ITW Dynatec DYNAMELT D15 Series Technical Documentation Manual Download Page 22

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Page 2-8 Description

Revised 10/14

ITW

Dynatec

D15/D25/D45

DCL

ASU

Manual

#20-63

Summary of Contents for DYNAMELT D15 Series

Page 1: ...IVE SUPPLY UNIT with V6 DynaControl with LCD or Touch Screen Controller Rev 1 16 Technical Documentation No 20 63 Rev 9 16 ITW Dynatec An Illinois Tool Works Company www itwdynatec com Adhesive Application Solutions ISO 9001 certified ...

Page 2: ...0 info itwdynatec cn service itwdynatec cn ITW Dynatec Tsukimura Building 5th Floor 26 11 Nishikamata 7 chome Ota ku Tokyo 144 0051 Japan Tel 81 3 5703 5501 info itwdynatec co jp service itwdynatec co jp Information about this manual Read all instructions before operating this equipment It is the customer s responsibility to have all operators and service personnel read and understand this informa...

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Page 5: ...n Hopper Access Cover 3 2 Installation 3 3 Customer Connections Chart 3 6 Location of V6 Modules Printed Circuit Boards PCBs 3 7 Adding Adhesive 3 8 Changing the Adhesive Formula 3 8 Rear Cover Hose and Head Electrical and Adhesive Connections 3 9 Adjusting the Pressure Relief Valve 3 10 Field Installation of Controller Options 3 12 Adjustment of the Optional Level Control 3 12 Typical Start Up an...

Page 6: ...on Menu 5 16 Accessing the Parameters 5 16 Temperature Unit Celsius or Fahrenheit 5 17 Language Selection 5 17 Zone Configuration 5 17 Pump Configuration 5 17 Setpoint Limitation 5 18 Hi Lo Alarm Tolerance 5 18 Standby Configuration 5 18 Level Detection 5 19 Heatup Sequence Priority 5 20 Access Code 5 21 0 5 RPM Increment 5 21 Temperature Offset 5 21 Customer Zone Names 5 22 Logbook Fault History ...

Page 7: ...apter 6 Preventive Maintenance General Cleaning 6 1 Preventive Maintenance Schedule 6 1 Output Filter 6 1 Hose Fittings 6 2 Fasteners 6 2 Primary Filter Cleaning 6 3 Pump Shaft Leak 6 4 Summary of Preventive Maintenance Schedule 6 4 Purging the Filter Manifold of Adhesive and Pressure 6 5 Flushing the System 6 5 Chapter 7 Troubleshooting General Troubleshooting Notes 7 1 Location of Components 7 2...

Page 8: ...Off Switch Circuit Breaker Replacement 8 2 Fuse Replacement 8 2 Printed Circuit Board Replacement 8 2 Module Replacement 8 2 Opening Modules 8 3 To Access the Pump or Motor 8 3 Gear Pump and Motor Removal 8 3 Pump Seal O ring Replacement 8 4 Re assembly Procedures 8 4 Chapter 9 Available Options Accessories Pressure Gauge Kit 9 1 Drop in Grids 9 1 Filter Options 9 1 Pressure Transducer Assembly 9 ...

Page 9: ...ystem Schematics Engineering Drawings Head Schematic all models 11 1 Hose Schematic all models 11 2 Typical Hydraulic Schematic 11 3 Level Control Schematic 11 4 ASU Wiring Diagrams end of chapter Appendix Pressure Transducer Appendix 3 Signal Isolator Appendix 2 Gear Pumps Appendix 1 ...

Page 10: ...Page viii Revised 11 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 ...

Page 11: ...any other person Never leave a hand held applicator s trigger unlocked when not actually in use Do not operate the hopper or other system components without adhesive for more than 15 minutes if the temper ature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until the adhesi...

Page 12: ... prevent serious injury from molten adhesive under pressure when servicing the equipment disengage the pumps and relieve the adhesive system s hydraulic pressure ie trigger the heads hand held applicators and or other application devices into a waste container before opening any hy draulic fittings or connections IMPORTANT NOTE Even when a system s pressure gauge reads 0 psi residual pressure and ...

Page 13: ...ut sources on the equipment Even after the equipment has been locked out there may be stored energy in the application system particularly in the capacitors within the panel box To ensure that all stored en ergy is relieved wait at least one minute after removing power before servicing electrical capacitors Choice of Adhesive Substance s being processed e g melted pumped applied by ITW equipment i...

Page 14: ...re related cross linking The ITW Dynatec equipment should not be left dormant sealed at ambient temperature with PUR inside for longer than recommended by your adhesive manufacturer The ITW Dynatec system especially applicators and nozzles should be thoroughly purged of adhesive using a PUR purge material if the system will be left dormant for extended time periods HMPUR viscosity increases the lo...

Page 15: ...se flexible temperature programming features the D15 D25 D45 system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time The temperature control can interlock the parent machine with preselected adhesive temperatures so that production automatically begins wh...

Page 16: ... TFE Teflon coated Filtration hopper bottom screen and large pleated pump outlet filters Weight empty D15 155 kg 342 lb D25 155 kg 342 lb D45 182 kg 401 lb Fluid outputs 1 to 4 metered 6 un metered Optional drop in grids D25 1 available D45 1 or 2 available Adhesive form accepts most forms Electrical Service Requirements 200 240 VAC 60 A 3p 50 60 Hz Delta 380 400 VAC 30 A 3p 50 60 Hz Wye Y Power c...

Page 17: ...b hr D45 w 2 optional grids 59kg hr 130 lb hr Adhesive pressure up to 68 bar 1000 psi maximum Maximum recommended pump speed 90 revolutions per minute gear pump Fuses 5x20 mm hose head T6 3AL time delay DynaControl V6 Controller Power board 5 zones per board modular construction Auxiliary board 5 zones per board modular construction Temperature control zones 5 15 triac output Fuses 13 on main powe...

Page 18: ...l 20 63 Installation Dimensions All mounting holes are 10mm diameter H B E I B K G F A C D DIMENSION A B C D E F G H I K 120 525 985 1015 500 1225 520 435 790 1345 4 72 20 7 38 8 40 19 6 48 2 20 5 17 1 31 1 53 870 34 3 D15 D25 mm D15 D25 inches mounting holes D45 mm D45 inches ...

Page 19: ...pacity WATTAGE D15 D25 D45 Hopper 2500w 2500w 2500w Up to 2 Optional Drop in Grids not 2500w 5000w 2500 w each Hose Applicator 1 2 3500w 3500w 3500w maximum Hose Applicator 3 4 3500w 3500w 3500w maximum Up to 4 AUX Zones 9600w 9600w 9600w 2400 w each Total System Wattage 19 100 w 21 600 w 24 100w applicable ...

Page 20: ...nual 20 63 Wattage Chart D15 D25 D45 The ASUs are available in 12 electrically different versions The following table shows the wattage and circuit breaker amps for each configuration 30Amp 30Amp 30Amp 30Amp 30Amp 32Amp 30Amp 60Amp 30Amp 60Amp 60Amp 60Amp 60Amp 30Amp 12500W ...

Page 21: ...evel control sensor M EtherCat communication N Nordson hose connector O EtherNet IP communication EXAMPLE D25V6LN2GBS2D1F2 GL D25 ASU with 25 kg hopper LCD controller without drop in grid 2 hoses a 3 22cc single gear pump 240 volts 3 phase one drive 100 mesh filters with optional analog pressure gauge and level control Model Designation Matrix SDS Dynamelt D XX V6X X X X X X X X X X DX FX X X X X ...

Page 22: ...Page 2 8 Description Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 ...

Page 23: ... lid may be rotated 90 degrees in any direction so that it can be set up to open in the most convenient direction For installation dimensions see illustration on page 2 4 D15 D25 Adhesive Supply Unit ASU DynaControl Controller Main On Off Disconnect Switch Hopper Cover Hopper Lid Hopper Access Cover Base Plate Front Door Lock Latch 1 of 4 Key Lock Panel Box Cabinet DANGER INSTALL ON FLAT SURFACE T...

Page 24: ...ch counter clockwise 4 Remove front door key and return Main On Off key to upright position To Open Hopper Access Cover Hopper Access Cover Side Panels 1 With the key supplied unlock the lock on the left or right hopper access cover 2 Insert a finger in each of the right or left side cover s two latches and push down The side cover will drop off from the top 3 Be aware of the grounding wire attach...

Page 25: ... any installation procedures All installation procedures must be performed by qualified trained technicians After the D15 D25 D45 SERIES ASU has been properly mounted the following general sequence should be followed for installation 1 Make sure that incoming line power to the ASU and that the unit s Main Power Switch are turned OFF 2 Open the panel box door Select correct plug for your ASU s ampe...

Page 26: ...lled in your ASU Before proceeding verify that this plug is correct for your operating voltage The voltage configuration connector is installed on the DynaControl V6 Power Module see module illustration below For location of the module see illustration on page 3 7 There are two different voltage configuration connectors available 240V Three phase P N 115725 Violet 400V Three phase P N 115726 Yello...

Page 27: ...ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Installation Page 3 5 Revised 10 14 Voltage Configuration Connector Schematics ...

Page 28: ...nput Recipe Selection 1 Recipe Selection 2 Reserved External Pump Start Stop activate to start pump Common for Inputs LINE COM G I or L I Line Speed Tracking Voltage 0 10V Line Speed Tracking Signal with Signal Isolator option Optional Install at the left of the Base Module Refer to schematic for details 4 At installation the customer must make the following terminal connections into the ASU s mai...

Page 29: ...ly Operator s Panel High Temp OverTemp Thermostat 2 Motor Speed Control Signal Isolator PCB 1 Motor Speed Control Fan Main Circuit Breaker On Off 30A standard Main Circuit Breaker On Off 60A option V6 Motor Module V6 Base Module V6 AUX Power Board V6 Temp Module Power Connects L1 L2 L3 N V6 Power Module V6 AUX Power Board located within cabinet ...

Page 30: ...ing to the second glue stream to ports 2 and 4 Use the same procedures for the second pump and filter manifold if applicable Install hoses with a bend radius of no less than 8 inches Maintain an air space between hoses to avoid hot spots Use proper belting type support Avoid pinching clamping squeezing or anything else that would compress the insulation around the hose resulting in hot spots which...

Page 31: ...o 4 from top of hopper Filter Guard Adjustable Pressure Relief Valve Pressure Gauge optional Hose Head Adhesive Port Adhesive Supply Hose Hose Head Electrical Connections are located on either side of the Filter Outlet Manifold 8 hose head model shown Adhesive Port Connections Hose Head 1 Hose Head 2 Hose Head 4 Hose Head 3 Auxiliary 4 Auxiliary 3 Auxiliary 2 Auxiliary 1 1 2 4 3 1 2 4 3 ...

