AltaSpray Plus Applicatorsemanuals.nordson.com/adhesives/English_Manuals/1121844.pdf · 2 AltaSpray...

AltaSpray� PlusApplicators

Customer Product ManualPart 1121844_01

Issued 5/13

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

This document contains important safetyinformation Be sure to read and follow allsafety information in this document and anyother related documentation.

Part 1121844_01 � 2013 Nordson Corporation

For CE Declaration, refer to equipment documentation.

Nordson Corporation welcomes requests for information, comments, and inquiries about itsproducts. General information about Nordson can be found on the Internet using the following

address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date2013. No�part�of�this�document may be photocopied, reproduced, or translated to another

language without the prior written consent of Nordson�Corporation. The�information�contained inthis publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build‐A‐Part,CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color‐on‐Demand, Control�Coat, Coolwave,

Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura‐Screen,Durasystem, Easy�Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized,

ETI‐stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix,Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, Kinetix,

Lean�Cell, Little�Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark,Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum,

Package of Values, Paragon, Pattern View, PermaFlo, PICO, PicoDot, Porous�Coat, PowderGrid, Powderware,Precisecoat, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn,Saturn with rings, Scoreguard, Seal Sentry, Select�Charge, Select�Coat, Select Cure, Signature, Slautterback,Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat, Sure‐Max, Sure Wrap, Tracking�Plus,

TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u‐TAH, Value Plastics, Vantage,VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, VP Quick Fit, Watermark,

When you expect more., and X-Plane are registered trademarks of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, Allegro, AltaBlue, AltaSlot, Alta Spray,Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate,

ClassicBlue, Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave, ContourCoat, CPX, cSelect,Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse,

e.dot+, E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue,G‐Net, Genius, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros,

MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke, Partnership+Plus,PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure,

Process Sentry, Pulse Spray, PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Quantum, Royal Blue,Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works,StediFlo, StediTherm, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH, ThruWave, Trade�Plus, Trilogy,

Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2�Rings (Design) are�trademarks of Nordson�Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their ownpurposes, could lead to violation of the owners' rights.

Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.

Table of Contents i

Part 1121844_01� 2013 Nordson Corporation

Table of Contents

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .User Qualifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .De‐energizing the System 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Guns 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Safety Precautions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limitations of Use 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key Components 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Equipment 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii


Installation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Items Needed 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Installation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Solenoid Valves 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mount the Applicator 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Installation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Supply Installation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Module‐Actuating Air 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect the Pattern Air 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Installation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect the Solenoid Valve 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connect Cordsets 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicator Flushing 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prepare for Applicator Flushing 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush the Hose 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush the Filter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush the Manifold 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush the Modules 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nozzle Installation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Testing 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Startup 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesive Pattern Adjustment 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Required Tools and Supplies 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommended Maintenance Schedule 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving System Pressure 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flushing a Filter 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Filter Screen 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Filter 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace the Filter Screen 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install the Filter 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents ii

Part 1121844_01� 2013 Nordson Corporation

Troubleshooting 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicator Heating Problems 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesive Output Problems 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesive Leakage Problems 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Supply Problems 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pattern Control Problems 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TroubleShooting Procedures 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking for Blockages 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking a Module 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Solenoid Valve Mechanical Operation 57. . . . . . . . . . . . . . . . . . . . . . . .Checking Solenoid Valve Electrical Operation 57. . . . . . . . . . . . . . . . . . . . . . . . . .Checking an Air Pressure Regulator 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking a Heater 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking a Sensor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Synchronizing Multi‐Module Adhesive Output (CF200 Only) 66. . . . . . . . . . . . . . . .Replacing a Module 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove a Module 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Install a Module 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rebuilding a Module 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing a Nozzle 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing a Nozzle 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Nozzles 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Heater 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing an RTD 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Parts 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single‐Module (50 mm) Applicator Parts 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm Applicator Parts 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 mm Applicator Parts 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 mm Applicator Parts 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 mm Applicator Parts 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 mm Applicator Parts 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 mm Applicator Parts 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 mm Applicator Parts 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 mm Applicator Parts 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 mm Applicator Parts 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Service Kits 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solenoid Valve Installation Kit Parts 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Module Parts 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Module Service Kits 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulating Jackets 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Regulators/Gauges 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T‐Style Splitter Cables 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T‐Style Extension Cables 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M‐Style Splitter and Adapter Cables 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M‐Style Extension Cables 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzles 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nozzle Adapter Part Numbers 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CF Nozzles 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Summit Nozzles 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SureWrap Nozzles 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Signature Nozzles 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blank Nozzle 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Spare Parts and Supplies 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator Specifications 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Specifications 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions and Clearances 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T‐Style Cable Wiring Diagrams 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M‐Style Cable Wiring Diagrams 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AltaSpray� Plus Applicators 1

� 2013 Nordson Corporation Part 1121844_01

AltaSpray� Plus Applicators

Safety

Read this section before using the equipment. This section contains recommendations andpractices applicable to the safe installation, operation, and maintenance (hereafter referredto as “use”) of the product described in this document (hereafter referred to as “equipment”).Additional safety information, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, and hazardavoidance procedures provided in this document can result in personal injury,

including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout this document toalert the reader to personal safety hazards or to identify conditions that may result in damageto equipment or property. Comply with all safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided, can

result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided, can

result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentially

hazardous situation that, if not avoided, can result in damage to equipment or

property.

Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuring that allinstructions and regulatory requirements for use of the equipment are met, and for qualifyingall potential users.

AltaSpray� Plus Applicators2


Safety Information

� Research and evaluate safety information from all applicable sources, including theowner‐specific safety policy, best industry practices, governing regulations, materialmanufacturer's product information, and this document.

� Make safety information available to equipment users in accordance with governingregulations. Contact the authority having jurisdiction for information.

� Maintain safety information, including the safety labels affixed to the equipment, inreadable condition.

Instructions, Requirements, and Standards

� Ensure that the equipment is used in accordance with the information provided in thisdocument, governing codes and regulations, and best industry practices.

� If applicable, receive approval from your facility's engineering or safety department, orother similar function within your organization, before installing or operating the equipmentfor the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are being followed.

� Re‐evaluate safety practices and procedures whenever changes are made to the processor equipment.

