Melter MC 20 / MC 21 with Foil Bagemanuals.nordson.com/adhesives/English_Manuals/397155.pdf · MC...

MelterMC 20 / MC 21with Foil Bag

Manual P/N 397155F− English −

Issued 05/06

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

P/N 397155F � 2006 Nordson CorporationMC20 / MC21

NoteThis document applies to the entire series, beginning with serial number LU03K07512.

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2002.No part of this document may be photocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information contained in this publication is subject to

change without notice.

© 2006 All rights reserved.

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem,Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry,Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson,OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus,ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat,Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat,Sure-Max, Tela-Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat,Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect more. are registered trademarks − ® − of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series,CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure,DuraBraid, DuraCoat, DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site,HDLV, Ink-Dot, iON, Iso-Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil,Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure,Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit,Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum,VersaPail, WebCure, 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 own purposes, could lead to violation of the owners’ rights.

Table of Contents I

P/N 397155F� 2006 Nordson Corporation MC20 / MC21

Table of Contents

Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Area of Use (EMC) 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Restrictions 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use − Examples − 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . Residual Risks 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note on Manual 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Series Overview 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Type Designation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . ID Plate 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration Code 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Model Bookbinding 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . Functioning 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melting Process and Adhesive Feeding 2-5. . . . . . . . . . . . . . . . . . . Temperature Control 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Undertemperature Interlock 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . Overtemperature Indication / Shutdown 2-6. . . . . . . . . . . . . . . . Temperature Setback 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Channel Allocation Symbols 2-7. . . . . . . . . . . . . . . . . . . . . . . . . .

Essential Components 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Lid and Pneumatic Cylinder with Punch 2-9. . . . . . . . . . . . . .

Air Conditioning Unit with Pressure Controller 2-9. . . . . . . . . . . Hinged Tank (Only MC 21) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor and Gear Pump 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Plate with Safety Valve 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . Protective Panels 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Hood 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportional Pressure Control Valve 2-11. . . . . . . . . . . . . . . . . . . . . . Pressure Sensor 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Cabinet 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light Tower 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acoustic Signal Transmitter (Special Feature) 2-13. . . . . . . . . . . Control System 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Switch Manual / Auto and Button Raise / Lower Punch 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . Key Switch Remote / Local and Indication Lamp Remote 2-14. Main Switch 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Week Timer (in Electrical Cabinet) 2-14. . . . . . . . . . . . . . . . . . . . . Electrical Cabinet Ventilation 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . Hose Receptacles 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Harness 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface XS 2 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface Profibus (Option) 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . Interface Key-to-line Mode 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . Pattern Control System 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked Unit) 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching Light Tower 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhausting Adhesive Vapors 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Laying Cable 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Voltage 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Voltage / Tach Generator 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . Interface XS 2 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface Profibus (Option) 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connection 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Safety Valve (Option) 3-4. . . . . . . . . . . . . . . . . . . . . . . .

Connecting Heated Hoses 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Open-jawed Wrench 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Values and Parameters − Notes − 4-2. . . . . . . . . . . . . . . . . . .

Speed, Pressure 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Safety Valve (Option) 4-2. . . . . . . . . . . . . . . . . . . . . .

Temperatures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Values 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Changing Time 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching System ON/OFF 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Startup 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Switchoff 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switching Off in an Emergency 4-4. . . . . . . . . . . . . . . . . . . . . . . . . .

Settings Record 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving Pressure 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Maintenance 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Cleaning 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Inspection for External Damage 5-2. . . . . . . . . . . . . . . . . . . . . . Tank 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Tank by Hand 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Melt Section (Reservoir) 5-3. . . . . . . . . . . . . . . . . . . . . . . . .

Overtemperature Thermostat 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . Check the air relief hole 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Type of Adhesive 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging with Cleaning Agent 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Cabinet Ventilation Maintenance 5-5. . . . . . . . . . . . . . . . . . Maintenance Record 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Tips 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with Control System 6-1. . . . . . . . . . . . . . . . . . . . . . .

Indication Lamps and Light Tower 6-2. . . . . . . . . . . . . . . . . . . . . . . . Red Indication Lamp is Lit 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Only the White Indication Lamp is Lit 6-5. . . . . . . . . . . . . . . . . . . . .

Troubleshooting Tables 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit not Functioning 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One Channel (Heating Zone) does not Heat 6-6. . . . . . . . . . . . . . . No Adhesive (Motor Rotating) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . No Adhesive (Motor does not Rotate) 6-7. . . . . . . . . . . . . . . . . . . . No Pilot Voltage 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Overheated 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incorrect Motor Rotation in Automatic Mode 6-8. . . . . . . . . . . . . . . Not Enough Adhesive 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive Pressure too High 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive Pressure too Low 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive Residues in Tank 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive Hardens in Tank 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Punch Does Not Move Up 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Data 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Data 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperatures 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Weights 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust hood 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flow Chart A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Safety 1-1


Section 1Safety

Observe and follow all safety instructions, the general safety instructionsincluded as a separate document,

as well as the specific safety instructions in all other related documentation.

Safety1-2


Introduction 2-1


Section 2Introduction

Intended UseMelters in the series MC 20 / MC 21 may be used only to melt and feedpolyurethane hot melt adhesives (PUR) from foil bags.

Any other use is considered to be unintended. Nordson will not be liable forpersonal injury or property damage resulting from unintended use.

Intended use includes the observance of Nordson safety instructions.Nordson recommends obtaining detailed information on the materials to beused.

Area of Use (EMC)The units are designed to be used in industrial areas (Also refer to includedDeclaration of Conformity).

Operating RestrictionsWhen using in residential, business or industrial areas, the equipment maycause interference with other units, e.g. radios.

Unintended Use − Examples −The unit may not be used under the following conditions:

� In defective condition

� When changes or modifications have been made by the customer

� Without heat protection and protective panels

� With electrical cabinet door open

� With tank lid open

� In a potentially explosive atmosphere

� When the values stated under Technical Data are not complied with.