Page 32: ...combined into one adjust one of the pressure relief valves fully clockwise to close it off and use the other valve to ad just that pump s pressure setting If using a dual pump with WARNING HIGH PRESSURE HOT ADHESIVE sleeved protective clothing must be worn to prevent the possibility of serious injury from the molten adhesive Refer to Chapter 1 and the section entitled SAFETY PRECAUTIONS for furthe...

Page 33: ...to decrease Note Though the speed of the motor is reduced there will be nochange inthe amount of adhesive flow coming out of the applicator This is because the pressure relief is designed to allow only a maximum adhesive pressure regardless of the motor speed past a certain point Then increase motor speed in smaller increments 1 to 5 until adhesive flow returns to the desired amount Note This is t...

Page 34: ...es turning the controller OFF will assure that the controller will retainits programmedparameters and configuration Re booting is not necessary Adjustment of the Optional Level Control To adjust the adhesive level sensitivity access the control s amplifier located on the panel mount under the pump and electronics cover On the amplifier diagrammed at right is a sensitivity adjustment screw Turn the...

Page 35: ...ill display READY in the upper left hand corner when all zones are within their hi lo tolerance range of the setpoint temperature More information about the display can be found in Chapters 4 and 5 4 When temperatures are ready the pump motor is enabled to pump adhesive a If Pump is in Auto Program Adhesive will begin to pump when the production line begins to operate b If Pump is in Manual Progra...

Page 36: ...ntrol in Linear Line Speed or Pump Control Pressure Control To select Pump Control in Linear Line Speed Adhesive will begin to pump when the production line begins to operate i Select the pump for programming under the Settings column on the Pump Overview Screen ii Select Linear Line Speed in the Current Pump Mode menu Press BACK iii Set the minimum and maximum setpoint value RPM The pump speed is...

Page 37: ...n the system are programmed Shut Down Procedures At the pump screen 1 If Pump is in Auto Mode a Press STOP or ALL PUMPS STOP b Turn OFF the Main Disconnect Switch 2 If Pump is in Manual Mode a Press STOP or ALL PUMPS STOP b Turn OFF the Main Disconnect Switch 3 If the Scheduler is in use Turn OFF the unit with the Control Switch On Off ie on the Main Screen press the Control but ton Then at the Co...

Page 38: ...6 3 Shut OFF all pressure and power sources 4 Release residual air pressure 5 Remove all residual adhesive and wipe components clean 6 Remove all air lines and all power supply cables 7 Pack the unit in a corrosion proof manner 8 Store the unit in such a way that it is protected from damage Disposal of the Unit 1 Shut OFF all pressure and power sources 2 Release residual air pressure 3 Remove all ...

Page 39: ...e Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and main tained Default Settings The factory set programmable system values that will be in effect if the user does not enter new val ues Error Indication Alarms Controller alarms which indicate that the programmed over temperature values have been exceeded for one or more hopper hose or...

Page 40: ... is the time period during which the hoses and applicators remain OFF while the hopper and optional drop in grid heats up Hoses and applicators may be independently programmed If hopper temper ature is above ready temperature when the ASU is turned ON the hose and applicator sequence is bypassed and they will be turned ON Sequential heating is restored after Standby is turned from ON to OFF Sequen...

Page 41: ...conditions will be dis played sequentially Temperature Zone Enable The temperature zone enable allows the operator to disable unused temperature zones in such a way that they do not appear on the controller s display and heating is switched OFF V6 Base Module The main control module of the system It controls and communicates with the temperature con trol module the operator interface and all auxil...

Page 42: ...e s via the DynaControl keypad or troubleshoot to cor rect the problem Low temperature alarms will not open the main contactor and are only indicated on the bar graph display and auxiliary alarm output contacts A sensor failure is displayed as a on the bar graph and power is switched off to the zone When the actual temperature exceeds the setpoint limitation plus a tolerance of a few degrees a is ...

Page 43: ...r must either turn Off the indicated temperature zone s or troubleshoot to correct the problem Then press the Acknowledge button in order to turn on the main contactor and reset the error If more than one alarm condition occurs simultaneously the alarms will be displayed se quentially and each alarm must be acknowledged When an alarm occurs the current display will be interrupted only if a sensor ...

Page 44: ...ty Feedback Failure Motor optional speed monitor pump addressed Over temperature hardware over temperature indication Communication Error there is a communication error between the touch panel and controller Parameter CRC Error parameter memory has been lost Call ITW Dynatec Technical Service Other Faults or Alarms call ITW Dynatec Technical Service Touch Screen Controller s Log Book The controlle...

Page 45: ...icular operation If Application Temperature is 177 C 350 F Hose and head temperature 177 C 350 F Hopper setpoint temperature 163 C 325 F Hi Lo limit deviation 12 C 20 F ASU operating range 149 C to 177 C 300 F to 350 F Standby condition temperature deviation 30 C 50 F Hopper over temperature setpoint 177 C 350 F Mechanical thermostat for the hopper over temperature 218 C 425 F For most operations ...

Page 46: ...F less than setpoint Actual temperature indication range 0 C to 260 C 32 F to 500 F Customer Programmable System Values Preset At The Factory ITW Dynatec can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the DynaControl con troller at the factory They may be changed by reprogramming through the cont...

Page 47: ...mmed setpoints Hi lo limit deviation for all temperature zones 20 C 36 F Temperature zone offset 0 C 0 F Setpoint limitation 218 C 425 F Automatic sleep mode Off Sequential heat up Off Power On motor Stop No Power On heater start Yes Global setpoints No Minimum pump speed 0 RPM Maximum pump speed 90 RPM The ITW Dynatec factory default settings may be re loaded in the controller per the instruction...

Page 48: ...l Ready status is attained and production can start The scale shown is 0 to 100 fully heated The ASU illustrated above is one quarter heated If you would like to display the controller s Scan Mode in order to watch the active temperature zones scroll while the unit is heating press the Input Knob once more Helpful Tips for the User When the ASU is turned ON all temperature setpoints and other oper...

Page 49: ... LCD HMI is the standard controller for the D Series ASUs In General Press the Return button to return to the Overview Screen seen on next page This controller utilizes the graphics indicating YES or ON or selected and indicating NO or OFF or not selected When there is no operator activity on a screen for approximately 30 seconds the controller will automatically return to the Overview Screen LCD ...

Page 50: ...nd the system as a whole It gives the status and speed of the pump Keypad Status 7 Day Scheduler Status Zone Symbols Zone Bar Graph Pump Motor Speed Go to Main Menu Go to System Configuration Menu Go to Pump Motor Screen Return to Previous Screen F1 F2 F3 F4 F5 Toggle On Off selected functions or Go To selected screens Status Line Input Wheel Press Knob to Enter Time of Day System Status Pump Stat...

Page 51: ...ones are within the setpoint window ALARM At least one zone is outside the setpoint window over or under temp STANDBY The system is in standby mode OVER TEMP The hopper is in over temperature condition all power circuits are shut off FAULT Atemperaturezonehasafaultandallpowercircuitsareshutoff orthemotordrivehasfaulted HOPPER EMPTY Adhesive in the hopper is low and must be replenished Temperature ...

Page 52: ...d bar graph indicates a temporarily de activated temperature zone A question mark indicates that the zone s RTD sensor is not valid An exclam ation mark inside a solid bar graph means that the temperature of the zone is significantly out side its setpoint window Scan Mode Scan Mode allows the operator to watch the currently active temperature zones scroll one at a time on the Overview Screen Each ...

Page 53: ...m pump parameters Return Return to the previous screen F1 F2 F3 F4 Go to the temperature zones use as shortcuts F5 Go to the Pump Motor screen alternative method Overview Screen Example The Overview Screen illustrated below illustrates an example of a typical system This melter has two premelt drop in grids and two hopper heaters for a total of four ASU temperature zones The screen also shows six ...

Page 54: ... slowly to view each temperature zone As the wheel is turned you will see the names of the individual temperature zones on the top line of the display Zone names may be re programmed to suit the user but ITW Dynatec s typical D Series zone names are PREMELT drop in grid HOPPER HOSE HEAD and AUX To select a zone simply stop turning the wheel when the desired zone s name appears example below HEAD 2...

Page 55: ... zones only requires that one Premelt setpoint be programmed one Hopper setpoint be programmed and one Filter Block setpoint be programmed NOTE on the D Series models there never more than one Hopper or one Filter Block Turning a Temperature Zone ON or OFF When a temperature zone is not used it can be de activated turned OFF A zone that is turned off no longer heats and is not monitored by the con...

Page 56: ...put Wheel If Auto or Stop modes are desired simply turn the Input Wheel to highlight that function Pump Screen Return to the Overview Screen if necessary by pressing the RETURN button Then press the Pump button or F5 to go to the Pump Screen The Pump Screen illustrated below shows the maximum number of pumps four The display shows the pump mode and speed for each pump If the ASU is equipped with t...

Page 57: ...ose and applicator head For instance if the input signal is 10VDC at 100 meters per minute and the pump percent of full speed is 100 maximum speed but the system is putting out too much adhesive adjusting the MAX value to 50 will allow the pump to slow down and adhesive output will decrease by 50 To Adjust Press the F5 button once to open a minimum RPM input field Turn the Input Wheel to select de...

Page 58: ...lect a function press its F button or turn the Input Wheel to highlight the desired func tion and then press the Enter Knob to select Recipe Management F1 A recipe or program is a set of temperature setpoints and parameters which the user has programmed and stored in the controller for future use Up to four recipes may be stored in the DynaControl controller F1 Recipes F2 Standby Setback F3 Setpoi...

Page 59: ...ones with in their bar graphs will be turned Off after re loading because the controller assumes those zones will not be used 2 If you have loaded a recipe any changes you make to the temperature or motor settings are not automatically stored in that recipe If your changes need to be stored go to the Recipe Man agement Screen and follow the steps to SAVE TO PROG Standby F2 In Standby mode the temp...

Page 60: ...ttons For example if your access code is 2453 press the sequence F2 F4 F5 F3 Note setup an access code on page 3 of the System Configuration Menu The ASU is shipped from ITW Dynatec with a default access code of 1111 Keypad is unlocked press F3 to lock it Keypad is locked enter access code to unlock it 7 Day Scheduler F4 The 7 Day Scheduler allows the user to program the ASU to automatically switc...

Page 61: ...he Enter Knob to highlight it As above turn the Input Wheel to program your desired time in hours and minutes then press the Enter Knob In the same manner if desired program another Switch On time and or Switch Off time To Program Additional Daily Programs Turn the Input Wheel to the second or third set of Days of the Week to program Switch On and Switch Off times for Daily Program 2 or 3 Program ...

Page 62: ... On at 8 15am and Switch Off at 12 15pm Set Current Time of Day and Day of Week While in the 7 Day Scheduler Set Up screen press the Configuration button or F1 to set the current time and day Turn the Input Wheel to select the item to be changed Press the Enter Knob Turn the Input Wheel to the desired time day and press F5 to confirm your entry Once all 7 Day Scheduler programming is completed pre...