User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed by governingregulations and best industry practices

� are familiar with the equipment owner's safety and accident prevention policies andprocedures

� receive equipment‐ and task‐specific training from another qualified individual

NOTE: Nordson can provide equipment‐specific installation, operation, andmaintenance training. Contact your Nordson representative for information

� possess industry‐ and trade‐specific skills and a level of experience appropriate to theirjob function

� are physically capable of performing their job function and are not under the influence ofany substance that degrades their mental capacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in the manner described inthis document. The information provided here is not meant to include all possible safetypractices, but represents the best safety practices for equipment of similar hazard potentialused in similar industries.



Intended Use of the Equipment

� Use the equipment only for the purposes described and within the limits specified in thisdocument.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordsonrepresentative if you have any questions on material compatibility or the use ofnon‐standard auxiliary devices.

Instructions and Safety Messages

� Read and follow the instructions provided in this document and other referenceddocuments.

� Familiarize yourself with the location and meaning of the safety warning labels and tagsaffixed to the equipment. Refer to Safety Labels and Tags at the end of this section.

� If you are unsure of how to use the equipment, contact your Nordson representative forassistance.

Installation Practices

� Install the equipment in accordance with the instructions provided in this document and inthe documentation provided with auxiliary devices.

� This equipment has not been certified for compliance with the ATEX directive nor asincendive and should be installed in potentially explosive environments.

� Ensure that the equipment is rated for the environment in which it will be used and that theprocessing characteristics of the material will not create a hazardous environment. Referto the Material Safety Data Sheet (MSDS) for the material.

� If the required installation configuration does not match the installation instructions,contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for clearancebetween the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all independentlypowered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code enforcement agency forspecific requirements.

� Ensure that fuses of the correct type and rating are installed in fused equipment.

� Contact the authority having jurisdiction to determine the requirement for installationpermits or inspections.

Operating Practices

� Familiarize yourself with the location and operation of all safety devices and indicators.

� Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is ingood working order and that the required environmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task. Refer to EquipmentSafety Information or the material manufacturer's instructions and MSDS for PPErequirements.

� Do not use equipment that is malfunctioning or shows signs of a potential malfunction.



Maintenance and Repair Practices

� Perform scheduled maintenance activities at the intervals described in this document.

� Relieve system hydraulic and pneumatic pressure before servicing the equipment.

� De‐energize the equipment and all auxiliary devices before servicing the equipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the MSDS supplied withequipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson are available atwww.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing the equipment back intooperation.

� Dispose of waste cleaning compounds and residual process materials according togoverning regulations. Refer to the applicable MSDS or contact the authority havingjurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damaged labels.

Equipment Safety Information

This equipment safety information is applicable to the following types of Nordson equipment:

� hot melt and cold adhesive application equipment and all related accessories

� pattern controllers, timers, detection and verification systems, and all other optionalprocess control devices

Equipment Shutdown

To safely complete many of the procedures described in this document, the equipment mustfirst be shut down. The level of shut down required varies by the type of equipment in useand the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels ofshut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulic connection orseal. Refer to the melter‐specific product manual for instructions on relieving systemhydraulic pressure.



De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from all power sourcesbefore accessing any unprotected high‐voltage wiring or connection point.

1. Turn off the equipment and all auxiliary devices connected to the equipment (system).

2. To prevent the equipment from being accidentally energized, lock and tag the disconnectswitch(es) or circuit breaker(s) that provide input electrical power to the equipment andoptional devices.

NOTE: Government regulations and industry standards dictate specific requirementsfor the isolation of hazardous energy sources. Refer to the appropriate regulation orstandard.

Disabling the Guns

NOTE: Adhesive dispensing applicators are referred to as “guns” in some previouspublications.

All electrical or mechanical devices that provide an activation signal to the applicators,applicator solenoid valve(s), or the melter pump must be disabled before work can beperformed on or around an applicator that is connected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.).

2. Disconnect the input signal wiring to the applicator solenoid valve(s).

3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve theresidual air pressure between the regulator and the applicator.

General Safety Warnings and Cautions

Table 1 contains the general safety warnings and cautions that apply to Nordson hot meltand cold adhesive equipment. Review the table and carefully read all of the warnings orcautions that apply to the type of equipment described in this manual.

Equipment types are designated in Table 1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, and applicators)



Table 1 General Safety Warnings and Cautions

EquipmentType

Warnings and Cautions

HM

WARNING! Hazardous vapors! Before processing anypolyurethane reactive (PUR) hot melt or solvent‐based materialthrough a compatible Nordson melter, read and comply withthe material's MSDS. Ensure that the material's processingtemperature and flashpoints will not be exceeded and that allrequirements for safe handling, ventilation, first aid, andpersonal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, includingdeath.

HM

WARNING! Reactive material! Never clean any aluminumcomponent or flush Nordson equipment with halogenatedhydrocarbon fluids. Nordson melters and applicators containaluminum components that may react violently withhalogenated hydrocarbons. The use of halogenatedhydrocarbon compounds in Nordson equipment can causepersonal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulicpressure before breaking any hydraulic connection or seal.Failure to relieve the system hydraulic pressure can result inthe uncontrolled release of hot melt or cold adhesive, causingpersonal injury.

HM

WARNING! Molten material! Wear eye or face protection,clothing that protects exposed skin, and heat‐protective gloveswhen servicing equipment that contains molten hot melt. Evenwhen solidified, hot melt can still cause burns. Failure to wearappropriate personal protective equipment can result inpersonal injury.



General Safety Warnings and Cautions (contd)

EquipmentType


HM, PC

WARNING! Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt applicators.Before working on or near an operating applicator, disable theapplicator's triggering device and remove the air supply to theapplicator's solenoid valve(s). Failure to disable the applicator'striggering device and remove the supply of air to the solenoidvalve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker,the equipment may still be connected to energized auxiliarydevices. De-energize and electrically isolate all auxiliarydevices before servicing the equipment. Failure to properlyisolate electrical power to auxiliary equipment before servicingthe equipment can result in personal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesiveequipment is not rated for use in explosive environments andhas not been certified for the ATEX directive or asnonincendive. In addition, this equipment should not be usedwith solvent‐based adhesives that can create an explosiveatmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics andlimitations. The use of incompatible solvent‐based adhesivesor the improper processing of solvent‐based adhesives canresult in personal injury, including death.

HM, CA, PCWARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use ofuntrained or inexperienced personnel to operate or service theequipment can result in injury, including death, to themselvesand others and can damage to the equipment.



