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BEVEL GEAR COUPLING

The connection between the ac-gear motor and the metering supply pump is performed by a
bevel gear coupling.
The coupling hub is made of steel and the coupling sleeve is made of polyamide.
Due to this combination of materials the coupling is absolutely maintenance-free.

SAFETY AND HIGH PRESSURE RELIEF VALVE

The high pressure relief valve is located on the side of the hose-connected manifold.
In case of overpressure (e.g. clogged filters) the high pressure relief valve automatically opens
and the adhesive is pumped back into the lower tank.

Before the applicator is shipped the high pressure relief valve is adjusted and set at 60 bar.

Chap. I Page - 16 -
ELECTRICAL ENCLOSURE

The panel is mounted onto the applicator and contains the complete electrical equipment
This consists of the temperature and motor controls, the speed indicator, the solid state relays,
fuses, protective covers, main switch and optional electrical components.

LEVEL SENSING SYSTEM

As an option the applicator is equipped with a level sensing system with a potential-free output..
Please consult the relevant wiring diagram.

RETURN MODULE

The return module is installed in the non-circulating system attached to the manifold.
In case of a machine breakdown the existing pressure is directed back into the container by the
return module.
This is operated by a 3/2-way solenoid valve, which is situated on the base frame to the right of
the manifold.
The solenoid valve is opened without current, i.e. while the machine is running a voltage of 24
VDC is required to close the return module.

Chap. I Page - 17 -
ELECTRONIC PRESSURE CONTROL VALVE (OPTIONAL)

The pressure control valve is located in place of a high pressure relief valve on top of the hose-
connected manifold. The electrical part , the proportional control valve, is located between the
electrical cabinet and the gear motors. By way of an electrical signal (0-10 VDC) a pressure is
asserted which is held constant by the proportional control valve (consult separate
specifications of the company FESTO) .
In the case of over pressure resulting from a defect (e.g. clogged filters) the safety function
activates the high pressure relief valve.

HEATED HIGH PRESSURE HOSES DN 10

These hoses have been specially developed for the conveyance of adhesives. The used
materials and the construction of the hoses guarantees a good flexibility and a high resistance
against pressure. The installed Pt-100 temperature sensor in combination with the temperature
controller ensure a precise temperature control for the entire length of the hose even at different
flow rates.

These hoses are manufactured with lengths from 1.0 to 10.0 m serially. Special lengths like
11,0 and 12,00 m are available but they are not stocked.

Length Type Order No. Power (Watt)


1.0 DE 100 1.010.112.001 200
2.0 DE 200 1.010.212.001 400
3.0 DE 300 1.010.312.001 600
4.0 DE 400 1.010.412.001 800
5.0 DE 500 1.010.512.001 1000
6.0 DE 600 1.010.612.001 1200
7.0 DE 700 1.010.712.001 1400
8.0 DE 800 1.010.812.001 1600
9.0 DE 900 1.010.912.001 1800
10.0 DE 1000 1.010.012.001 2000

Chap. I Page - 18 -
PREPARATION FOR PLACING INTO OPERATION

HEATED HIGH PRESSURE HOSES

The connection nipples for the hoses can be found on the face side of the applicator on the
hose connection manifold. Depending on the place of installation the hoses can be fitted straight
or by the help of the provided angled connectors. The angled connectors are of the swiveling
variety and can be locked in any desired position. On the gun side the adhesive pressure hoses
are provided with a round 12-pole plug and on the applicator side with a rectangular 16-pole
plug.
The socket for the 16-pole plugs can be found on the back of the electrical enclosure.

For the machines DTA-20 to DTA-180 and LT-4040 to LT-5200 :


For the fitting of the hoses the lateral and front walls have to be removed. The leads must be
put into the applicator to the sockets on the backside of the switch cabinet. All the hose
connection nipples and sockets are provided with identification plates.

SUPPLY = supply hose


RETURN = return hose (only at circulating systems)

Chap. I Page - 19 -
APPLICATION GUNS

The application guns have to be installed at the designated position on the machine. The hoses
have to be connected accordingly and the electric connection has to be established.

ATTENTION: When the hoses are connected to the application guns it is essential that the
adhesive pressure hoses are laid without any twists in them to avoid
unnecessary mechanical strain on the hose fittings.

In case of circulating systems the supply- and return flow hoses must not be mixed up.

The solenoid valves as supplied must be fitted to the application guns with pipes or hoses.
When hoses are used the solenoid valves have to be fixed to a part of the machine. The
necessary air connections must be installed.

The required air pressure is 6 bar.

ATTENTION: In any case the air must be clean, dry and oil-free!

ELECTRICAL MAIN CONNECTIONS OF THE UNIT

The electrical main connection has to be fitted according to the attached wiring diagrams.