Page 63: ...description ie HOPPER and zone ie Z 2 actual temperature heat up priority Ie PR 1 and location of its corresponding RTD sensor is given The screen also shows the physical location of the RTD connectors of the temperature module This information can help in troubleshooting errors in wiring All zones are shown here even those that are not in use on the ASU Press F5 to go to the next Info Screen Info...

Page 64: ...an access code to prevent un authorized programming 0 5 RPM Increment allows faster manual mode programming of the pump speed Temperature Offset fine tuning allows compensation for temperature gradients Customer Zone Names allows personalization of the temperature zone s names Logbook Fault History records the time and date of controller events and faults Power On Configuration allows custom setti...

Page 65: ...select the Zone Configuration parameter and press the Enter Knob Press and hold the F1 button for five seconds then press F2 to restore de faults and wait for the controller to reboot Pump Configuration P1 This menu configures the ASU s pump by listing pump type Most pump parameters are setup at the ITW Dynatec factory There are two user programmable pump parameters Pump Enable Temperature and Ind...

Page 66: ... will activate an under temp alarm when the zone s temperature falls below 140 C and will activate an over temp alarm when the zone s temperat ure rises above 160 When this zone s temperature is within the tolerances 140 and 160 it is considered Ready When programming only one value is chosen This value applies to all temperature zones and is both the high and low tolerance After turning the Input...

Page 67: ...me delay parameter ie Standby X min After Press the Enter Knob Turn the Input Wheel again to select your desired minutes value Confirm your choice by pressing the Enter Knob Now turn the Input Wheel to select the After Ext Contact After Pump Stop field Press the Enter Knob and then turn the Input Wheel to highlight your choice of activation Confirm your choice by pressing the Enter Knob Sleep Mode...

Page 68: ...ely after the ASU is powered on Zones with higher priority numbers Priority 2 through Priority 6 do not begin heating until all zones with lower priority values have reached the low limit of their set points Zones which are switched OFF are not applicable The most common heating sequence is first hopper then hose head and auxiliary zones This al lows the larger mass of adhesive in the hopper to be...

Page 69: ...mperature Offset P3 Temperature Zone Offsets are mathematical factors which compensate for differences in tem perature within components Each temperature zone may be programmed with an offset if de sired Standard equipment does not usually require temperature offsets Note Entering a positive numbered offset will raise the temperature reading of that zone Since the controller attempts to equate set...

Page 70: ...h the zones and see their current zone names or numbers These names can be re programmed one at a time Each new name may consist of two lines with a maximum of 12 characters in each line Note the factory set numeric names correspond to RTD inputs Customer Zone Name Programming Screen Programming keys Using F2 F3 F4 F5 Programming Keys F5 press to Clear the entire zone name F2 press to select upper...

Page 71: ... confirm the new character 7 Repeat steps 3 through 6 to spell desired zone name 8 Press the Return button to select another zone to program Repeat steps 1 through 6 for each zone desired 9 Press Return again when all temperature zone name programming is completed Logbook Fault History P4 The Logbook provides a read only history of the last 65 maximum controller faults and events Controller faults...

Page 72: ...uire a manual start when the ASU is turned on choose NO NOTE If you choose NO the heaters will not begin to heat until the Enter Knob is pressed at start up From the System Configuration Menu after turning the Input Wheel to select Power On Config uration press the Enter Knob The first parameter Power On Motor Stop will be activated see illustration below Press the Enter Knob to choose YES or NO T...

Page 73: ...or head by 5 degrees or if you press again by 10 degrees press again for 15 degrees and press again for 20 degrees Once setup all of the hoses will increase over the hopper setpoint by the same amount 0 5 10 15 or 20 degrees and likewise all of the heads will increase over the hopper setpoint by the same amount as you program here Once Global Setpoints are set you simply program the hopper as desc...

Page 74: ...llresult ifthe V6 modules onthe DIN rail are not connec tedproperly Abusconnector nearthe rail connectsone module tothe next Modules canbecome disconnected during transport or during repair procedures 4 A fault such as this indicates an over temperature or an RTD sensor fault The solution is not simply topresstheRETURNbuttontoconfirm Thesolutionistotroubleshootandsolvetheproblemwhich caused the fa...

Page 75: ...nate in this mode As seen above the question mark is placed on the zone with the faulty sensor ie Head 1 After troubleshooting the fault reference the Error Indication Alarm Troubleshooting Guide on the previous pages of this chapter and solving the problem with the sensor press the RETURN button Or if Head 1 is not in use press F5 to turn the zone Off TEMP SENS FAULT PRESS F5 Zone Off Status Stat...

Page 76: ...Page 5 28 LCD Programming Revised 10 14 ITW Dynatec D SERIES V6 DCL ASU Manuals ...

Page 77: ...am selection pump or motor conditions and heating priority If desired temperature zone offsets and or a temperature zone enable may be selected Numeric Entry Keypad Use the numeric entry keypad to enter or change numeric parameters values In the top window the temperature zone name and its setpoint value will be displayed This is a typical example of the numeric entry keypad Item Description 1 By ...

Page 78: ... temperature zone name will be displayed This is a typical example of an alphabetic keypad Item Description 1 By pressing the OK button the entered text will be confirmed and stored in the controller The alphabetic entry keypad closes and you will return to the previous screen 2 By pressing the ESC button any entered but not yet confirmed text will be discarded and you will return to the previous ...

Page 79: ...lly when the unit is switched ON The Main Screen provides a comprehensive overview of the status of each of the temperature zones and the system as a whole It gives the status and speed of the pump along with any adhesive pressures and level status Main Screen if seven or more zones in any column are activated 11 1 5 4 2 3 6 7 8 9 10 Selected System ...

Page 80: ...Page 5 4 ITW Dynatec Revised 1 16 V6 DCL Touch Screen Controller for Dynamelt M D ASUs Main Screen if six or fewer zones in any column are activated 3 ...

Page 81: ... the screen Depending on the selection of the unit of temperature and pressure C and bar or F and psi made under Unit Date Selection the appearance of the date display is affected also With the C bar selection the date is displayed as day month year while in F psi mode the date is displayed as month day year The time is displayed as hour minutes seconds ie 11 48 25 pm By pressing the status line y...

Page 82: ...opriate primary pressure transducer input will be displayed with number 1 The primary pressure input can be controlled via the Pressure Set Point in Pump Control Pressure Control Screen Secondary pressure If a second pressure sensor is equipped usually in combination with dual pump outlets the appropriate pressure transducer input will be displayed with number 2 The secondary pressure input is jus...

Page 83: ...zone that is turned Off no longer heats and is not monitored by the controller for over or under temperatures Item Description 1 Set values Display of the temperature setpoint values To edit values Touch a zone input box and a numeric entry keypad will appear Enter your new setpoint value and confirm by pressing OK NOTE Must be below the maximum setpoint value listed below The Set values are displ...

Page 84: ...rily Some zones e g Hopper cannot be deactivated The switch is colored light green if ON and light red if OFF 2 By pressing the OK button the entered values will be confirmed and stored in the controller The numeric entry keypad closes and you will return to the previous screen 3 By pressing the ESC button any entered but not yet confirmed values will be discarded and you will return to the previo...

Page 85: ...eed Pressure Control on next pages Item Description 1 Pump Overview SETTINGS Press Pump 1 Pump 2 etc to go to the appropriate Pump Control screen MANUAL The pump speed is adjusted manually by the ASU operator When selected the MANUAL icon is highlighted green STOP The pump is stopped until AUTO or MANUAL is selected When selected the STOP icon is highlighted red AUTO The pump speed is controlled v...

Page 86: ...ch Screen Controller for Dynamelt M D ASUs Item Description 2 All Pumps Buttons Press one of the All Pumps buttons either MANUAL STOP or AUTO to set all pumps to the desired function at one time 3 BACK Button Press to return to the previous screen ...

Page 87: ...gram the Auto Mode Settings Setpoint minimum maximum RPM at 0 10VDC external signal control and Manual Mode Settings Manual Setpoint RPM Pump 2 Example Item Description 1 Pump 2 is the selected pump All the settings and speeds displayed on this screen correspond to Pump 2 2 Auto Mode Settings Setpoint The minimum and maximum setpoint values of the pump are displayed The programmable range is 0 to ...

Page 88: ...h the hose and applicator head For instance if the input signal is 10VDC at 100 meters per minute and the pump percentage of full speed is 100 maximum speed but the system is putting out too much adhesive adjusting the MAX pump percentage to 50 will cause the pump to slow down over the parent machine s entire speed range and adhesive output will be decreased 6 Settings Button Press this button to ...

Page 89: ...Pump Mode Settings Screen Linear Line Speed Pressure Control To go to this screen press the Settings button on the Pump Control screen The Extended Pump Mode Settings screen allows you to select the Current Pump Mode and to go to the Automatic Ramp Compensation ARC screen System 1 Pump 1 Example 3 1 6 2 3 4 5 ...

Page 90: ... go to the appropriate screen 4 Automatic Ramp Compensation ARC Button Press to go to the Automatic Ramp Compensation screen 5 Optional Minimum Input Pressure This field appears only if the pump is configured for a minimum input pressure lock The Minimum Input Pressure is a customer parametrizable value which has to be reached for the according pumps on decentralized pump Applicator or Metering St...

Page 91: ...creen A plausible limit value of Input Pressure a minimum pressure of not less than 2 bar is recommended has to be entered to avoid a dry run of the pumps otherwise the pump can be damaged See point Extended Pump Mode Settings Screen Linear Line Speed Pressure Control on previous pages Pump 2 Example Item Description 1 Pump 2 is the selected pump All the settings and speeds displayed on this scree...

Page 92: ...a 0 10VDC signal that is provided by an external device pattern control equipment or parent machine input If AUTO is selected the icon is highlighted green A minimum speed is necessary to keep the pump turning in order to maintain a minimum amount of adhesive pressure through the hose and applicator head For instance if the input signal is 10VDC at 100 meters per minute and the pump percentage of ...

Page 93: ...c Ramp Compensation button on the Extended Pump Mode Settings Linear Line Speed screen The Automatic Ramp Compensation screen allows you to program parameters in order to compensate the adhesive amount when the speed of the main machine accelerates and decelerates With Linear Pump Control Line Speed without Pressure PID Loop With Pressure Control PID Loop 1 4 2 3 5 6 ...

Page 94: ...ime in seconds within this time the compensation is reduced to the normal application rate in order to prevent an elastic impact Corr Glue Amount Correction Factor in Allows an adjustment of pump speed if a speed correction is required due to measured deviations of the adhesive amount Decel Compensation for Deceleration Ramp This is the subtracted percentage or rpm of pump speed to compensate the ...

