As an option the unit can be configured for 120 ohm nickel sensors Ready Temperature The programmable temperature on gear pump models which allows the ASU pump to turn ON The default ready temperature range is a deviation of 20 C 36 F from the setpoint The set point minus the deviation is the low limit of the range and the setpoint plus the de
146. ears by the drive shaft which is either a through shaft as in the packing gland type of pump or a shaft with a tang that engages a universal seal coupling The coupling is both a connection to external power and the rotating member of mechanical seal In order to develop the high pressures demanded the clearance between the metering gears and their housing must be as small as possible yet large enough to allow ade quate lubrication Because of these close running clearances in many cases as low 00025 Zenith Pumps require careful maintenance and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure 2 General Operating Requirements i ee Since Zenith Pumps depend upon metered fluids for lubrica tion of their internal bearing surfaces their recommended optimum operating speed range is between 10 and 75 rpm depending upon viscosity and operating pressures Increasing their operating speed improves their efficiency but also pro vides less time to fill the gear tooth spaces Cavitation may occur if sufficient inlet pressure is not pro vided Cavitation or the failure to fill the tooth spaces com pletely causes low delivery and excessive wear It also encourages the introduction of air through seals Under ideal conditions speeds up to 200 r m have been maintained over long periods of time You can however expect accelerated wear in such instances
147. egree 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 A nother 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 T he car burization process usually takes between 3 and 12 hours depending on the polymer type temperature pump size and furnace load cont Appendix 20 iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 CAUTION Avoid exposing the pump to thermal shock when using this method of cleaning A fter gradually cooling to room temperature the pump should be thoroughly flushed in a clean solvent t 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 perform ing 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
148. erature d Alarm Lo the pump enable thermostat undertemp thermostat is preventing operation due to a low temperature condition e Standby the system is in a programmed standby state 2 Actual Temperatures or Zone Status of all zones is displayed a 3HHE a three digit number indicates zone s actual temperature b HOLD zone is waiting for release Temperatures have not risen to setpoint range C Arrow up zone is over temperature d Arrow down zoneis under temperature there is no sensor Zone needs troubleshooting f there are more temperature zones not seen on the current display To view them press C on the numeric keypad bottom row first key 3 7 Day Scheduler A ctive display shows that the 7 Day Scheduler is programmed and in use 4 Pump Info Lines indicate pump mode A uto on the illustration on page 5 6 and external refer ence percent or set speed percent 5 f the optional Actual RPM display shown on page 5 3 is installed actual pump rpm may be monitored Page 5 8 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Setpoints Programming Screen SYSTEM Alarm Lo Tue 3 36 PM P d e5 D SETPOINTS F Next Page Press C Premelt SYM DEF Progmelt 2 3 Filterblock 380 Hose 275 Head 215 JKL MNO Aux Zone 5 6 INFO UPPER PREMELT GRID Set 300 F Act 300 F Tol x30 F TUV WXY 8 9 0 gt ABC 123 ITV Dynatec Controller iden
149. f hours that the system has been running Not resettable Press 9 to Change Security Lock for Service Page 2 Enter your 4 digit access code Press Enter Press F1 or F2 to select desired function Press F3 to Lock or Unlock function from programming Repeat for each desired function Press Return F4 Press Return F4 again to go to Actual Temp Screen Service Page 3 All of the functions on Service Page 3 are ITW D ynatec accessible only No operator programming is possible SYSTEM Ready Service Page 3 Press for Zone Arrangement PI Loop Setup Split Hopper Setup Gear Ratio RPM Display Yes No Pump Clutch Yes No Level Control Yes No Troubleshooting wo Change Security Lock RETURN Page 5 22 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Programming at Main Scheduler Screen The M ain Scheduler Screen functions include Standby Date amp Time Clock 7 Day Scheduler and Program R ecipes Press the Scheduler K ey to advance to the M ain Scheduler Screen Main Scheduler Screen Scheduler Key SYSTEM Ready Tue 3 36PM L EQ D Activate Deactivate Standby Change Time amp Date 1 SYM DEF 2 Program Scheduler 3 4 5 2 3 Select Recipes Activate Deactivate Scheduler JKL MNO 5 6 TUV WXY RETURN 8 29 F4 0 gt ABC 123 ITV Dynatec ITW Dynatec c 2000 Programming Page 5 23 DYNAMELT M ASU Manual 20 36 20 37 20
150. from Basket pump pump to to hose o hose Adhesive flow through Adhesive flow through filter block to hose filter block to hose Operation of the Adjustable Adhesive Pressure Relief Valve iTV Dynatec 2000 Troubleshooting Page 7 23 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Operation of the ASU s Gear Pump Manual or Automatic Pump Operation Choose M anual Stop or Automatic gear pump operation via the M otor pushbutton see icon above on the controller s keypad When the Dynamelt s pump is to be operated manually that is without a line following signal the manual mode is used to control pump speed and adhesive output For the gear pump to be operated in the automatic mode a tach generator or equivalent at tached to the parent conveyor line must be provided and the following set up procedure should be performed 1 The tach generator or the signal isolator must be adjusted so that the voltage from the speed controller is 0 to 10 VDC but not more than 10 V DC when the conveyor is at maximum speed This voltage is measured at either on the otor Control Interface PCB for a tach generator or at terminals 9 and 10 of the Signal Isolator B oard 2 The Automatic setting then changes pump speed for any given 0 to 10 VDC incoming tachometer signal Voltage will vary given production speed The motor speed can be adjusted trimmed in automatic mode by setting maximum and
151. g 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 A N 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 time table 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 1 4 ITW Dynatec 1997 Revised 3 97 ALL MODELS ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions i TV Dynatec 2000 Description amp Specifications Page 2 1 DYNAMELT M ASU Manual 20 36 Revised 10 00 Chapter 2 DESCRIPTION AND SPECIFICATIONS Description The DY NAM ELT M Series adhesive supply units A SU are comp
152. h motor away from pump and coupling Slide the coupling off the pump shaft Remove the four pump mounting bolts Shaft Key coupling C Pump Seal O ring Replacement R emove the pump from the A SU see instructions above b Remove the external pump seal from its groove on the back of the pump adapter plate Pump this is the seal located between the adapter plate E 5 and the hopper Install the new seal gt Adapter 9 Plate 99 Screws Re Assembly Procedures Unless noted the M Series ASU s re assembly is simply the reverse sequence of the disassembly procedures H owever the following precautions should be followed whenever they apply for proper re assembl y 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 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 lubri
153. he user to make changes to the temperature setpoints on the hotmelt unit The PLC can read the changes from the corresponding IN words but the temperatures in the OUT area will not be effective on the hot melt unit Setting LocalAccessTemps to 0 switches the control back to PLC control All temperature OUT words will be transferred to the hot melt unit A local change of temperature setpoints is not possible since the PLC will instantly overwrite the entry LocalAccessMotors controls the access to pump settings analog to the description above After a local change of setpoints the PLC first must read the new setpoints before switching back to PLC control Itis not possible to deactivate a temperature zone locally on the hot melt unit since the PLC always sends the ZoneEnable Disable information Zones Enabling Disabling Temperature zones that are temporarily not used can be remotely deactivated by setting a corresponding value to OUT word 70 to 75 Each bit of this word represents one temperature zone zonel 1 1 zone2 etc Setting the bit will activate the zone Resetting will deactivate the zone Pump Control There are several ways to control pump speed 1 Manual Mode the pump speed can be programmed locally on the hot melt machine In order to allow this mode the OUT word 50 for pump 1 must be set to 77 4 16 ITW Dynatec c 2005 Revised 8 05 DYNAMELT M ASU Manuals 20 36 20 37 20 38 ASCII
154. heck condition of the remote switch controlled by a remote the hand held applicator switch i e a hand held applicator the switch or switch circuit may be open 3 Low temp alarm 3 Verify that ASU is warmed up and that hopper temperature is above the factory set pump enable temperature 4 Faulty M otor Control 4 f the board is faulty it must be Interface B oard replaced Page 7 26 Troubleshooting iTV Dynatec c 2000 Revised 6 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Pump doesn t operate 1 Parent machine is not 1 Check parent machine in Auto mode running power lightis ON hopper is at ready 2 A uto motor is set at 2 Re program motor conditon zero at controller keypad e 3 No incoming line 3 Check for presence of 0 to 10 VDC following signal control signal at X 3 of M otor Control Interface PCB If signal is not present s check connection at X 3 and tachometer HE drive connections If control signal is 5 X3 present there the problem is within the ASU Motor Control Interface PCB 4 Internal A SU connections 4 Check for the presence of 0 to 10 VDC or Motor Control Interface control signal at X 3 of M otor Control PCB inoperative Interface PCB Check A SU connections S1 amp S2 If the signal is not present the problem is in the connection If the signal is present there the problem is most likely a faulty M otor Control Interface B oard 5 System is
155. 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 Placethe 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 resist ant lubricant and install Torque the screws in even increments to the manufacturer s recom mended 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 W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 600 grit paper W hen 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 iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 from the packing housing 12 Inspect the drive shaft at the seal area making sure that it is not scored shouldered or worn Worn shafts will result in premature seal leakage and should be replaced 13 Inspect
156. iency 1 Worn gear s 2 Worn bearings 3 Process conditions changed Remedy Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair Increase inlet pressure Replace lip seal Return pump to ITW Dynatec for repair Return pump to ITW Dynatec for repair 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 25 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec c 2000 67991 55 33 59 MV3M1S 1 AVAAAY S3LON 335 AlIOVdvO U3OMON LuYd 931VNAQ AMLI HOLA H3SY NMOHS AJUDO 8672 NOLL 412930 SW3iI SudHSVM x ONh GLE SWALI W O NO Q3On NI 51706 ONILNNOW 1 3LDN 310H 1796 ONILNNOW 995 Xz 1404 L37NI 197 5370 ONTIN vIQ 909 1809 L371n0 YIG NI OGC 2 MN 7 227222204 462709 AAAA SCHON 49 A3H 23 JALYNAOZMLI iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 Appendix 26 Revised 10 00 REVIS ONS DESCRIPTIONS SECTION C C 010101010101010 22 OAS NZI NV TANI Ny 6 POSS r em DELIVERY ITW DYNATEC 084 E432 1 168 553 NE CC REV PORT SS LASER ETCH 13 ITW DYNATEC NDA PART NUMBER CEU A I G
157. ined above Optional Drop in 1 Setpoints have been 1 Re program setpoints allowing a Grid Heater programmed without larger deviation between the high 2500w 935 enough deviation and low limits 2 Grid sensor inoperative 2 Examine grid sensor assembly for intermittent break in sensor lead Remove sensor bulb from grid Replace grid sensor if resistance does not comply with the resistance table in this chapter iTV Dynatec 2000 Troubleshooting Page 7 17 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 3 Grid control solid state 3 Use a clamp on ammeter to monitor relay inoperative current R eplace inoperative solid state relay Optional Drop In 1 Sensor cable has become 1 Verify that grid sensor cable is Grid Sensor Open unplugged from CPU properly connected at X 14 on the CPU PCB 2 Disconnection between 2 Verify that all connections are properly Power PCB and the CPU made on the CPU PCB PCB 3 Drop in grid sensor 3 Replace sensor if resistance does inoperative not comply with the resistance table in this chapter Optional Drop in 1 Short circuit caused by 1 Verify that sensor plug is clean and Grid Sensor Short debris where sensor plugs correctly connected at X 14 on the into CPU PCB CPU PCB 2 Pinched sensor lead wire 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the se
158. ion does not move with the ap plicator and hose the problem is probably in the ASU Motor Speed Control PC Board Re set Anytime the AC drives s M otor Speed Control printed circuit board must be re set due to line surges or over currenting the motor turn the ASU OFF by the main power switch and wait at least 20 seconds before attempting to re start This will allow the pcb to re set See the table on page 7 7 to troubleshoot Page 7 2 Troubleshooting ITW Dynatec c 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 High Temperature Redundant Overtemp Thermostat The ASU includes a mechanical redundant overtemp thermostat that acts as a safety backup If the ASU s hopper temperature should exceed 232 C 450 F the thermostat will cause the A 50 5 cir cuit breaker to open and power to the hopper and all hoses and heads will be cut off The mechani cal thermostat must be manually re set after the hopper temperature falls below 204 C 400 F The overtemp thermostat is located behind the motor access door see Chapter 8 To reset turn OFF the ASU s main power switch push the center of the thermostat s insulator to re set restart the ASU Pump Enable Thermostat The pump enable thermostat is a low temperature safety feature of the Dynamelt ASU designed to prevent the pump from powering on before the adhesive is molten It is a cartridge thermostat and it is factory set at 135 C 275 F The thermostat is adjustable so