Table 1 General Safety Warnings and Cautions (contd)

EquipmentType


HMCAUTION! Hot surfaces! Avoid contact with the hot metalsurfaces of applicators, hoses, and certain components of themelter. If contact can not be avoided, wear heat‐protectivegloves and clothing when working around heated equipment.Failure to avoid contact with hot metal surfaces can result inpersonal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting toprocess PUR in equipment not specifically designed for thispurpose can damage the equipment and cause prematurereaction of the hot melt. If you are unsure of the equipment'sability to process PUR, contact your Nordson representative forassistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound onor in the equipment, read and comply with the manufacturer'sinstructions and the MSDS supplied with the compound. Somecleaning compounds can react unpredictably with hot melt orcold adhesive, resulting in damage to the equipment.

HM

CAUTION! Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipateplasticizer. Certain hot melt materials can react with Type Rfluid and form a solid gum that can clog the equipment. Beforeusing the equipment, confirm that the hot melt is compatiblewith Type R fluid.

Other Safety Precautions

� Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, or leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.



First Aid

If molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melt has cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medicalpersonnel providing treatment.

Safety Labels and Tags

Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment.Table 2 provides an illustration of the hazard identification symbols that appear on eachsafety label and tag, the meaning of the symbol, or the exact wording of any safety message.

Figure 1: Safety labels and tags



Table 2 Safety Labels and Tags

Item Part Description

1. Warning, CE, electrical shock (screen print)

2. Warning, CE, hot (screen print)

3. Warning, CE, pressure (screen print)

4. 243352

WARNING: Fire, injury or equipment damage can result ifcleanout materials do not meet the followingrequirements:

1. Minimum flash point to be 550 �F (288 �C).

2. Liquid and vapor to be non‐toxic at use temperature inequipment.

3. Chemical reactions with adhesive and equipmentmaterials must not be violently heat producing.

4. Cleanout material must not corrode or otherwiseweaken equipment materials.

CAUTION: This equipment is factory tested with Nordsontype R fluid containing Polyester Adipote plasticizer.Certain adhesives may react with the type R fluid residueto form solid gum which can be difficult to remove.

To avoid equipment damage check with adhesive supplierregarding compatibility and cleanout procedure beforeputting adhesive into the system.



Safety Labels and Tags (contd)

Table 2 Safety Labels and Tags (contd)

Item Part Description

600103 CAUTION: This unit is equipped with ______ �F presetthermostat. Use only adhesive formulated for applicationat this temperature. Before changing adhesive consultinstruction manual for changing operating temperature.Failure to follow instructions may result in personal injuryor property damage.

CAUTION: This applicator is RTD (resistancetemperature detector) controlled. Prior to operation andbefore changing adhesive consult instruction manual forchanging operating temperature. Failure to followinstructions may result in personal injury or propertydamage.

600137 WARNING: Disconnect power and remove systempressure before disassembly or maintenance. Failure tofollow these instructions may result in serious personalinjury.



Description

This manual describes the installation and use of Nordson AltaSpray Plus applicators.AltaSpray Plus applicators apply thermoplastic hot melt adhesive to various products. Whennecessary, the reader is referred to the documentation supplied with other Nordson productsor products supplied by third parties.

AltaSpray Plus applicators are available in a variety of configurations, includingsingle‐module and multi‐module (up to 1200‐mm width) versions. Modules and solenoidvalves are ordered separately. AltaSpray Plus applicators can accommodate CF200, UM25,and UM50 modules. A wide variety of compatible nozzles are available, as listed underParts.



Description (contd)

Figure 2: Typical AltaSpray Plus applicator configurations

1. Single‐module applicator with a UM25 module

2. 200 mm applicator with UM50 modules

3. 1000 mm applicator with UM25 modules

Note: Modules and solenoid valves are sold separately. Solenoid valves are not shown.



Intended Use

AltaSpray Plus applicators are specifically designed to:

� dispense liquified materials at temperatures below 191 �C (375 �F)

� be used with compatible hot melt equipment manufactured by Nordson Corporation

� be used in non‐explosive environments

Limitations of Use

Use AltaSpray Plus applicators only for the purpose for which they are designed. Theyshould not be used:

� to dispense polyurethane reactive hot melt materials or any other material that creates ahealth or safety hazard when heated

� in environments that will require the equipment to be cleaned using a water wash orspray



Key Components

Figure 3: Key parts of an AltaSpray Plus applicator (single‐module applicatorshown)

1. Mounting rod

2. Filter

3. Electrical cover

4. Air manifold

5. Nozzle location

6. Dispensing module (UM25 module shown; see Note)

7. Hose connection

8. Cordset

9. Drain valve

10. Pattern air connection

Note: Modules and solenoid valves are ordered separately. The solenoid valve is not shown.



Theory of Operation

Adhesive is heated to application temperature, which is typically about 191�C�(375�F), in amelter. The melter pumps the adhesive through a heated hose to the applicator. Theapplicator then dispenses the adhesive through dispensing modules onto a product. Thetype of nozzle used on the modules determines the type of adhesive pattern produced.

The applicator requires two air supplies: one to actuate the modules (module‐actuating air)and one to supply the air that shapes or fiberizes the adhesive exiting the nozzles (patternair). The module‐actuating air is controlled through one or more solenoid valves that areinstalled on the applicator and connected to a module‐actuating air supply line with an airpressure regulator. The pattern air is likewise controlled through an air pressure regulatorinstalled in a pattern air supply line.

The applicator is heated by cartridge‐type heaters. Power is supplied to the heaters througha cordset, which is connected electrically to the hose or to some combination of splitter andextension cables. Resistance temperature detectors (RTDs) sense the temperature of theadhesive or air in the applicator and relay the temperature through the cordsets, hoses,and/or cables to a melter control system or to a standalone temperature controller.

The pattern in which adhesive is dispensed onto the product is determined by:

� the choice of nozzle

� the distance at which the nozzle is placed above the product

� the production line speed

� the adhesive add‐on weight (melter pump speed)

� the pattern air pressure

� the pattern air temperature (if applicable)

� the adhesive application temperature

� the type of adhesive used

� the viscosity of the adhesive used

Optional Equipment

Optional equipment may be ordered to expand the functionality of an AltaSpray Plusapplicator, including, but not limited to, the following:

� insulating jackets

� pressure regulators/gauges

Refer to Parts for a complete list of optional equipment.



This page intentionally left blank.



Installation

This section provides procedures for installing the applicator and preparing it for operation.Before performing any installation procedures, review Safety.

Unpacking

Exercise normal care to prevent equipment damage during unpacking. After unpacking theapplicator, inspect if for any damage that may have occurred during shipping. Look for anydents and scratches and make sure all fasteners are tight. Report any damage to yourNordson representative.