The regulations of the VDE and local power supply organization


have to be observed during connection

The main switch of the electrical panel may only be activated when the hoses and application
guns have been correctly electrically connected to the electric panel.

Attention!
Chap. I Page - 20 -
Main switch has no emergency-stop function!

Emergency-stop has to be realized for the total system!

INTERLOCKS AND MACHINE CONTACT

The AC-motors are locked automatically in case of over- and undertemperatures.

All heaters are immediately switched off in case of overtemperature.

For the non-circulating systems the machine contact must be connected according to the wiring
diagrams. In the case of a machine stoppage the motors are switched off via this contact.

CONNECTION OF AN EXTERNAL CONTROL

If the unit is fitted with a communication interface, the connection must be installed over the
adaptor before the adhesive application unit can be set in operation.

RETURN MODULES

If the application system is equipped with a return module, the 3/2-way solenoid valve (located
on the back panel of the electrical cabinet) has to be connected both electrically and
pneumatically.
The solenoid valve is opened without current, thus, in the case of machine, stoppage the
existing pressure will be reduced by way of the return module.
The 3/2-way solenoid valve must be correctly installed, as this is a safety device.

Chap. I Page - 21 -
PLACING INTO OPERATION
The applicator should only be started up when all preparations for the initial operation have
been executed. Therefore this manual should be read carefully.

ATTENTION: Hot melt adhesive can cause serious burns during their operating
temperature. Therefore protective gloves and protective goggles should
always be worn when working with the heated-up applicator.

Before delivery the applicator has been checked with hot melt adhesive for its correct mode of
operation.

The following instructions for the initial operation are based on the assumption that the
installation of the applicator has been carried out in accordance with the details already given,
i.e. adhesive pressure hoses, application guns and the solenoid valves have been mounted
according to the given instructions.

POURING-IN OF ADHESIVE

The quantity of the adhesive which will be poured in should be chosen correctly so that the
cover of the tank can be closed properly. If the tank is not closed dirt can get into the system
and cause malfunctions.

ADJUSTMENT OF THE TEMPERATURE

It is vital that the temperature quoted by the manufacture of the adhesive is observed.
If the temperatures are set incorrectly, the adhesive and the unit could be damaged, also
combustion in the unit and unsatisfactory adhesion can occur.

The applicator is equipped with one or more 10-zone micro-processor controllers. The
adjustment of the controllers can be seen in the provided description. The description should
also be read carefully.

Before the applicator is delivered the temperatures for all heating zones as well as the values
for the over- and undertemperature are determined. The standard parameters are listed on a
separate sheet and do not need to be changed in case of a temperature adjustment.

ACTIVATING OF THE APPLICATOR

The applicator is switched on by operating the main switch on the electrical cabinet.
On units with external control, these must be switched on separately.

WARM-UP-PHASE
Chap. I Page - 22 -
During the first heating phase, all swivel connectors on the hoses have to be checked and
tightened, if necessary.

After about 45-60 minutes, when the desired temperatures have been reached, the following
operations, according to system, must be performed.

A) NON-CIRCULATING APPLICATION GUNS

1) Open the application gun at the solenoid valve manually with the hand lever.
2) Set potentiometer for the speed adjustment into position "0".
3) Set selector switch AUTO-MAN on position "MAN".
4) Switch on Motor 1.
5) Set about 5-10 revolutions at the potentiometer.

The application guns must be kept open until the adhesive comes out continuously and
without bubbles

6) Switch off Motor 1.


7) Manually close the solenoid valve with the hand lever.
8) Set the “AUTO-MAN” selector switch to “AUTO”.

This procedure can perhaps be repeated for other available motors.

The required rotational speed of the machine in selector switch “AUTO” is set by the lead
machine.

B) CIRCULATING APPLICATION GUNS AND COATING GUNS

This procedure can perhaps be repeated for other available motors.

1) Open the application gun at the solenoid valve manually with the hand lever.
2) Set potentiometer for the speed adjustment into position "0".
3) Set selector switch AUTO-MAN into position "MAN".
4) Switch on Motor 1.
5) Set about 5 - 10 revolutions at the potentiometer.

The application guns must be kept open until the adhesive comes out continuously and
without bubbles.

6) Switch off Motor 1


7) Manually close the solenoid valve with the hand lever.
8) Set the “AUTO-MAN” selector switch to “AUTO”.

This procedure can perhaps be repeated for other available motors.

Afterwards the solenoid valves on the application head can be manually switched over to
Circulation. The system is ready for operation.

The required rotational speed of the machine in selector switch “AUTO” is set externally.

Chap. I Page - 23 -
C) APPLICATION SYSTEMS WITH EXTERNAL PUMPS

1) The supply hose has to be unscrewed.