159. ispersion 154 or a similar heat re sistant lubricant and install Torque the screws in even increments to the manufacturer s rec ommended 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 W hen a carbon seal plate is used always use a new carbon seal that has been lightly polished on 400 600 grit paper W hen using a carbon seal the coupling housing screws 27 should be torqued to the manufacturer s recommended lim it 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 L ubricate or an equivalent silicone based oil 14 Install lip seals into seal housing 22 as shown 15 Tighten seal housing screws to 60 Ibs in Check for rotation iTV Dynatec 2000 Appendix 23 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread Torque L ubricated T hreads UNC Alloy Steel L bs in Nxm Lbs ft 10 24 w carbon seal gasket 50 5 4 2 10 24 w o carbon seal gasket 64 7 2 5 3 312 24 120
160. ive W heel O ring 224 M 3 0 5 x 5mm Flat Point Set Screw M 4 0 7 x 12mm Button Head Screw M 4 0 7 Hex Nut Torsion Spring 56 OD x 063d Electric Clutch K it Option used in place of Coupling Clutch Power Supply M4 x 25 mm SHC Screw M4x 0 7 Nut M6x1 0Nut Terminal Butt 16 14 Insulation Not Shown Terminal Spade 22 18 GA 6 Insulation Not Shown Qty LB PPP BBP UU PPP BB N Lr Dual Qty CO N 4 CO TV Dynatec c 1999 Component Illustrations amp BOM s Page 10 11 DYNAMELT ASU M Manual 20 36 Revised 9 02 Digital RPM Readout Option Electric Clutch Option in place of coupling Component Illustration DYNAMELT AC Drive Assembly 107942 amp 107943 Page 10 12 Component Illustrations amp BOM s Revised 3 07 1999 DYNAMELT M ASU Manual All M35 Models Bill of Materials for DYNAMELT M35 Melt amp Grid Assemblies Item No 1 Part Number 036B015 036B013 N07958 106189 105883 105881 L00006 108298 N07370 N00686 N00697 103749 N00210 108827 105885 106001 048J018 107441 107604 N05889 107389 048J015 048J018 108828 104166 104165 104164 103538 N00181 104696 003 023 036 103 106174 104802 107645 N00192 102446 N07416 078A055 084Q465 069X064 012G009 104072 N00754 105968 805216 105149 N00192 108297 N00181 106103 105097 107392 072X093 Description Pu
161. k iue beue roter Rer 5 18 Service Page eps ML rco peo stesse char Lr 5 19 Customer Zone Names svo ore pS vr v Ir RE EC eee WE e Ies 5 19 Power On Configuratioh i e eee ra rH RI RE Wrap Re e P RARE 5 19 Factory Defaults REESE Ra RE ETUR iR 5 20 Keypad Locking iste Ren RN eR cR RR NOE e 5 20 PGiEmle oe jst stots eifdem tous ama esas 5 20 Language pre ER prp LES aha etes 5 20 TV Dynatec c 2000 Table of Contents Page v DYNAMELT M ASU Manual 20 36 Revised 4 06 ECD Contt st 2 Cede Rd e e e eden ege 5 20 System Logbook elc a etd cete a Rd 5 20 Change Security 221 pA tue soe 5 20 3 eeu d Dee apa 5 21 Programming at Main Scheduler Screen 1 7 5 22 Use of the Main Scheduler Screen 5 23 Programming of 7 Day Scheduler 0 5 24 Use of the 7 Day Scheduler Screen 4 00 5 25 Programming x od uetus CO vete zt Fete 5 25 Up Downloading Instructions Controller to Remote PC PC Link
162. l box assembly Note When multiple PCBs are installed to accomodate multiple components ie two motor speed control PCBs and two motor control interface PCBs to accomodate two motors as illustrated be low make connections to all PCBs Neutral for 380v only Motor Speed Control Motor Speed Control Fuse Ground Drive 1 Drive 2 Terminals Terminals Main Ground Side Panel PE Terminal res AYE race Main Circuit Breaker RS232 485 Communication Board Contactor Pressure E 2 3 4 111213 Circuit 5 Typical Panel Box Layout i TwDynatec 2000 Installation Page 3 5 DYNAMELT M ASU Manual 20 36 Revised 4 01 4 The adhesive hoses are connected at the rear cover see illustration on page 3 6 Each hoseis connected at both an adhesive port and an electrical connect M ake your electrical hose connections at the numbered connects above the filter manifolds R oute hoses so that there is at least an eight inch radius at any bend Do not hang hoses without proper support Do not crimp clamp squeeze or tie hoses Two feed hose adhesive ports are located at the bottom of each filter manifold When making hose connections use the numbered guides shown on the illustration to coordinate ie when using one hose make your hookup to electrical connection 1 and adhesive port 1 When using two heads h
163. l fasteners for tightness 3 Inspect filter shutoff Clean or replace as required Tv Dynatec c 2000 Preventive Maintenance Page 6 5 DYNAMELT M ASU Manual 20 28 and 20 36 Revised 9 00 Flushing the System Contaminated adhesive accumulation of residue in the system and hopper or changing the adhesive formulation may require the system to be flushed To flush the system have at least 6 liters 1 5 gal lons of flushing fluid on hand PN L 15653 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 A SU s pump pressure to zero Note the hose used in the following process is merely for the convenience of depositing flushing fluid This procedure does not have to be repeated for each hose in the system 3 Disconnect one of the supply hose s adhesive feed from its applicator head Do not disconnect the electrical power to the head since that would disable the pump Put the hose in a secured position within a container which will catch the used flushing fluid 4 Addflushing 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 h
164. larm This tri color stack light eases remote monitoring of the system s status xi The lower white light illuminates when the system is turned ON The arm middle green light indicates that the system has warmed up to temperature setpoints ready The upper red light illuminates only in an alarm condition and is accompanied by audible alarm The audible alarm is 22 housed within the upper black section of the stack Power n The status lights may be wired to indicate either high low temperature low adhesive level or open short sensor See Chapter 11 for wiring diagram Settings for a Typical Operation Note The values given here are approximate settings for a typical packaging operation The values you choose will be based on the type of equipment and adhesive you are using and the nature of your particular operation If Application Temperature is 177 C 350 F Hose and head temperature 177 C 350 F Hopper setpoint temperature 163 C 325 F Hi Lo limit deviation 12 C 20 F ASU operating range 149 C to 177 C 300 F to 350 F Standby condition temperature deviation 30 C 50 F Hopper over temperature setpoint 177 C 350 F Mechanical thermostat for the hopper over temperature 219 C 425 F For most operations temperature fluctuations will be very small and of short duration For these reasons the settings above are recommended ITW Dynatec c 2000 Controller Setu
165. lear mounting hole of plastic Instollation resdue Mounting Torque 50 inch pounds recommended 500 inch pounds max cont Appendix 36 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 Start up Trouble and Removal Shooting Checklist Gulde PROCEDURE SYMPTOM TYPICAL CAUSE Start Up Make swe thot tha extruder is of Inckcotor ot Full n open Perform desired temperature before or Unstable continuity checks with ohm the extruder drive is Operated indication metet Removal of Always remove the transducer of zero instrument Replace ond Transducer pror cleoning Ihe exkuder but use of tepa of ratum fS ond remove only while the coitxotion extuder is ot termperature procedure Pracuces no Cleaning of Wipe the transducer fip with o Change in reoding Transducer Tip Cloth while Ihe transducer is sti hot Do not use sharp tools on responds Tronsducer is damaged Rehan fip fo col retion to procedure bot does not indicate pressure Installation Wiring Diagrams ded fi M eda ee Models 0100 0701 0102 0103 Models 0103 0143 0123 0110 0114 0512 0113 Males 148 Mi 164 dm Hers tpi cipt Preti matr 0110 0114 0412 Models 0420 0124 0122 0123 0120 0121 0122 Ai son r0 Uer tb TIG ant Conclat rc Te 004 PULL itatoa CLP M Lil 94
166. 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 L ubricate or an equivalent silicone based oil 15 Install lip seals 15 into seal housing 9 as shown 16 Tighten seal housing screws 22 in a cross pattern to 60 Ibs in Check for free rota tion SCREW TORQUE VALUES Standard Alloy Steel Screw Size amp Thread Torque L ubricated T hreads UNC Alloy Steel L bs in Nxm Lbs ft 10 24 w carbon seal gasket 50 57 4 2 10 24 w o carbon seal gasket 64 7 2 5 3 312 24 120 13 6 10 1 4 20 150 16 9 12 5 5 16 18 305 33 9 25 3 8 16 into aluminum 360 40 6 30 7 16 14 block hopper 480 54 2 40 Table 1 n 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 iTV Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 TROUBLESHOOTING GUIDE Trouble Probable C ause Pump will not turn 1 Low pump temperature 2 Drive malfunction 3 Process conditions changed 4 Entrained particle 5 Possible internal damages Excessive seal 1
167. lters 101247 Filter Basket 100 mesh 2 per manifold 101246 Filter Basket 40 mesh optional 2 per manifold 109482 Filter Basket 200 mesh optional 2 per manifold 105967 Filter Shutoff Assembly Left 1 N07588 Lubricant O ring L15653 Kit Flushing Fluid 1 gallon 001U002 Hi Temp Lubricant tube 102717 Check Valve pressure relief 101340 Motor Brushes Baldor optional DC motor 2 per motor 106313 Motor Brushes Lenze optional Lenze motor 2 per motor 108012 Filter Pressure Relief Plug Assembly 1 Page 9 6 Options amp Accessories iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions TV Dynatec c 2000 Component Illustrations Page 10 1 DYNAMELT M ASU Manual 20 36 Revised 3 05 Chapter 10 COMPONENT ILLUSTRATIONS amp BILLS OF MATERIAL All parts must be periodically inspected and replaced if worn or broken Failure to do this can affect equipment s operation and can result in personal injury Chapter Format This chapter contains the component illustrations exploded view drawings for each assembly of the DYNAMELT M SERIES ASU These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Note most common nuts bolts and fasteners can be obtained locally at your hardware store Spe cialty fasteners are available by contacting Dynatec s Customer Service Page 10
168. lue the Status LED light will illuminate red indicating an overload condition Turn ing clockwise increases the current limit value turning counter clockwise decreases it T he current limitis factory preset so no adjustment is necessary ACC and DEC B adjusting pots These pots change the time required for the pump motor to accelerate A CC or de accelerate Turning full counter clockwise equals 0 3 seconds Turning full clockwise equals 20 0 seconds Factory default for either pot is 10 0 seconds cont J 1 umper A M J umper Auto Manual PWR Power LED Green unitis ON FSR J umper amp connection to drive enable of Motor Interface PCB Interface PCB 5 Potentiometers Factory Set Do Not Adjust Line 12 Spade connectors CL Current Limit 2 to incoming 11 Main Power MAX z inactive MIN Minimum RPM DEC B Decelerate gt ACC Accelerate COMP IR Comp Spade Connectors Motor V 3 to Motor U ST Status Led Red yellow green See table below ST LED Color Function Function ST LED Color State Slow Flash Normal Operation Red Yellow Quick Flash Undervoltage Red ON Current Limit Red Yellow Slow Flash Overvoltage Red Quick Flash Overload Yellow ON Stop Red Slow Flash Short Circuit Layout of Components on Motor Drive Board Page 7 8 Troubleshooting ITW Dynatec c 2000 Revised 7 01 DYNAMELT M A
169. ly qualified technicians perform such installations The installation of options that require specific procedures and or calibration are outlined in this chapter Before controller options are installed always turn the controller s main power switch OFF In most cases turning the controller OFF will assure that the controller will retain its programmed parameters and configuration Re booting is not necessary Page 3 8 Installation iTV Dynatec c 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 Adjusting the Pressure Relief Valve The function of the pressure relief valve is to protect the gear pump s and the pump drive compo nents 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 sleeved protective clothing must be worn will require the hot melt adhesive to prevent the possibility of serious injury O to be at a high temperature from the molten adhesive Refer to the application system to have Chapter 1 and the section entitled substantial pressure Safety SAFETY PRECAUTIONS for further glasses insulated gloves and long 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
170. m z 42 4 odor rhet veo Een demo ten M SERA 11 8 Power Wiring Diagram 240v 22 7 11 9 Signal Wiring Diagram 4Hose 4 Head 240v 11 10 Power Wiring Diagram 380v 2 11 12 Instruction Sheet for Pump amp Zone Configuration 11 13 Special Dynamelt ASU 5 end of chapter Appendix Optional Dynatec Zenith Standard Accuracy Gear Appendix 1 Optional Dynatec Zenith High Accuracy Gear Pumps Appendix 15 Optional Zenith Melt Spinning Pumps Appendix 28 High Accuracy Pump Performance Chart Appendix 34 Pressure Transducer iiu vos RE WAS NE ERE A Appendix 35 Electric rue e Eu E I e eu EN Ce de ROS Appendix 37 Optional TSHA Pumps 2 9 44 Era eene re a ENS etr deu e S exe des Appendix 39 Page viii Table of Contents T Dynatec 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 ITW Dynatec An Illinois Tool Works Company ITW Dynatec Adhesive Application Systems ITW Dynatec 1997 ALL MODELS Page 1 1 Revised 1 07 Chapte
171. med on Service Page 2 menu item 1 the zone s setpoint the zone s actual temperature the zone s tolerance programmed on Service Page 1 menu item 1 and the zone s identification number Page 5 10 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Pump Programming Screen c Optional p ERAS SYSTEM Ready Tue 3 36 L D D Press Enter and Select Mode Set Min SYM ABC DEF Pump Mode 96 2 3 1 MANU 2 JKL MNO 3 STOP 5 6 INFO RIGHT PUMP 2 3 my wy 0 gt ABC 123 ITV Dynatec Alternative programming function keys EEA ES ITW Dynatec c 2000 Programming Page 5 11 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Pump s Programming Screen Each of the pump s is programmed individually by using the function keys as follows Press This To Function Key Scroll Up or Down F1 2 Selecta pump Stop To stop all pumps in system Re Start F 4 To re start all pimps M anual F 1 Choose M anual M ode for the selected pump Automatic F2 Choose A utomatic M ode for the selected pump Stop Choose Stop M ode for the selected pump Clutches F 2 Go to the Clutch Programming Screen if clutches are installed Return F4 Return to the A ctual Temperatures Screen Enter Enter a numeric value Programming 1 Scroll to select a pump Press Enter 2 Press M anual A utomatic or Stop as desired