Page 95: ... Controller for Dynamelt M D ASUs Revised 1 16 Control Switch On Off and Standby Switch To go to this screen press the Control button on the Main Screen This screen allows you to turn the system On or Off and to activate deactivate standby condition 3 2 1 ...

Page 96: ...button will be highlighted blue When Standby is activated all zone temperatures will be set to the standby value programmed on the General Settings Screen and all pumps will be disabled 2 On Off Switch Press the On Off button to toggle the system On or Off When the system is On the button will be highlighted green When the system is Off the button will be highlighted red 3 BACK Button Press to ret...

Page 97: ...ASUs Revised 1 16 Systems Screen To go to this screen press the Systems button on the Main Screen This screen displays all attached systems and allows you to select the desired system to control it For example System 2 is selected The system will be indicated over the Status Line 2 1 ...

Page 98: ...h system is assigned with a number Press the desired number to go to the appropriate system to control and to edit its parameters The button is highlighted green when the system is RUNNING or READY yellow when NOT READY grey when in STANDBY and red when in ALARM condition 2 BACK Button Press to return to the previous screen ...

Page 99: ...current language is displayed Press the button to select any language from the ones listed on the menu 2 Unit Date Selection Select the unit of temperature and pressure choose either C and bar or F and psi Depending on the selection made the appearance of the date display is affected also With the C bar selection the date is displayed as day month year while in F psi mode the date is displayed as ...

Page 100: ... switch the zone OFF PRIO1 the zone will heat first PRIO2 the zone will begin to heat after the PRIO1 zones have reached their setpoints PRIO3 the zone will begin to heat after the PRIO2 zones have reached their setpoints OFF the zone is OFF It will not heat and it will not be displayed on the Main screen 2 Press the OK button to confirm your entered values and return to the previous screen 3 Pres...

Page 101: ...llows you to enter zone names and to set Offset Temperature and other Control Settings for each zone Zone Configuration Screen Example Item Description 1 Touch a zone input box to go to the Zone Settings Zone is highlighted yellow if an Offset Temperature has been set for this zone Square bracket is displayed if a custom zone name has been entered for this zone 2 BACK Button Press to return to the...

Page 102: ...nces in temperature within components Each temperature zone may be programmed with an offset if desired Standard equipment does not usually require temperature offsets Note Entering a positive numbered offset will raise the temperature reading of that zone Since the controller attempts to equate setpoint and actual temperature this lowers the actual temperature by the amount of the offset For exam...

Page 103: ...nly 6 Press the OK button to confirm your entered values and return to the previous screen 7 Press the ESC button to discard any non confirmed values and return to the previous screen 8 Zone Status Zone status is indicated ALM is highlighted if zone has an alarm RTD is highlighted if temperature sensor error occurs WT is highlighted if zone is in wait status because of heating priority setting HT ...

Page 104: ...ldbus Address Item Description 1 Fieldbus Address Touch the input box and a numeric entry keypad will appear Enter the Fieldbus Address of the unit Confirm by pressing OK After programming the Fieldbus Address the system must be re started To re start the system with changed parameters 1 Press OK to accept changes 2 Wait at least one minute 3 Switch unit Off via the main switch 4 Switch unit On vi...

Page 105: ...ature Settings tab has been selected 2 Pump Enable Temperature The Pump Enable Temperature is a low limit value e g 100 C 212 F which protects the pump pump shaft motor and motor control module by preventing the pump from turning on until a minimum adhesive temperature is achieved Caution should be taken to avoid setting this value too low because attempting to rotate the pump when the adhesive in...

Page 106: ... Window which allows the unit to remain in Ready condition as temperatures stabilize The Temperature Alarm Hysteresis is a deviation e g 2 C 3 F from the Temperature Alarm Window The Temperature Alarm Window minus the deviation is the low limit of the Temperature Alarm Hysteresis and the Temperature Alarm Window plus the deviation is the high limit of the Temperature Alarm Hysteresis The programma...

Page 107: ...ble range is 0 150 C 0 270 F Touch the input box and a numeric entry keypad will appear Enter your desired Standby Setback Temperature value and confirm by pressing OK 3 Standby Delay External Contact The Standby Delay is the programmed number of minutes until the unit goes into standby mode after activation by an external contact for example a PLC or an external switch The programmable range is 0...

Page 108: ...eft pointing arrow to go to the previous General Settings screen 6 Press the right pointing arrow to go to the next General Settings screen 7 Press the OK button to confirm your entered values and return to the previous screen 8 Press the ESC button to discard any non confirmed values and return to the previous screen ...

Page 109: ... via a Minimum Level message on the display that the hopper needs to be refilled After expiration of the time delay the message Minimum Level will be indicated on the display The programmable range is 0 31 minutes Touch a zone input box and a numeric entry keypad will appear and the values can be edited Enter the value and confirm by pressing OK 3 Press the left pointing arrow to go to the previou...

Page 110: ...es Touch a zone input box and a numeric entry keypad will appear and the values can be edited Enter the value and confirm by pressing OK 4 Warning Level Min Template dependent parameter not used in standard configuration 5 Switch Level Start If system is configured as refiller control this parameter defines the refill start level 6 Switch Level Stop If system is configured as refiller control this...

Page 111: ...n on the Settings Screen Item Description 1 Parameter Selection tabs The Pressure Zero Calibration tab has been selected 2 OK Button Before calibrating the optional pressure transducers all pumps must be in STOP mode and the system must be fully depressurized After taking the appropriate steps confirm this by pressing the OK button You will then go to the Calibrating Screen 2 1 ...

Page 112: ... pressing the appropriate Cal button Note before calibrating pressure transducers all pumps must be in STOP mode and the system must be fully depressurized 3 Calibrate All Press the Calibrate All button to calibrate all pumps to zero at one time Note before calibrating pressure transducers all pumps must be in STOP mode and the system must be fully depressurized 4 Press the left pointing arrow to ...

Page 113: ...mes Editor program is supplied with your unit The program allows the character sets of many different languages To utilize this feature 1 Install the program from the CD into your computer 2 Write your personalized zone names in this program 3 Load your personalized program onto a thumb drive 4 Insert the thumb drive into the V6 touch panel 5 Load the new names into the controller by pressing Load...

Page 114: ...deactivated or if there was an error in loading the names 4 Press the left pointing arrow to go to the previous General Settings screen 5 Press the right pointing arrow to go to the next General Settings screen 6 Press the OK button to confirm your entered values and return to the previous screen 7 Press the ESC button to discard any non confirmed values and return to the previous screen ...

Page 115: ...The Support tab has been selected 2 If requested by ITW Dynatec Support you can insert USB Flash Drive to create a system dump file This file can be send to ITW Dynatec for offline diagnostics 3 Press the left pointing arrow to go to the previous General Settings screen 4 Press the right pointing arrow to go to the next General Settings screen 5 Press the OK button to confirm your entered values a...

Page 116: ...nd speed 2 Using the up and down arrows select a number to assign to your recipe 3 Press the Adhesive Unit to SD button The recipe will be saved To Load a Saved Recipe 1 Using the up and down arrows select a recipe number 2 Press the SD to Adhesive Unit button The recipe will be loaded and the saved parameters will be set 2 Recipe Name Touch the input box and an Alphabetic Entry Keypad will appear...

Page 117: ...he Touch Panel Press this button to restore recipe collection from USB Flash Drive into the Touch Panel 6 Backup Recipes This button is visible only if USB Flash Drive is inserted into the Touch Panel Press this button to save recipe collection from Touch Panel to the USB Flash Drive 7 Erase Recipe 1 Using the up and down arrows select the number of the recipe you wish to erase 2 Press Erase Recip...

Page 118: ...e current date and time will be displayed at right item 5 2 Scheduler Settings The controller s scheduler will automatically turn On the unit at the programmed start time and turn it Off at the programmed stop time on the programmed days cycle Up to three scheduler timers may be programmed either for System On Off or for Standby On Off Each scheduler timer is programmed with a start time a stop ti...

Page 119: ...ssing the Enable Scheduler button the programmed parameters will be confirmed and the selected timer is activated To change a timer program first select the desired timer Then press the Disable Scheduler button Now the selected timer can be re programmed with new parameters as described above The clock icon appears in the status line on main screen if a timer is activated and disappears if the tim...

Page 120: ...Page 5 44 ITW Dynatec Revised 1 16 V6 DCL Touch Screen Controller for Dynamelt M D ASUs Example The display on the right shows that Timer 3 is not programmed and not activated ...

Page 121: ...y the HMI all events will be listed here Item Description 1 The most recent event is recorded at the top of the Event List Examples of events System Status OFF READY RUNNING STANDBY NOT READY Recipe loaded Examples of controller faults RTD Fault Temperature Alarm Minimum Level Drive Failure Parameter CRC Error Over temperature Communication error See point Faults Alarms 2 BACK Button Press to retu...

Page 122: ...arameters Item Description Security unlocked access to the Security Settings is unlocked and settings may be changed by all users The crossed out Key icon shown above means Security is unlocked After pressing the Key button it will disappear and the Security Settings will be locked Security locked access to the Security Settings is locked and settings may only be changed by entering a password Con...

Page 123: ...nce personnel only by using a Maintenance password 2 Press the OK button to confirm your entered values and return to the previous screen 3 Press the ESC button to discard any non confirmed values and return to the previous screen 4 Change Maintenance Password Button Touch the Change Password button and a numeric entry keypad will appear Enter desired numeric password at least one digit Press OK t...

Page 124: ...bout the V6 controller and its modules The screen is read only Item Description 1 Information about the controller and its modules is displayed The illustration above shows an example only 2 The real System Runtime respectively pump runtime is displayed The runtime of each day will be added 3 Licenses Button Press to go to the License Management screen 4 BACK Button Press to return to the previous...

Page 125: ...nse with basic functions is installed on all units The following licenses are available HMI Advanced License activates additional features HMI Professional License activates all available features HMI Feature License ARC activates the Automatic Ramp Compensation ARC feature HMI Feature License Multi System activates the Multi System feature 3 BACK Button Press to return to the previous screen 4 So...

Page 126: ...to this screen press the Software Licenses button on the License Management Screen Item Description 1 Display Software Licenses Click on Entry for detailed license information 2 Scroll Buttons Press the arrow buttons to scroll up and down through licenses 3 BACK Button Press to return to the previous screen 1 2 3 ...

Page 127: ... Touch Screen Controller for Dynamelt M D ASUs Revised 1 16 Acknowledge Button The Acknowledge Button is on the Main Screen Temperature Zones Set Screen 1 no faults or alarms indicated 1 Fault indicated Fault alarm Description in Status Line ...

Page 128: ... fault Minimum Level adhesive level has dropped below the level sensor and the hopper is empty Feedback Failure Motor optional speed monitor pump addressed Overtemperature hardware over temperature indication Communication Error Communication error between the touch panel and controller Parameter CRC Error parameter memory is lost Call ITW Dynatec Technical Service Other Faults or Alarms Call ITW ...