2) Set potentiometer for the speed adjustment into position "0".
3) Set selector switch AUTO-MAN into position "MAN".
4) Switch on motor 1.
5) Set about 5 - 10 revolutions at the potentiometer.
6) When glue comes out of the hose please screw the hose onto the application gun.
7) Switch on motor 2. Please control the rotational speed.
8) This procedure can perhaps be repeated for other available motors.

The tank pumps should deliver approximately 25 percent more than the external pumps. For
this reason the flow-rate of the metering pumps have to be identical and not the number of
revolutions.
See diagrams of the pump capacities.

When the adhesive comes out of all nozzles continuously and without any bubbles the system
is ready for operation.

The necessary rotational speed of the pumps is set into position "AUTO" of the selector switch
“AUTO-MAN”.

Chap. I Page - 24 -
DIAMETER OF NOZZLES

The diameter of the nozzles, the viscosity of the adhesive and the speed of the pump determine
the pressure in the system.

The diameter of the nozzles has to be selected in such a way that the high pressure relief valve
does NOT open during the normal operation. Only if the high pressure relief valve is closed –
can a uniform, clean and controlled application of adhesive be guaranteed.

If the type, the operating temperature and the output of the adhesive are known before the
applicator is delivered the most favorable diameters of the nozzles will be calculated and the
most appropriate nozzles will be supplied. If these details are not known the pressure in the
system has to be measured while the applicator is set into operation and the correct diameter of
the nozzles can be calculated. A special pressure measuring devices is necessary for this
operation.

DISTANCE BETWEEN NOZZLE AND MATERIAL

The distance between the nozzle and the material should be kept as short as possible (5 - 10
mm) as the adhesive can cool down too rapidly when the distance is longer.

Contact nozzles are available for a number of applications. These nozzles always have to touch
the material while the machine is running. For certain materials, e.g. PE films, either the
complete application gun or the material has to be swung away when the machine stops.

HIGH PRESSURE RELIEF VALVES

The high pressure relief valves are set at 60 bar prior to delivery. A change of this setting
according to the requirements of the system is possible. But for safety reasons it should only be
done by our service technicians as a special pressure measuring device is necessary for this
setting.

Chap. I Page - 25 -
SPEED SETTING FOR TANK PUMP

The adjustment of revolutions for the tank pump complies with the required adhesive quantity
(See diagrams of the pumps, figure I to IV).

The size of the pump is determined according to the required adhesive quantity.

A maximum speed of 80 rpm must not be exceeded otherwise a larger pump with a higher
capacity has to be installed.

The number of revolutions appears on the digital display of the temperature controller. (Zone n1
or n2).

The required adhesive quantity is set with the potentiometer R1 - Rxx on the panel (See
diagrams of the pumps, figures I to IV).

Chap. I Page - 26 -
GENERAL MAINTENANCE AND REPAIR NOTES

FILTERS

The fine filters in the pressure part of the system should be checked regularly. The frequency is
governed by the level of contamination. The filters can be cleaned in a cleaning solvent
recommended by the manufacturer. According to the condition of the filter a replacement would
be advisable. The o-rings on the filter screw should be checked for damage and greased with
silicon-grease before the filters are re-fitted.

Damaged o-rings should be replaced immediately!

The filter can only be removed when the applicator is hot.

Grease o-ring before installation


Use silicon grease
Part-No. 9.900.100.001

ATTENTION! The system has to be free of pressure before


the filter is removed.

1) Switch off the motor!

2) For all systems open the application guns via the


hand lever of the solenoid valves so that the existing pressure
can be discharged!

Chap. I Page - 27 -
BEVEL GEAR COUPLINGS

Due to their construction the bevel gear couplings are maintenance-free. While fitting new gear
motors or pumps please consider that the clearance between the two coupling halves is 4 mm

Pump Motor

Chap. I Page - 28 -
CLEANING OF THE SYSTEM

It is essential that the complete system is cleaned at regular intervals, depending on the degree
of contamination.

A cleaning solvent recommended by the manufacturer should be used.


There are relevant process and user instructions for these cleaning materials.
The cleaning materials can be drained through the application guns (without nozzles) and the
tank drain valve.

Filters and nozzles should be cleaned separately.

ATTENTION! Normally the cleaning solvents also have to be heated up, therefore burns
may be caused.

Protective goggles and gloves have to be worn!

ATTENTION! If the adhesive type will be changed, the system has to be totally drained
and cleaned thoroughly with cleaning solvents!
In case of non-observance, malfunctions and damages at the system are
possible!