172. minimum percent of full speed values on the controller s keypad MAX 96 of Full Speed will be the true motor Speed at 10 volts input This value cannot exceed 10096 To make the motor speed adjustment follow the programming instructions in Chapter 5 Pump Output Adjustment W hen the adhesive in the SU s hopper has reached a temperature high enough for the pump to op erate safely the controller will place the hopper in Ready condition and power will be supplied to the pump The pump is self priming Pump output is adjusted by the motor speed control on the controller s keypad However if less pressure is needed maximum pressure of the pump can be decreased or increased by adjusting the pressure relief valve installed on the pump output manifold To change the setting of this valve re fer to instructions in Chapter 3 The relief valve is factory set at 34 bar 500 psi for Dynamelt M gear pumps Page 7 24 Troubleshooting iTV Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Troubleshooting the ASU s Gear Pump No special tools are needed for working on the ASU pump See Chapter 8 of this manual for diaas sembly 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
173. 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 T Dynatec c 2000 Appendix 41 DYNAMELT M ASU Manual 20 36 Revised 4 06 shaft to put end thrust on the pump Rotation Ensure drive rotates in correct direction generally counter clockwise at the pump drive spindle The pump must be checked for smooth operation by hand Fixing and Lubrication The pump must be fixed securely to maintain position and alignment When secured by lubricated bolts torque them evenly to the suggested torque see Maintenance Start drive and bring up to speed slowly Flush with process fluid Note motor baseplate assemblies should be pre checked in case the drive alignment has been dis turbed Gland Leakage If oil seal is fitted there should not be any fluid leakage Problem finding Chart Problem Remedy LEAKAGE Screws not tight Re torque Seal scratched or worn Replace seal FLOW RATE ERROR Gear worn on diameter Return to ITW Dynatec or width Gear teeth damage Return to ITW Dynatec Plates worn scratched or not Return to ITW Dynatec flat Low inlet pressure cavitation Check process High outlet pressure slippage Check process Appendix 42 T Dynatec 2000 Revised 3 05 DYNAMELT M ASU Manual 20 36 Cleaning Before removal from machine the pump should be rotated for a short period with inlet supply shut off to di
174. mp Enable Thermostat N O 1 2 Dia Pump Enable Thermostat N C 1 2 Dia Temperature Sensor Hopper Support Hopper Assy Heater Plate Spacer 8 x 30mm HHC Screw M6 x 30 SHC Screw Flat Washers 1 4 Lock Washer 1 4 Filter Shut off Plug used in place of or opposite Filter Shut off O ring 912 Junction Box Assembly Junction Box Prog Melt M70 140 Cover Junction Box Bushing Plastic Cap 1 2 Terminal Rail 11 5 Block Terminal Terminal x8 1 2 Sealtite Connector Plastic Bushing Conduit 1 2 Sealtite 20 Over Temp Switch Assembly Sold as an assembly only Insulator Over Temp Thermostat Overtemp Reset Thermostat M4 X 6mm Pan Head Grid Group O ring 014 Flange Cover Temperature Sensor Sensor Adapter Cast Heater 5 16 ID Conduit O ring M4 0 70 x 10mm SHC Screw 8 x 35mm SHC Screw 10 24 x 3 16 SHS Screw Filter Block see your order for part number Pump see your order for part number Pump Block Off Assembly O ring 2 041 Block off Plate M10 x 100 Stud Level Seal Plug Filter Shutoff Assembly Alim TFE Grid Block Off Assembly Option Block off Plate O ring 2 032 8 x 20mm HHC Flange Screw O ring 014 Ball Valve Assembly Option M6 x 30mm SHSet Screw 8 Nut With Washer 1 2 NPT Level Seal Plug Qty ROR OR RNR RR N N PBN RP RRR RRB mR RR RRP RR 1 N Revised 3 07 Componen
175. n electrical power and the serial communication connections come in from below the unit and connect under the Dy naControl keypad so access is needed there For installation dimensions see illustration on page 2 4 Hopper Lid Controller Keypad ue a Panel Main Disconnect Box S witch 72 Keylock Access Door Keylock Manifold Cover Panel Box Hose Head Electrical Connections The DYNAMELT M35 DCL ASU Page 3 2 Installation iTV Dynatec c 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 Re read Chapter 1 Safety Precautions before performing any installation procedures All installa tion procedures must be performed by qualified trained technicians lt ON To Open Close Panel Box Door Position 1 With the key supplied unlock the panel box door 2 Turn the main disconnect switch counterclockwise to Reset while pushing the tab clockwise with your thumb 3 Pull door open 4 To close Turn switch to ON Hold door closed while turning swith to Reset and then back to ON 5 Lock the panel door with the key Installation After the DY NAM ELT M SERIES ASU has been properly positioned the following general sequence should be followed for installation 1 Make sure that incoming line power to the ASU and that the unit s main disconnect switch are turned OFF Main Disconnect Switch DANGER HIGH VOLTAGE Disco
176. natec typically determines the main circuit breaker by the mains load for a system which by codes should be 12596 to 15096 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 section of the indented bill of materials inserted at the back of this manual The main circuit breaker is the largest amperage cir cuit breaker listed in that bill of materials Page 2 6 Description amp Specifications T Dynatec c 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 Definition of Code DYNAMELT DM 35 ASU w DynaControl Controller ASU Code M XX D X D PX X M35 DN 1GASj1Z2LS 2 02 2 2 240V Delta no neutral 380V 3P Star neutral only Code PN Base Unit 35 106049 35kg 77 1 Hopper D DynaControl Controller Total number of drives Drive Setup Code PN Grids Drives Front Rear Motor Drive Groups 1 pump N n a Standard 1 drive 1 0 G 804634 Add Drop in Grids 2 1 n a Omit Drop in Grids Code PN Panel Box Assembly Qty Code PN Pump s PA 806456 1 drive 2 hose 2
177. nce these pumps are not self priming a flooded suction is usually the minimum inlet pres sure 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 D ynatec 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 B ecause 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 pres sure side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate The Standard A ccuracy Pumps are designed for high temperature and high pressure opera tion 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 D ynatec should be notified immediate ly W hile the pump is composed of steel it is a preci
178. ne hour after the external contact is closed The ASU enters Sleep M ode three hours after entering Standby Press 4 to program Setpoint Limitation Enter a numeric value Press Enter Press Return 4 The Setpoint Limitation is a universal maximum temperature for all temperature zones ie the overtemperature limit The controller will not allow the operator to program a higher setpoint than the value of the setpoint limitation The default setpoint limitation is 218 C 425 F The se lectable range for the setpoint limitation is 40 C 232 C 100 F 450 F Function 5 is not active in the present controller configuration No programming is possible Page 5 18 Programming ITW Dynatec c 2000 Revised 7 02 DYNAMELT M ASU Manual 20 36 20 37 20 38 Service Functions Screens Page 1 cont Press 6 to program Temperature Offset Enter a numeric value for the first zone selected Press Enter Scroll to next desired zone and repeat until all zones are programmed Press Return F4 Note to enter a negative value enter the value then press N egative The Temperature Zone Offset is a mathematical factor which compensates for differences in tem perature between the placement of the system s heaters and sensors An offset is often used for large applicator heads printrolls printwheels or other custom devices U sually no offset is re quired for standard heads The offset may be programmed up to 50 degrees C or F of the zone
179. ng C appears at the upper right of the HELP screen Press 6 to program Language Scroll to desired language Press F4 to Return to menu Press 7 to program LCD Contrast Press F1 to increase contrast or F2 to decrease contrast of display Press F4 to Return to menu ITW Dynatec c 2000 Programming Page 5 21 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Service Functions Screens Page 2 cont Press 8 to program System L ogbook The System Logbook has the following functions 1 System Logbook a list of the last 1 000 controller events Use F1 and F2 to move forward or backward thru the logbook U se F3 Configuration to choose to log all system data or errors only 2 Data Logger a list of the last 1 000 lines of actual temperatures for up to five selected zones The time interval at which these temperatures are recorded is programmable The first screen of the D ata Logger is the actual data list M ove through the data by pushing F1 Forward or F2 Backward To program press Configure The Data Logger programming screen is seen below Use the ar rows to select a desired function U se the numeric keypad to enter zone numbers or the time interval in 1 10ths of a minute Press Enter to confirm your choices Toggle to select M ode SYSTEM Ready Tue SelectZones 4 12 20 Enter Time Interval 0 1 min Mode Run Stop RUN name of the selected zone Zone 2 RETURN 3 Elapsed Hours the number o
180. ngineers have relied on Zenith to provide precision fluid han dling 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 C apability Operating temperatures to 550 degrees F 288 degrees C Maximum L ife 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 M aximum 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 iTV Dynatec 2000 Appendix 17 DYNAMELT ASU Manual 20 36 20 37 20 38 Revised 3 01 SPECIFICATIONS Pump Type Rotary external spur gear single stream Rotation Clockwise O perating Speed 3 120 rpm depending upon application conditions and fluid viscosity Temperature To 550 degrees F 288 degrees C DESIGN D ynatec Zenith High A ccuracy M etering Pumps consist of two gears rotating in mesh with in a closely fitted housing that is comprised of thre
181. niques Please contact us concerning plans for such a visit or with any questions you may have regard ing the application or maintenance of your Zenith Melt Spinning Pumps Parker Hannifin Corporation Zenith Division 48 Woerd Avenue Box 9115 Waltham MA 02254 617 894 0650 Telex 263905 Appendix 33 Revised 3 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 iTV Dynatec c 2000 4 DW Y 376815 234VNLT H1 LZ 52033580 026 0970 LNDAVT NVA 1 Lud THY ear WADI 0403100 VAM 004 VIHIMAFQ ANDINA ELD OINA aMOwIS M POLLO Werke ve Spins aU ao gojeuAqa LAVH NAGHS MIDI JINIHAdDAddy 3H9S 9 2 13X20 91 104 NIINE OL 34v SdH d 717 E 3312VHVH2J Ser Hil NAOHS 801193907 LY A4NJH32VT4SlQ 1 1599 HILI 2 XSdWnd AYID unn vnd NO 5131100 0310934935 5370 3 3HLl 5918 4939 DAL TIONIS 0 ATTIVNSSINIT NAOC 225 IM NO 3794 123NN02 SINDH 0549 DAL IHL 1 01350 38 NYI 78 355 4319404 0863 80 53104 9073980 507380 6283900 sov3rao 8 1 X racvazo 009 cr A38 23 02621 00 3 80 90r3r80 03680 653790 lt 0 3 80 6 2 X 91 8 6 861 870 8087 Cool e
182. nnect and lock out input power to the application system using the lockout safety illustrated above before starting any installation procedures Make sure there is no electrical power on the leads you will be connecting 2 Within the panel box assembly Connect 3 electrical leads with the appropriate voltage to the main circuit breaker and connect one electrical lead to the ground PE terminal see diagram following 380v 505 only In addition to above connect one lead to the neutral terminal CAUTION Grounding conductors never carry electrical current The use of a neutral conducting wire as earth ground is incorrect and may cause damage to the controller cont i TwDynatec 2000 Installation Page 3 3 DYNAMELT M ASU Manual 20 36 Revised 6 01 3 Atinstallation the customer must make the following terminal connections into the A SU s printed circuit boards PCBs The boards do not need to be removed from the A SU in order to make connections See the detailed layout on the next page for locations and refer to the detailed layout drawings of the PCBs in Ch 7 if needed Required connections for standard 240 vac ASU Input Power from M ain Power 240vac M ain Power Switch L1 L2 L3 PE Ground Terminal rail Required connections for 380 vac ASU Input Power from M ain Power 380 vac M ain Power Switch L1 L2 L3 N PE Neutral Ground Terminal rail Non essential connections connect if feature is desired R1 R2 No
183. nsor lead to the plug at X 14 on the Power PCB Repair or replace any damaged wire 3 Drop in grid sensor 3 Replace sensor if resistance does inoperative not comply with the resistance table in this chapter X14 Page 7 18 Troubleshooting Revised 10 00 iTW Dynatec c 2000 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Optional Drop in Grid H eater Open Heater Leads 1 Inspect grid s heater wiring for proper connections 1 Disconnection in grid s heater circuit 2 Verify that the Power PCB is properly connected to the solid state relay 2 Disconnection between Power PCB and solid state relay 3 Refer to the schematic in Chapter 11 to locate the grid s circuit breaker If itis tripped do not re set it without checking for causes Visually and electrically inspect for a short circuit 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 Drop in grid circuit breaker tripped 4 Atthe terminal rail use an ohmmeter to measure resistance as follows Forlgrid H1A amp 380v H1A amp H1B 240v For 2nd grid H2A amp N 380v H2A amp H2B 240v 4 Open drop in grid heater element NOTE TheDM 35 ASU ma have 1 or 2 grids The DM 70 140 ASU may have from 1 to 4 grids For 3rd grid H13A amp N 380v The DM 210 A SU may have H13A amp H13B 240v from 1 to 6 grids For 4th grid H14A amp N 380v H14A amp
184. nter Press the numeric key of your language choice followed by Enter OR Scroll V7 A to your choice then press Enter Note To quickly return to the English language turn the controller OFF Then press both Enter and 9 and hold while turning the controller ON Temperature Scale Selection Press the Service K ey twice to advance to Service Page 1 Press 8 on the numeric keypad followed by Enter Toggle to make your choice between C scale F scale Press Enter Press Return F4 to Go to the Actual Temperatures Screen Page 5 6 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Actual Temperatures Screen The Actual Temperatures Screen serves as the controller s main menu From here you can go to any other screen The A ctual Temperatures Screen is also the most useful screen to display for monitoring purposes Scheduler Key Controller t t 7 D heduler Acti System Status ay Scheduler Active Senice On Off Key SYSTEM Alarm lt Tue 3 36 4 e5 D Actuals F Next Page Press C 2 Premelt C SYM DEF Progmelt 2 3 Filterblock Wu f JKL MNO Aux Zone 5 6 TUV WXY PRESSURE 3 0 gt ABC 123 11 Pump Info Lines Use of the Actual Temperatures Screen Press This To Function Key On Off Toggle display pumps and heaters power ON or OFF Setpoints F 1 Go to the setpoints programming screen Pumps F
