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26

Hwang Sun Enterprise Co., Ltd.

26 Edition 2012/02

CHAPTER 4 PREVENTIVE MAINTENANCE

4.0 INTRODUCTION

This chapter contains the prevention and maintenance procedures of HS2510-N Hot
Melt  Applicator.  These  procedures  are  organized  according  to  the  utility  rate  of
machine  performance  for  daily,  weekly,  monthly,  semiannual  and  periodical
maintenance.  The  periodical  maintenance  does  not  affected  by  any  factors,  like
operation condition, environment, etc. Doing the preventive maintenance is not only
keeping high efficiency, but also to extend machine’s lifetime.

4.1 SAFETY PRECAUTIONS

Always wear the protective glasses, clothing and heat-resistant gloves to avoid
being burned by hot surface of components or molten glue.

Make sure the external power supply is disconnected before replace any
control panels, electrical components or covers to prevent the personnel injury
or damages to machine.

Make sure inner air pressure is exhausted before plugging or unplugging the
connectors of pressure system or connection device for safety.

Before remove the protective lid of driving system, shut off the motor power,
make sure the motor is stopped, in order to avoid the finger being clipped by
the motor.

Never heat any glue-contaminated components with a torch or other open
flame. If necessary to be heated or clean, please use the electrical heating gun.

4.2 DAILY MAINTENANCE

1.  Always keep the equipment and surrounding clean.
2.  Check if the regulator had water inside, and, it should be discharged promptly.
3.  Make sure there is no impurities in hot melt adhesive before loading, these

impurities may cause unstable glue flow or block and damage the filter
assembly or heating hose. Therefore, please close the tank lid immediately after
loading.

4.3 MONTHLY MAINTENANCE

4.3.1 MAINTENANCE OF FILTER ASSEMBLY

It’s suggested to clean the filter assembly monthly, until the operator depending on
the operation experience, may reduce its cleaning rate.
Please refer to the following detailed steps to clean filter assembly :

1.Keep working temperature of the applicator before disassembling the filter

assembly.

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Содержание HS2510-N

Страница 1: ...Hwang Sun Enterprise Co Ltd 0 Edition 2012 02 00 ...

Страница 2: ... N Hydraulic and Electrical Control System 7 2 2 SPECIFICATION 7 2 3 FUNCTIONAL DESCRIPTION OF STANDARD 8 2 3 1 Driving System 8 Figure 2 4 Motor Device 8 2 3 2 Hydraulic System 11 Figure 2 5 Gear Pump 12 Figure 2 6 Manifold 12 Figure 2 7 Filter 13 2 3 3 Electrical System 14 CHAPTER 3 OPERATION INSTRUCTION 16 3 0 INTRODUCTION 16 3 1 SAFETY PRECAUTIONS 16 3 2 INSTRUCTIONS OF OPERATION PANEL 17 FIGU...

Страница 3: ...AGRAMS AND SPARE PARTS 38 6 0 INTRODUCTION 38 6 1 THE USE OF PARTS ATLAS 38 FIGURE 6 1 1 TANK ASSEMBLY 39 FIGURE 6 1 2 TANK ASSEMBLY 41 FIGURE 6 1 3 GEAR PUMP ASSEMBLLY 43 FIGURE 6 1 4 GEAR PUMP ASSEMBLLY 46 FIGURE 6 1 5 MANIFOLD ASSEMBLY 48 FIGURE 6 1 6 BY PASS VLAVE 50 FIGURE 6 1 7 FILTER ASSEMBLY 52 FIGURE 6 1 8 WIRING DIAGRAM 54 FIGURE 6 1 9 WIRING DIAGRAM 55 FIGURE 6 1 10 WIRING DIAGRAM 56 FI...

Страница 4: ...th a thermal safety cut off is installed between the apparatus and the primary generator 4 Always operate the apparatus in accordance with the recommended current and voltage If the apparatus is operate at voltages and currents other that recommended it may create potential fire risk 1 2 SAFETY DURING OPERATION Do not operate the equipment near volatile or other explosive gases or materials Do not...