Introduction2-2


The unit may not be used to melt and feed the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Residual RisksIn the design of the unit, every measure was taken to protect personnelfrom potential danger. However, some residual risks can not be avoided.Personnel should be aware of the following:

� Risk of burns from hot adhesive

� Risk of burns on the hot tank lid

� Risk of burns when filling tank

� Risk of burns from hot accessories, e.g. heated hoses and hot meltapplication heads

� Material fumes can be hazardous. Avoid inhalation.

Note on ManualA unit with one gear pump and one hose connection is described here, butthe description is valid for all MC 20 / MC 21 models.

NOTE: The position numbers in the illustrations do not correspond to theposition numbers in the technical drawings and parts lists.

Introduction 2-3


Series OverviewThe following units are included in the series.

Unit Motors/pumps Hose connections perpump

MC 20/21-1x1 1 1

MC 20/21-1x2 1 2

MC 20/21-2x1 2 1

Explanation of Type DesignationThe unit MC 20-2x1 is used as an example.

MC 20-2x1

1 hose connection per pump

2 motors/pumps

Tank volume for 20 liter foil bag

Designation for Nordson units in the Meltexproduct line that process polyurethane hot meltadhesive.M = MoistureC = Curing

ID Plate

Fig. 2-1

Information Description UnitCode Unit designation and configuration code −

P/N Article number −Ser. Serial number −U Operating voltage VoltI Fuse protection Ampèref Line voltage frequency HertzP Power consumption of unit WattPmax Maximum power consumption of unit and connected accessories Watt

Introduction2-4


Configuration CodeThe configuration code is engraved on the ID plate.

NOTE: An X indicates that the function or component was not ordered,meaning that it is unavailable. An S indicates that the model deviates fromthe configuration code. Such deviations are described in a supplement thatis then added to this manual.

Box Code Key

Ser

ies

1 M Series or unit designation

MC21: Model with hinged tank2 C

3 2

4 0

1

5 − −

Eq

uip

men

t

6 1 One pump

2 Two pumps

7 x −

8 1 One hose connection per pump

2 Two hose connections per pump

9 A Operating voltage 400 VAC 3 phase Y

B Operating voltage 400 VAC 3 phase delta

C Operating voltage 480 VAC 3 phase delta

10 1 Pump 1 Type: PR 6 (0,90 ccm/rev)

2 Pump 1 Type: PR 12 (1,80 ccm/rev)

3 Pump 1 Type: PR 12m2 (3,60 ccm/rev)


11 1 Pump 2 Type: PR 6 (0,90 ccm/rev)

2 Pump 2 Type: PR 12 (1,80 ccm/rev)



12 / −

Op

tio

ns

13 A Profibus

14 B Connections for six additional heating zones (distributed onto three connectingreceptacles)

15 C Pneumatic safety valve

Special Model Bookbinding

In addition to configured units, there is a special model available for thebookbinding industry; it is equipped with additional components.

Also refer to supplementary documents on the Bookbinding System as wellas manuals for the additional components.

Introduction 2-5


Functioning

Melting Process and Adhesive FeedingThe opened foil bag is placed in the tank. There is a heated grid (1, low meltsection) in the tank. The adhesive is melted there and fills a reservoir (3,high melt section, approx. 3 liters). The adhesive flows from the reservoir tothe gear pump (12). The gear pump feeds the adhesive to the hoseconnection (7).

A pneumatically operated punch in the tank applies sufficient pressure tothe foil bag on the grid. The pressure is automatically switched on and offaccording to whether adhesive is dispensed or not.

The low melt and high melt sections are heated separately. This way only asmall amount (approx. 3 liters) of adhesive is heated to processingtemperature. This adhesive supply ensures continuous adhesivedispensing, even when the foil bag is changed.

3 4 6

11

7 8

12 9

5

10

1

2

Fig. 2-2 Principle drawing

1 Low melt section (grid)2 High melt section (reservoir)3 Motor4 Coupling5 Bypass plate

6 Safety valve7 Hose connection8 Heated hose (accessory)9 Suction bore

10 Pressure bore

11 Bypass hole12 Gear pump

Introduction2-6


Temperature ControlAlso refer to manual Control System. The temperature is measured bysensors and is electronically controlled by the control system.

Undertemperature InterlockThe undertemperature interlock prevents the unit or system from beingstarted up before the adhesive has exceeded the temperature setpointminus undertemperature value. However, every time initial heating occurs,the interlock is not released until the actual temperature is 3 °C (5.4 °F)below the temperature setpoint.

The undertemperature interlock locks the motors, solenoid valves and, insome cases, other components of the hot melt application system. Refer tothe wiring diagram to determine which components are locked.

Overtemperature Indication / ShutdownThe independently operating overtemperature shutdown mechanismsprotect the unit and adhesive from overheating. For overtemperatureshutdown, the heating and motor are switched off. The red indication lampCollective fault lights up.

� Overtemperature indication through temperature controller: When thetemperature setpoint plus overtemperature value has been reached, therelay output Collective fault is switched and the red indication lampCollective fault lights. The unit remains ready for operation.

� Overtemperature shutdown by temperature controller: Theovertemperature shutdown value is set automatically 30 °C (54 °F)higher than the highest temperature setpoint value.

� Overtemperature shutdown by thermostat(s): Serves as an emergencyswitch OFF in case the overtemperature shutdown of the temperaturecontroller does not function properly. Refer to section Technical Data forshutdown value.

WARNING: When the overtemperature shutdown is triggered, there iseither a fault in settings or unit malfunction. Switch off the unit and have thefault remedied by qualified personnel.

Introduction 2-7


Temperature SetbackServes to protect the adhesive and save energy during interruptions inproduction or work stoppages. Setback value and setback period areadjustable.

Channel Allocation Symbols

1 2 3 4 5

Fig. 2-3

1 Low melt section2 High melt section

3 Heated hose (accessory)4 Application head or assembly

handgun (accessory)

5 Additional temperature channel

Introduction2-8


Essential Components

1

2

3

4

7

6

5

9

8

1413121110

Fig. 2-4 The actual model can deviate from the illustration.