185. o 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 amp 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 Re move the old seal 4 Clean all pump parts paying particular attention to the pump shaft seal groove 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 f
186. o allow adequate lubrication All parts are ma chined to extreme accuracy critical dimensions are held between one and two ten thousanths of an inch 0001 0002 B ecause of these close running clearances cont iTV Dynatec 2000 Appendix 5 DYNAMELT ASU Manual 20 36 20 37 20 38 Revised 3 01 these pumps require careful maintenence and handling especially of component parts The slightest burr nick or particle of foreign matter can cause scoring or even seizure These pumps are precision instruments you can t keep them too clean Please treat them with care and if it s at all possible set aside a separate clean area for pump maintenance To clean High A ccuracy M etering 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 temper ature 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 A nother 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 car burization process usually takes between 3 and 12 hours depending
187. ocket If the new hose number is then displayed as malfunct ioning the problem is in the hose that was moved Repair or replace hose head or ASU hose harness as appropriate 2 Disconnection between 2 Check connection Verify that solid solid state relay and state relay is operative check schematic Power PCB or inoperative Chapter 11 for relay location Use relay clamp on ammeter to monitor hose Head current If current does not cycle on and off the relay has failed and must be replaced 3 Disconnection between 3 Visually inspect wiring inside head cartridge heater and cable that cartridge heater leads are assembly inside head properly connected in the service block area Sensor 4 noperative hose head 4 Refer to schematic in Chapter 11 for Heater circuit breaker location of circuit breaker If itis Dim found to be tripped do not re set it TN 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 Plug Sensor amp 5 Open hose head heater 5 Use an ohmmeter to measure hose element head heater resistance See resistance table in this chapter for resistance values Infinitely high resistance indi cates an open heater element Heater 6 Open wiring inside ASU 6 Visually inspect ASU wiring and use an ohmmeter and the wiring diagram to locate open wires in head heater
188. oder is installed onto these board connections MAX Speed Adjustment potentiometer X2 connections are internal and not for customer s use lt 0 5 VDC speed reference Ground not used Pump enable lt Pump enable Flat cable connectto CPU PCB atJ1 X1 Encoder pulse E MEE S not used Transformer Fuse gt lt Ground lt Encoder supply voltage Transformer d Handgun trigger input amp pump enable lt Handgun trigger input amp K pump enable 0 0 10 VDC input web speed NES msx 40v 240 VAC input 3 Web Speed Scaling potentiometer Factory Set Do Not Adjust Layout of Components on Motor Control Interface Board ITW Dynatec c 2000 Troubleshooting Page 7 7 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 1 03 Motor Speed Control Printed Circuit Board The M otor Speed Control PCB is connected to the M otor Control Interface Board via spade connc tors P1 and P2 P3 is not used The three jumpers FSR J1 and A M factory set do not change 1 jumper is always set in the upper position The A M Jumper is always present CL adjusting pot The current limit CL adjustment will limit the maximum current available to the AC pump motor during overload This will protect the motor from damage T he setting is facto ry set to deliver 100 of the rated horsepower for the ASU When the motor load exceeds the cur rent limit va
189. ogramming Screen 1 5 11 Programming eden d ep a e er e vens 5 11 Monitoring er a te D UL I Pu e peas 5 11 Optional Clutch Programming Screen 0 5 12 Use of the Optional Clutch Programming Screen 5 13 Programming 4 aaa aera en Ace a E im DUE Ee EC 5 13 Monitoring saci aoe vede Ru REN Rua dag Gals Ep RR ane 5 13 Optional Pressure PSI BAR Programming Screen 5 13 Use of the Optional Pressure PSI BAR Programming Screen 5 15 Programming i sit eu E a VA oe eG ee OE Ba 5 15 Monitoring TTL 5 15 Service Functions SCreens us a vo a SAS AAS SOAS AWS 5 16 Service Page 1 525 e eve ULIS e Cede 5 16 High Low Temperature Deviation 5 17 Standby Temperature ie ee ten dee ae A E EON IEEE 5 17 Standby Sleep Setup coute p ee ee RE ede eb e E Hs 5 17 Setpoint Limitation imer Na eq ed Rr eue aq en A eg PRAE 5 17 Temperature Offset eer In e er eere E eR aH A be 5 18 Sequential Heating cet neret es eere do OU oboe Sete oc d 5 18 Temperature Scale iem eI EIU eR as 5 18 Change Security Loc
190. ol 26H 5 t 1 9 2 97 C 1 6 g er WHT BRN 1 4 CoO SAAS ARRAS Regs KH LT E A 378 2 ED 7 s CBB 2 2L1 7 H8 V8H Ceo p x NN 1 8 d 04 zd C r L3 2 1 23 7 cer 8 2 E 14 dr aft dr fe af dd sped dos E 16A nz van 5 8 Ld 9d CB7 uve pd E N 22 2 mi VIH L6 3508 EZH L tier zi sr gt 16A 0 L OOOO m usd L XEOH pum VGH ESH 1 ag QviH 5 21 OSH EGH pus 1 1 2 215 H3 oF ee d E es vd M i mr W 4 212 7 H4 VyH 151 154 152 J53 15 EIE CBI gt 22 Hl net 15 drm LLHAG3Nd 5 i P j CB2 A 214 2 igt VZH CLTSAGSd 16A O as 9 9 lt e 2 My e x 2 Ez ou Tag hast o s 2 ES aut ome o Oo S epe 855 Bs NE 1609 a ar Bea Dra a a d gt Lm pr 2 S S ss yes DEDE o 228 226 e e 528 Be e E z2 z2 Goo Me Sy ATA 1k3 I e a ls mo A N 112 n
191. ons Due to technical advances in electronics many rectifier controls with a 115 VAC 60 Hz input are able to deliver an output of approximately 103 VDC when connected to a coil This is not harmful to a 90 100 VDC rated coil in a clutch or brake For Stearns Tor ac units the leads provided by the Tor ac module should be connected to a fused relay or switching contro source of 105 to 125 VAC 50 60 Hz See Figure B for a typical wiring connection of Tor ac controlled units Appendix 37 Revised 10 00 Restraining i 1 ba RN f SS de TaN A optional Magnet body and assembly field shell Figure A Table A Maximum Allowed Hub Rotor Gap Open Magnet Misalignment inches reference Armature Gap inches inches Angular 1 32 010 to 030 1 16 010 to 030 3 32 010 to 030 1 16 010 to 030 1 8 010 to 030 Off Fuse lt lt AC clutch 115 VAC p leads Neutral Fuse 0 5 ampere fast acting Figure B On units with cord grips do not remove cap or turn hex portion of fitting Wires may be twisted and torn off it attempted Enclosure Normally the machine housing provides sufficient enclosure Care must be taken to protect unit from grease oil or airborne materials Slippage and excess heating of the unit may result if proper protection is not provided Care should be taken that high ambient tempera
192. or leaks Appendix 44 TW Dynatec 2000 Revised 3 05 DYNAMELT M ASU Manual 20 36 Rebuild Kit for 8 5cc TSHA Pump PN 111939 The rebuild kit for the PN 108875 8 5cc TSHA pump consists of the following parts Description Description 111699 Drive Shaft 111707 Retaining Ring 111699 Idler Shaft 111709 Screw 10 24 111701 Bushing Front Plate 807729 Pump Shaft Seal 111702 Bushing Back Plate 111705 Key 111704 Dowel 0781001 Key Woodruff
193. ore of the connections in which this module is the target has timed out This state is only left if all timed out connections are re established or if the module is reset Steady Red Duplicate IP Address The module has detected that its IP address is already in use Flashing Self Test The module is performing a power on self test Green Red 2 Active This led flashes green each time a packet is received or transmitted 3 Mod Stat Module Status Green Red State Summary Description Steady Off No power The module has no power Steady Green Device operational The module is operating correctly Flashing Green Standby The module has not been configured Flashing Red Minor Fault A minor recoverable fault has been detected Steady Red Major Fault A major internal fault has been detected Flashing Self Test The module is performing a power on self test 4 20 ITW Dynatec 2005 Revised 8 05 DYNAMELT M ASU Manuals 20 36 20 37 20 38 4 Link Link Activity Color State Description Green On The module has a link Off The module does not sense a link Configuration File The EtherNet IP module contains a file ethcfg cfg that is read by the module at start up This file defines the network properties of the module Any text editor can be used to edit the parameters Note It is very important to follow the exact syntax specification otherwise the module might have
194. ormed by qualified trained technicians Disassembly Procedures Note Use the exploded view drawings referenced with each procedure in conjunction with the in structions outlined in this chapter Read the cautions on page 8 4 before re assembling the ASU To Remove the Access Doors There are two access doors one on either side of the ASU Use the key to unlock the door then lift it off being careful not to pull off the ground wire attached Remove the ground wire and re attach when the door is re installed These doors allow access to the motor pump junction box optional drop in grids filter shutoff and optional ball valve To Open J unction Box The junction box is on the right hand side of the hopper Within the juction box are the thermostats heater terminals and the hopper sensor The junction box cover is removed via the two screws at the bottom of the cover Panel Box Assembly Access Door i Keyloc Q d d 7 2 gt A A A 2 Filter Shutoff Assembly ap 57 Ne 7 Me Ball Valve Assembly i d Filter Manifold option P J unction Box Thermostat Over Temp Reset Manifold Cover Thermostat Page 8 2 Disassembly amp Re assembly iTV Dynatec c 2000 Revised 9 00 DYNAMELT M ASU Manual 20 36 J unction Hopper Box cover BAN J unction Cutouts for conduit connectors for filter manifold heater and sensor Over Temp Reset Thermostat
195. oses hookup hose head 1 to electrical connection 1 and adhesive port 1 then hookup hose head 2 to electrical connection 2 and adhesive port 2 etc Two return hose adhesive ports are located at the top of each filter manifold Use the illustration to coordinate adhesive port and electrical connections as above Return hoses are designated as auxiliary ports 5 Connect optional PSI transducers at the PSI ports labeled on the filter manifold Position them from left to right across the manifolds as shown in the lower illustration on page 3 6 Transducers measuring adhesive pressure before it enters the filter use the ports stamped Pre PSI and transducers measuring pressure after the filter use the ports stamped Post PSI Transducers must be wired into the pressure printed circuit board Units not using transducers may use either a PSI port or a feed hose port to mount a optional pressure gauge If all ports are in use the pressure gauge may be installed in line with a hose Refer to the hose and applicator manuals for further details on these items Page 3 6 Installation iTV Dynatec 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 Hose Head Electrical Connections Closeable Cross Channel Tamper Proof Screw Bleed Valve Port Heater Channel Retainer Plate Sensor Channel Purge Drain Hose Head Electrical and Adhesive Connections Electrical Up to Two Filter Blocks with Electrical up
196. p 1 Pump seal is incorrectly 1 Remove seal and bearing from pump shaft seal positioned inside the seal Verify that all components are and bearing assembly correctly positioned Seal Assembly RearPlate 2 Pump seal inoperative 2 Remove seal from pump inspect it Ss O ring and replace it if worn or damaged Be sure there are no burrs or other sharp edges on pump shaft or on installation tools that could damage a new seal A dhesive leak at pump 1 O ring in pump s rear 1 Remove seal from pump inspect it to hopper interface plate is inoperative and replace it if worn or damaged Be sure there are no burrs or other sharp edges on the rear plate o ring groove that could damage a new o ring 2 Pump assembly screws are 2 Verify that all four pump screws missing or loose tightly assembled to the hopper 3 Helicoil insert pulled out 3 Remove pump and inspect hopper of hopper Repair or replace hopper as necessary Page 7 28 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 ITW Dynatec An Illinois Tool Works Company iTWDynatec Adhesive Application Solutions I Tv Dynatec c 2000 Disassembly amp Re assembly Page 8 1 DYNAMELT M ASU Manual 20 36 Revised 4 01 Chapter 8 DISASSEMBLY amp RE ASSEMBLY PROCEDURES Note Re read Chapter 1 Safety Precautions before performing any disassembly procedures All disassembly and repair procedures must be perf
197. p Page 4 7 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 System Values That Are Factory Programmed not customer programmable Minimum setpoint value 10 C 50 F Maximum setpoint value Setpoint limitation 218 C 425 F for high temp mode enabled 505 232 450 F Maximum alarm deviation 50 C or F Minimum alarm deviation 5 C or F Maximum standby temperature 150 C or F less than setpoint Minimum standby temperature 30 C or F less than setpoint Actual temperature indication range 0 C to 260 C 32 F to 500 F Customer Programmable Values Preset At The Factory ITW Dynatec can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the DynaControl con troller at the factory They may be changed by reprogramming through the keypad These are not the default settings see following section Applicator head and hose setpoints varies from 138 to 149 C 280 to 300 F Hopper setpoint 143 C 290 F All zones are switched off except for the hopper and the optional drop in grid Motor rpm 0 in the OFF mode Standby 80 C 140 F under setpoint Hi and low alarms 12 C 20 F from setpoint Pump enable temperature 132 C 270 F Page 4 8 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Default Setting