Страница 5: ...electrical power supply while power is on Dangerous voltage exist at several point in the equipment 6 Disconnect the electrical supply before removing any protection case or changing any electrical component 7 If possible stand on a rubber insulating mat when carrying out maintenance on the hot melt applicator Do not work on wet floor in very damp surrounding 8 Always use protective gloves and clo...

Страница 6: ... is adequately ventilated 4 Avoid prolonged or repeated breathing of solvent vapors IF MOLTEN MATERIAL COMES IN CONTACT WITH THE SKING If molten adhesive comes in contact with the skin do not forcefully remove hot melt material from the skin Immediately cool affected skin areas with cold clean water till the adhesive stuck on the skin is completely cooled down then cover the affected area with a c...

Страница 7: ...ides general information of HS2510 N Hot Melt Applicator also with the machine drawing figure2 1 equipment dimension figure 2 2 and diagram of hydraulic system and electrical diagram figure 2 3 to provides the used for equipment installation Figure 2 1 The Appearance Of HS2510 N Figure 2 2 Equipment dimension unit mm ...

Страница 8: ...e to the manifold and the filter assembly then guide through the hose to the dispensing nozzle or gun unit and deliver the ADHESIVE to the substrate The hot melt tank heating hose and the dispensing nozzle for automatic application are all controlled by individual temperature controller separately The hot melt tank is controlled by P I D temperature controller and the heating device are controller...

Страница 9: ...IFICATION DESCRIPTION HS2510 N POWER REQUIREMENT AC440V 20A 50 60Hz 3Φ 4W TANK HEATING POWER 9 5KW WEIGHT 120KG DIMENSIONS 850 x 540 x 970 mm TANK CAPACITY 20 LITER MELTING RATE 20KG HOUR OPERATING TEMPERATURE MAX 220oC VISCOSITY 100000CPS MOTOR SPC 1 2HP 220VAC 3Φ 1 40GR AVAILABLE HOSE GUN 1 TYPE OF BYPASS AUTO MANU ...

Страница 10: ...the motor starts the connection shaft will drive the driving shaft of gear pump in clockwise rotation as shown in figure 2 4 And the glue flowing rate is controlled by the speed of the gear pump on the other hand indirectly controlled by the speed of the motor which is controlled by a inverter There is a rotary knob with the digital display on the inverter turn the knob to increase clockwise or re...

Страница 11: ...em V F or Sensorless Vector Control Output Frequency Resolution 0 1Hz Torque Characteristics Torque can be set to enhance the accurate level Overload Endurance 150 of rated current for 1 minute Accel Decel Time 0 1 3600 seconds 2 Independent settings for Accel Decel Time Control Characteristics V F Pattern Adjustable V F pattern External Signal Setting 1 External variable resistor 0 10V 0 20mA 10 ...

Страница 12: ... inverter with the same capacity as that of the motor 3 Check the motor 4 Check the wiring 5 Replace the IGBT module OC C Over current at fixed speed 1 Transient load change 2 Transient power change 1 Increase the capacity of the inverter 2 Rerun parameter auto tuning 0 06 1 3 Reduce stator resistance 14 0 if the above remedies are helpless OC D Over current at deceleration The preset deceleration...

Страница 13: ... easily There are some fins set in the internal wall of tank to increase melting rate Temperature control is accomplished by means of the k type RTD sensor mounted at the bottom of the tank to detect the temperature and transfer into signal to pass to temperature controller 2 Gear Pump The gear pump of HS2510 N applicator is installed at the bottom of the tank which be driven by the 3 phase motor ...

Страница 14: ...manifold to melt down the adhesive material in the tank and keep the molten material in the setting temperature There are two temperature sensors K CA type inserted in the both sides of the tank to pass the heat signal to PID and mechanical temperature detector to control the operation temperature of heating system 4 Manifold The manifold of the HS2510 Hot Melt Applicator is bring mounted by four ...

Страница 15: ...VALVE at the by pass path to adjust the adhesive amount feeding back to the tank And the rest of adhesive flow though the distributive path to filter device and the main path then deliver to two glue outlet path and out of manifold to heating hose 5 Filter Assembly This device is installed inside the manifold all hot molten adhesive extruded from the gear pump must flow through here then distribut...