1 Pneumatic cylinder with punch2 Air conditioning unit with pressure

controller3 Compressed air connection4 Tank lid5 Proportional pressure control

valveB

6 Exhaust hood7 Protective cover8 Electrical cabinet9 Hose connection

10 Gear motor11 Coupling12 Gear pump*13 Bypass plate with safety valve*14 Tank

Note: There are separate manuals available for components marked with an asterisk (*).Note: The components marked with a B are available only in conjunction with the special model Bookbinding.

1

1

2

Introduction 2-9


Tank Lid and Pneumatic Cylinder with PunchThe tank lid is fastened with a hinge, allowing it to be swiveled out with thepneumatic cylinder.

Reed contacts (1) on the pneumatic cylinder detect the position of thepneumatically operated punch and thus the level in the foil bag. The signalsfrom the Reed contacts are processed by a PLC.

The lid can not be opened until the punch has triggered the upper Reedcontact.

The lower Reed contact triggers the empty indication; the height isfactory-set to complete emptying of common foil bags, but it can bemodified. The middle Reed contact serves to trigger the Almost emptyindication.

When the punch has reached its lowest position (foil bag empty), it isautomatically moved up. The foil bag can then be changed.

Air Conditioning Unit with Pressure Controller

The pressure controller (1) is used to set pneumatic pressure to be appliedto the pneumatic cylinder. The setting must be modified according to theprocessed material and the output quantity (2 to 6 bar / 29 to 87 psi).

Pressure Switch

A pressure switch (2) switches off the main contactor when the inletpressure falls below 2 bar.

Hinged Tank (Only MC 21)The tank is hinged and can be folded back to clean the high melt sectionand the grid.

2

1

Introduction2-10


Motor and Gear PumpThe electronically controlled motor drives the gear pump. This speed isindicated on the control system CS 20. Refer to manual Control System forinstructions on setting speed.

NOTE: With the special model for the bookbinding industry, the speed isnot regulated to a preset value; the pressure at the material outlet isregulated. This way the required material pressure is available as soon as aconnected application head is triggered (opened). Refer to manual ControlSystem for instructions on setting pressure.

CAUTION: Nordson gear pumps may not be operated without hot meltmaterial. Before switching on the motor, ensure that the tank is filled.

CAUTION: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min-1 (rpm) or continuously exceed 80 min-1 (rpm).

Bypass Plate with Safety ValveThe mechanical safety valve limits the adhesive pressure generated by thegear pump and keeps it constant. When the set pressure is exceeded, thesafety valve opens, allowing the adhesive to circulate within the bypassplate.

The pneumatic safety valve (1, option) serves to adjust the adhesivepressure by means of control air. The pneumatic control pressure ist setmanually e.g. at a separate control unit (2, accessory).

Protective PanelsWARNING: Do not operate without protective panels.

The protective panels can be detached for installation, maintenance andrepair.

1

1 2

1

Introduction 2-11


Exhaust HoodThe fumes created when polyurethane hot melt adhesives (PUR) areprocessed should be suctioned off directly at the tank. An exhaust hood (1)is integrated for this purpose.

The exhaust hood must be connected to the customer’s exhaust device(Also refer to Installation, Exhausting Adhesive Vapors).

Proportional Pressure Control ValveNOTE: The proportional valve is a standard component only with thespecial model Bookbinding.

The proportional valve (1) supplies a pneumatic outlet pressure based onthe speed of the book binding machine. This outlet pressure serves as thecontrol pressure for an application head (EP 48-V); it keeps the applicationweight steady.

The assembly contains a pressure controller (2) to adjust the inlet pressure.

Pressure SensorNOTE: The pressure sensor (1) is a standard component only with thespecial model Bookbinding. When the pressure sensor is added to otherMC 20 units, it simply enables the pressure to be monitored by an externalunit.

The pressure sensor directly at the material outlet enablespressure-controlled operation of the MC 20. The frequency converter, whichcontrols the motor speed, is parameterized a certain way for this purpose.

This pressure is set and indicated on the control system CS 20. Refer tomanual Control System.

Also refer to manual Pressure Control for Applicators MX/MC.

Introduction2-12


Electrical Cabinet

1

2

3

4

5

7

8

9

1410 11 12 13

6

Fig. 2-5 The actual model can deviate from the illustration.

1 Light tower2 Button Raise punch3 Mode switch Manual / auto4 Button Lower punch5 Control system CS 20*

6 Key switch Remote / local andindication lamp Remote (only withthe option Profibus)

7 Main switch8 Hose receptacles9 Electrical cabinet ventilation

10 Cable harnessB

11 Interface XS 212 Interface Key-to-line mode13 Interface Profibus (option)*14 Pattern control systemB*

Note: There are separate manuals available for components marked with an asterisk (*).Note: The components marked with a B are available only in conjunction with the special model Bookbinding.

Introduction 2-13


Light Tower

White Unit switched on

Red Collective fault

Yellow(flashing)

Foil bag almost empty

(middle Reed contact on pneumatic cylinder)

Yellow Foil bag empty

(lower Reed contact on pneumatic cylinder)

Green Unit ready for operation

Also refer to section 6 Troubleshooting and manual Control System forinformation on Collective fault.

NOTE: Automatic motor/pump standstill does not occur after the indicationFoil bag empty until an adjustable time − Changing time − has expired.When the empty indication occurs, the amount of adhesive in the reservoirshould be sufficient to ensure uninterrupted feeding while the bag is beingchanged. Refer to Operation, Filling the Tank, Setting Changing Time.

Acoustic Signal Transmitter (Special Feature)Generates an acoustic signal when Drum empty occurs.

Control SystemOn the control system, values and parameters are set, and operatingmodes and faults are displayed. Refer to separate manual.

Mode Switch Manual / Auto and Button Raise / LowerPunchWARNING: Risk of squash from moving punch when tank lid is swiveledout! Do not lower punch onto protective cover or edge of tank.

Position Manual. The punch can be controlled manually with the buttonRaise/lower punch, e.g. to clean the punch plate.

Position Auto: The punch is controlled automatically, depending on theoperating mode of the unit.

1

Introduction2-14


Key Switch Remote / Local and Indication Lamp RemoteWhen set to Remote, the system is not controlled by the internal controlsystem but via the interface Profibus (Option).

Main SwitchNOTE: The main switch must be set to I/ON when using the week timer.