198. per control solid state 3 a Verify that the relay is not shorted by relay inoperative removing all of its output wires and verifying that resistance is greater than zero b Verify condition of relay by discon necting 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 Relay iTV Dynatec 2000 DYNAMELT ASU Manual 20 36 20 37 20 38 Troubleshooting Page 7 15 Revised 10 00 1 Sensor cable has become unplugged from CPU PCB Hopper Sensor Open 2 hopper sensor Hopper Sensor Hopper Sensor Short 1 Short circuit caused by debris where sensor plugs into CPU PCB 2 Pinched sensor lead wire 3 Inoperative hopper sensor 1 Verify that hopper sensor cable is properly connected on X 14 on the CPU PCB 2 Replace hopper sensor if resistance does not comply with resistance table in this chapter 1 Verify that sensor plug is clean and correctly connected on X 14 on the CPU PCB 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity from the sensor lead to the plug at the CPU PCB Repair or replace any damaged wire 3 Replace hopper sensor if resistance does not comply with resistance table in this chapter Page 7 16 Troubleshooting iTV Dynatec 2000 Revised 10
199. perdio DYNAMELT M ASU Manual 20 36 Revised 4 06 TOOL STEEL HIGH ACCURACY GEAR PUMPS USER S GUIDE Pump Identifier Displacement Type Gears Plates Shaft Seal 108863 0 160 cc rev 807729 108864 0 160 cc rev 807729 108865 0 297 cc rev 807729 108866 0 297 cc rev 807729 108867 0 584 cc rev 807729 108868 0 584 cc rev 807729 108869 1 168 cc rev 807729 108870 1 168 cc rev 807729 108871 1 752 cc rev 807729 108872 2 920 cc rev 807729 108873 4 500 cc rev 807729 108874 2 920 cc rev 807729 108875 8 500 cc rev 808680 110290 30 0 cc rev 808680 110291 45 0 cc rev 808680 amp gt CORO FN FN nw Nn Ww Tool Steel High Accuracy Customer should read and thoroughly understand this manual before installation and operation of pump If necessary any Dynatec pump requiring maintenance can be returned to the factory for complete repair and overhaul Please contact our Rebuild Department for further details Appendix 40 T Dynatec 2000 Revised 3 05 DYNAMELT M ASU Manual 20 36 Description ITW Dynatec s metering gearpumps are manufactured to precise tolerances To retain their high performance these pumps must be carefully installed and maintained These pumps are CE Dec laration of Conformity rated Health amp Safety Dismantling Internal components are precisely machined and have sharp edges and corners These features are essential to th
200. play is switched off and the controller then switches off the faulty zone until the ASU is ready for operation again W hen the actual temperature exceeds the setpoint limitation plus a tolerance the overtemperature alarm window is displayed and main power is switched off Examples of Error Alarms The Overtemperature A larm indicates that the named zone has exceeded its programmed setpoint limitation Zone Name The controller will shut off power to the heaters Press F4 and troubleshoot the problem Overtemperature The Sensor Failure Alarm can indicate either a sensor open or asensor short Sensor open is accompanied by Sensor Failure a blinking up arrow on the actual temperatures display screen Sensor short is accompanied by a blinking down Zone Name Ht arrow Press F 4 to reset the error message and then either a manually turn the zone OFF via Setpoints F 1 indi cated zone On Off F3 or b troubleshoot the problem The Hopper Overtemp A larm indicates that adhesive temperatures in the A SU s hopper have exceeded the Hopper Overtemp setting of the mechanical redundant thermostat Press F4 and troubleshoot the problem The Communication Error Alarm indicates an internal failure unrelated to zone temperatures Call ITW 22 D ynatec for assistance Communication error Page 4 6 Controller Setup ITW Dynatec c 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Optional System Status Lights Audible A
201. pplication Systems IN Area Dynacontrol PLC Version V5 15a Word Address Function Zone Name Valid Range Reserved Reserved Setpoint Premelt 1 Setpoint Premelt 2 Setpoint Premelt 3 Setpoint Premelt 4 Setpoint Premelt 5 Setpoint Premelt 6 Setpoint Progmelt 1 Setpoint Progmelt 2 Setpoint Progmelt 3 Setpoint Filterblock 1 Setpoint Filterblock 2 Setpoint Filterblock 3 Setpoint Hose 1 Setpoint Hose 2 Setpoint Hose 3 Setpoint Hose 4 Setpoint Hose 5 Setpoint Hose 6 Setpoint Hose 7 Setpoint Hose 8 Setpoint Hose 9 Setpoint Hose 10 Setpoint Hose 11 Setpoint Hose 12 Setpoint Head 1 Setpoint Head 2 Setpoint Head 3 Setpoint Head 4 Setpoint Head 5 Setpoint Head 6 Setpoint Head 7 Setpoint Head 8 Setpoint Head 9 Setpoint Head 10 Setpoint Head 11 Setpoint Head 12 Setpoint Auxiliary 1 Setpoint Auxiliary 2 Setpoint Auxiliary 3 Setpoint Auxiliary 4 Setpoint Auxiliary 5 Setpoint Auxiliary 6 Setpoint Auxiliary 7 Setpoint Auxiliary 8 Setpoint Auxiliary 9 Setpoint Auxiliary 10 Setpoint Auxiliary 11 Setpoint Auxiliary 12 Motor Mode 1 Motor Mode 2 S 83 Stop Motor Mode 3 M 77 Manual Local manual speed Motor Mode 4 65 Auto 0 to 10V Motor Mode 5 B 66 Bus EtherNet IP OUT 56 to 61 Motor Mode 6 Motor Speed 1 Motor Speed 2 Motor Speed 3 0 to 1000 0 0 to 100 0 500 50 0 Motor Speed 4 Local manual speed Motor Speed 5 Motor Speed 6 NI On
202. problems interpreting it which can result in a faulty or non expected behavior The file can be uploaded and after modification downloaded using the FTP function e g open a Windows Explorer window Type 192 168 23 180 The format of the file is shown as follows FORMAT IP address 192 168 23 180 Subnet mask 255 255 255 0 Gateway address 0 0 0 DHCP BOOTP ON SPEED Auto EXPLANATION IP Address Subnet mask Gateway address DHCP BootP ON Enabled OFF Disabled Speed Auto Default Auto Negotiation will be used 100 Forces the module to operate at 100Mbit s only 10 Forces the module to operate at 1OMbit s only 21ITW Dynatec 2005 4 21 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Revised 8 05 FORMAT Duplex Auto SMTP address 0 0 0 0 SMTP username username SMTP password password DNS1 address 0 0 0 0 DNS2 address 0 0 0 0 Domain name hms se Host name EXPLANATION Duplex Auto Default Auto negotiation will be used Full Forces the module to operate at full duplex only Half Forces the module to operate at half duplex only SMTP server login settings SMTP server login settings SMTP server login settings Primary and Secondary DNS Primary and Secondary DNS Domain Name Optional Host Name Optional Dynatec Dynacontrol EtherNet IP Data Table eene of Adhesive A
203. programmed Adhesive will begin to pump once the pump enable thermostat closes and Ready condition is attained Shut Down Procedures At the pump screen 1 If Pump is in Auto Mode a Press STOP or STOP ALL F3 b Turn OFF the Main Disconnect Switch 2 If Pump is in Manual Mode a Press STOP or STOP ALL F3 b Turn OFF the Main Disconnect Switch 3 If 7 Day Scheduler is in use Turn ON and OFF with the Controller On Off pushbutton Note Except in the case of the 7 Day Scheduler use of the Main Power Switch to turn the unit OFF will avoid unexpected ASU activation in the event of a power outtage Page 3 16 Installation TW Dynatec 2000 Revised 4 06 DYNAMELT M ASU Manual 20 36 Storage and Disposal of the DYNAMELT M Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN 115653 following the instructions detailed in chapter 6 of this manual Clean or replace both the outlet filter and the primary filter following instructions detailed in chapter 6 Shut OFF all pressure and power sources Release residual air pressure if applicable Remove all residual adhesive and wipe components clean Remove all air lines if applicable and all power supply cables Pack the unit in a corrosion proof manner Store the unit in such a way that it is protected from damage Disposal of the Unit 1 2 Shut OFF all pressure and power source
204. ptional Clutch es Program Optional Pressure Transducers xi Service Page 1 1 High Low Temperature Deviation 6 Temperature Offset 2 Setback Temperature 7 Sequential Heating 3 Setback Sleep Setup 8 Temperature Scale 4 Setpoint Limitation 9 Change Security Lock or Access Code x2 Service Page 2 1 Customer Zone Names 6 Language 2 Power On Configration 7 LCD Contrast 3 Factory Defaults 8 System Logbook 4 Keypad Locking 9 Change Security Lock 5 PC Link ay To Program Scheduler 1 Manual Standby Activation 4 Select Program Recipes 2 Time amp Date Clock 5 Manual Scheduler Activation 3 Program 7 Day Scheduler End ITW Dynatec c 2000 Programming Page 5 5 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Controller Setup Below is the step by step process of setting up the controller Note Whenever an Access Code is required enter your individual code The default code is 9999 If you have lost your code call ITW D ynatec Customer Service 1 800 538 9540 in the U SA or con tact your local repsentative Turn the Controller ON Turn the controller ON using the ASUs main On Off switch Language Selection English is the default language If you desire another language choices are German French Ital ian Spanish Swedish Portugese J apanese and Dutch make your selection Press the Service K ey two times to advance to Service Page 2 Press 46 on the numeric keypad followed by E
205. pull the filter shutoff assembly out 5 a Replace the clogged filter shutoff assembly or b Emerse the assembly in flushing fluid PN 115653 to loosen contaminants Remove assembly from fluid and use a hot air gun if necessary and rags to clean all contaminants from it 6 Apply a coat of anti sieze compound onto the threads of the filter shutoff nut before re inserting into the ASU 7 Replace the filter shutoff o ring Lubricate the new o ring with lube PN 07588 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 1 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 aleaking pump to exit the ASU Inspect the area under the baseplate cutout every month for adhe sive A leaking pump shaft indicates a worn pump seal See instructions in Chapter 8 for replace ment 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 re quired Every Three Months or as experience dictates 1 Check all hose fittings for tightness 2 Check al
206. pump mode Press E nter 3 If in M anual mode enter pump speed 1 the Set column a Use numeric keypad to enter desired rpm value b Press Enter 4 If in Automatic a Scroll to M in to program minimum pump speed Enter value as described above Note typically at 0 volts this value will be between 0 and 10 default 096 b Scroll to M ax to program maximum pump speed Enter value as described above Note typically at 10 volts this value will be between 0 and 10096 depending on motor installed on ASU default 100 5 Scroll to select next pump to be programmed R epeat steps 2 thru 5 until all pumps are pro grammed 6 If clutches are installed on A SU Press Clutches F2 to program see next page Monitoring 1 RUN indicates the pump motor is enabled 2 HOLD indicates that the controller is preventing the pump motor from running due to a low temperature a standby condition etc 2 The Info Line indicates the user defined name for the selected pump programmed on Service Page 2 menu item 1 3 If the optional Actual RPM display is installed actual pump rpm may be monitored With this option the RUN HOLD column is eliminated The Actual RPM display is also seen on the A ctual Temperatures Screen Page 5 12 Programming ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Optional Clutch Programming Screen The Clutch screen is active as a subset of the Pump Programming Screen
207. r 1 SAFETY PRECAUTIONS All operators and service personnel must read and understand this manual before operating or servicing equipment maintenance and service on this equip ment must be performed by trained techni cians Electrical DANGER HIGH VOLTAGE Dangerous voltages exist at several points in this equipment To avoid personal injury do not touch exposed connections and components while input power is on Disconnect lockout and tag external electrical power before removing protective panels A secure connection to a reliable earth ground is essential for safe operation A disconnect switch with lockout capability must be provided in the line ahead of the unit Wiring used to supply electrical power should be installed by a qualified electrician High Temperatures WARNING HOT SURFACE Severe burns can occur if unprotected skin comes in contact with molten adhesive or hot application system parts Safety glasses gloves and long sleeved clothing must be worn whenever working with or around adhesive application systems 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
208. r Yos accepts most forms Electrical S pply voltage si v e bu seat eee E 200 240 VA C 3p 50 60 Hz 380 400 VA C 3p Wye Y or 5 wire connection 50 60 Hz M inimum supply amperes see circuit breaker size Power consumption hopper and 0 0 7500 watts Hopper heater W Pew 542 M pe o Y o EE EA ka va cast in tubular Temperature control microprocessor based proportional integral derivitive Temperature 5 5 100 Ohm Platinum RTD standard 120 Ohm Nickel RTD optional Electrical 6 2 bot Pe e oen mie etl edd durable latching connectors 1 4 hp alternating current TEF C motor direct drive horizontal orientation M aximum current available for each hose head 10 ampere totally enclosed fan cooled TV Dynatec c 2000 Description amp Specifications Page 2 3 DYNAMELT M ASU Manual 20 36 Revised 5 03 Performance Adhesive temperature control range 40 C to 232 C 100 F to 450 F Standby adhesive temperature range up to 80 C 150 F lower than setpoint Hopper ready adhesive temperature deviation factory set field adjustable 20 C 36 F from setpoint Over temperature cutoff for hopper er b Rer ede ea
209. r open circuit Repair or replace hose hose harness or Power PCB as appropriate Alternately problem can be isolated by connecting the effected hose to a different ASU hose socket to tell whether the problem is in the hose or the Power PCB Sensor 1 C If head to hose and hose to A SU 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 Plug Sensor amp Heater 1 Disconnection between hose and ASU ose Head No Sensor Open Im Visually examine connection where hose plugs into A SU socket for proper contact and seating If pins or housings are damaged repair or replace hose or hose harness in ASU Page 7 20 Troubleshooting iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Note Vertical configuration is for 2 Hose sensor harness DM 35 only Larger ASUs are unplugged from Power arranged horizontally PCB 2 Verify that effected hose is properly connected to Power Replace or repair damaged hose harness as necessary 3 Disconnection between th 3 Verify that all PCBs are properly Power PCB s and the mounted inside the panel box PCB s flat cables 4 Hose H ead sensor circuit 4 Replace head