Страница 16: ...ature controller Both shown by mode When the main power is turned on the temperature control system will automatically check inner circuit checking relay and RTD are normal or not And this system will start all temperature controllers in order 1 P I D Temperature Controller A PID temperature controller is a temperature controller that combines Proportional Integral and Derivative It is an accurate...

Страница 17: ...the liquor will be transferred to the temperature controller through the pressure conduit the spring blade inside is kicked off and cuts off the power and the heater stops continuous heating When the temperature begins to drop the blade automatically come up to where it is kicked off And once the heater is passed on the power source will start to continue to heat up ...

Страница 18: ...n steps of this hot melt applicator and how to load or change hot melt adhesive 3 1 SAFETY PRECAUTIONS 1 Always wear the protective glasses clothing and heat resistant gloves to avoid being burned by hot surface of components or molten glue 2 The joint of hoses and guns may possibly contain high voltage only the qualified personnel could operate this equipment 3 Do not touch the hot nozzle during ...

Страница 19: ...17 Hwang Sun Enterprise Co Ltd 17 Edition 2012 02 3 2 INSTRUCTIONS OF OPERATION PANEL ...

Страница 20: ...l show the current operation temperature of the tank The functions of PID temperature controller as below FIGURE 3 2 PID TEMPERATURE CONTROLLER 1 PV Present temperature value PV When the main power is on this P I D temperature controller will measure the present temperature of the hot melt tank 2 SV is for set temperature value Press key the SV indicator will flicker and set the desired temperatur...

Страница 21: ...on shift key Repeat pressing this key the following function data will be displayed and can be re set with Setting Value key to re set The following is the introduction to each function Auto calculation setting When set to YES PID carries out automatic calculation When set to NO PID does not carry out automatic calculation Setting of upper limit and lower limit of temperature to set the required t...

Страница 22: ... power and shut down the external power supply to keep off the remained high voltage in all connectors 2 Main Power Switch Put this Main Power Switch on ON position then the indicator will light to show the power of the applicator is on 3 START button for motor power Press this START button to turn on the motor when the temperature of the tank up to the setting point the motor will start 4 STOP bu...

Страница 23: ...ir pressure detector green indicator the motor will stop for safety reason 4 Connect the air source to the dispensing nozzle and adjust the air pressure to 2 5 4Kg cm2 5 Turn on the external power supply 6 Turn on the power switch on operation panel the ON position 7 Set the temperatures of all systems of the applicator to the required temperature and other recommended value ...

Страница 24: ...to start the motor Operate the dispensing gun and make the adhesive in the tank to flow out and clean the impurities or bubbles along with the flowed adhesive 10 Make sure the flowed adhesive without bubbles and impurities then stop triggering the nozzle the applicator is ready to work 3 4 DAILY OPERATION 3 4 1 DAILY STARTUP 1 Turn on the external power supply 2 Put the Main Power Switch on the pa...

Страница 25: ... set the temperatures 5 After all parts temperature reach the individual setting point and the adhesive material in the tank becomes molten turn on the power of the motor Note If the indicator PASS THE MOTOR START not light please check if the air pressure below the range of air pressure detector green indicator and adjust the air pressure as the instruction on chapter 3 3 6 Inspect the air pressu...

Страница 26: ...ion 2 Trigger the dispensing nozzle to relieve any trapped air pressure inside 3 Relieve the air pressure of the main machine 3 5 THE ADJUSTMENT OF GLUE AMOUNT 1 To adjust by the inverter The inverter use the frequency to alter the motor speed To adjust the pump operation with the Potentiometer on the inverter to effect the ...

Страница 27: ...alve This device is used to adjust the hydraulic pressure and the first glue flow When adjust the screw in a clockwise direction it will increase and in an anti clockwise direction to decrease Once completed tighten the nut Note This valve is not entirely locked in order to avoid the excessive internal pressure easily damage the motor and gear pump ...

Страница 28: ...ing or unplugging the connectors of pressure system or connection device for safety Before remove the protective lid of driving system shut off the motor power make sure the motor is stopped in order to avoid the finger being clipped by the motor Never heat any glue contaminated components with a torch or other open flame If necessary to be heated or clean please use the electrical heating gun 4 2...