Used to switch on/off the unit.

Position 0/OFF = Unit is switched off.

Position I/ON = Unit is switched on.

Padlocks can be used to protect the main switch from unauthorized access.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by ahigher-ranking system; the higher-ranking main switch is on that system.The black main switch does not perform the EMERGENCY OFF function.Connected components can still be switched on!

Week Timer (in Electrical Cabinet)

The week timer (1) is used to automatically switch the system on and off.The main switch must be set to I/ON (switched on) when using the weektimer. Refer to separate manual.

Electrical Cabinet Ventilation

Electrical cabinet ventilation (fan with filter) reduces the temperature insideof the electrical cabinet. The filters must be serviced regularly. Refer toMaintenance.

Hose ReceptaclesUsed for electrical connection of two heating zones each (heated hose andapplication head). Depending on the design, one or more hose receptaclesare connected. Refer to wiring diagram.

Introduction 2-15


Cable HarnessNOTE: The cable harness is a standard component only with the specialmodel Bookbinding.

The cable harness is used to connect the application head EP48-V. Theheating zones Application head and Filter are controlled via the cableharness.

Interface XS 2Serves as a connection between the system and external devices.

Interface Profibus (Option)The PROFIBUS interface (2) enables Remote operation by a higher-rankingcontrol unit. Refer to separate manual.

Interface Key-to-line Mode

NOTE: Key-to-line mode is also referred to as Automatic mode in Nordsonliterature.

In key-to-line mode the motor/pump speed is regulated synchronously to thespeed of the parent machine.

The pilot voltage can be supplied e.g. by a tach generator (accessory)driven by the parent machine. Refer to Installation.

Pattern Control SystemNOTE: The pattern control system is a standard component only with thespecial model Bookbinding.

The pattern control system Eclipse is used to trigger application headsdependent on the product position. Refer to separate manual.

Door LockWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

The electrical cabinet can be opened for installation, maintenance andrepair. Store the included key such that it is accessible only to qualified andauthorized personnel. The system may not be operated when the electricalcabinet is open.

Introduction2-16


Installation 3-1


Section 3Installation

WARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

UnpackingUnpack carefully. Then check for any damage caused during shipping. Savespecial pallet and angle brackets for later use. Reuse packaging materialsor dispose of properly according to local regulations.

Transport� Refer to Technical Data for weight. Use only suitable transport devices

� If possible, use the pallet on which the system was delivered, and fastenthe system to the pallet

� Protect from damage, moisture and dust with suitable packing material

� Avoid jolts and vibrations.

Lifting (Unpacked Unit)Refer to the Technical Data for weight. Lift only at the unit frame usingsuitable lifting equipment or a forklift.

RemovalRun the unit until empty, separate all connections from the unit, and allowthe unit to cool down.

1

Installation3-2


StorageDo not store unit outside! Protect from humidity, dust and extremetemperature fluctuations (formation of condensation).

DisposalProperly dispose of unit according to local regulations.

Setup� Set up only in an environment that corresponds to the stated Degree of

Protection (Refer to section Technical Data).

� Do not set up in a potentially explosive atmosphere!

� Protect from vibration

� Remove transport protection (if present)

� Check all plug and screw connections for tightness

� Leave enough free space around the unit.

Attaching Light TowerThe light tower must be screwed onto the electrical cabinet (It was removedfor transport).

Exhausting Adhesive VaporsEnsure that adhesive vapors do not exceed the prescribed limits. Alwaysobserve the safety data sheet (MSDS) for the material to be processed.

NOTE: The exhaust hood must be connected to the customer’s exhaustdevice. Refer to Technical Data.

Installation 3-3


Electrical ConnectionsWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

Laying CableEnsure that cables do not touch rotating and/or hot unit components. Do notpinch cables and check regularly for damage. Replace damaged cablesimmediately!

Line VoltageWARNING: Operate only with the line voltage stated on the ID plate.

NOTE: Permitted deviation from the rated line voltage is +5% / −10%.

NOTE: The cross-section of the power cable must correspond to the ratedcurrent. Refer to ID plate for rated current.

The mains terminals are located in the electrical cabinet. Refer to wiringdiagram for connecting arrangement.

Pilot Voltage / Tach GeneratorFor key-to-line mode, pilot voltage must be connected to XS5. The pilotvoltage can be supplied e.g. by a tach generator (accessory) driven by theparent machine.

CAUTION: The pilot voltage may not exceed 160 VDC. Failure to observewill result in damage to succeeding components.

NOTE: Some models with two pump drives have separate pilot voltageinputs for both pump drives.

21

2

1

Installation3-4


Interface XS 2Serves as a connection between the unit and external devices. The actualconnecting arrangement is described in the wiring diagram.

NOTE: Use only shielded cables/lines. Connect the shield to ground incompliance with electromagnetic compatibility regulations.

NOTE: Inductive loads (e.g. solenoid valves) connected to the unit must beequipped with a protective device (e.g. recovery diode) that disables theinductive voltage generated when an inductive load is switched off.

Interface Profibus (Option)The PROFIBUS interface enables Remote operation by a higher-rankingcontrol unit. Refer to separate manual.

Pneumatic ConnectionConnect dry, clean and non-lubricated compressed air (1). Set air pressurefor pneumatic cylinder to approx. 2 bar (0.2 MPa / 29 psi) on the pressurecontroller (2). The setting must be modified according to the processedmaterial and the output quantity (max. 6 bar / 87 psi).

Pressure Switch

A pressure switch switches off the main contactor when the inlet pressurefalls below 2 bar.

Pneumatic Safety Valve (Option)The pneumatic safety valve (1, option) serves to adjust the adhesivepressure by means of control air. The pneumatic control pressure ist setmanually e.g. at a separate control unit (2, accessory). Refer to separatemanual.

1 2 3

Installation 3-5


Connecting Heated HosesWARNING: Hot! Risk of burns. Wear heat-protective gloves.

Second Open-jawed WrenchUse a second open-jawed wrench when connecting and disconnecting theheated hose. This prevents the unit’s hose connection from turning.

ConnectingIf cold material can be found in the hose connection, these components(1, 2) must be heated until the material softens (approx. 80 �C, 176 �F).