Items Needed

You will need the following items to install the applicator:

� melter or temperature controller, hoses, and associated manuals

� solenoid valve(s)

� electronic control device for solenoid valve(s)

� air line tubing and fittings

� applicator mounting hardware

� device to lift and position the applicator

� personal protective equipment for working with hot adhesive

� tool kit, including wrenches and screwdrivers

� anti‐seize lubricant

� drain pans and waste containers suitable for waste adhesive

� PTFE paste or tape

Applicator Installation

Follow these procedures to install the applicator. Applicator installation includes installing asolenoid valve (if applicable) and mounting the applicator.



Install Solenoid Valves

If the solenoid valve for your applicator is not already installed, install it at this time. Aninstallation configuration like the one shown in Figure�4, 5, or 6 is recommended. Theinstallation shown in Figure 6 is recommended only for continuous adhesive application andshould not be used for applications in which the modules will be intermittently cycled on andoff.

Solenoid valves are used to control the module‐actuating air. All modules are normallyclosed, requiring air to open them. Use the following guidelines:

� Use only clean, dry, unlubricated air.

� Install the solenoid valve as close as possible to the module‐actuating air inlet to reducethe lag time between actuation and module opening.

2

2

3

2

1

4

8mm OR 5/16 O.D.

12mm O.D.

PART NUMBER466500

TUBING, PART NUMBER 252998

TUBING,PARTNUMBER418889

Figure 4: Recommended solenoid valve installation (straight fitting)

1. Solenoid valve

2. Compression fitting

3. Air transfer tube

4. Silencer

Note: These items are available in a service kit. Refer to Parts.



SOLENOID ORIENTATIONFOR RIGHT ANGLE FITTING

1

Figure 5: Recommended solenoid valve installation (right‐angle fitting)

1. Right‐angle fitting

Note: The right‐angle fitting is included in the solenoid valve kit. Refer to Parts.

8mm OR 5/16 O.D.TUBING, PART NUMBER 252998

12mm O.D.TUBING, PART NUMBER 418889

PART NUMBER466561

PART NUMBER

REF. ALTERNATE INSTALLATION(CUSTOMER SUPPLIED ACTUATION AIR)

466500

Figure 6: Alternate installation method—customer‐supplied actuation air

Note: The fittings shown in this illustration are included in the solenoid valve kit. Refer to Parts.



Mount the Applicator

Mounting the applicator includes selecting an appropriate mounting location and installingany necessary mounting hardware on the production line.

1. Select a mounting location. Use the following guidelines:

� Make sure there will be enough clearance to

‐remove the filter from the adhesive manifold

‐drain adhesive from the drain valve

‐replace heaters or sensors

‐replace a solenoid valve, module, or nozzle

‐route and replace air tubing and hoses

NOTE: Refer to Technical Data for applicator dimensions and recommendedclearances.

� Choose a location that will not subject the applicator to extreme temperature variationsor equipment vibration. The ambient temperature should be 0-49 C (32-120 F).

� Choose a location that will allow you to properly route the hoses from the applicator tothe melter. Figure 8 provides hose routing guidelines.

� Choose a location close to a supply of dry, regulated, unlubricated air.

2. See Figure 7. If applicable, install any hardware that will be required on the production lineto accommodate the applicator mounting rods. If possible, use mounting hardware thatwill allow you to adjust the height of the applicator between 13-76 mm (0.5-3.0 in.) after itis mounted.

3. Move the applicator into position on the production line (use an appropriate lifting device ifneeded) and secure the applicator at the mounting location. Adjust the applicator heightand angle as appropriate.

NOTE: For installation best practices, obtain an application guide specific to yourapplication from http://emanuals.nordson.com/, or contact your Nordson representativefor assistance. In most installations, the applicator should be perpendicular to thesurface onto which the adhesive is to be applied.



Figure 7: Location of the mounting hardware (single‐module and eight‐moduleapplicators shown; solenoid valves not shown)



Hose Installation

Follow this procedure for each hose hydraulic connection you are making. Do not connectthe hose cordsets at this time.

1. Connect the hose to the adhesive supply port on the applicator, using a hose fitting asnecessary. Use two wrenches to connect the hose as shown in Figure 8.

NOTE: The hose cordset should be located at the melter end (where adhesive entersthe hose). This ensures that the hose sensor measures the temperature of the adhesiveexiting the hose.

NOTE: Refer to the parts section of the melter manual for available hose fittings.

2. Install the insulation cuff from the ship‐with kit over the hose connection.

CAUTION! Risk of equipment damage. Do not use nonconductive pipe compound

or tape on hose fittings.

CAUTION! Improper routing and venting of hoses could result in overheating,

damage, and poor adhesive flow. To ensure proper operation, do not bundle or

tie‐wrap hoses, do not bend hoses at sharp angles, and do not allow hoses to lay

on concrete floors or other cool surfaces that could conduct heat away from the

hoses.

3. Route the hose to the melter and connect it to the melter hydraulically and electrically asdirected in the melter manual. Follow the hose routing guidelines shown in Figure 8.



ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

P/N 111 940

X=13 mm (0.50 in.)

R=203 mm (8.00 in.)

P/N 271 486 − 8 mm (5/16 in.)P/N 274 174 − 16 mm (5/8 in.)

X

P/N 274 174 − 29 mm (1 1/8 in.)

Figure 8: Hose installation guidelines



Air Supply Installation

Follow these procedures to connect air supplies to the applicator. Air is supplied to theapplicator for two reasons: (1) to actuate the modules (module‐actuating air) and (2) tosupply the modules with the air that shapes or fiberizes the adhesive being applied by themodules (pattern air).

Connect the Module‐Actuating Air

See Figures Figure�4, 5, or 6, as applicable. Connect a supply of dry, regulated, unlubricatedair to the module‐actuating air inlet on the applicator solenoid valve.

Nordson Corporation recommends installing an air pressure regulator and filter in themodule‐actuating air supply line that is capable of regulating the air pressure up to6.2�bar�(90�psi). For the module‐actuating air pressure range, refer to ApplicatorSpecifications under Technical Data.

NOTE: Nordson Corporation offers a selection of air pressure regulators/gauges. Referto Parts for part numbers.



Connect the Pattern Air

See Figure 9. Use the 8‐mm or 5/16‐in. internal‐diameter (ID) tubing (1) from the ship‐with kitto connect a supply of dry, regulated, unlubricated air to the to the compression fitting�(4). Asan alternate, a clamp (2) and fitting (3) may be used with 1/4‐in. ID tubing (not supplied). Besure to connect the high‐temperature end of the tubing assembly (white or clear tube) to theapplicator pattern air fitting. To determine where the pattern air inlet on your applicator islocated, refer to the applicator‐specific reference drawing under Parts.