Страница 29: ... 6 Follow the below orders to disassemble the filter assembly unscrew the screw 6 take out the screen 5 then the screen holder 4 remove the bung 1 to slip off the back up ring 3 and o ring 2 7 Check mesh screen to see if any crack or fold on screen if yes please replace a new mesh screen 8 Check O Ring and Back Up Ring to see if any crack on surface If yes please replace it 9 Check related metal c...

Страница 30: ...ng burned by molten adhesive or hot surface of components Relieve system air pressure before plugging or unplugging the connectors of pressure system or connection device for safety 4 4 1 GENERAL MAINTENANCE Clean the filter of the air regulator Clean the inside of the electrical control chamber do not loosen any electrical terminal in case of short circuit Check if the connector of cable end is s...

Страница 31: ...e to the equipment 2 Do not try to disassemble any components of manifold hose and gun assembly until the pressures on these system is completely relieved 3 Before remove the protective lid of gear driving system shut off the motor power make sure the motor is stopped in order to avoid the finger being clipped by the motor 4 Always wear safety gloves protecting glasses and long sleeved clothing to...

Страница 32: ... the heater hose is out of function Replace with new temperature controller The temperature sensor RTD out of function Replace with new sensor When the power is on the heater hose can not heat The heater spiral nickel chromium wire of the heater hose is broken Replace with new heater hose Fuse holder becomes loose or fuse burnt Replace new fuse and lock up the fuse base Temperature controller of d...

Страница 33: ...plate Place RTD into the heating plate completely SSR is broken Replace with new SSR The P I D temperature controller is out of function Replace with new P I D Heater of tank keep heating and out of control RTD get short too early Check the wiring of replace with new RTD Temperature of nozzle assembly is too high Re set the temperature for nozzle assembly Nozzle tip not tightened enough Tighten th...

Страница 34: ... the adhesive completely melted Re set the proper temperature if it is too low The gear pump does not turn on Start the motor until the temperature up to the setpoint No adhesive flow out The gear pump cannot be in motion One of the heating system applicator hose or nozzle assembly does not heat or cannot reach pre set temperature MOTOR START switch broken or in trouble Check as below steps 4 13 i...

Страница 35: ...t be relieved The manifold normally flow glue and not flow glue through the blocked heater hose The By pass valve is fully open The motor or the reduction gear is stuck The chain comes off the gear Clean the nozzle tip Set air pressures at working value Or change the broken regulator parts Check the wiring for loose or poor connection or replace the broken components Change the nozzle Clean the fi...

Страница 36: ...eflow of By pass valve is too much The operating temperature of the nozzle assembly is too low The operation temperature of the heater hose is too low The ball valve not fully open due to the shaft of the nozzle assembly comes off the ball valve valve The nozzle tip is blocked partly The filter of the nozzle assembly is blocked Adjust the inverter to increase the speed of the motor Increase the op...

Страница 37: ...adhesive at beginning of bead deposit 1 Too much pressure to the gear pump 2 Nozzle is too far from the substrate 3 The nozzle partially plugged Adjust the pressure of pressure regulator or the inverter to reduce the motor speed Move nozzle to the distance of 0 5 12 7mm from substrate Dismantle the nozzle and clean it Excessive adhesive at the end of bead deposit 1 Insufficient pressure to gear pu...

Страница 38: ...of all heating zones Adjust the pressure of the pressure regulator or the inverter to reduce the motor speed Suggest to adjust the operation temperature or use same kind of adhesive with higher CPS value Change the nozzle with smaller orifice Waviness in bead deposit 1 Ambient temperature in the application area is below freezing 2 A draft or breeze is blowing across the nozzle assembly or guns 3 ...

Страница 39: ... adhesive representative for compatible adhesive Increase the operation temperature or air pressure to the gear pump or use a larger orifice nozzle for higher flow rate Suggest to use same kind of adhesive with lower viscosity Air or moisture bubbles in adhesive bead 1 The level of adhesive in the tank is too low cause the air into the gear pump 2 Viscosity of adhesive is too high 3 The substrate ...

Страница 40: ... is convenient to identify the components and replace the damaged parts while disassembling and maintaining the hot melt applicator 6 1 THE USE OF PARTS ATLAS 1 Please find out the correct page of component according to the contents in front page of manual 2 All the components can be found out by looking up the figures in this chapter Kindly note the marked items in the figures 3 The serial number...