Page 129: ...eaning The ASU parts that require regular periodic maintenance are as follows Output Filter The output pump filter should be replaced monthly during the first few months of operation After you gain experience with your system you can determine how often you need to replace it The out put filter is located on the output filter manifold on the hose connection panel of the ASU See il lustration of th...

Page 130: ...coat of anti seize to the threads of the filter nut Re install the filter basket and the filter nut Tighten the filter nut until it is seated firmly against the manifold body taking care not to cut the o ring as it enters the manifold Tighten the purge screw Hose Fittings All hose fittings should be checked for tightness after every three months of operation Use 11 16 wrenches to remove and hold t...

Page 131: ...d and use a hot air gun if necessary and rags to clean all contaminants from the fil ter If filter cannot be cleaned replace the filter 6 Apply a coat of anti seize compound onto the threads of the filter retaining nut before re insert ing into the ASU 7 When re installing the filter assembly turn the filter s cut out hole toward the pump Align the filter shutoff knob in its open vertical position...

Page 132: ...ump shaft indicates a worn pump seal See instructions in Chapter 8 for replacement of this seal Summary of Preventive Maintenance Schedule Monthly or as experience dictates Inspect output filter basket Replace as required Check for leaking adhesive under the base plate caused by a worn pump seal Replace as required Every Three Months or as experience dictates Check all hose fittings for tightness ...

Page 133: ...t re tighten the purge screw Flushing the System Contaminated adhesive accumulation of residue in the system and hopper or changing the adhesive formulation may require the system to be flushed To flush the system have at least 6 liters 1 5 gal lons of flushing fluid on hand PN L15653 1 Pump out as much of the molten adhesive from the hopper as possible WARNING PPE REQUIRED Failure to wear a face ...

Page 134: ...ng fluid to mix with any adhesive remaining in the hopper 5 Slowly increase the pump pressure Pump about half of the fluid through the hopper pump and adhesive supply hose into the flushing container 6 Reduce the pump speed to zero 7 Add new adhesive to the hopper and allow it to reach application temperature 8 Slowly increase motor speed to the pump 9 Actuate each of the heads until all the flush...

Page 135: ...ng Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunction does not move with the ap plicator and hose the problem is probably in the ASU Before disconnecting a hose or applicator al...

Page 136: ...nel High Temp OverTemp Thermostat 2 Motor Speed Control Signal Isolator PCB 1 Motor Speed Control Fan Main Circuit Breaker On Off 30A standard Main Circuit Breaker On Off 60A option V6 Motor Module V6 Base Module V6 AUX Power Board V6 Temp Module Power Connects L1 L2 L3 N V6 Power Module V6 AUX Power Board located within cabinet ...

Page 137: ...cuit Board The operator display panel s printed circuit board contains a lithium battery which powers the sev en day scheduler s clock The normal life of this battery is about ten years When the battery needs replacement the scheduler s clock does not function but other controller features remain intact Re turn the board to ITW Dynatec for battery replacement DynaControl V6 Modules The DynaControl...

Page 138: ...3 When removed from the ASU each PCB must be individually packaged inside a metallized static drain envelope Do not place the removed PCB on a table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the PCB to him 5 When unwrapping a PCB from...

Page 139: ...34 The V6 Base Module is the main control module of the DynaControl V6 controller Most of the in ternal and external components are connected to the Base module The Base module is always the top first module on the DIN rail ITW Dynatec recommends using dry contacts for connecting to DynaControl V6 cont ...

Page 140: ...ion could be a defective tem perature sensor an over or under temperature situation a motor driver fault etc Normally closed Relay 3 Hopper Empty Signal This contact closes when the adhesive level in the hopper drops below a certain level It can be used to indicate this situation via an external light or an audible alarm Normally open Note Depending on the controller s settings one or more of the ...

Page 141: ...eactivating an input does not affect the process It is possible to load a new program manually independent from the input situation Item 6 This item is not applicable to the D Series ASUs Item 7 This input is connected to the over temperature thermostat on the hopper In the unlikely event that that hopper temperature exceeds 450F 232C the thermostat will open and cause the power to all the heaters...

Page 142: ...r the actual speed a RPM reading device gear pumps or stroke counter piston pumps can be connected to this terminal In order for a gear pump to follow the line speed of a parent machine a 0 10VDC voltage is required This input voltage is connected to these terminals The input is polarity sensitive When an optional signal isolator is installed the line speed input is located on the signal isolator ...

Page 143: ... Depending on the configuration of the ASU the RTDs may be PT100 DynaControl or NI120 Nordson Configuration is determined by a jumper located within the module see below to left of module illustration Each of the maximum 15 zones has a status LED which shows its heating status in the following manner if the zone is switched off the LED is Off if the zone is heating the LED is On if the zone is nea...

Page 144: ...ply and motor drive Each zone can provide a maximum of 10 Amps The maximum total load of the board is 40 Amps 20 per phase The board has its own heat sink which is mounted on the panel box insert for good heat conductivity Head 2 Heater Hose 2 Heater Head 1 Heater Hose 1 Heater Hopper Heater Motor Drive DC Power supply Main Voltage Supply from main On Off switch Power supply for additional power b...

Page 145: ...After checking or replacing fuses the cover must be re installed Heater and motor driver circuits are fused on both legs with a 10A fuse The output for the DC power supply has a 6 3A fuse Always replace fuses with the same type of fuse Voltage Configuration Connector The appropriate voltage configuration plug must be installed for the machine to operate properly Two different connectors plugs are ...

Page 146: ... protective cover The cover should only be removed after the ASU is switched Off and disconnected from the main power supply After check ing or replacing fuses the cover must be re installed All heater circuits are fused on both legs with a 10A fuse Always replace fuses with the same type of fuse The maximum total load current of the board is 40 Amps 20 per phase Connect to V6 TEMP Module Fuses un...

Page 147: ...t and an en coder input A wide variety of encoders ie a ring kit may be adapted to the input Each motor may be assigned its individual line speed input but it is also possible to use a common line speed input This also applies to the pump enable input Each motor module has four pressure transducer inputs transducer type is 4 20mA One or two pressure transducers may be assigned to each motor Motor ...

Page 148: ...Page 7 14 Troubleshooting Revised 10 14 ITW Dynatec D SERIES V6 DCL ASU Manuals ...

Page 149: ...ing diagrams and other details on the following optional PCBs can be found on the main ASU schematic in Chapter 11 Adhesive Level Sensor hopper low level detection Signal Isolator gear pump auto mode Trigger Switch Pump Enable hand held applicators swirl kits EtherNet IP EtherCat or Profibus communications protocols ...

Page 150: ...he correct resistance for your hose length and voltage as shown The Nominal Head Heater Resistance table gives values for several different head wattages A suspected head heater problem can be isolated by measuring head heater resistance and comparing it to the resistance for the appropriate wattage of your system The Nominal Hopper Heater Resistance table gives heater resistance for the hopper he...

Page 151: ...2 150 157 320 160 161 338 170 164 356 180 168 374 190 172 392 200 176 410 210 180 428 220 183 Watts Resistance in Ohms 200 288 270 213 350 165 500 115 700 82 Nominal Head Heater Resistance ASU Drop in Grid Qty Heaters 2 1 or 2 Resistance in Ohms 22 ea for each heater 200 240 v 19 4 24 ea 380 400 v 57 8 66 7 ea Note Resistance is measured at ambient temperature 20 C 68 F Hose Length Resistance Mete...

Page 152: ...ANGER HIGH VOLTAGE Some of the procedures in the following Troubleshooting Guide require poten tially dangerous electricity to be present Only qualified service personnel should perform these procedures Problem Possible Cause Hopper tank 1 Setpoints have been Overtemp programmed without enough deviation 2 Hopper sensor inoperative 3 Hopper control triac on V6 Power Module is inoperative Sensor Sol...

Page 153: ...ative Sensor Solution 1 Verify that hopper sensor cable is properly connected at X3 on the Temperature Module 2 Replace hopper sensor if resistance does not comply with resistance table 1 Verify that sensor plug is clean and correctly connected at X3 on the Temperature Module 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measure continuity fr...

Page 154: ...rature Modules 3 Visually and electrically inspect for a short circuit to ground in the hopper heater circuit This will be limited to between the hopper triac on the Power Module and the hopper heater 4 Remove both lead wires from hopper heater plate Use an ohm meter to measure resistance across the plate Infinitely high resistance values indicate an open heating element and heater plate which mus...

Page 155: ...d sensor inoperative Solution 1 Verify that grid sensor cable is properly connected at X3 or X2 on the Temperature Module 2 Replace grid sensor if resistance does not comply with resistance table 1 Verify that sensor plug is clean and correctly connected at X3 or X2 on the Temperature Module 2 Visually inspect sensor lead wire for break kink damage etc If no obvious damage use an ohmmeter to measu...

Page 156: ...en Drop in Grid heater element AUX Power PCB Sensor Solution 1 Inspect grid s heater wiring for proper connections on AUX Power PCB 2 Remove system power then remove the fuse from the grid circuit Check fuse visually or with an ohmmeter 3 Remove all lead wires from both grid heater elements Use an ohm meter to measure resistance across each element Infinitely high resistance values indicate an ope...

Page 157: ...AUX Power Module are properly connected to the Temperature Module 4 a Visually examine hose head socket connections Verify that pins are properly seated If pins or plug housings are damaged repair or replace hose If socket is damaged repair or replace harness b If hose to ASU plug and socket are okay hose may have intermittent short or open circuit Repair or replace hose hose harness Power Module ...

Page 158: ...harness in ASU 2 Verify that affected hose is properly connected to Power or AUX Module Replace or repair damaged hose harness as necessary 3 Replace head sensor if resistance does not comply with resistance table Use hose schematic to check hose sensor resistance at ASU socket repair or replace hose hose harness Power or AUX Power Mod ule as appropriate 1 Visually inspect hose plug and ASU socket...

Page 159: ...an open heater Replace cartridge heater as appro priate 5 If fuse is found to be blown do not re place it without first finding cause Look for a short circuit to ground in the head heater circuit particularly inside the head at the connections in the service block area If replaced fuse also blows Power or AUX Power Module may be the cause However fuse failure is usually due to a problem in the hea...

Page 160: ...ive and must be re placed 3 a Visually examine Aux socket connections Verify that pins are properly seated If pins or plug hous ings are damaged repair or replace hose If socket is damaged repair or re place harness b If Aux to ASU plug and socket are okay Aux may have intermittent short or open circuit Repair or replace Aux Aux harness or solid state relay as appropriate c If Aux sockets and cabl...