1. First connect the hose (3) electrically to the unit. For more than onehose: Every hose connection is allocated to a corresponding receptacle.Do not mistakenly exchange!

2. Heat the system and hose to approx. 80 �C (176 �F).

3. Screw on heated hose.

NOTE: Close unused hose connections with Nordson port plugs.

DisconnectingWARNING: System and material pressurized. Relieve system pressurebefore disconnecting heated hoses. Failure to observe can result in seriousburns.

Relieving Pressure

1. Set motor speed to 0 min-1 (rpm); switch off motor(s).

2. Place a container under the nozzle(s) of the application head/assemblyhandgun.

3. Activate the application head / assembly handgun electrically ormanually. Repeat this procedure until no more material flows out.

4. Properly dispose of adhesive according to local regulations.

Installation3-6


Operation 4-1


Section 4Operation


Initial StartupAfter the unit has been properly installed, initial startup can take place.Some of the individual steps are described in detail in the subsequent text.

1. Set main switch to I/ON.

2. Set values and parameters on the control system.

3. Fill the tank.

4. Wait until the unit is ready for operation (green lamp lit).

5. Switch on motor.

6. Set motor/pump speed (or pressure) as needed for the desired adhesivequantity.

Operation4-2


Setting Values and Parameters − Notes −Values and parameters − except air pressures for the pneumatics − are seton the control system.

For additional information, refer to manual for control system used.

Speed, PressureWith the special model for the bookbinding industry, the speed is notregulated to a preset value; the pressure at the material outlet is regulated.

In automatic mode, the speed and thus the output quantity is determined bya pilot voltage. The pilot voltage is supplied e.g. by a tach generator drivenby the parent machine.

Pneumatic Safety Valve (Option)

The pneumatic safety valve serves to adjust the adhesive pressure bymeans of control air. The pneumatic control pressure ist set manually e.g. ata separate control unit.

TemperaturesCAUTION: The temperature setting is determined by the processingtemperature prescribed by the adhesive supplier. The maximum operatingtemperature for the product described here and heated components maynot be exceeded.

Nordson will grant no warranty and assume no liability for damage resultingfrom incorrect temperature settings.

Recommended ValuesThe values stated in the tables are general values determined byexperience; deviation may prove necessary.

Heating zone / temperature / time SettingLow melt section Approx. 5 to 10 °C (9 to 18 °F) above softening temperatureHigh melt section (reservoir and pump) 10 °C (18 °F) below prescribed processing temperatureUndertemperature value 15 °C (27 °F) (deviation from setpoint)Overtemperature value 15 to 30 °C (27 to 54 °F) (deviation from setpoint)Temperature setback value (standby) As neededSetback period As neededApplication head (accessory) Prescribed processing temperatureHeated hose (accessory) Prescribed processing temperature

1

Operation 4-3


Filling the TankNOTE: Automatic motor/pump standstill does not occur after the indicationFoil bag empty until an adjustable time − Changing time − has expired.When the empty indication occurs, the amount of adhesive in the reservoirshould be sufficient to ensure uninterrupted feeding while the bag is beingchanged.

WARNING: Hot! Risk of burns. Wear safety goggles and heat-protectivegloves. Hot adhesive can splash out of the tank.

1. Open tank lid (swivel out).

2. Cut a round opening of 200 to 220 mm diameter in the middle of the endof the foil bag, then place the bag in the tank with the open end down.

NOTE: The size and centering of the opening are essential to properemptying. Nordson recommends using the stencil P/N 789668 to cut thehole.

3. Close tank lid (swivel in).

The punch is lowered automatically.

Setting Changing TimeAfter the indication Foil bag empty (light tower: yellow), the changing timebegins. If the foil bag is not changed before this time expires, themotor/pump automatically comes to a standstill.

The changing time can be set on the timer relay 231K5 (1) in the electricalcabinet.

Operation4-4


Switching System ON/OFFNOTE: Before initial startup, read and observe the instructions in InitialStartup. Start up only as described under Initial Startup.

NOTE: The main switch must be set to I/ON (switched on) when using theweek timer. Refer to separate manual.

NOTE: When external system release via interface XS2 is used, the mainswitch must be set to I/ON (switched on).

Daily StartupNOTE: Nordson gear pumps may not be operated without hot meltmaterial. Before switching on the motor, ensure that the tank is filled.

1. Set main switch to I/ON.

2. Wait until the unit is ready for operation.

3. Switch on motor.

Daily Switchoff1. Switch off motor.

2. Set main switch to 0/OFF.

3. If necessary, secure main switch with padlock against unauthorizedaccess.

Switching Off in an EmergencyWARNING: Switch off the unit immediately in any emergency situation.

1. Set main switch to 0/OFF.

2. After standstill and before switching the unit on again, have themalfunction remedied by qualified personnel.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by ahigher-ranking system; the higher-ranking main switch is on that system.The black main switch does not perform the EMERGENCY OFF function.Connected components can still be switched on!

Operation 4-5


Settings Record

Production information:

Adhesive: Manufacturer

Processing temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Reference channel: High melt section (reservoir and pump) (factory set)

Processing temperatures (Setpoint temperatures):

Low melt section (grid)

High melt section (reservoir and pump)

Heated hose (accessory) 1) 2) 3) 4)

Application head (accessory) 1) 2) 3) 4)

Motor/pump speed, with models for the bookbinding industry: Setpoint pressure

Motor/pump

Air pressure: bar MPa psi

Operating pressure

Notes:

Name Date

Operation4-6


Maintenance 5-1


Section 5Maintenance


NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the lifetime of the unit. It should not beneglected under any circumstances.

WARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Some maintenance work can only be done when thesystem is heated up.

Relieving PressureWARNING: System and adhesive pressurized. Relieve system of pressurebefore disconnecting heated hoses, application heads and assemblyhandguns. Failure to observe can result in serious burns.

1. Set motor speed to 0 min-1 (rpm); switch off motor(s).

2. Place a container under the nozzle(s) of the application head / assemblyhandgun.

3. Activate the solenoid valve(s) electrically or manually; or, pull the triggerof the assembly handgun. Repeat this procedure until no more adhesiveflows out.