210. re 1 Turn the application system ON and raise the temperatures of all components to normal operating temperatures 2 Turn main power OFF and open the panel box door Restore power to the ASU 3 Atthe controller keypad verify normal operation in AUTO STOP and MANUAL modes refer to M otor Control Programming in Chapter 5 if needed 4 Atthe controller keypad set motor speed to MANUAL mode and to 10096 full speed 5 With an external tachometer measure the motor RPM 6 Onthe M otor Control Interface PCB turn the M AX ADJUST potentiometer until the RPM of the external tachometer reads 1800 rpm 7 Calibration of this motor is complete If additional motors are used on your application System repeat the above procedure for each motor 8 Close the panel box door and restore application system to normal operation Page 3 12 Installation iTV Dynatec 2000 Revised 4 01 DYNAMELT M ASU Manual 20 36 Installation of the Optional Tach Generator or a DC Tracking Signal The installation of a tach generator or a similar DC tracking signal allows speed tracking of the gear pump through voltage following M ultiple motor boards may be wired in parallel to the tach generator On the controller voltage following is referred to as the AUTO M ode 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 appli
211. riving melering gear 6 Carefully lower the center plate over the gears 7 Position the rear side plate 8 Rotate the gears to ensure free rotation 8 Press the dowels into place moving in the direction of the shortest press distance Usually from the rear side of the pump 10 Lubricate the binder screws with DAG Dispersion 154 or a similar heat resistant lubricant and install Torque the screws in even increments to the manufactutrer s recom mended limit It is especially important to rotate the gears frequently during this operation 11 Reassemble the seal arrangement making sure the seal ing surfaces are perfectly clean and free of scratches nicks 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 coupl ing housing screws should be torqued to 3 the manufac turer s recommended torque limit For pumps equipped with a compression packing seal be sure all old packing is removed from the packing housing 12 Inspect the drive shaft at the sea area making sure that it is nat scored shouldered or worn 13 Dip the packing rings into high temperature oil and graphite This aids assembly and of the packing Nichols Copyright 1987 Parker Hannifin Corporation Zenitn Division iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 20 37 20 38 H Place the first packing over the shaft an
212. rmally Open Ready parent machine interlock Power PCB J5S4 pins 1 amp 2 and Power PCB JS2 pins 1 amp 2 A1 A2 Normally Closed A larm controller display alarms CPU PCB X1 pins 1 amp 2 E1 E2 External Standby controller standby mode CPU X4 connect 5 and 9 or 10 P1 P2 Program Select 1 amp 2 controller program selection CPU X4 connect 1 to 9 or 10 P3 P4 Program Select 3 amp 4 CPU X 4 connect 7 to 9 or 10 Power On Output Power PCB JS1 pins 1 amp 2 Options Make connections for the following if installed on your ASU Tachometer line speed tracking MCI X3 0 ground amp 10 Hand Held A pplicator Footswitch MCI X3 TR Low Adhesive L evel output alarm CPU PCB X1 pins 3 amp 4 Pressure Transducer s 1 to 4 transducers PSI PCB X1 X2 X4 Pressure Transducer s high amp low psi alarms PSI PCB X6 Clutch Customer Enable for motor 1 Clutch PCB JS1 pins 1 amp 2 Clutch Customer Enable for motor 2 Clutch PCB JS1 pins 3 amp 4 Ribboncable RS232 485 Communication Display CPU PCB MCI otor Control Interface PC Board Program Selection Table User Connections P1 P2 P3 P4 Riogram Pin 1 Pin 7 open Program 1 closed Program 2 open Program 3 closed Program 4 Page 3 4 Installation iTV Dynatec 2000 Revised 6 01 DYNAMELT M ASU Manual 20 36 Printed Circuit Board Location Diagram The printed circuit boards PCBs are located within the main pane
213. rned ON Likewise if the scheduler is in Switch OFF at the time of a power ON the heaters will be turned OFF W hen the seven day scheduler is programmed and active the scheduler icon on the controller screen flashes continuously 7 Day Scheduler Screen 7 Day Scheduler Active Indicator Keypad On Off SYSTEM Ready Tue 3 36PM L DOD Event Action Day Time 1 Standby El SYM DEF 2 Switch On Mon Fri 1 2 3 3 Standby Mon Fri 4 on Mon F ri 5 S witc Mon Fri 2 Everday GHI JKL No 7 Monday 8 Tuesday 3 PRS WXY RETURN 7 1 e 0 gt ABC 123 T Dynatec Enter ITW Dynatec c 2000 Programming Page 5 25 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the 7 Day Scheduler Programming Screen Press This To Function Key Scroll U p Down or Right F1 2 3 Select an individual action day or time Return F4 Return to the M ain Scheduler Screen a Enter Enter a chosen selection Programming 1 Press F3 to scroll to the Action column Then scroll to the first event you desire to program 2 Press Enter 1 until the desired ction Standby Switch On Switch Off or no event is displayed 3 Scroll F3 to the Day column 4 Press Enter until the desired Day ie Mon Fri Everyday or any individual day is displayed 5 Scroll F3 to theTime column 6 Press Enter to display the time you desire the event to start Enter hour minutes an
214. roprocessor from external interference 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 A n optional remote control panel gives control and monitoring flexibility Digital readout of system conditions is provided A security code can restrict access to system pro gramming and parameters The CPU monitors the electronic circuitry and provides alarms for error conditions The Dynamelt M ASU uses an extremely dependable gear pump s to assure a smoother and higher precision flow The single or dual pumps are driven by individual drives The Dynamelt s teflon coated hopper accepts adhesive in all popular forms including pellets slugs and blocks The ASU can accomodate air actuated automatic applicators heads electric applica tors hand held applicators and or special applicators Options available include pressure gauge drop in grid pendant control adhesive level control digital pressure readout and electric clutch Page 2 2 Description amp Specifications iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 Specifications Environmental Storage shipping temperature 40 C to 70 40 F to 158 F Ambient service temperature 7 C to 50 C 20 F
215. rs 1 2 Hoppers 1 2 X16 eT CPU dat X1 Power ON 18235 13 for heer 8 5 151 LED Power ON LED Hopper 1 Ready S ystem System 1 54 Ready S outputs to MU S LED Hopper 2 Ready supplied Future LED O Future 16 PLC S 15 Q 14 System System 1 8 i i 5 snubbed System 2 S 12 lie outputs Transformer Future 8 O 0 8 O Input L1 7 L2 N S 6 240 O 5 53 4 3 2 Q 1 O JF2 Transformer Fuse 5x20 1 amp Connect to CPU lat J6 Solid state relay driver outputs 1 per zone Green zone is heating OOOO OOOO OOOO OOOO Connect to CPU 3at J6 Connect to CPU2at 6 Layout of Components on 48 Zone Power Board Page 7 10 Troubleshooting Revised 6 01 Optional Clutch Printed Circuit Board ITW Dynatec c 2000 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 The Clutch PCB allows installation of up to six optional clutches on the ASU The dip switches SW 1 are turned ON to reflect the number of clutches on the system Clutch Coil Leads Connects Customer Enable S witches for a footswitch hand held applicator etc Relay Green LED clutch is activated Clutch 3 Clutch 4 240 VAC Input Layout of Components on Clutch Board Optional RS232 485 Printed Circuit Board Pin Configuration RS232 2 RxD 3 TxD 5 Gnd S Shield Pins not li
216. s 3 Check voltage supply as close to coil as feasible Compare t to 4 Nameplate data if incorrect apply proper voltage For Tor ac units check voltage supply as close to the module as possible If this value is not between 105 125 VAC E variable voltage input is not being used corect the voltage source E and replace burnt out parts 4 5 Coil resistance correct Resistance of the 90 VDC coils and coils are tabulated in Table B For others contact factory n the splines between he retaining ring LER and iTW Dynatec 2000 DYNAMELT M ASU Manual 20 36 90 100 VDC and 115 VAC Tor ac Coil Resistances a sscocas 89 eoa 7 4 De OO 5 Start time on clutches normally should not exceed one second If excessive recheck torque rating versus load characteristics 26 Orir l ase springs check for broken missing or substituted springs not of our manufacture T Check for oil grease on friction If this is found replace ment is recommended of complete unit or affected elements 8 Are control limit switches operating properly and set in proper 7 switch malfunction may appear to be loss of torque 9 Is unit fully burnished If not see Burnishing Instructions 10 Check that the restraining bracket is properly secured See Step 3 of Installation i 11 During the life of the unit friction ma
217. s Release residual air pressure if applicable Remove all residual adhesive Remove all air and adhesive hoses and all power supply cables Dismantle all components and sort into mechanical and electrical components Arrange for all components to be recycled ITW Dynatec c 2000 Controller Setup Page 4 1 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 Chapter 4 DynaControl CONTROLLER SET UP Temperature Control Functions in General The DynaControl microprocessor based proportional temperature control in the ASU performs a number of functions that help to maintain adhesive setpoints in all temperature zones of the DYNA MELT system It maintains permanent system values fixed proportional and integration values that have been programmed at the factory such as the maximum temperature setpoint It enables the user to program temperature settings and heater on off sequencing that are appropriate to a specific ap plication It displays all programmed values and it includes self diagnostic malfunction alerts and failure alarms Note Some D ynaC ontrol functions are direct temperature conversions between de grees Celsius and F ahrenheit Other parameters are independently selected values Defining DynaControl Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained CPU Module The central processing unit
218. s On Off Filterblocks On Off Hoses On Off Heads On Off Aux Zones On Off Premelts Waiting Progmelts Waiting Filterblocks Waiting Hoses Waiting Heads Waiting Aux Zones Waiting Premelts Heating Progmelts Heating Filterblocks Heating Hoses Heating Heads Heating Aux Zones Heating Premelts Ready Progmelts Ready Filterblocks Ready Hoses Ready Heads Ready Aux Zones Ready Premelts Alarm Progmelts Alarm Filterblocks Alarm Hoses Alarm Heads Alarm Aux Zones Alarm Each zone is represented by the corresponding bit in these words BitO to Bit 5 BitO to Bit2 Bito to Bit2 0 Zone is OFF 1 Zone is ON Bito to Bit 1 BitO to Bit11 BitO to Bit11 0 Zone is not waiting 1 Zone is waiting 0 Zone is not heating 1 Zone is heating 0 Zone is not ready 1 Zone is ready 0 Zone has no alarm 1 Zone has alarm Watchdog Signal toggles every 0 5sec 0 1 Dynatec Dynacontrol EtherNet IP Data Table ponens S Adhesive Application Systems PLC to Dynacontrol Version V5 15M Word Address Function Zone Name Valid Range Reserved Reserved Setpoint Premelt 1 Setpoint Premelt 2 Setpoint Premelt 3 Setpoint Premelt 4 Setpoint Premelt 5 Setpoint Premelt 6 Setpoint Progmel
219. s and parameters as follows EU European Setup Temperature scale is Centigrade pressure is measured in BAR pumps are in STOP mode at startup and heaters are active at startup U S United States Setup Temperature scale is F ahrenheit pressure is measured in PSI pumps start in the mode they were left in at shutdown and heaters are active at startup Press 4 to program eypad Locking Scroll to either Temperature Settings or Pump Settings Press F3 to toggle Locked or Free Scroll to other setting and press F3 to toggle Locked or Free Press F4 to Return to menu Selecting Locked prevents further programming to either temperature setpoints or pumps Select ing F ree allows further programming Press 5 to program optional PC Link serial communication Scroll to select either Load from Computer to this Controller or Save From this Controller to Computer Press F1 to Load Press F2 to Save Press to Configure BAUD rate or FIFO The message Waiting indicates the controller computer is processing data message Transmission Done indicates the computer controller has completed transmission Press F4 to Return to menu The D ynaControl is capable of bi directional data transfer of all system parameters to a remote computer If this option is installed on your ASU program it at this step To program your remote computer see page 5 27 When PC Link is installed and the external serial communication is ON a flashi
220. s of the DynaControl Controller Default settings are the manufacturer s preset values to which the system will return if the Dyna Control is subjected to an internal memory reset also referred to as a re boot While you can change your programmed values to anything within the system s limits the default settings cannot be changed Defaults Language English Setting for Customer Access Code 9999 Temperature setpoint for each zone Hopper ready temperature 135 C 270 F Over temperature limit Your chosen setpoint limitation 10 C or F For example if your setpoint limitation is 218 C 425 F then your over temp limit 228 C 435 F Standby temperature for all zones 80 C 140 F lower than programmed setpoints Hi lo limit deviation for all temperature zones 20 C 36 F Temperature zone offset 0 C 0 F Sequential heating first hopper zones then hose head zones and auxiliary zones Setpoint limitation 218 C 425 F Minimum pump speed 0 of full speed Maximum pump speed 100 of full speed Proportional Integral values P I values for Premelt Hopper and Filterblock temperature zones P 15 and 3 For all other zones P 12 and I 2 ITW Dynatec 2000 Controller Setup Page 4 9 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 11 01 Helpful Tips for the User When the ASU is turned ON all temperature setpoints and other operating parameters will be exactly where the
221. scharge 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 im mersion 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 max Bolt Size amp Qty M5 4 Bolt Location Torque Nm Ft lbs retainer cap 71 2542 10 12 4 M10 12 4 mounting bolts mounting bolts 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 Ib when machine is at ambient temperature 1 Nm 8 85 11 65 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 TwDynatec c 2000 Appendix 43 DYNAMELT M ASU Manual 20 36 Revised 4 06 Reconditioning Should reconditioning overhauling become necessary return the pump t