Page 161: ...affected Aux is properly connected to Temp Module Replace or repair damaged Aux harness as neces sary 3 Replace Aux sensor if resistance does not comply with resistance table Use schematic to check Aux sensor resistance at ASU socket repair or replace Aux Aux harness or Temperature Module as appropriate 1 Visually inspect Aux plug and ASU socket for cleanliness and proper contact and seating of pi...

Page 162: ... AUX Power PCB plug Check for loose leads debris and proper contact 3 Use an ohmmeter to measure resistance of Aux cartridge heater Refer to resist ance table for resistance values Infinitely high resistance indicates an open heater Replace cartridge heater as appropriate 4 If fuse is found to be blown do not re place it without first finding cause Look for a short circuit to ground in the Aux hea...

Page 163: ...te This adjustment should be done with a melt pressure gauge or a pressure transducer in stalled Failure to use proper equipment can result in excessive pressure levels 1 Turn the application system ON and raise the temperatures of all components to normal operating temperatures 2 At the controller set the motor speed to 0 so that the gearmotor is not turning 3 Locate the pressure relief assembly ...

Page 164: ...e module The 0 10VDC signal must be connected to the LINE terminal See customer connector S1 S2 2 The AUTO setting then changes pump speed for any given 0 to 10 VDC incoming tachometer signal Voltage will vary given production speed The speed can be adjusted trimmed in automatic mode by setting maximum and minimum RPM values on the DynaControl keypad To make speed adjustments follow the programmin...

Page 165: ...apter 8 of this manual for dis assembly assembly procedures for the ASU pump and Chapter 10 for locating pump parts on the component illustrations exploded view drawings Gear Pump Priming Start Up The pump is self priming CAUTION DO NOT continue to run the pump if no glue is coming out This could damage the pump since it uses the glue as a lubricant Stop and troubleshoot ...

Page 166: ...hed ready condition Verify that hopper has reached ready Re program hopper operating setpoint and ready setpoint if necessary 3 Check to see if ASU temperature control is operating If not check for presence of incoming supply voltage 1 Re program pump 2 Check condition of the remote switch the hand held applicator 3 If the control is faulty it must be replaced WARNING HOT SURFACE ADHESIVE Some of ...

Page 167: ...of 0 to 10 VDC control signal at LINE and COMMON terminals on V6 Base module If signal is not present check connection at tachometer drive connections If control signal is present there the problem is within the ASU 1 Add adhesive to hopper 2 Check pump wiring to schematic 1 Remove and inspect filter basket and primary filter 2 Verify that system components are at appropriate temperatures and that...

Page 168: ...maged Be sure there are no burrs or other sharp edges on the rear plate o ring groove that could damage a new o ring 2 Verify that all four pump retaining nuts are tightly assembled to the studs 3 Remove pump and inspect hopper Repair or replace hopper as necessary Problem Possible Cause Adhesive leak at pump 1 Pump seal is incorrectly shaft seal positioned inside the seal and bearing assembly 2 P...

Page 169: ... of the hopper side cover 2 Lift cover up and off Mechanical Thermostat Over temp Replacement Use the latches to remove the right side hopper cover Remove the 2 screws and slip the terminals and the hopper ground wire off of the thermostat before re moving the thermostat from the base of the hopper To Access the RTD Sensors Use latches to remove the hopper access side cover a RTD for ASU Each ASU ...

Page 170: ...fuses which can be accessed without removing the boards from the ASU These are mounted on the side electrical mounting plates inside the panel box d Printed Circuit Board Replacement Reference the section entitled Handling Printed Circuit Boards on page 7 4 1 Remove 4 screws in corners of desired PCB to re lease Remove wiring connects 2 Wire the new PCB to original locations Mount into ASU with 4 ...

Page 171: ...plication system to the operating temperature to aid in the pump disassembly process Otherwise a heat gun or other controlled heating method is recommended to melt hardened hot melt material Never use a torch or an open flame on any of the components of the application system Once the system is up to temperature disconnect all incoming power before proceeding Front View Back View Front Door Hopper...

Page 172: ...rmly seated against the pump body or other surface Excessive torque may damage straight threaded parts and the use of power wrenches is not recommended CAUTION HOT MELT RESIDUE should be cleaned from parts before they are re assembled particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts should always be re tightened at operating tem...

Page 173: ... Outlet Filter PN 106273 Some situations call for a finer mesh outlet filter A dirty adhesive or one with a short pot life are examples Systems utilizing very high temperatures or systems running in a dusty environment also benefit from a 150 mesh filter Standard equipment is a 100 mesh filter PN 101247 Pressure Transducer Assembly PN 680545 A pressure transducer is an electronic probe that allows...

Page 174: ...N 084E430 1 168 cc rev single high accuracy Gear Pump PN 084E434 2 920 cc rev single high accuracy Gear Pump Dual Pumps PN 111254 0 15 cc rev dual standard accuracy cast iron Gear Pump PN 109909 0 55 cc rev dual standard accuracy cast iron Gear Pump PN 100863 1 54 cc rev dual standard accuracy Gear Pump PN 100864 3 18 cc rev dual standard accuracy Gear Pump PN 084E389 0 584 cc rev dual high accura...

Page 175: ...motely by each touch panel LCD Pendant Control Assembly PN 680520 The Pendant Control option gives the DynaControl keypad mobility via an up to 30 meter 100 ft cable The Pendant Control Panel Kit replaces the standard built in keypad An optional re set switch and on off light can be mounted on the front panel V6 Communications Adapters V6 EtherNet Assembly PN 680619 V6 Profibus Kit PN 680618 V6 Et...

Page 176: ...rds Fuse 6 3A 5x20mm Power boards Power Supply 24VDC 25W RTD Sensor PT 100 Over Temp Thermostat Insulator Assy Hi Temp Over Temp Thermostat Assy option Pressure Relief Valve O ring 041 Pump Shaft Seal Pump Shaft Seal Zenith TSHA high accuracy pumps O ring 041 O ring 21x2 O ring 9 5x1 8 O ring 028 O ring 125 O ring 24x3 O ring 5 005 O ring 5 005 Hi Temp option O ring 125 Hi Temp option O ring 9 5x1...

Page 177: ...ssembly of the D15 D25 D45 SERIES of ASUs These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Note most common nuts bolts and fasteners can be obtained locally at your hardware store Spe cialty fasteners are available by contacting ITW Dynatec s Customer Service WARNING All parts must be periodically inspected and replaced if worn or broken ...

Page 178: ...P COVER D15 V6 1 33 111345 M6 Split Lock Washer 24 34 610141 Flat Washer M6 24 35 104662 M6x1 0 x 16mm Socket Head Cap Screw 40 36 610167 Hole Plugs 12 37 106110 NUT HEX M5 BLK OX 6 38 680549 LID BASE D25 45 V6 2 38 680513 LID BASE D15 2 39 110734 Screw PH FLTHD M4X0 7X8 ZN 4 40 680646 Hinge CL252 304 stainless steel 4 41 106242 Screw SHC M5X16 4 42 600730 Handle Hopper Lid 1 43 048K769 HOT WARNIN...

Page 179: ...lustrations Page 10 3 Revised 10 14 Cabinet Assembly Assembled View 1 2 3 4 5 6 7 8 13 9 10 11 12 14 15 16 17 18 19 20 21 24 22 23 26 27 29 28 30 31 33 34 35 36 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 25 68 64 65 66 67 32 37 38 39 40 41 42 43 44 45 46 47 48 ...

Page 180: ...Page 10 4 Component Illustrations Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Electrical Panel Box Assembly ...

Page 181: ...ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Component Illustrations Page 10 5 Revised 10 14 Electrical Panel Box Assembly ...

Page 182: ...Panel Assembly Item No PN ITW PN Description Qty 1 115893 PCB Assy V6 LCD HMI 1 118135 Touch Panel Assy V6 option not shown 1 2 115792 SCR PH 4 20X3 8 TF ZP 8 3 680453 Bezel Display 1 820487 Bezel HMI Touch Panel option not shown 1 4 106110 Hexagon Nut M5x0 8 1 5 106318 External Tooth Lock Washer 5mm 1 ...

Page 183: ...ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Component Illustrations Page 10 7 Revised 10 14 D25 D45 Front Panel Assembly 1 2 3 4 5 ...

Page 184: ...10 1 5X110 Stud GRD 8 8 8 11 100861 Pump shown for reference only 2 12 069X064 O ring 041 2 13 103518 Socket Head Cap Screw M10x1 5 x 30mm 4 14 107538 M10 Split Lock Washer 10 15 610169 M10 Flat Washer 10 16 012G009 Block off Plate 1 17 610701 Hopper D25 1 610722 Hopper D45 1 680510 Hopper D15 1 18 610204 Spacer L 40MM 6 19 104072 M10 1 5X85 Stud GRD 8 8 6 20 610122 Spacer L 8 5MM 6 21 610210 Hex ...

Page 185: ...ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Component Illustrations Page 10 9 Revised 10 14 Drive Assembly Assembled View Dual Drive ...

Page 186: ...1 8 680510 Hopper D15 1 9 104166 Mechanical O T Thermostat Assembly option 1 10 106236 M4 External Tooth Lock Washer 3 11 108698 M4 x 0 7 x 6mm SHC Screw 3 12 610704 O ring 24x3 1 13 610705 Socket Set Screw Cup Point M6x1 0 x 30mm 1 14 610702 Filter Shut Off Assembly 1 15 102411 Insulator Heater Plate 2 Grid Block Off Assembly 16 N00192 O ring 032 1 17 105149 Block off Plate use in place of grid 1...

Page 187: ...ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 Component Illustrations Page 10 11 Revised 10 14 Grid and Melt Section Drop In Grid option Grid Block Off Assembly 16 17 18 19 20 21 22 23 24 23 or ...

Page 188: ...Page 10 12 Component Illustrations Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 PN 680029 Right and PN 680030 Left Filter Manifold Assemblies Item No PN ITW PN Description Qty ...

Page 189: ... D15 D25 D45 V6 DCL ASU Manual 20 63 Component Illustrations Page 10 13 Revised 10 14 PN 680029 Right and PN 680030 Left Filter Manifold Assemblies 25 26 27 28 29 30 26 28 or Optional Pressure Gauge Assembly or or ...

Page 190: ...9X160 Seal Retainer Bearing Housing 1 069X061 Lip Seal 1 018X041 Bearing Sleeve 2 100866 100867 Front Plate Assembly 1 012D080 012D078 Driven Gear Shaft 1 018X031 Ball 1 8 Diameter see illustration for quantity 2 4 012C020 012C019 Drive Gear 2 069X064 Pump Seal 2 078F017 Shaft Retaining Ring 4 018X041 Bearing Sleeve Rear Plate 2 100865 Rear Plate Assembly 1 100908 M4 x 25 SHC Screw 2 104158 M10 Fl...

Page 191: ...5 Revised 10 14 PN 100860 PN 100861Single Gear Pump Assemblies 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10 11 16 9 17 Pump 100860 has one bearing in this shaft Pump 100861 has two bearing in this shaft Pump 100861 has two bearing in this shaft Pump 100860 has one bearing in this shaft 18 ...