Nordson Corporation recommends installing an air pressure regulator and filter in the patternair supply line that is capable of regulating the pattern air flow up to a 56.6 nlm (2�scfm) flowrate per module. For the pattern air pressure operating range, refer to ApplicatorSpecifications under Technical Data.

Figure 9: Pattern air supply connection (single‐module applicator shown)

1. Tubing

2. Clamp

3. Fitting

4. Compression fitting



Electrical Installation

Electrical installation involves connecting the solenoid valve to a triggering device andconnecting the cordset. Before making any electrical connections, complete the proceduresunder Applicator Installation, Hose Installation, and Air Supply Installation.

Connect the Solenoid Valve

Electrically connect the solenoid valve to a triggering device so that the module will open andclose at the appropriate times.

1. Ensure that the voltage ratings of the solenoid valve and the triggering device match. Thesolenoid valve power requirement is 8.5 W, 24 VDC.

2. See Figure 10. Remove the electrical connector (1) screw and disconnect the connector.Save the gasket.

3. Separate the terminal block from the connector housing.

4. Loosen the electrical connector strain relief nut (2).

2

1

Figure 10: Removing the quick‐disconnect connector from a solenoid valve

1. Electrical connecter 2. Strain relief nut



CAUTION! Solenoid valves must be rated for the output voltage of the triggering

device. Make sure the ratings match.

5. See Figure 11. Thread a 0.75-0.34 mm2 (18-22 AWG) three‐conductor cable through thestrain relief; then connect

� the positive and negative leads to terminals 1 and 2 [normal polarity,1 = (+) and 2 = (-)]

� the ground wire to the ground terminal

6. Ensuring correct configuration of the terminal block (see Figure 11), snap the block backinto the connector and tighten the strain relief nut.

7. Align the gasket on the connector and plug the connector into the solenoid valve, securingit with the screw removed earlier.

8. Connect the three‐conductor cable to the triggering device. Refer to the instructions thatcame with the triggering device.

Normal polarity:1=(+) positive, high2=(−) negative, neutral

= ground

Figure 11: Solenoid valve terminal block configurations



Connect Cordsets

Cordsets provide heater power and temperature sensing and establish an electrical ground.There are two basic ways to connect cordsets: through the hose or through extension and/orsplitter cable(s). See Figures 12-16 for the most typical ways in which cordsets areconnected. Use this illustration to make your cordset connections, or contact your Nordsonrepresentative for assistance. Refer to Parts for splitter, adapter, and extension cable partnumbers.

NOTE: T‐style applicator cordsets for channels with up to 800 W use a rectangularconnector and may be powered through the hose. T‐style cordsets for channels greaterthan 800 W use a square connector and must be connected through an extensioncable. M‐style applicator cordsets for channels with up to 1,000 W use a squareconnector and may be powered through the hose. M‐style cordsets for channelsgreater than 1,000 W use a round connector and must be connected through anextension cable. In all cases, the capabilities of the melter or standalone controller mustbe considered.

NOTE: Nordson melters have multiple electrical connectors for hose/applicator pairs(two electrical channels are accommodated by each electrical connector), and in allcases there is a maximum wattage allowed per electrical channel as well as a maximumwattage allowed for the combined channels. Refer to the melter manual for additionaldetails or contact your Nordson representative for assistance.

WARNING! Risk of personal injury or death. Allow only qualified personnel to

perform electrical installation, troubleshooting, or repair procedures. Before

performing any electrical procedure, review Safety and disconnect and lock out

electrical power to the system.



Figure 12: Connecting a single cordset through a hose

1. Applicator cordset

2. Hose

3. Hose cordset

4. Melter electrical receptacle

Figure 13: Connecting a single cordset through an adapter cable and an extensioncable

1. Applicator cordset

2. Adapter cable

3. Extension cable




Connect Cordsets (contd)

Figure 14: Connecting two cordsets: one through a hose and one through anadapter and extension cable

1. First applicator cordset

2. Adapter cable

3. Extension cable


5. Second applicator cordset

6. Hose

7. Hose cordset

Figure 15: Connecting two cordsets: one through an extension cable and onethrough a splitter cable


2. Extension cable



5. Extension cable

6. Splitter cable



Figure 16: Connecting two cordsets: each through an adapter cable and anextension cable


2. First adapter cable

3. First extension cable



6. Second adapter cable

7. Second extension cable



Applicator Flushing

Flushing the applicator removes cleaning solution, adhesive, and other contaminants fromthe equipment. The applicator should be flushed before initial use and anytime you changethe adhesive in the hot melt system. This helps prevent clogging of the filter or nozzles andmakes the applicator work more efficiently.

Prepare for Applicator Flushing

1. Determine whether you need to flush the applicator with adhesive or with cleaning fluidand then with adhesive. Refer to Table 3.

Table 3 Applicator Flushing Situations

Situation Flushing Materials to Use

Initial startup Adhesive only

Changing adhesive in the system a. Cleaning solution compatible with both the oldand new adhesives

b. New adhesive (to remove the cleaningsolution)

2. Heat the system to application temperature. Refer to the melter manual as needed.

3. Stop the melter pump(s).

4. Place drain pans under the applicator drain valves, the hose connections, and themodules.

WARNING! Risk of burns. Failure to relieve system pressure can cause hot

adhesive to spray from a connecting point. Relieve system pressure before

loosening or removing a hose, module, or any other part of the hot melt system.Wear heat‐protective clothing, safety goggles (ANSI Z87.1 or equivalent), and

safety gloves.

5. Relieve system pressure. Refer to Relieving System Pressure under Maintenance.

6. Flush the applicator by performing the following procedures with each flushing material tobe used:

� Flush the Hose

� Flush the Filter

� Flush the Manifold

� Flush the Modules



Flush the Hose

Follow this procedure to flush the hose. Refer to the melter manual as needed forinstructions on starting and stopping the melter pump(s).

1. Disconnect the hose from the applicator and direct the end of the hose into a wastecontainer.

2. Start the melter pump(s).

3. When the adhesive flowing from the hose is free of any solvent or contaminants, stop themelter pump(s).

4. Wipe any adhesive from the hose connector.

5. Reconnect the hose to the applicator.

Flush the Filter

Refer to Flushing a Filter under Maintenance to flush the filter. Return here to continue.

Flush the Manifold

Follow this procedure to flush the manifold. Refer to the melter manual as needed forinstructions on starting and stopping the melter pump(s).