Chap. I Page - 29 -
REMOVAL OF THE METERING SUPPLY PUMPS FROM THE TANK

Before a tank-pump is removed from the heated and filled tank, the pump-shut-off-valve has to
be closed. These valves are located at the relevant hose-connection-manifolds.

ATTENTION: The pump-shut-off-valve is opened for the normal operation.(see


picture 1.1) The motors are only allowed to be switched on in this
position.

If the pump-shut-off-valve is closed, the pump can be dismantled


(see picture 1.1) It is NOT allowed to switch on the motors.

The following operations have to be carried out:

1) Remove the ac-gear motors.


2) Unscrew the metering pump.
3) Install new pumps and motors.

It is essential to ensure that the screwed surfaces of the pump and the connecting plate are
clean.

The pump screws should be tightened up with a torque wrench.

Depending on the pump, please use the following :

For M 8 = 17.0 Nm

For M 10 = 34.0 Nm

ATTENTION! Prior to operating the unit again, ensure the shut-off valve has been re-
opened. (picture 1.1)

Chap. I Page - 30 -
CONFIGURATION OF THE METERING PUMP

The drawings show schematically a single and a double metering pump in an assembled state.

The metering pump consists of a few essential parts that are interchangeable among pumps of
the same type due to their production accuracy. This makes cleaning easier and reduces stock
of spare parts.

Replacement pumps are provided with a protective coating of oil in order to prevent corrosion.

Chap. I Page - 31 -
DISMANTLING THE PUMP

The pumps can only be dismantled when they are hot.

The following points have to be observed:

1) Unscrew screws (16), remove feather key (19), remove seal housing (4)
with sealing bushing (23).

2) Unscrew screws (15), take off top plate (3) with molded bearing axle (6).

3) Draw out drive shaft (7) with gear wheel (9) from the base plate (1) and from
the housing (2). Remove gear wheel (9) from drive shaft (7). Take cylindrical
pin (18) from drive shaft (7).

4) Remove gear wheel (10) from the housing (2). Remove the housing (2) from the
base plate (1).

5) If necessary, press out the molded bearing axle (6) from the top plate (3).

CLEANING OF THE DISMANTLED PUMP PARTS

All parts of the dismantled pump can be boiled up and cleaned with a cleaning solvent
recommended by the manufacturer of the adhesive. Please ensure that the surfaces of the
pump parts are not damaged.

If the parts are NOT put together again, it is necessary that they are protected against corrosion
by a coating of a preserving oil (e.g. SHELL: Ensis fluid 256 - II, VALVOLINE: Tectyl 900).

ASSEMBLY OF THE CLEANED PUMP

When reassembling the pump ensure all parts are absolutely clean; only in this way the exact
delivery rates of the pump can be guaranteed.
Before reassembling the pump all parts have to be checked for any damage.
Damaged parts should not be used again.

Chap. I Page - 32 -
When reassembling the pump ensure the following operations are observed :

1) Press the bearing axle (6) with the flat bevel into the drilled hole in the top plate (3) with hand
lever press.

2) Clamp base plate (1) in a vice and place the housing (2) on it (the pump serial number has to
lie on top of each other and it has to be read in the same direction).

3) Put the cylindrical pin (18) into the drive shaft (7), slide the gear wheel (9) on to the drive
shaft (7) and insert the drive shaft (7) with the gear wheel (9) into the base plate (1) and
housing (2). Put the gear wheel (10) into the housing (2).

4) Place the top plate (3) with the molded bearing axle (6) on the housing (2) (the serial number
has to lie on top of each other and it has to be read in the same direction). Insert the
cylindrical screws (15) and tighten them up in crosswise fashion (see below for required
torque).

5) Insert the sealing ring (23) into the seal housing (4), push together onto drive shaft (7) and
tighten up with cylindrical screws (16) (see below for required torque).

6) Check manually if the pump runs easily by turning the drive shaft (7). Insert the feather key
(19).

ATTENTION!
When the pump is put into operation again the cylindrical screws (15) need to be tightened up
again.

TORQUE FOR CYLINDRICAL SCREWS

M 5 = 4.2 Nm
M 6 = 7.0 Nm
M 8 = 17.0 Nm
M 10 = 34.0 Nm
M 12 = 60.0 Nm

Chap. I Page - 33 -
Replacement And Cleaning Of Filter Pad
The proper function of the fan is only guaranteed if the pad is cleaned regularly.
Remove the cover to replace the filter pad. Wash the filter pad in water of up to 40°C
(104°F); mild detergent customary in trade can be used.
It is also possible to beat, vacuum-clean or to blow with compressed air.

In case of greasy substances: Wash the filter pad in benzene, trichloroethylene or


warm water with grease solvent addition.

Do not wring out and do not use sharp water jet.

Chap. I Page - 34 -