222. sensor if resistance does inoperative not comply with resistance table in this chapter Use hose schematic to check hose sensor at ASU socket Repair or replace hose hose harness or Power PCB as appropriate lt lt 2 2 1 Debris at connection between hose head and ASU 1 Visually inspect hose plug and ASU Socket for cleanliness and proper contact and seating of pins Hose H ead No Sensor Short 2 Hose H ead sensor circuit 2 Using the hose schematic check hose inoperative sensor resistance at ASU socket An ohmmeter can be used to isolate a pinched wire in the hose harness When cause is isolated replace hose hose harness or Power PCB as appropriate b If head to hose and hose to A SU 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 i TV Dynatec 2000 Troubleshooting Page 7 21 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 10 00 LINE ION Hose Head No 1 Disconnection between 1 Visually examine effected hose plug H eater O pen hose head and ASU and ASU socket for cleanliness and proper contact and seating R efer to the wiring diagram for pin identifica tion The problem can be isolated by plugging the effected hose head into another A SU s
223. side The amount of slippage depends on four factors fluid viscoisty speed differential pressure and pump clearances U nder reasonably stable operating conditions slippage is re peatable and predictable and pump operation can be adjusted to compensate High Accuracy Pumps are designed for high temperature and high pressure operation 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 D ynatec should be notified immediately While the pump is composed of steel itis a precision instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat them as you would any other precision gauging instrument D ynatec 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 M ount the pump to a block with a flatness of true flat to
224. sion instrument Dropping the pump or hit ting with a non yielding material can cause serious damage to the components materials are through hardened to maximum hardness resulting in brittle material Treat cont Appendix 4 iTV Dynatec 2000 Revised 10 00 DYNAMELT M ASU Manual 20 36 20 37 20 38 them as you would any other precision gauging instrument D ynatec 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 M ount 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 M ounting bolts should be a Grade 8 or better M ake sure mounting bolts are lubricated with a high temperature anti seize com pound such as DAG Dispersion 154 Bolts should be alternatively torqued in even incre ments up to D ynatec s recommended limit for the bolt size used See Table 1 page 10 for torque values The following is a brief standard installation procedure For any special applications con siderations or simply to ask our advice please conta
225. sted are not used RS485 3 TxB 4 TxA 8 RxB 9 RxA S Shield Green LED System Power ON Connect to 48 Zone Power Board F1 Dip Switches 1 clutch switch 1 is ON 2 clutches switch 1 amp 2 are ON 3 clutches switch 1 2 amp 3 are ON 4 clutches switch 1 2 3 amp 4 are ON 5 clutches switch 1 2 3 4 amp 5 are ON 6 clutches all switches are ON Ribboncable connect to Display CPU PCB Layout of Components on Communication Board Input connections from Transducers ITW Dynatec c 2000 Troubleshooting Page 7 11 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 4 01 Optional Pressure PSI Printed Circuit Board Each Pressure PSI PCB on the ASU allows the controller to monitor up to four pressure transduc ers The DM 35 ASU can accept one PSI PCB four transducers the DM 70 140 A SUs can accept up to two PSI PCBs up to eight transducers and the DM 210 ASU can accept up to three PSI PCBs up to 12 transducers Each CPU board can accomodate one PSI PCB The 8 pairs of terminals at the top edge of the board as seen below are for the high and low alarm outputs of the relays The eight jumpers for the high low alarm output relays E1 thru E8 are facto ry set to Normally Open default and are illustrated below in default position The leads from the pressure transducers are connected at the left of the board as seen below Note the quantity of pressure transducers on an A SU is
226. still turns freely after burnout pressure test it and add a high temperature lubricant to prepare it for return to service store Jor future use simply add a rust preventative oil Appendix 31 Revised 3 01 d 6 Disassembly If pumps are to be disassembled on a regular basis we recommend that you establish a pump room with the necessary tools and equipment for disassembly and cleaning with a separate clean area for assembly testing and storing of rebuilt purnps If maintenance 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 reassembly 1 Remove the sea arrangement 2 Remove all binder screws 3 Remove dowels and arbors with an arbor press in the direction which disengages the press fit the shortest distance NOTE Most dowels and arbors are press fit in the front side plate and slip fit in the center and rear side plates When this is the case it is preferable to press from the front drive side Separate the plates by lightly tapping them with a soft head hammer If pry slots are available the pump you may use them instead of or in conjunc tion with the above method In either case great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 4 After disassembly clean ai components in a glass bead blast
227. t 1 Setpoint Progmelt 2 Setpoint Progmelt 3 Setpoint Filterblock 1 Setpoint Filterblock 2 Setpoint Filterblock 3 Setpoint Hose 1 Setpoint Hose 2 Setpoint Hose 3 Setpoint Hose 4 Setpoint Hose 5 Setpoint Hose 6 Setpoint Hose 7 Setpoint Hose 8 Setpoint Hose 9 Setpoint Hose 10 Setpoint Hose 11 Setpoint Hose 12 100 F 425 F Setpoint Head 1 only active if Local Access Temps O Data 62 is set to 0 Setpoint Head 2 Setpoint Head 3 Setpoint Head 4 Setpoint Head 5 Setpoint Head 6 Setpoint Head 7 Setpoint Head 8 Setpoint Head 9 Setpoint Head 10 Setpoint Head 11 Setpoint Head 12 Setpoint Auxiliary 1 Setpoint Auxiliary 2 Setpoint Auxiliary 3 Setpoint Auxiliary 4 Setpoint Auxiliary 5 Setpoint Auxiliary 6 Setpoint Auxiliary 7 Setpoint Auxiliary 8 Setpoint Auxiliary 9 Setpoint Auxiliary 10 Setpoint Auxiliary 11 Setpoint Auxiliary 12 Pump Mode 1 Pump Mode 2 S 83 Stop Pump Mode 3 M 77 Manual Local manual speed Pump Mode 4 65 Auto 0 to 10V Pump Mode 5 66 Bus EtherNet IP OUT 56 to 61 Pump Mode 6 Set Speed Pump 1 Set Speed Pump 2 Set Speed Pump 3 0 to 1000 0 0 to 100 0 500 50 0 Set Speed Pump 4 only active when pump in in Bus Mode Set Speed Pump 5 Set Speed Pump 6 o
228. t 1 amp 2 are switched ON IN word 150 003Fh 0000 0000 0000 0011 1111 6 heads are switched ON IN word 156 003Fh 0000 0000 0000 0000 1111 4 heads are in waiting position IN word 159 00018 0000 0000 0000 0000 0001 the progmelt hopper is heating IN word 167 0020h 0000 0000 0000 0010 0000 hose 6 is ready IN word 175 0011 0000 0000 0000 0001 0001 auxiliary zones 1 amp 5 show alarm 17ITW Dynatec c 2005 Page 4 17 DYNAMELT M ASU Manuals 20 36 20 37 20 38 Revised 8 05 Identification Word OUT word 79 is used as an identification word This word must be set to a certain value to validate the communication If this word is set differently the hot melt unit will not accept the OUT area although the IN area will show proper values Dynamelt M hot melt units require ID word set to 68 Examples for a typical communication Initializing Set OUT 76 to 1 Switches the controller on Set OUT 79 to 68 Identifies the communication Set OUT 77 to 0 No standby normal mode 4 Hose Operation Set OUT 73 to 15 Hoses 1 to 4 are switched ON Set OUT 74 to 15 Heads 1 to 4 are switched ON 6 Hose Operation Set OUT 73 to 63 Hoses 1 to 6 are switched ON Set OUT 74 to 63 Heads 1 to 6 are switched ON Check Ready Condition Compare IN 146 with 164 Compare IN 147 with 165 Compare IN 148 with 166 Compare IN 149 with 167 Compare IN 150 with 168 Compare IN 151 with 169 If all comparisons are equal the system is ready Check Alarm Condition Read
229. t Illustrations amp BOM s Page 10 13 DYNAMELT M ASU Manual All M35 Models TWDynatec 1999 to base plate Page 10 14 Component Illustrations amp BOM s TwDynatec 1999 Revised 9 00 DYNAMELT M ASU Manual 20 36 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 No Part Number Description Qty 100860 100861 1 012D079 012D077 Drive Shaft 1 2 0781001 Key Woodruff 1 3 101626 M5 x 12 SHC Screw 4 4 069X160 Seal Retainer amp Bearing Housing 1 5 069X061 Lip Seal 1 6 018X041 Bearing Sleeve 2 7 100866 100867 Front Plate Assembly 1 8 012D080 012D078 Driven Gear Shaft 1 9 018X031 Ball 1 8 Diameter See illustration for quantity 2 4 10 012C020 012C019 Drive Gear 1 54 cc rev 2 11 069X064 Pump Seal 2 12 078F017 Shaft Retaining Ring 4 13 018X041 Bearing Sleeve Rear Plate 2 14 100865 Rear Plate Assembly 1 15 100908 M4 x 25 SHC Screw 2 16 104775 104776 M10 1 5 x 75mm 80mm 4 17 NPN M10 Flat Washer 4 iTW Dynatec c 1999 Component Illustrations amp BOM s Page 10 15 DYNAMELT M ASU Manual 20 36 Rev Eng JW Revised 9 00 Pump 100860 has one bearing in this Shaft Pump 100861 has two bearing in this shaft Pump 100861 has two bearing in this Shaft Pump 100860 has one bearing in this shaft In some cases the pumps are mounted with the following hardware 104158 M10 Flange Nut 104
230. tem pressure to drop to 0 The controller will display Waiting After a few seconds the Pressure Screen will appear and in its last column will list if each pressure transducer has Passed or Failed the calibration Note Failed indicates a problem with the transducer or the Pressure PCB 6 Press Return F4 to return to Pressure Screen 7 Press Return F4 again to return to A ctual Temperatures Screen Monitoring 1 Actual pressure values may be monitored for each transducer on either screen 2 Over pressure or Under pressure arrows indicate conditions 3 A question mark indicates that no transducer is installed or that installation is not complete for this transducer position Page 5 16 Programming ITW Dynatec c 2000 Revised 7 02 DYNAMELT M ASU Manual 20 36 20 37 20 38 Service Functions Screens The three Service Function Screens are designated Service Page 1 Service Page 2 and Service Page 3 They are accessed by pressing the Service K ey 1 2 or 3 times Functions coded are active and require no code to program Functions coded with a key 7 are locked and require entry of a code before programming For example as seen on the diagrammed screen below Setpoint Limitation is locked from further programming Functions coded m6 F ITW Dynatec factory setups and are not user accessible Program the Service Functions as described on the following pages M any functions are pro grammed simply b
231. terial and metal dusts accumulate due to normal cycling This dust may be removed by vacuuming or brushing Removal of ace eed dusts and dirt will prolong the unit life B Fuse in power supply blows 4 Never put in a higher rating fuse or replace with slo blow type 2 Check resistance of coil if shorted replace magnet body and coil assembly If not shorted obtain actual coil resistance and compare to reading in Table B or value obtained from factory Check for grounded lead wire s between unit and fuse If grounded correct problem In above correct problem before installing new fuse 3 if cause was not found in 2 above Check Tor ac module by removing all loads and replacing fuse If fus blows when AC is applied to Tor ac module module is defective Replace b Ifcause was not found in Step 2 above check rectifier bridge by removing all loads and replacing fuse If fuse blows when AC is applied to rectifier bridge is shorted Replace bridge if feasible or discard control and replace du Unit falls to engage C T 1 8ee Items under A this Section 22 armature for free movement of the pins in hub or pulley 3 Check voltage output from Tor ac or rectifier contro when applying 115 VAC should be approximately 103 VDC with coil connected Replace Tor ac module control if it is defective effective 7 6 94 TV Dynatec c 2000
232. 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 fitin the center 2 and side plates 3 cont iTV Dynatec 2000 Appendix 21 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 3 01 4 Separate the plates by pry slots Great care should be taken not to scratch or damage the internal pump surface when prying the plates apart 5 After disassembly clean all components in a glass bead blast cabinet to remove any debris remaining after heat cleaning Alternative non destructive cleaning methods such as Water jet or solvents are also acceptable 6 Wash components in an ultrasonic cleaning tank and air dry Be careful not to bang parts together 7 Inspect all parts for nicks burrs score marks and other signs of wear 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 Sincethe 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 lap ping these components is not necessary and should not be done under any circumstances
233. tification number for zone Zone Info Lines ITW Dynatec c 2000 Programming Page 5 9 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Setpoints Programming Screen Each of the temperature zones is programmed individually by using the function keys as follows Press This To Function Key Scroll Up Down or Right F1 2 3 Select each zone s setpoint Return F4 Return to the A ctual Temperatures Screen a Enter Enter a numeric value All F1 All zones in a category ie All Hoses All Heads etc On Off Toggle a zone on or off Clear F4 Eliminate an error message or alarm Programming 1 Scroll to the first temperature zone setpoint you desire to program 2 On the numeric keypad enter the desired setpoint value 3 Press Enter 1 4 Scroll to the next setpoint to be programmed and repeat steps 2 and 3 N otes a To turn a zone OFF scroll to zone press Enter to select press ON OFF F3 b When turning a switched off zone back ON it will retain its previous setpoint c To change all zones in a category ie all hoses or all aux zones etc scroll to one item in that category enter desired value then press F1 this does not apply to zones which are turned OFF Monitoring 1 Zo the number which appears here is the controller s identification number for this zone This number cannot be changed by user 2 The Zone Info L ines indicate the user defined zone name program
234. to Calibration of the Optional Tach Generator or DC Tracking Signal Tv Dynatec c 2000 Installation Page 3 13 DYNAMELT M ASU Manual 20 36 Revised 4 01 Calibration of the Optional Tach Generator or DC Tracking Signal After installation of a tach generator or a similar DC tracking signal the device must be cali brated at the D ynaControl controller Prior to calibration turn the application system ON and allow all components to warm up to nor mal operating temperatures above ready temperatures 1 Perform the following sequence at the controller keypad for each motor a Go to M otors screen b Choose AUTO mode Press E nter c Scroll to M in and enter a value of 0 Press Enter d Scroll to M ax 96 and enter a value of 100 Press Enter 2 Energize the parent line tracking signal to its full speed atleast 10 V DC atthe 0 and 10 terminals at X 3 on the M otor Control Interface printed circuit board 3 On the M otor Control Interface printed circuit board see illustration in Chapter 7 locate and adjust the web speed scaling potentiometer V R 1 clockwise until the SET 96 is below 99 8 Then adjust counter clockwise until it equals 99 896 4 The system is now calibrated so that full parent machine speed corresponds to full speed of the gear pump The amount of adhesive dispensed can now be adjusted by trimming the pump RPM atthe AUTO menu of the controller by adjusting the MAX 96 value down from the