1. Set the pattern air pressure so that there is just enough pressure to prevent adhesive fromentering the air ports on the heated air manifold.

2. Remove the modules from the manifold. Refer to the module removal procedure underRepair as needed.

3. Place a drain pan under the manifold.


5. Allow some adhesive to drain from the manifold. When the adhesive flowing from themanifold is free of any contaminants, stop the melter pump(s).

6. Wipe any adhesive from the manifold.

7. Reinstall the modules on the manifold. Refer to the module removal procedure underRepair as needed.



Flush the Modules

Follow this procedure to flush the modules. Refer to the melter manual as needed forinstructions on starting and stopping the melter pump(s).

1. Ensure that nozzles are removed from the modules.

2. Set the pattern air pressure to 0.1-0.3 bar (2-5 psi).

3. Turn on the module‐actuating air.


5. When the adhesive flowing from the modules is free of any contaminants, stop the melterpump(s) and turn off the module‐actuating air.

6. Wipe any adhesive from the modules.

Nozzle Installation

Install nozzles before placing the applicator into operation. Refer to Repair for nozzleinstallation and removal procedures.

Applicator Testing

Perform tests as needed to ensure that the applicator output meets the requirements of yourapplication. When testing, proceed systematically by changing only one production variable(such as the system pressure) at a time. If changing the variable does not produce thedesired result, return it to its original state and try changing a different variable. Proceed inthis manner until the desired applicator performance is achieved. Contact your Nordsonrepresentative for assistance as needed.



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Operation

This section provides procedures for operating the applicator. Before you operate theapplicator for the first time, make sure you have

� completed the installation procedures under Installation

� flushed the applicator by completing the applicator flushing procedure under Installation

� optimized the applicator output for your application as described in Applicator Testingunder Installation

Before you perform any operating procedures, review Safety.

Startup

NOTE: Because the melter supplies the adhesive and the electrical power to theapplicator, the procedures for starting and stopping the applicator vary depending onthe type of melter you are using. Refer to the melter manual for complete startup andshutdown procedures.

1. Start the melter and heat the system to application temperature.

2. Turn on the pattern air.

3. Turn on the module‐actuating air.


5. Start the production line.

NOTE: Pneumatic and hydraulic pressure ranges are provided under Technical Data.



Shutdown

NOTE: Because the melter supplies the adhesive and the electrical power to theapplicator, the procedures for starting and stopping the applicator vary depending onthe type of melter you are using. Refer to the melter manual for complete startup andshutdown procedures.

1. Stop the production line.

2. Stop the melter pump(s).

3. Shut off the module‐actuating air.

4. Shut off the pattern air.


6. Shut down the melter.

Adhesive Pattern Adjustment

Use the following techniques to modify the adhesive pattern:

� adjust the adhesive add‐on weight (melter pump speed)

� adjust the electronic control device (timer or pattern controller)

� adjust the pattern air pressure

� adjust the pattern air temperature (if applicable)

� adjust the adhesive application temperature

� change the type of adhesive used

� change the nozzle type or size

� adjust the applicator height

If you experience problems obtaining the desired adhesive pattern, refer to Pattern ControlProblems under Troubleshooting.



Maintenance

This section contains a list of recommended maintenance activities and a recommendedschedule for performing those activities. Attempting any other maintenance procedures canresult in equipment damage, improper system operation, or personal injury.

Before you perform any maintenance procedures, review Safety.

Required Tools and Supplies

To perform maintenance or repairs, you will need:

� a set of metric socket wrenches

� a set of metric Allen (hex) wrenches

� a set of metric T‐handle hex keys

� a set of metric open‐ended wrenches

� flat‐blade and Phillips‐head screwdrivers

� drain pans and large waste containers

� other tools and supplies as noted

You will also need a sufficient inventory of spare parts and supplies. Each maintenance andrepair procedure in this manual is preceded by a list of the parts and supplies you will need.Refer to Parts for the part numbers of parts and supplies.



Recommended Maintenance Schedule

Table 4 provides a list of recommended maintenance activities. Base how often you performthese activities on your specific operating needs. The frequency shown is for reference only.

Table 4 Recommended Maintenance Schedule

Frequency Maintenance ActivityDaily � Keep the supply of adhesive clean and free of

contaminants. Foreign particles in the adhesive can clogthe filter or nozzles.

� Clean all exterior applicator surfaces. Accumulatedadhesive can char and cause erratic operation.

� Check the hose connections for leaks. If a leak is found,replace the hose fitting and/or O‐ring as appropriate.

Weekly � Clean nozzles. Refer to Nozzle Cleaning underMaintenance.

As needed � Clean or replace the filter screen. Refer to the filterservice procedures under Repair.

� Verify that all electrical connections are secure. Vibrationand heating or cooling cycles can loosen terminalblocks.

� Clean the air pressure regulator filter elements. Refer tothe air pressure regulator documentation.

� Clean the system. Refer to the system cleaningprocedure in the melter manual.



Relieving System Pressure

System pressure must be relieved before you can safely proceed with many of themaintenance, troubleshooting, and repair procedures in this manual. Follow this procedurewhenever you need to relieve system pressure.

WARNING! Risk of burns. Failure to relieve system pressure can cause hot

adhesive to spray from a connecting point. Relieve system pressure beforeloosening or removing a hose, module, or any other part of the hot melt system.

Wear heat‐protective clothing, safety goggles (ANSI Z87.1 or equivalent), and

safety gloves.

1. Stop the melter pump(s). Refer to the melter manual.


3. Place drain pans under all melter and applicator DRAIN valves.

4. See Figure 17. Use a flat‐blade screwdriver to open the melter and applicator drain valvesby turning the drain valve screws counterclockwise. Some adhesive will drain from thevalves.

5. Trigger all modules at the solenoid valves.

6. Close the applicator and melter drain valves.

1 2

Figure 17: Opening drain valves

1. Typical melter drain valve

2. Typical applicator drain valve



Flushing a Filter

The filter should be flushed

� before initial use

� as needed to maintain your system pressure settings

� if the filter screen is replaced

� if you change the adhesive in your hot melt system

You will need a flat‐blade screwdriver and a drain pan.

1. Heat the system to application temperature.

2. Relieve system pressure. Refer to the previous procedure, Relieving System Pressure.

3. Trigger the applicator solenoid valves briefly to relieve any remaining pressure.


5. Decrease the pattern air pressure. Leave just enough air pressure to prevent adhesivefrom entering the pattern air inlet.