4. Properly dispose of adhesive according to local regulations.

Maintenance5-2


Regular MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on operating environment, production conditions and hours ofoperation, other scheduled maintenance tasks may prove necessary.

Unit part Activity Interval Refer to

Entire unit External cleaning Daily Page 5-2

Inspect for externaldamage

Daily Page 5-2

Condensate collector ofair conditioning unit

Empty As needed −

Tank Visual inspection forpollution in tank; clean ifnecessary

Before filling every time −

Punch plate Check deaeration holes forblockage; unclog ifnecessary

Before filling every time Page 5-4

Electrical cabinetventilation

Clean fan screens, cleanor replace filter

Daily, if dust accumulation issevere

Page 5-3

Gear pump Refer to separate manual

Safety valve Refer to separate manual

Pressure sensor Refer to separate manual

External CleaningExternal cleaning prevents impurities created during production fromcausing the unit to malfunction.

CAUTION: Observe the unit’s Degree of Protection when cleaning (Referto Technical Data).

CAUTION: Do not damage or remove warning labels. Damaged orremoved warning labels must be replaced by new ones.

Only remove hot melt adhesive residue with a cleaning agent recommendedby the adhesive supplier. Heat with an air heater if necessary.

Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.

Visual Inspection for External DamageWARNING: When damaged parts pose a risk to the operational safety ofthe unit and/or safety of personnel, switch off the unit and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

3

2

14

1

Maintenance 5-3


Tank

Cleaning Tank by Hand

Cold material can usually be peeled off of the sides of the tank. If necessary,first heat tank to material softening temperature.

NOTE: The inside of the tank is release coated. Do not use metallic tools toclean. Do not use wire brushes! This could damage the release coating.

High Melt Section (Reservoir)

MC 20

Before the high melt section (3) can be cleaned, the low melt section (2)must be detached:

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

1. Disconnect the system from the power supply.

2. Close tank lid (swivel in).

3. On low melt section (2): Detach electrical connections to heatercartridges and overtemperature thermostats.

4. Release all screws (4) and lift off upper tank section (1) by the eyelets(on the pneumatic cylinder) with a suitable lifting device. Secure the lowmelt section to prevent it from falling.

When reassembling, tighten screws with 25 Nm / 220.

MC 21

The tank is hinged and can be be folded back to clean the high melt sectionand the grid.

1. Remove the protective cover.

2. Open the tank lid (swivel out).

3. Release the four clamps (1).

4. Fold back the top section of the tank. Keep in mind that the tank isheavy!

1

1

Maintenance5-4


Overtemperature ThermostatThe overtemperature thermostats (1) serve as an automatic switchoff incase the overtemperature shutdown of the temperature controller does notfunction properly.

NOTE: Depending on the type of adhesive used, the overtemperaturethermostats of the tank may need to be adapted to the maximumprocessing temperature of the adhesive (This may mean replacing it). Referto Technical Data.

Check the air relief hole1. Slide the protective panels aside.

2. Swivel out the tank lid.

3. Use a wooden or plastic pick to pierce the air relief holes (1).

NOTE: Do not use metallic tools to clean. This could damage the releasecoating.

ÂÂÂÂÂÂÂÂÂÂÂÂ

ÂÂÂÂÂÂÂÂÂÂÂÂ

ÂÂÂÂÂÂÂ

Â

Maintenance 5-5


Changing Type of AdhesiveRemove the old adhesive by running until empty or by draining the unit.

NOTE: Before changing the type of adhesive, determine whether the newadhesive may be mixed with the old adhesive.

� May be mixed: Remaining old adhesive can be flushed out using thenew adhesive.

� May not be mixed: Thoroughly purge the unit with a cleaning agentrecommended by the adhesive supplier.

NOTE: Properly dispose of the old adhesive according to local regulations.

Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the adhesivemanufacturer. Observe the Material Safety Data Sheet for the cleaningagent. Use only cleaning agents in foil bags.

Before starting production again, flush out cleaning agent residue using thenew adhesive.

NOTE: Properly dispose of cleaning agent according to local regulations.

Electrical Cabinet Ventilation MaintenanceThe electrical cabinet fan is maintenance-free. The filter must be cleaned orreplaced, depending on dust accumulation.

A dirty filter can be recognized by its dark color. It is cleaned by shaking thefilter out.

Maintenance5-6


Maintenance Record

Unit part Date / name Date / name Date / name

Tank

Electrical cabinet ventilation

Condensate collector

Gear pump

Safety valve

Pressure sensor

Troubleshooting 6-1


Section 6Troubleshooting


WARNING: Troubleshooting activities may sometimes have to be carriedout when the unit is energized. Observe all safety instructions andregulations concerning energized unit components (active parts). Failure toobserve may result in an electric shock.

Some TipsBefore systematic troubleshooting is begun, the following should bechecked:

� Are all parameters set correctly?

� Is the XS 2 interface connected correctly?

� For automatic mode: Is pilot voltage present?

� Do all plug connections have sufficient contact?

� Have fuses been activated?

� Could the fault have been caused by an external PLC?

� Are external, inductive loads (e.g. solenoid valves) equipped withrecovery diodes? The recovery diodes must be directly allocated to theinductive load, e.g. through luminous sealings.

Troubleshooting with Control SystemThe control system offers the following troubleshooting aids, described inthe manual Control System:

� Indication lamps and light tower

� Diagnosis program in the temperature section

� Automatic fault display in the temperature section

� Service display Error in the motor section

� LEDs on the modules and boards.

Troubleshooting6-2


Indication Lamps and Light TowerWith the exception of the yellow light on the light tower, the indication lampsand the light tower indicate the same modes as the control system:

� Red = Collective fault. The red lamp indicates that the control systemhas recognized a fault.

Refer to table Red indication lamp is lit.

� White = Switched ON. After switching on and during the heatup phase,at first only the white indication lamp is lit (normal condition). A fault hasonly occurred when the temperature does not increase (observetemperature display) and when the green indication lamp is not lit afterthe heatup phase has ended (1 hour and longer).

Refer to table Only the white indication lamp is lit.