Страница 41: ...39 Hwang Sun Enterprise Co Ltd 39 Edition 2012 02 FIGURE 6 1 1 TANK ASSEMBLY THIS DIAGRAM SUIT TO APPLICATOR SHIPPED BEFORE JAN 2012 ...

Страница 42: ...RIAL Q TY 1 350T01 TANK A6061 1 2 350T07 PRE HEAT TANK A6061 1 3 350T03 SUPPORTER SS42 2 4 350T04 SUPPORTER SS42 2 5 350T05 2 MANIFOLD A6061 1 6 350T06 WASHER 2 7 350P00 3N PUMP ASSEMBLY SS41 1 8 HTA4V80W27 5 16 HEATER 7 9 HTA4V80W37 5 12 HEATER 3 10 HTA4V50W23 5 12 HEATER 3 11 2510T01 STORAGE TANK 1 12 350T09 SEAL 1 ...

Страница 43: ...41 Hwang Sun Enterprise Co Ltd 41 Edition 2012 02 FIGURE 6 1 2 TANK ASSEMBLY THIS DIAGRAM SUIT TO THE APPLICATOR SHIPPED AFTER JAN 2012 ...

Страница 44: ... 1 350T01 TANK A6061 1 2 350T07 PRE HEAT TANK A6061 1 3 350T03 SUPPORTER IRON 2 4 350T04 SUPPORTER IRON 2 5 350T05 2 MANIFOLD A6061 1 6 350T06 WASHER ASBESTOS 2 7 350P00 1G PUMP ASSEMBLY SS41 1 8 HTA4V80W27 5 16 HEATER 7 9 HTA4V80W37 5 12 HEATER 3 10 HTA4V50W23 5 12 HEATER 3 11 2510T01 STORAGE TANK 1 12 350T09 SEAL ASBESTOS 1 ...

Страница 45: ...43 Hwang Sun Enterprise Co Ltd 43 Edition 2012 02 FIGURE 6 1 3 GEAR PUMPASSEMBLLY THIS DIAGRAM SUIT TO THE APPLICATOR SHIPPED BEFORE JAN 2012 ...

Страница 46: ... COVER FC25 1 8 350P06 2 GEAR BASE FDC45 1 9 1500P03A PEDESTAL FDC45 1 10 350P09 DRIVEN SHAFT SK2 1 11 1500P07 GLUE PIPE SS41 1 12 350P07 1 DRIVING GEAR 1 13 350P08 1 DRIVEN GEAR SS41 1 14 1500P11 SUPPORTER 1 15 OP20V O RING 1 16 OB20 BACK UP RING 1 17 K04 8C KEY 1 18 K05 KEY 1 19 C35B C SNAP RING 1 20 U6302ZZC3 BEARING 1 21 SC061273B HEXAGONT BOLT 3 22 SC063073B HEXAGON BOLT 3 23 SC066573B HEXAGO...

Страница 47: ...prise Co Ltd 45 Edition 2012 02 MODULE NO 350P00 3N GEAR PUMP ASSEMBLLY ITEM SERIAL NO DESCRIPTION MATERIAL Q TY 29 350P013 SEAL TEFLON 1 30 OP15V O RING 1 31 SC052573B HEX SOCKET SCREW 2 32 SC041673B HEX SOCKET SCREW 3 ...

Страница 48: ...46 Hwang Sun Enterprise Co Ltd 46 Edition 2012 02 FIGURE 6 1 4 GEAR PUMPASSEMBLLY THIS DIAGRAM SUIT TO THE APPLICATOR SHIPPED AFTER JAN 2012 ...

Страница 49: ...EALING COVER FC25 1 8 350P06 2 GEAR BASE FDC45 1 9 1500P03A PEDESTAL FDC45 1 10 350P09 DRIVEN SHAFT SK2 1 11 1500P07 GLUE PIPE SS41 1 12 350P07 1 DRIVING GEAR 1 13 350P08 1 DRIVEN GEAR SS41 1 14 1500P11 SUPPORTER 1 15 OP20V O RING 1 16 OB20 BACK UP RING 1 17 K04 8C KEY 1 18 K05 KEY 1 19 C35B C SNAP RING 1 20 U6302ZZC3 BEARING 1 21 SC061273B HEXAGON BOLT 3 22 SC063073B HEXAGON BOLT 3 23 SC066573B H...