6. Place a drain pan under the applicator DRAIN valve.

7. See Figure 18. Open the DRAIN valve.


9. When the adhesive flowing from the drain valve is free of contaminants, stop the melterpump(s).

10. Close the DRAIN valve.

Figure 18: Opening an applicator DRAIN valve (single‐module applicator shown)



Replacing a Filter Screen

Replace the filter screen when the flushing the filter screen no longer solves the problem ofdiminished adhesive flow or pressure buildup in the system. For most applications, the filterscreen should be replaced monthly. You will need the following items:

� drain pans and disposable rags

� flat‐blade screwdriver

� socket wrench

� replacement filter screen

� replacement filter O‐ring (if needed)

Remove the Filter


2. Relieve system pressure. Refer to Relieving System Pressure earlier in this section.

3. Trigger the applicator solenoid valves briefly to relieve any remaining pressure.


5. Decrease the pattern air pressure. Leave just enough air pressure to prevent adhesivefrom entering the pattern air inlet.

6. See Figure 19. Use a socket wrench to loosen the filter assembly and then remove theassembly by hand over a drain pan.

NOTE: To continue operation immediately, skip to Install the Filter to install a new filterassembly.

Figure 19: Removing a filter (single‐module applicator shown)



Replace the Filter Screen

1. See Figure 20. Disassemble the filter.

2. Inspect the O‐ring for cuts, hardening, or other damage and replace as necessary.

CAUTION! Be careful not to mix up in‐out and out‐in filter screens. Doing so can

cause the filter to burst, filling the applicator with char and debris. An in‐out filter

screen has coarse outside mesh. An out‐in filter screen has fine outside mesh.

3. Apply O‐ring lubricant to the O‐ring and reassemble the filter.

ÎÎÎÎÎÎÎÎÎÎÎÎ

3

2

1

5

4

Figure 20: Removing a filter

1. Bung

2. O‐ring

3. Tube

4. Screen

5. Screw



Install the Filter


2. Apply anti‐seize lubricant to the filter screw threads, insert the filter in the adhesivemanifold, and turn it clockwise by hand until it seats.

3. Remove all nozzles and pump adhesive through the applicator. This removes any loosechar remaining in the applicator or modules. Refer to the nozzle installation/removalprocedures under Repair as needed.

4. Reinstall nozzles and restore the system to normal operation.



Troubleshooting

This section contains troubleshooting procedures. These procedures cover only the mostcommon problems that you may encounter. If you cannot solve the problem with theinformation given here, contact your Nordson representative for assistance.

Troubleshooting begins when the flow of adhesive from the applicator stops or diminishesunexpectedly or when a control system alerts you of a problem through an alarm or visualdisplay.

Troubleshooting Tables

The troubleshooting tables in this section describe the kinds of problems you may encounterand provide corrective actions for those problems. When necessary, the tables refer to moredetailed troubleshooting procedures located under Troubleshooting Procedures.

Refer to the appropriate troubleshooting table for the type of problem you are experiencing:

� Applicator Heating Problems

� Adhesive Output Problems

� Adhesive Leakage Problems

� Air Supply Problems

� Pattern Control Problems

To troubleshoot melter or hose problems, refer to the melter manual.



Applicator Heating Problems

Refer to this troubleshooting table if the applicator does not heat, underheats, or overheats.

NOTE: Each heated component in a hot melt system (typically the grid, the reservoir,each hose, and each applicator) is referred to as a heated zone. The applicator'sheated zones are the adhesive manifold and the heated air manifold. Some applicatorsmay have multiple adhesive manifold and heated air manifold zones.

WARNING! Risk of personal injury or death. Allow only qualified personnel to

perform electrical installation, troubleshooting, or repair procedures. Before

performing any electrical procedure, review Section 1, Safety, and disconnect and

lock out electrical power to the system.

Problem Possible Cause Corrective Action

1. Applicator doesnot heat

System power not on Verify that the system power isturned on.

Loose electricalconnection

Verify that all electricalconnections (cordsets andcables) at the melter and theapplicator ends of the hose aresecure.

Broken or missingelectrical pins

Check for broken or missing pinsat all electrical connections.Repair or replace damagedcomponents.

Adhesive or heated airmanifold temperaturesetpoints too low

Adjust the temperature setpointsas necessary. Refer to the melteror temperature controller manual.

Continued on next page



Applicator Heating Problems (contd)


2. Applicatorunderheats oroverheats

System in standby orsetback mode

Take the system out of standbyor setback mode.

Adhesive manifold, heatedair manifold, or hosetemperature setpoints toolow or too high


Failed heater, sensor, orcable

Check the heaters, sensors, andcables for the problem zone.Refer to the appropriateprocedures underTroubleshooting Procedures.



Adhesive Output Problems

Refer to this troubleshooting table if the adhesive output is too low or too high or if there is noadhesive output.

NOTE: Each heated component in a hot melt system (typically the grid, the reservoir,each hose, and each applicator) is referred to as a heated zone. The applicator'sheated zones are the adhesive manifold and the heated air manifold. Some applicatorsmay have multiple adhesive manifold and heated air manifold zones.


1. Adhesive outputtoo low or toohigh

Heated zone temperaturesetpoints too low or toohigh


Melter pump not supplyingcorrect amount of adhesive

Troubleshoot and correct theadhesive supply problem fromthe melter. Refer to the meltermanual.

Blockage inhose‐to‐applicator orhose‐to‐melter connection

Check for blockages in theconnections. Check also for acold connection. Install insulationaround any cold connections. Ifthe adhesive output does notimprove, install a heated inlinefilter at the connection.

Clogged filter Replace the filter screen. Refer toReplacing a Filter Screen underMaintenance.

Blockage in module ornozzle

Check for blockage in the moduleor nozzle. Refer to Checking forBlockages underTroubleshooting Procedures.




Adhesive Output Problems (contd)


2. No adhesiveoutput

Adhesive not at applicationtemperature

Wait for the system to reachapplication temperature.

Heated zone temperaturesetpoints too low or toohigh


Adhesive level in melterlow

Add adhesive to the melter. Referto the melter manual.

Blockage inhose‐to‐applicator orhose‐to‐melter connection

Check for blockages in theconnections. Check also for acold connection. Install insulationaround any cold connections. Ifthe adhesive output does notimprove, install a heated inlinefilter at the connection.

Clogged filter Replace the filter screen. Refer toReplacing a Filter Screen underMaintenance.

Blockage in module ornozzle

Check for blockage in the moduleor nozzle. Refer to Checking forBlockages underTroubleshooting Procedures.