Page 192: ... 1 2 4 078I001 Key Woodruf 404 1 069X061 Shaft Seal 1 069X064 O ring 041 2 108588 M4x25mm Blk SHC Screw 2 101626 M5 0 8 x 12mm SHC Screw 4 109685 Pump Body 10cc rev 1 109686 Rear Bearing Plate 10cc rev 1 109689 Gear 10cc rev 2 109687 Drive Shaft 10cc 20cc 1 109688 Driven Shaft 10cc 20cc 1 069X160 Shaft Seal Retainer 1 001U002 Dow Corning 112 Lubricant not shown 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 ...

Page 193: ...haft 1 078I001 Key Woodruff 1 101626 M5 x 12 SHC Screw 4 069X160 Seal Retainer Bearing Housing 1 069X061 Lip Seal 1 018X041 Bearing Sleeve 2 100868 Front Plate Assembly 1 012D073 Driven Gear Shaft 1 018X031 Ball 1 8 Diameter 4 012C018 Drive Gear 4 5 cc rev 2 069X064 Pump Seal 2 078F017 Shaft Retaining Ring 4 018X041 Bearing Sleeve Rear Plate 2 100865 Rear Plate Assembly 1 100908 M4 x 25 SHC Screw ...

Page 194: ...9X061 Lip Seal 1 018X041 Bearing Sleeve 2 100866 Front Plate Assembly 1 012D082 Driven Gear Shaft 1 018X031 Ball 1 8 Dia 3 012C020 Pump Gear 1 5 cc rev 4 069X064 O ring 041 3 078F017 Shaft Retaining Ring 4 018X041 Bearing Sleeve Rear Plate 2 100865 Rear Plate Assembly 1 101692 M4 x 35 SHC Screw 2 104158 M10 1 5 x 100 Flange Nut 4 100869 Middle Plate 1 N00198 O ring 113 2 104073 M10 1 5 x 105 All T...

Page 195: ...onent Illustrations Page 10 19 Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 PN 100863 1 54 cc rev Dual Gear Pump Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10 11 16 10 10 11 18 17 9 19 20 ...

Page 196: ...using 1 069X061 Lip Seal 1 018X041 Bearing Sleeve 2 100867 Front Plate Assembly 1 012D087 Driven Gear Shaft 1 018X031 Ball 1 8 Diameter 5 012C019 Drive Gear 4 069X064 O ring 041 3 078F017 Shaft Retaining Ring 4 018X041 Bearing Sleeve Rear Plate 2 100865 Rear Plate Assembly 1 101691 M4 x 40 SHC Screw 2 104158 M10 Flange Nut 4 100870 Middle Plate 1 N00198 O ring 113 2 114890 M10 1 5 x 110 Stud 4 107...

Page 197: ...onent Illustrations Page 10 21 Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10 11 10 10 11 16 18 17 9 19 20 PN 100864 3 2 cc rev Dual Gear Pump Assembly ...

Page 198: ...I001 Key Woodruff 404 1 069X061 Shaft Seal 1 069X064 O ring 041 2 100908 M4 0 7 x 25mm SHC Screw 2 101626 M5 0 8 x 12mm SHC Screw 4 109906 Plate Front 55 cc rev 1 100865 Rear Bearing Plate 55 cc rev 1 109907 Gear 55 cc rev 2 012D079 Drive Shaft 1 5 cc rev Dual 1 012D080 Driven shaft 1 5 cc rev Dual 1 069X160 Shaft Seal Retainer 1 001U002 Dow Corning 112 Lubricant not shown 1 2 3 4 5 6 7 8 9 10 11 ...

Page 199: ...6 078F017 Snap Ring 1 2 4 078I001 Key Woodruff 404 1 069X061 Shaft Seal 1 069X064 O ring 041 2 101692 M4 0 7 x 35mm SHC Screw 2 101626 M5 0 8 x 12mm SHC Screw 4 109906 Plate Front 55 cc rev 1 100865 Rear Bearing Plate 55 cc rev 1 109905 Plate Middle Gear 55 cc rev 1 N00198 O ring 113 2 109907 Gear 55 cc rev 4 012D083 Drive Shaft 1 5 cc rev Dual 1 012D082 Driven Shaft 1 5 cc rev Dual 1 069X160 Shaf...

Page 200: ...I001 Key Woodruff 404 1 069X061 Shaft Seal 1 069X064 O ring 041 2 100908 M4 0 7 x 25mm SHC Screw 2 101626 M5 0 8 x 12mm SHC Screw 4 111251 Plate Front 15 cc rev 1 100865 Rear Bearing Plate 55 cc rev 1 111252 Gear 15 cc rev 2 012D079 Drive Shaft 1 5 cc rev Dual 1 012D080 Driven shaft 1 5 cc rev Dual 1 069X160 Shaft Seal Retainer 1 001U002 Dow Corning 112 Lubricant not shown 1 2 3 4 5 6 7 8 9 10 11 ...

Page 201: ...Snap Ring 1 2 4 078I001 Key Woodruff 404 1 069X061 Shaft Seal 1 069X064 O ring 041 2 101692 M4 0 7 x 35mm SHC Screw 2 101626 M5 0 8 x 12mm SHC Screw 4 111251 Plate Front 55 cc rev 1 100865 Rear Bearing Plate 55 cc rev 1 111252 Plate Middle Gear 55 cc rev 1 N00198 O ring 113 2 109907 Gear 55cc rev 4 012D083 Drive Shaft 1 5 cc rev Dual 1 012D082 Driven Shaft 1 5 cc rev Dual 1 069X160 Shaft Seal Reta...

Page 202: ...Page 10 26 Component Illustrations Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 PN 680424 Pneumatic Pressure Relief Valve Kit Item No Part Number Description Qty ...

Page 203: ...Component Illustrations Page 10 27 Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 PN 680424 Pneumatic Pressure Relief Valve Kit Illustration shows two Dual Pump Configuration SCHEMATICS ...

Page 204: ...Page 10 28 Component Illustrations Revised 10 14 ITW Dynatec D15 D25 D45 V6 DCL ASU Manual 20 63 ...

Page 205: ...11 1 Revised 10 14 Chapter 11 SYSTEM SCHEMATICS ENGINEERING DRAWINGS HEAD SCHEMATIC PN 103117 REV B Notes 1 ALL WIRE MIL W 22759 10 OR 12 MINIMUM 600 VOLTS 260 DEG C 2 SOLENOID S VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION 3 RTD WILL BE PLATINUM 100 OHM ...

Page 206: ...Page 11 2 Schematics Revised 10 14 ITW Dynatec D SERIES V6 DCL ASU Manuals HOSE SCHEMATIC PN 101082 REV G ASU to Applicator ...

Page 207: ... SERIES V6 DCL ASU Manuals Schematics Page 11 3 Revised 10 14 Pump Bypass Motor Filter Basket Gauge Transducer TYPICAL HYDRAULIC SCHEMATIC Single Pump Motor Bypass Filter optional Transducer optional Pressure Gauge ...

Page 208: ...Page 11 4 Schematics Revised 10 14 ITW Dynatec D SERIES V6 DCL ASU Manuals LEVEL CONTROL SCHEMATIC PN 802972 REV A ...

Page 209: ... STOP MAIN SWITCH MOTOR RESISTOR RTD SWITCH PROXIMITY SWITCH TERMINAL TERMINAL STRIP PLUG SOCKET CONNECTION SOLENOID CONTROL GEAR PLC MODULE COMPONENT DESIGNATORS ADHESIVE SUPPLY UNIT D15 25 45 DynaControl V6 POWER SUPPLY 3 PHASE 4 WIRE DELTA PE 50 60HZ VOLTAGE MAX WATTAGE 240VAC 50 60HZ MAX CURRENT EXAMPLE K20 5 CONTACTOR ON PAGE 20 SHEET 2 COLUMN 5 SCHEM D15 25 45 V6 MOTOR CIRCUITS PANEL BOX LAY...

Page 210: ...VAC 3 PHASE N WYE F20 2 F20 3 M20 3 M20 4 M20 4 M20 3 F20 2 PANEL BOX FANS PANEL BOX FANS 1AT 1AT AWG8 AWG8 AWG8 AWG10 BLU Y CAP A20 2 A20 2 Y CAP TO A30 8 V6 AUX PCB TO A30 5 V6 AUX PCB L1 30 0 L2 30 0 L3 30 0 L3 30 0 L2 30 0 L1 30 0 AWG10 BLK SHORT CIRCUIT PROOF AWG8 BLK L1 30 0 L3 30 0 L3 30 0 L2 30 0 TO A30 8 V6 AUX PCB TO A30 5 V6 AUX PCB N 30 0 N 30 0 FUSE BLOCK F20 4 24A FUSE BLOCK F20 4 24...

Page 211: ... N 20 3 V6 AUX 1 PN 115733 V6 AUX 2 PN 115733 V6 POWER PCB PN 115732 VIOLET P N 115725 YELLOW P N 115726 J1 VOLTAGE CONFIGURATIOPN PLUG J1 VOLTAGE CONFIGURATIOPN PLUG 3 4 2 1 1 2 F2 F1 X3 V6 POWER PCB PN 115732 X2 F13 TO DC POWER SUPPLY TO MOTOR DRIVE 1 TO MOTOR DRIVE 2 A30 0 A30 0 A30 5 A30 8 A30 5 A30 8 L50 0 N50 0 N60 3 L60 3 L60 4 N60 4 PN PN PN PN 680470 PN 680465 PN 680465 L3 20 3 L2 20 3 L1...

Page 212: ...K BLU RED F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 V6 POWER PCB PN 115732 V6 AUX PCB PN 115733 4 5 14 15 7 6 11 10 TO V6 TEMP X13 X7 TO V6 TEMP X12 TO V6 TEMP X11 A30 0 A30 5 A30 8 XS40 3 9 8 HOSE 3 HEATER HEAD 3 HEATER PE 7 8 11 12 XS40 5 13 XS40 8 8 7 AUX 2 HEATER 12 AUX 1 HEATER 7 8 XS40 9 F1 F2 F4 F3 F6 F5 F7 F8 R X5 X4 X3 F9 F10 F10 F9 X3 X4 X5 R F8 F7 F5 F6 F3 F4 F2 F1 X7 2 1 X1 1 2 4 3 X6 X2 3 4 2 1 ...