� Green = Ready for operation. The green indication lamp lights when allchannels have reached their setpoint temperatures.

� Yellow:

� Flashing = Low tank level, as set by customer

� Lit = Lower tank level, as set by customer.

Red

Green

White

17

18

19

1 2 3 54 6 7

1 1 2 2 3

M1 min−1

1

barpsi

2 3 54 76

8 109 11 12

CF

3 44 21

8 9 10 11 12

Fig. 6-6 (Refer to manual Control System for position numbers)

Troubleshooting 6-3


Red Indication Lamp is Lit

Problem Possible Cause Corrective Action Refer to

Overtemperatureindication fromcontrol system(Display 5: Hiblinking)

� � Manual Control System,Service DisplayError

Overtemperatureshutdown bycontrol system(displays 3, 4 and5: blinking)

� �

Overtemperatureshutdown by tankthermostats

� �

Motor switched offdue to overheating(thermistorlocated in themotor)

� �

Undertemperatureduring operation(Display 5: Loblinking)

Adhesive was refilled Wait until the temperaturehas been reached

−


Ambienttemperature toohigh (Displays 3, 4 and5: AM bIE nTblinking)

Ambient temperature toohigh

Decrease ambienttemperature by cooling orairing out

Filter of the electrical cabinetfan dirty

Clean or replace Section 5

Electrical cabinet fandefective

Replace −

Temperaturesensorshort-circuit(Display 5: − S −blinking)

� Replace −

Temperaturesensorinterruption(Display 5: − E −blinking)

� Replace −

Main contactordefective ordropped


Pneumatic inlet pressure fallsbelow 2 bar

Check pneumatic connection Section 3

Continued...

Troubleshooting6-4


Problem Refer toCorrective ActionPossible Cause

Speed alarmDisplay 30: r_d

� � Manual Control System,Service DisplayError, Parameter r_d,Display Overview

Overpressure(with specialfunction Pressuremonitoring)Display 30: Phi

� � Manual Control System,Service DisplayError, Parameter Phi,Digital Module

Underpressure(with specialfunction Pressuremonitoring)Display 30: Plo

� � Manual Control System,Service DisplayError, Parameter Plo,Digital Module

Safety valve hasopenedDisplay 30: bPo(special function)

� � Manual Control System,Display Overview,Digital Module

Other faults � � Manual Control System,Service Display inMotor Section,Service DisplayError

Troubleshooting 6-5


Only the White Indication Lamp is Lit

Problem Possible Cause Corrective Action Refer to

Temperaturesetpoint(s) of oneor more heatingzones are notreached

Release unit not bridged ornot activated

Bridge or activate thecorresponding contacts of theXS 2 interface

Wiring diagram

Activate diagnosis program ofthe temperature section

� Manual Control System

Fuse(s) defective (fuses arealso located on the modulesand boards)

Switch on or replace Manual Control System

Wiring diagram

Cable loose or broken Fix or replace −

Overtemperature thermostat(on the tank) defective

Replace Spare parts list

Temperature sensor(s)defective

Replace Spare parts list

Solid-State-Relay defective Replace Spare parts list

Heater(s) defective Replace (heaters in the tankand heated hose can not bereplaced)

−

Temperature setback switchedon

Switch off or wait until thesetback period has expired

Manual Control System

Automatic temperaturesetback after motor standstillactivated

Stop temperature setback Manual Control System

Troubleshooting6-6


Troubleshooting TablesThe troubleshooting tables serve as an orientation for qualified personnel.They cannot, however, replace targeted fault location with the help of wiringdiagrams and measuring instruments. They also do not include all possibleproblems, only those which most typically occur.

Unit not Functioning

Possible Cause Corrective Action Refer to

No line voltage Connect line voltage Section 3

Main switch not switched on Switch on main switch Section 2

Main switch defective Replace main switch −

Main circuit breaker activated Check for short circuit in unit oraccessories

Wiring diagram

Fuse Control voltage (UN / UL) activated Check for short circuit in unit oraccessories

Wiring diagram

One Channel (Heating Zone) does not Heat


Channel is switched off Switching on Manual Control SystemChannel is switched to measuring mode Switch to control mode

Channel/Heating zone defective Activate diagnosis program of thetemperature section

No Adhesive (Motor Rotating)


Tank empty Fill tank Section 3

Adhesive feed bore to the pump orsuction bore of the pump clogged

Remove the pump and clean the feedbore or suction bore �

Manual Pump

Pump does not turn, because couplingscrews are loose

Tighten −

Punch does not press on material Check punch function −

Troubleshooting 6-7


No Adhesive (Motor does not Rotate)


Motor overheated Remedy cause Troubleshootingtable Motoroverheated

Unit not yet ready for operation(Undertemperature during the heatupphase)

Wait until the unit has heated up and thegreen indication lamp is lit

Table Only the whiteindication lampis litUnit at present not ready for operation

(Undertemperature during operation).Adhesive was refilled

Wait until the unit has heated up and thegreen indication lamp is lit

Motor not switched on Switch on (motor must be selected) Manual Control System

Motor not selected Select motor and then switch on −

Motor startup protection activated Switch on motor(s) again

Speed (rpm) not set Set speed

Automatic mode selected, however unitshould be in manual mode

Switch to manual mode

No external Release motor via XS 2interface2

Bridge or activate the correspondingcontacts of the XS 2 interface

Section 3

Wiring diagram

Automatic mode selected and no pilotvoltage present

Provide pilot voltage Manual Control System,Troubleshootingtable No pilot voltage

Threshold value switch not properly set Set parameters SLo and Shi accordingly Manual Control SystemTemperature setback switched on Switch off or wait until the setback period

has expired

Automatic temperature setback aftermotor standstill activated

Stop temperature setback

Motor defective Replace −

Motor not supplied with voltage Technical inspection Wiring diagram

Digital module defective or incorrectly set Set or replace Manual Control SystemCentral module of the motor section

defective or incorrectly setSet or replace

Control panel board of the motor sectiondefective or incorrectly set

Set or replace

Troubleshooting6-8


No Pilot Voltage


Parent machine not operating Start up parent machine −

Tach generator (Accessories) defective Replace −

Pilot voltage falsely poled Reverse polarity −

DIP switch of the central moduleincorrectly set or analog board of thecentral module not aligned properly