Corrective ActionPossible CauseProblem

2. No adhesiveoutput (contd.)

Failed module or moduleloading screw not properlyadjusted on adjustablemodules

Check the module. Refer toChecking a Module underTroubleshooting Procedures. Foradjustable modules, check theloading screw adjustment toensure that the travel of themodule‐actuating spring has notchanged. If this spring istightened down too much, themodule will not open. Refer toSynchronizing Multi‐ModuleApplicator Adhesive Output(CF200 Only) under Repair.

Failed solenoid valve Check the solenoid valve. Referto Checking Solenoid ValveMechanical Operation andChecking Solenoid ValveElectrical Operation underTroubleshooting Procedures.

Failed or faulty solenoidvalve triggering device

Troubleshoot the triggeringdevice. Refer to themanufacturer's documentation.




Adhesive Output Problems (contd)


3. Modules onmulti‐moduleapplicator nottriggering atsame time

Not enough solenoidvalves for the number ofmodules

Add solenoid valves.

Solenoid valves too farfrom applicator

Reinstall the solenoid valves sothat they are as close as possibleto the applicator.

(Adjustable modules only)Modules not properlysynchronized (loadingscrews not properlyadjusted)

Refer to SynchronizingMulti‐Module ApplicatorAdhesive Output (CF200 Only)under Repair.



Adhesive Leakage Problems

Refer to this troubleshooting table if you find adhesive leaks.


1. Leaks betweenthe adhesivemanifold and themodule

Insufficient torque onmodule socket‐headscrews

Tighten the module screws to3.4�N�m (30�in.‐lb).

Damaged or worn O‐ringson back of module

Replace the O‐rings.

2. Leaks at bleedhole on module(see Figure�21)

Adhesive seal failure Replace or rebuild the module.To replace a module, refer toReplacing a Module underRepair. To rebuild a module,order a module rebuild kit andfollow the instructions in the kit.Refer to Parts.

3. Leaks at nozzle System pressure too high Decrease the system pressure.Refer to the melter manual.

Damaged or worn O‐ring inmodule seat

Replace the O‐ring.

4. Leaks at hoseconnection

Loose hose connection Tighten the connection.

Failed hose fitting O‐ring Replace the hose fitting O‐ring.Refer to the procedure forreplacing the O‐ring in the meltermanual.

Figure 21: Location of the module bleed hole



Air Supply Problems

Refer to this troubleshooting table if you experience problems related to the air supply.


1. Air leaks from thetop of a module

Air seal failure Replace or rebuild the module.To replace a module, refer toReplacing a Module underRepair. To rebuild a module,order a module rebuild kit andfollow the instructions in the kit.Refer to Parts.

2. Nomodule‐actuatingair

Failed solenoid valve Check the solenoid valve andreplace if necessary. Refer toChecking Solenoid ValveMechanical Operation andChecking Solenoid ValveElectrical Operation underTroubleshooting Procedures.

Failed air pressureregulator or insufficient airsupply to the regulator

Check the regulator and the airsupply to the regulator. Refer toChecking an Air PressureRegulator under TroubleshootingProcedures.

3. No pattern air Failed air pressureregulator or insufficient airsupply to the regulator

Check the regulator and the airsupply to the regulator. Refer toChecking an Air PressureRegulator under TroubleshootingProcedures.

Clogged air passage innozzle

Clean or replace the nozzle.Refer to nozzle cleaning underRepair.

Pattern Control Problems

To troubleshoot pattern control problems, obtain application‐specific troubleshootinginstructions from http://emanuals.nordson.com/, or contact your Nordson representative forassistance.



TroubleShooting Procedures

Use these troubleshooting procedures as directed in the Troubleshooting Tables part of thissection.

Checking for Blockages


2. Place a drain pan under the applicator.

3. Decrease the pattern air pressure. Leave just enough air pressure to prevent adhesivefrom entering the pattern air outlet.

4. See Figure 22. Remove a module from the adhesive manifold.

5. Observe the adhesive opening (the lower opening) on the adhesive manifold:

� If there is no adhesive flow from the adhesive opening, there may be blockage in theadhesive manifold. Clean the system or replace the applicator. Refer to the systemcleaning procedure in the melter manual.

� If adhesive is flowing from the adhesive opening, there is no blockage in the adhesivepassage. Continue to the next step.

6. Trigger the applicator at the solenoid valve and observe the module‐actuating air opening(the upper opening):

� If no air flows from the module‐actuating air opening, there may be blockage in theadhesive manifold. Clean the system or replace the applicator. Refer to the systemcleaning procedure in the melter manual.

� If air flows from the module‐actuating air opening, there is no blockage in the airpassage. Reinstall the module and return to the appropriate troubleshooting table.

NOTE: Tighten the module screws to 3.4 N�m (30�in.‐lb), heat the system toapplication temperature, and tighten the screws again.

Figure 22: Removing a module



Checking a Module

Use one of the following procedures to check a module. The first procedure is the easiest toperform.

Quick Check

See Figure 23. Insert a pin or similar tool into the center hole on the top of the module andtrigger the module at the solenoid valve. If the pin moves up and down and adhesive flowsfrom the module as it is triggered, the module is operating properly. If the pin does not moveup and down or if adhesive does not flow from the module, the module has failed. Replace orrebuild the module. To replace a module, refer to Replacing a Module under Repair. Torebuild a module, order a module rebuild kit and follow the instructions in the kit. Refer toParts.

Figure 23: Quick‐check of module operation

In‐Depth Check


2. Remove the nozzle from the module. Refer to the nozzle removal/installation proceduresunder Repair as needed.

3. Trigger the applicator at the solenoid valve and observe the output:

� If no adhesive flows from the module, the module has failed. Replace or rebuild themodule. To replace a module, refer to Replacing a Module under Repair. To rebuild amodule, order a module rebuild kit and follow the instructions in the kit. Refer to Parts.

� If adhesive flows from the module, it is operating properly. Reinstall the nozzle on themodule and return to the appropriate troubleshooting table.



Checking Solenoid Valve Mechanical Operation

Solenoid valves are used to control the module‐actuating air. Follow this procedure to checkthe mechanical operation of a solenoid valve. To check the electrical operation of a solenoidvalve, refer to the next procedure, Checking Solenoid Valve Electrical Operation.

1. Turn on the air supply to the solenoid valve.

2. Trigger the applicator at the solenoid valve and check for adhesive flow:

� If adhesive flows from the module, the solenoid valve is operating normally. Return tothe appropriate troubleshooting table.

� If no adhesive flows from the module, continue to the next step.

3. Manually trigger the solenoid valve and listen to its response:

� If you hear a clicking

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