Страница 50: ...48 Hwang Sun Enterprise Co Ltd 48 Edition 2012 02 FIGURE 6 1 5 MANIFOLD ASSEMBLY ...

Страница 51: ...MBLY ITEM SERIAL NO DESCRIPTION MATERIAL Q TY 1 350T05 2 MANIFOLD A6061 1 2 350EA00 1 NOZZLE 1 3 350C00 BY PASS VALVE 1 4 350F00 FILTER ASSEMBLY 1 5 1500D01 BUSHING A6061 1 6 OG35V O RING 1 7 OP16V O RING 1 8 ST 3 8 83B PLUG SCREW 3 9 ST 1 8 83B PLUG SCREW 1 10 TD0303AO CONNECTOR 1 ...

Страница 52: ...50 Hwang Sun Enterprise Co Ltd 50 Edition 2012 02 FIGURE 6 1 6 BY PASS VLAVE ...

Страница 53: ...2 02 MODULE NO 350C00 BY PASS VLAVE ITEM SERIAL NO DESCRIPTION MATERIAL Q TY 1 350C01 VLAVE BASE SS41 1 2 350C02 ADJUSTABLE ROD SS41 1 3 1102C08 FIXED NUT SS41 1 4 1102C09 WASHER CU 1 5 OP9V O RING 1 6 OP14V O RING 1 7 SC050883B SOCKET SET SCREW 1 ...

Страница 54: ...52 Hwang Sun Enterprise Co Ltd 52 Edition 2012 02 FIGURE 6 1 7 FILTER ASSEMBLY ...

Страница 55: ...ERIAL NO DESCRIPTION MATERIAL Q TY 1 1102F01A ADJUSTABLE ROD SS41 1 2 OB18 BACK UP RING 1 3 OP18V O RING SS41 1 4 1102F02 SUPPORTER A6061 1 5 350F01 MESH SCREEN SUS304 1 6 350 20 MESH SCREEN SUS304 1 7 LCIS02A09 FIXED RING SUS304 1 8 LCIS02A10 FIXED RING SUS304 1 9 SC059573B HEXAGON SCREW 1 ...

Страница 56: ...54 Hwang Sun Enterprise Co Ltd 54 Edition 2012 02 FIGURE 6 1 8 WIRING DIAGRAM ...

Страница 57: ...55 Hwang Sun Enterprise Co Ltd 55 Edition 2012 02 FIGURE 6 1 9 WIRING DIAGRAM ...

Страница 58: ...56 Hwang Sun Enterprise Co Ltd 56 Edition 2012 02 FIGURE 6 1 10 WIRING DIAGRAM ...

Страница 59: ...57 Hwang Sun Enterprise Co Ltd 57 Edition 2012 02 FIGURE 6 1 11 COMPONENTS WIRING CONFIGURATION ...

Страница 60: ...58 Hwang Sun Enterprise Co Ltd 58 Edition 2012 02 FIGURE 6 1 12 COMPONENTS WIRING CONFIGURATION ...

Страница 61: ...59 Hwang Sun Enterprise Co Ltd 59 Edition 2012 02 FIGURE 6 1 13 PANEL EXTERNAL WIRING CONFIGURATION ...

Страница 62: ...60 Hwang Sun Enterprise Co Ltd 60 Edition 2012 02 FIGURE 6 1 14 PARAMETER SETTING OF INVERTER ...

Страница 63: ...r Loss and Restart 0001 Momentary power loss and restart enable 2 03 Number of Auto Restart Attempts 0002 3 00 Frequency upper Limit 60 0 Modify according to the actual operation 3 02 Acceleration Time 1 Seconds 10 0 sec Modify according to the actual operation 3 03 Deceleration Time 1 Seconds 10 0 sec Modify according to the actual operation 3 12 DC Injection Break Time 000 0 sec 4 00 Motor Curre...

Страница 64: ...62 Hwang Sun Enterprise Co Ltd 62 Edition 2012 02 1 Parameters that aren t shown on above list are original value 2 The operation pressure 7000kPa normal operation 7000kPa overload ...

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