Check switch positions and align theboard if necessary

Manual Control System,Central Module

Central module defective Replace central module Manual Control System,Central Module,Service DisplayUin

Motor Overheated

Ambient temperature too high Decrease ambient temperature by coolingor airing out

−

Cooling air intake grill dirty Clean Section 5

Pump blocked by foreign matter Replace pump Manual PumpPump operates too sluggish Replace pump

Adhesive too cold Set temperature accordingly Data sheet ofthe adhesivesupplier

Incorrect Motor Rotation in Automatic Mode


Parameter rLo, rhi and Uhi not setincorrectly

Set parameters accordingly Manual Control System

Pilot voltage fluctuation despite constantmachine speed

Drive element (e.g. belt) slips. Eliminateslip

−

Troubleshooting 6-9


Not Enough Adhesive

Possible Cause Corrective Action Refer toAdhesive feed bore to the pump orsuction bore of the pump partly clogged

Remove pump and clean feed bore orsuction bore

Manual Pump

Pump block of the gear pump worn Replace pump

Safety valve defective Clean or replace Manual Safety Valve

Processing temperature set too low Correct temperature setting Data sheet ofthe adhesivesupplier

Adhesive Pressure too High


Mechanical safety valve dirty (and therebyblocked)

Disassemble and clean or replace Manual Safety Valve

Mechanical safety valve defective Replace

Mechanical safety valve incorrectly set Set to default −

Pneumatic safety valve (option)pressurized with too high pressure

Reduce pressure

Adhesive Pressure too Low


Mechanical safety valve dirty (and therebyblocked)

Disassemble and clean or replace Manual Safety Valve

Mechanical safety valve defective Replace

Mechanical safety valve incorrectly set Set to default

Pneumatic safety valve (option)pressurized with too low pressure

Increase pressure

Troubleshooting6-10


Adhesive Residues in Tank


Tank setpoint temperature set too high Correct temperature setting Data sheet ofthe adhesivesupplier

Adhesive Hardens in Tank


Tank setpoint temperature set too high Correct temperature setting Data sheet ofthe adhesivesupplier

Punch Does Not Move Up


Charred material is blocking the holes inthe punch plate and causing a vacuum

1. Air conditioning unit with pressure con-troller: Set pneumatic cylinder pressureto maximum. If the punch begins torise slowly: Wait until the punch is outof the tank

Page 2-9

2. If the punch is still not moving: Un-screw the heated hose, allowing air toflow through the gear pump and underthe punch. As soon as the hose is re-connected, feed enough material to en-sure that no air remains in the pump orhose!

Page 3-5

3. If the punch is still not moving: ConsultNordson customer service

Check air relief holes for blockage beforefilling every time; unclog if necessary

Page 5-4

Technical Data 7-1


Section 7Technical Data

General Data

Adhesive pressure 5 to 70 bar / 0.5 to 7 MPa / 72.5 to 101.5 psiMelting capacity 20 l/h (dependent on adhesive used)Noise emission 70 dBAMotor type A.C. motor

Speed setting range 1.0 to 100 min-1

To prevent excessive wear, the motor/pump speedshould not continuously fall below 5 min-1 (rpm) orcontinuously exceed 80 min-1 (rpm).

Degree of protection IP 32

Electrical DataCAUTION: The unit is designed for only one operating voltage. Operateonly at the operating voltage shown on the ID plate.

Operating voltage Refer to ID plate

Operating voltage frequency 50/60 HzFuse protection Refer to ID platePower consumption P Refer to ID platePower consumption Pmax Refer to ID plateLoad per hose receptacle (2 channels) Heated hose 1200 watt

Application head 1200 watt

Max. pilot voltage (input voltage) 160 VDC

The pilot voltage may not exceed 160 VDC. Failureto observe will result in damage to succeedingcomponents.

or 0 - 10 V

The pilot voltage must be adjusted (Refer tomanual Control System).

Technical Data7-2


Temperatures

Min. ambient temperature 10 °CMax. ambient temperature 40 °CMin. operating temperature 50 °CMax. operating temperatures (tank) Overtemperature thermostat Order

numberStandard 140 °C 150 °C 300 °F 271936Special feature 170 °C 177 °C 350 °F 272825Special feature 200 °C 204 °C 400 °F 271931

NOTE: Depending on the type of adhesive used, the overtemperaturethermostats of the tank may need to be adapted to the maximumprocessing temperature of the adhesive (This may mean replacing it).

Dimensions and Weights

Unit dimensions Length Approx. 1050 mm

Width Approx. 820 mm

Height Approx. 1830 mmTank opening Ø 283 for foil bag Ø 280

Ø 291 for foil bag Ø 288

Weight See consignment note

Exhaust hood

Nominal air quantity (recommendation) 205 m3/h

Pressure loss at nominal air quantity 50 Pa

Connecting sleeve ∅ 100 mm

Flow Chart A-1


Appendix AFlow Chart

Flow Chart A-2


Ready foroperation

Yes

Key-to-line mode

Start motor (CS 20)

Lower punch

Manual mode(service mode)

Start motor(CS 20)

Button Raise

Punch moves up

Button Lower

Punch movesdown

10 sec. alarm

30 sec. pause

Light tower: Lit yellow

Acoustic signaltransmitter

(special feature)

Main switch On

CS 20

No material inthe tank

Material in thetank

NoFault

Motor stops

Filling timeexpired

Motor not switched on

After 3 min: Pneumaticcylinder is deaerated

Timer relay K231.5 is reset

Start filling time (time to fill the tank) timer relayK231.5

Foil bag is halfempty

Foil bag empty

Punch moves upautomatically

Open the cover

Fill the tankClose the cover

Light tower:Flashing yellow

Pneumatic inlet pressure:2 to 6 bar / 29 to 87 psi

Melter MC 20 / MC 21 with Foil Bagemanuals.nordson.com/adhesives/English_Manuals/397155.pdf · MC...

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Transcript of Melter MC 20 / MC 21 with Foil Bagemanuals.nordson.com/adhesives/English_Manuals/397155.pdf · MC...