235. transducers on the ASU will vary per ASU For DM 35 thereis a maximum of four pressure transducers For DM 70 140 there is a maximum of eight pressure transducers For DM 210 thereis a maximum of twelve pressure transducers Pressure Screen 1 cont SYSTEM Ready Tue L 60 D Pressure PSI BAR SYM ABC DEF Sensor Act 1 2 3 100 Pre Filter Pump 1 1004 Post Filter Pump 1 cam pur Pre Filter Pump 2 1004 PostFilter Pump 2 TUV WXY PR LIMITS RETURN 8 9 0 gt ABC 123 ITV Dynatec 5 14 ITW Dynatec c 2000 Revised 5 01 DYNAMELT M ASU Manual 20 36 20 37 20 38 Optional Pressure PSI BAR Programming Screens cont Pressing Setup F3 on Screen 1 brings up a message screen ons O PSI BAR NENNEN System depressurized Pressure Screen 2 SYSTEM Ready Tue L D D Pressure 51 Alarm 51 SYM ape c Sensor Act Low High 100 1004 100 q JKL MNO 5 6 TUV WXY lt gt 10 19 0 gt 123 ITV Dynatec ITW Dynatec c 2000 Programming Page 5 15 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 5 01 Use of the Optional Pressure Programming Screens Press This To Function Key Pr Limits F2 Go to Pressure Screen 2 to set low and high alarms Setup Enter
236. ts are lubricated with DAG Dispersion 154 for example and alternately torqued in even in crements up to the manufacturer s recommended limit for the bolt size used see Table Screw Torque Values Standard Alloy Steel Screw Size amp Torque Ib in Thread UNC Lubricated threads 024 w Carbon Seal Gasket 50 10 24 Carbon Seal Gasket 80 1224 das 120 TEM C ausvsees eiae rx ra 160 WIES S doses orba Vna 325 3 816 wee rar nn 360 E2d3 s 900 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 con structed to type high temperature alloy steel provide extremely high creep resistance 4 Heat the pump thoroughly and evenly including the seal arrangement S Tighten the mounting bolts and coupling housing screws to the manufacturer s recommended torque at that operating temperature If your pump has a packing seal take up firmly and evenly on the seal gland screws to compress the packing then back off turn of the screws Be sure to adjust the gland properly Do not over tighten Adjustment may be made during operation to control excessive leakage Time Saving Heating Alternative Maintain the cle
237. tures do not exist Provide proper ventilation and cooling Burnishing Full torque of a new unit will not develop until the mating friction surfaces have been burnished or run in Burnishing can be accomplished by cycling the clutch brake under normal operating conditions Burnishing may also be accomplished by slipping under load at reduced voltage for short periods of time Consult factory for additional burnishing instructions If normal cycling does not provide for sufficient burnishing in your application be prepared to discuss specifics such as horsepower rpm position and environment when talking to factory personnel Component Descriptions After proper installation no further adjustment should be required for the life of the unit Appendix 38 Revised 10 00 PN 105729 Electric Clutch A Rotor or drive hub The rotor is constructed to be mounted and veyed toa rotating shaft and held in place with set screws or other means of fastening An outer pole and inner pole are separated by friction material A ball bearing is mounted on the rotor shaft for the purpose of providing support to the 1 magnet and maintaining proper air gaps on this assembly Driven hub The driven hub is to be mounted to separate shaft Iti is to be keyed and held in place with set screws or other means of fastening A spline on the outside diameter of this hub on which the clutch armature is to be assembled A retaining ting is normally placed
238. ull 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 iTV Dynatec 2000 Preventive Maintenance Page 6 3 DYNAMELT M ASU Manual 20 28 and 20 36 Revised 9 00 still pressure in the system Stop and verify that the motor pump is turned OFF and the applicator s valves are open before proceeding Then repeat step 5 6 Pull the cap and the filter plug up and out of the filter cavity Due to adhesive and the o ring seals there will be some resitance before the plug exits the cavity Note the filter basket hangs from the plug by a spring clip If the filter pulls free of the spring clip and remains in the cavity use a hooked tool to extract it 7 Pull thefilter 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 A pply hi temp lubricant PN 001U 002 to a new o ring before installing maintaining system pressure A cut or scuffed scratched o ring can allow CAUTION The condition of the lower o ring PN 069X275 is especially critical to N 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
239. used 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 1997 ALL MODELS Always have first aid information and supplies available Page 1 3 Revised 1 07 Call a physician and or an emergency medical technician immediately Service Refer all servicing to qualified personnel only Explosion Fire Hazard Never operate this unit in an explosive environment Use cleaning compounds recommended by ITW Dynatec or your adhesive supplier only Flash points of cleaning compounds vary according to their com position 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 impor tant 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 partic ularly in the capacitors within the panel box To ensure that all stored energy is relieved wait at least one min ute before servicin
240. uter controlled hot melt supply units designed on metric standards Their control panels with choice of display languages provide comparative data of all setpoints motors etc on a few convenient comprehensive display screens The Dynamelt M Series 505 are available in three cabinet sizes and offer four hopper sizes The Dynamelt 35 uses a microprocessor temperature control to closely control the temperature of hot melt adhesive for up to 4 hoses and 4 heads Temperature setpoints are operator selected for up to 16 zones and the system automatically provides warnings and alarms for operator errors and system malfunctions The Dynamelt D ynaControl 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 A SU is not in active use enabling rapid return to normal operation seven day scheduler allows programmable automatic startup and shutdown of the ASU throughout the workweek With these flexible temperature programming features the Dynamelt system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the System up to normal operating temperatures in the shortest possible time A four layered shielded CPU board protects the mic
241. viation is the high limit of the range Recipe A program recipe is a set of temperature setpoints and parameters which the user has programmed and wishes to store in the controller for future use Up to four recipes may be stored in the Dyna Control controller Sequential Heating The heating sequence which allows the slower heating hopper to reach operating temperature with out unnecessary use of electricity for faster heating hoses and applicators Sequential heating is the time period during which the hoses and applicators remain OFF while the hopper and optional drop in grids heats up Hoses and applicators may be independently programmed If hopper tem perature is above ready temperature when the ASU is turned ON the hose and applicator cont ITW Dynatec 2000 Controller Setup Page 4 3 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Revised 5 01 Sequence is bypassed and they will be turned ON The heat up sequence is restored after Standby is turned from ON to OFF Sequential heating is not needed for most applications and can delay total system warm up time Standby Condition The system condition where the A SU hose and head temperatures are maintained at predeter mined reduced temperature values Standby temperatures are set lower than setpoint temperatures in order to reduce adhesive degradation and energy consumption when the system is temporarily inactive and to permit rapid system warm up when run condition is selected
242. vot tr 38 29 26 1 66 3 80 9083980 903500 6163780 053550 v t X 91 8 E 991 870 Sora 7009 2904 v 38 32 9 8663980 f EE 5073480 9573586 5403980 soravao 2 X 91 8 6 851820 6601 cw wiwi 38 33 8 0 6863980 9007 sso x 33 33 0910 2823980 609 oszi lt 2 gt JINIS 38 22 0262 2203980 0627 2 JINIS 33 22 2641 9463 80 0001 027 lt 25 INIS 34 32 8911 3 80 0601 0621 3194 3H 22 vaso r C3v50 lt gt 3 0NIS 38 29 2620 EcE3v00 9001 952112 3154 38 22 09 0 22380 i E 9073900 9093900 630 sorirBo b c 2 x 91 976 851 840 sect oori ceat 9 wha 383 32 2620 8003 890 X X X 2 2x 90 3v89 5092960 0 lt 0 3 80 2 X 91 8 6 acivazo 9053960 vorirG 6463960 cov3rao X 9 8 t 0904840 9073700 o0r3eso 6zC3r80 x lt 093 80 2 X 91 8 9669820 0v3r80 6463980 0 3 80 8 5 2 x 91 B 969820 Or3v 6263760 S r3v8 8 6 2 X 91 8 9ccvazo 0r3ra0 62Ear60 8 5 2 91 8 9659040 07360 6 63 80 0 8 S 2 X 91 0 E 9 lt 8 0 226 45229 WM L0324 ANOD amp 8314 0 17 5 u3lgvavl ASv 8314 4 UBLAVG
243. y a toggle or by a single numeric entry Service Page 1 Service Key SYSTEM Ready Tue 3 36 PM 4 Service 1 Press 3 for Next Page Hi Lo Temperature Standby Temperature Standby Sleep Setup Setpoint Limitation N A Temperature Offset Sequential Heating C F OY Ui Change Security Lock RETURN 0 gt 123 T Dynatec Alpha Numeric Keypad Enter ITW Dynatec c 2000 Programming Page 5 17 DYNAMELT M ASU Manual 20 36 20 37 20 38 Revised 7 02 Service Functions Screens Page 1 cont Function Press 1 to program High Low Temperature Deviation Enter a numeric value for the first zone selected Press Enter to confirm Scroll to next desired zone and repeat until all zones are pro grammed Then Press Return F4 to return to menu Note after entering one value in any catego ry you may press All xxx F1 to change all the items in that category The High Low Temperature Deviation is a range representing the high and low temperature limits of each setpoint D uring operation these limits activate the error alarms which alert the op erator to over temp and under temp conditions in the temperature zones The smallest deviation programmable is 5 C or F and the largest is 50 Press 2 to program Standby Temperature Enter a numeric value for each category Press E nter Press Return F 4 Note if the same Standby Temperature is desired for all zones enter
244. y were when the ASU was turned off When the ASU is turned ON all system heaters go ON if the automatic heater startup is enabled and if setpoints are programmed unless sequential heatups have been set However if hopper temperature is above ready temperature when the ASU is turned ON all hose and head sequential heatups will be bypassed and hoses and heads will be turned ON If the system is turned OFF and then ON again the standby condition will be disabled Page 4 10 Controller Setup ITW Dynatec c 2000 Revised 9 02 DYNAMELT M ASU Manual 20 36 20 37 and 20 38 Serial Protocol for RS232 and RS485 Options V5 00 d amp up Specifications RS232C no handshake RS485 4 wires baud rate 1200 57600 baud character format 8 databits 1 startbit 1 stopbit parity no parity check General information DynaControl is always slave The controller is only reacting when addressed by a master DynaControl is only responding when own slave address is received Slave address is programmable via front panel PC LINK Setup Multi digit values are transferred most significant digit first each digitis ASCII coded Used control characters STX 02 Start of Text ETX 03 End of Text EOT 04 End of Transmission ENQ 05 Enquiry ACK 06 Positive A cknowledge NAK 15 Negative A cknowledge Structure of commands Master transmits to D ynaControl EOT addr opcode 0 n data bytes ENQ DynaControl responds STX 1 n data bytes
245. ynatec Adhesive Application S olutions TW Dynatec c 2000 Table of Contents Page iii DYNAMELT M ASU Manual 20 36 Revised 4 06 TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Electrical RENTE e 1 1 High Temperatures ier a Debes pd AES QA pe ec 1 1 High Pressure ER CR NES e re AE We Rs 1 1 Protective COVEIS c inr voL beue E tr hU en LES bitrate ctus 1 1 Eye Protection amp Protective Clothing 2 1 2 Safe Installation and Operation 22 1 2 Treatment for Burns From Hot Melt Adhesives 1 2 SERVICE ic eub D soon athe wth eh wei A a athena toit SP dre ete AUI be t SUR 1 3 Expl sion Eire Hazatd ru prete E CBAR RR eA E aa Mw ese RR qe 1 3 Lockout Tago t 4 2 6 9 Se Iu ue Ere EE DI ex Qe EE 1 3 Chapter 2 Description amp Specifications P UM 2 1 Specifications e 2 2 Installation DimernslOnS ib I CERE Re depicted Ue 2 4 Total System Wattage Capacity 2 5 Main Circuit Breaker Determination
246. ze at 107 C 225 F then For thermostats with purple amp black wire leads or tan leads Pump EnableThermostar turn the thermostat s adjustment screw counter clockwise to increase Em the temperature or clockwise to decrease it until the pump s caca mdor begins turning A djust no further b For thermostats with tan with tracer wire leads turn the thermostat s adjustment screw clockwise to increase the temperature or counter clockwise to decrease it untilthe pump s motor begins turning A djust no further 92 i 4 Replace the side door 5 Atthe keypad re set the hopper temperature setpoint to its correct run temperature i Tv Dynatec c 2000 Installation Page 3 11 DYNAMELT M ASU Manual 20 36 Revised 6 01 Calibration of the Optional Voltage Tachometer A voltage tachometer allows the system operator to monitor gear pump motor speed from the controller This information is useful since the amount of glue dispensed per product can be var ied by adjusting the motor rpm an increase in rpm an increase glue dispensed DANGER WARNING HIGH VOLTAGE T HOT SURFACE Dynamelt systems use electrical power that can be life threatening and hot melt adhesives that can cause serious burns Be sure to read and follow the safety procedures in Chapter 1 of this manual Only qualified persons accustomed to working with live electrical circuits should per form this procedure on the Dynamelt system Calibration Procedu

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