Page 213: ...HEAD 3 RTD HEAD 2 RTD HEAD 1 RTD AUX 1 RTD AUX 2 RTD AUX 3 RTD AUX 4 RTD ORANGE BLUE GRAY WH BL ORANGE BLUE GRAY WH BL ORANGE BLUE GRAY WH BL ORANGE BLUE GRAY WH BL GRAY WH BL GRAY WH BL GRAY WH BL GRAY WH BL X14 A50 1 A50 0 A50 5 L30 2 N30 2 ORA GRY BLK RED BLU WHT BLU 0 10V PUMP 1 PUMP 2 if GLOBAL CONTROL CUSTOMER CONNECTION READY EMPTY ALARM CUSTOMER CONNECTION PN 680470 PN 680479 PN 680007 PN ...

Page 214: ...STOMER CONNECTION LINE SPEED PUMP START 8 7 6 ENC4 N C N C 5 6 7 8 10 9 AC MB MC AC S1 A1 SC SC A1 S1 AC MC MB 1 5 4 3 2 MOTOR CONTROL 3 MOTOR CONTROL 4 ENC1 ENC2 ENC3 LINE 4 LINE 3 START 4 START 3 START 2 START 1 M L 1 2 3 4 MB MCSC S1 A1 AC SC S1 MC MB MOTOR CONTROL 1 LINE 1 LINE 2 A1 MOTOR CONTROL 2 MA BLU RED BLK BLU WHT GRY ORA S L2 R L1 A60 6 AWG14 BLK N30 2 L30 2 RFI FILTER RFI FILTER GRY O...

Page 215: ...0 A50 1 A50 5 A60 6 A50 0 V6 TEMP16 OUT11 15 X9 OUTPUT V6 BASE4 GP X8 MOT CTRL 24V IN2 IN1 24V P PUMP IN6 INPUT IN3 IN4 IN5 N P COM COM T STAT 24V PP PP OV T ERR COM 1 X6 X2 X5 X4 X3 X8 X7 PR COM 0 10V GP PR COM ENC LINE 24V OUT16 2 3 PWR ON OUTPUT 1 OUT1 5 1 OUT6 10 1 X10 V6 MOTOR Dynatec V6 BUS PN 117382 ON ERR ITW Dynatec 117382 Rev x RoHS S N xxxxxxx J O ITW A60 1 A60 5 A70 6 OPTION A20 2 Y CA...

Page 216: ...ECEPTACLES MOTOR CABLES NOTE IF MORE THAN ONE WIRE IS CONNECTED TO ONE TERMINAL OF THE GROUND BAR THOSE WIRES HAVE TO BE CRIMPED TOGETHER IN ONE APPROPRIATE FERRULE ALL GROUND WIRE HAVE TO BE YELLOW GREEN ALL GROUND TERMINALS HAVE TO BE APPROPRIATELY LABELED AWG16 HEAT SINK A20 6 AWG12 XP XS40 5 PE XS40 3 PE XS40 2 PE XS40 0 PE HOSE HEAD PN 680023 HOPPER COVER LEFT HOPPER COVER RIGHT PN 680018 PN ...

Page 217: ...0 6 A1 LINE 2 LINE 1 MB MC S1 SC AC A1 S1 SC MC MB 4 3 2 1 L M START 1 START 2 START 3 START 4 LINE 3 LINE 4 ENC3 ENC2 ENC1 2 3 4 5 1 MB MC AC S1 A1 SC SC A1 S1 AC MC MB AC 9 10 8 7 6 5 N C N C ENC4 6 7 8 V6 MOTOR R Q I L G V L mA N G M PUMP 2 LINE SPEED R Q N M G V L mA L G I LINE SPEED PUMP 1 PUMP 2 if GLOBAL CONTROL L N PE 24V POWER SUPPLY 24VDC 2A USB ETHERNET 9 7 8 N R FIELD BUS CABLE KIT P N...

Page 218: ... 6 XS40 7 XS40 8 XS40 9 A60 3 A60 4 A60 5 M60 2 M60 5 D15 25 45 V6 BOM 32A 63A 600V POWER PCB 115732 1 A50 1 1 BASE MODULE AUX PCB 2 A30 5 A30 8 LINE FILTER 1PH 2 MOTOR DRIVE BOARD 2 A60 1 MOTOR AC 3PH 2 A50 2 1 KEYPAD DISPLAY PCB A50 0 A50 9 2 SIGNAL ISOLATOR PCB OPTION OV TEMP 1 OVER TEMP THERMOSTAT A50 0 DC POWER SUPPLY 1 A50 5 TEMP MODULE 1 A70 6 MOTOR MODULE 1 115735 115734 680090 116823 XP X...

Page 219: ...and the fluid is displaced The fluid flows out of the pump through the discharge port s There may be multiple driven gears each with its own associated discharge port There may be single or dual stream pump assemblies This manual will not cover all situations which might arise with regard to installation operation inspection and maintenance of the pump supplied ITW Dynatec assumes the personnel as...

Page 220: ...ds protective electrical connections temperature monitoring devices pressure monitoring devices and sealing apparatus are installed and operational prior to starting the pump Pumps may not be used with foodstuffs Do not allow the pump to change temperature rapidly Do not apply open flame to a pump Do not allow leaking fluid to combust Do not expose the pump to liquid nitrogen or other extremely co...

Page 221: ...or smooth operation by hand Fixing and Lubrication The pump must be fixed securely to maintain position and alignment When secured by lubricated bolts torque them evenly to the suggested torque see Maintenance Start drive and bring up to speed slowly Flush with process fluid Note motor base plate assemblies should be pre checked in case the drive alignment has been disturbed In order to ensure nor...

Page 222: ...ure prior to starting the motor Heat soak the pump sufficiently to ensure all recesses are at process temperature Pump outlet pressure and speed limits are dependant on fluid viscosity and throughput Pump inlet pressure is an important feature for lubrication and fluid stability Materials for pump construction are important for corrosion and wear resistance Consult ITW Dynatec for detailed applica...

Page 223: ...ning be cautious to complete the operation in less than 1 minute If the pump is to be stored or if it will sit for a long period without operation or protection apply rust preventative oil to all internal and external surfaces Restarts On restart where the product fluid has hardened and solidified in the pump during the shutdown the fluid must be softened and made completely liquid again prior to ...

Page 224: ... in pump inlet outlet hose If applicable shut off any pneumatic or other fluid supply lines to the pump Visually check equipment frequently for signs of damage or leakage from shaft seals gaskets or O rings Be sure all connections are tight If seal leakage is more than about 10 drops per hour per seal shut down equipment and repair or replace necessary parts Shaft seals have a limited finite life ...

Page 225: ... the packing follower properly Do not over tighten the packing follower Over tightening will cause damage to the packing and the shaft Other sealing options are available Re adjust the packing follower several times through the running in period until the seal is thoroughly seated and the rate of leakage is stable Cleaning Before removal from machine the pump should be rotated for a short period w...

Page 226: ...rive couplings 3 Process conditions changed Check process conditions for proper melt temperature pressures viscosities and materials 4 Foreign particle Send pump for repair to ITW Dynatec 5 Possible internal damages Send pump for repair to ITW Dynatec Excessive seal assembly leakage 1 Worn seal plate Send pump for repair to ITW Dynatec 2 Low temperature pump start Increase temperature Allow heat s...

Page 227: ...ication system Once the system is up to temperature disconnect all incoming power before proceeding Pump Shaft Seal O ring Replacement In most cases the pump does not have to be removed from the ASU in order to replace the shaft seal 1 Disconnect the drive coupling so that the pump may be accessed 2 Remove the four screws in the pump cap and remove the cap 3 Within the cap is the pump shaft seal R...

Page 228: ...and note that hot fluid may flow from the pump Guard against skin contact with hot fluids or with a hot pump Follow all precautions of the fluid manufacturer in the handling of the fluid In the event that a pump needs to be stored always protect the pump against water and other contaminants Store the pump in a clean dry and warm environment Pumps are delivered filled with suitable lubricant and wi...

Page 229: ...er in heavy environmental conditions found in industrial applications The DAT 4531 D is in compliance with the standard 89 336 CEE on the Electromagnetic Compatibility It is housed in a plastic enclosure of 12 5 mm thickness suitable for DIN rail mounting in compliance with EN 50022 and EN 50035 standards User Instructions The converter must be powered by a direct voltage applied to the terminals ...

Page 230: ...the dip switches using the wizard of the configuration software following the procedure described in the section Configuration by PC until the step 6 and slicking on Switch DIP Switch Configuration Tables TAB 1 Settings NOTES If the dip switches SW1 1 4 are all set in the position 0 Default the device will follow the configuration programmed by PC Input and output type and options Eventual wrong d...

Page 231: ... to 0 15000psi 2 x FS 1 5 x FS above 500bar 7500psi Extensimetric 10 30Vdc 32mA 1000 MOhm 20mA 4mA Autozero function See Manual See diagram 1ms 0 025 FSO 80 FSO YES 0 85 C 30 105 C 40 125 C 0 02 FSO C 315 C 600 F 0 04 bar C 0 005 bar C 100 p 500 bar 0 0022 FS C p 500 bar Diaphragm 17 7PH corrugated diaphragm with GTP Stem 17 4 PH STD type J isolated junction IP65 FSO Full scale output 1 BFSL metho...

Page 232: ...5 A B C Ch Hex D1 D2 D3 D4 D5 A B C Ch Hex ø16 0 08 ø0 63 0 003 ø18 ø0 71 6 0 26 0 24 0 01 14 8 0 4 0 58 0 016 19 0 75 19 3 4 ø7 8 0 05 ø0 31 0 002 ø10 5 0 025 ø0 41 0 001 ø10 67 ø0 42 ø12 7 ø0 5 5 56 0 26 0 22 0 01 11 2 0 44 15 74 0 62 16 5 8 ø16 0 4 ø0 63 0 016 WE1 WE3 WE2 WE0 Exposed capillary D1 1 2 20UNF D2 307 305 7 80 7 75mm D3 414 412 10 52 10 46mm A 125 120 3 18 3 05mm B 318 312 8 08 7 92...

Page 233: ... color code 42 1 65 The Autozero function is activated through a magnetic contact exter nal magnet supplied with the sensor See the manual for a complete Autozero fun ction explanation The diagram shows the optimum ratio between the load and supply voltage of the 4 20mA transmitter For a correct use choose any combination of load resistance and supply voltage in the shaded area ELECTRICAL CONNECTI...

Page 234: ...E0 WE1 WE2 Available on request 1 38mm 2 50mm 3 76mm 6 350mm 7 400mm 8 456mm 6 12 5 1 5 2 3 14 16 18 FLEXIBLE LENGTH mm inches 457mm D 610mm E Standard WE0 Available on request A 76mm B 152mm C 300mm 18 24 3 6 12 760mm F 30 none 0 Standard WE1 WE2 100 B01C 70 B07D RANGE 35 50 B35U B05D 200 bar psi B02C 500 B05C 350 B35D 700 B07C 1500 P15C 1000 P01M 500 750 P05C P75D 3000 P03M 7500 P75C 5000 P05M 1...

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ITW Dynatec DYNAMELT D15 Series, Technical Documentation Manual

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