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Preventive Maintenance Tips

TANK PUMP  

Warning: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury.

Frequency Maintenance Activity

Based on run time of heaters  
Every 8 hours Clean the exterior surfaces of the units and guns
  Check the o-rings and gaskets on hose connectors and plugs for
leaks. Refer to HOSE MAINTENANCE
  Flush the manifold filter. Refer to MANIFOLD FILTER MAINTENANCE

Every 40 hours Clean the manifold filter. Refer to MANIFOLD FILTER
MAINTENANCE
  Clean removable nozzles. Refer to NOZZLE MAINTENANCE

Every 160 hours Check all electrical connections and terminal blocks for tightness, including those inside the electrical enclosure.

As needed Piston Pump Clean the filter element of the air regulator.Clean the inside of the electrical enclosure.Check electrical connections and terminal blocks for tightness. Check the hose connections. Flush the system with a flushing material. Refer to FLUSHING THE SYSTEM 

As needed Gear Pump Clean the inside of the electrical enclosure.Check electrical connections and terminal blocks for tightness. Check the hose connections.Disassemble and clean the gear pump. Refer to GEAR PUMP REPAIR. Flush the system with a flushing material. Refer to FLUSHING THE SYSTEM 

Check run time of heaters 1. Press the Move up and Move down keys until the SYSTEM SETTINGS light turns on.
2. Press the Up key below the Selector display until feature number 26 appears in the display.

 

HOSE

Warning: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury.

Frequency Maintenance Activity
Daily

1. Make sure to have safety gloves on. Wipe off any hot melt
material on the hose fittings or the hose braid. Built up material
can cause kinking when the hose is moved from the position to
another.

2. Clean any dust and debris from the hose cover. Accumulated dust can create hot spots in a hose and become a fire hazard.

Periodic

Flush the entire hot melt application system, including the
hoses periodically. Flushing removes excess dirt and charred
material. Also, clean the system if the adhesive in the system is
changed, and the old and new adhesives are incompatible.

Inspecting Hose Hydraulic Connections

1. Heat the system to operating temperature.

2. Relieve system pressure by performing all the following actions:

Systems with a piston pump:

  • Reduce pump air pressure to zero and disconnect the supply (incoming) air line.
  • Place the air pump ON/OFF switch in the OFF position.
  • Systems with a gear pump:
    - Turn the motor speed dial to 0%.
    - Place the motor ON/OFF (or START/STOP) switch in the OFF (or STOP) position.

3. Trigger all guns to relieve any trapped hydraulic pressure.

4. Disconnect the solenoids and/or photoeyes to prevent accidental triggering of the guns.

5. Reduce air pressure to the guns:

  • Systems with automatic guns:
    - Reduce gun air pressure to zero at the regulator.
  • Systems with handguns:
    - Place the gun trigger safely in the locked position. Hang the handgun by the hole in its handle.

6. Disconnect and lock out power to the main circuit breaker for the applicator input power line.

7. Inspect the hose to applicator and hose to gun fittings for
tightness.

8. Tighten any loose connections using two wrenches place one wrench on the applicator manifold or gun fitting and the other wrench on the hose fitting.

Note: Always use two wrenches to tighten any hose fittings.

Inspecting Hose Electrical Connections 1. Disconnect and lock out power to the main circuit breaker for the applicator input power line.

2. Check that all hose electrical plug pins are in good condition.
Repair any damaged pins. Refer to RECOMMENDED SPARE PARTS for the required hose end repair kit.

3. Check that all hose electrical plug connections are tight.
Tighten any loose plugs.

H200 Gun Applicators / Modules

Warning: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury.

Frequency Maintenance Activity
Daily

Clean the gun and the work area daily. Accumulated adhesive can char and cause erratic gun operation.

Weekly Clean nozzles weekly unless operational history indicates that
more or less frequent cleaning is required. Nordson offers a nozzle cleaning kit. Refer to RECOMMENDED SPARE PARTS for the part number.
Semiannual Inspect the gun wiring semiannually.

Flush the system semiannually unless operational history indicates that more or less frequent flushing is required.
As needed Flush the system before changing to a different adhesive.



Nozzle

Warning: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury.

Frequency Maintenance Activity
Weekly

Clean nozzles weekly unless operational history indicates that
more or less frequent cleaning is required. Nordson offers a nozzle cleaning kit. Refer to RECOMMENDED SPARE PARTS for the part number.

   
MANIFOLD FILTER (CLEANING)
 
Use this procedure to clean the manifold filter. Cleaning the filter removes excess dirt and charred material that can clog the system and cause poor system performance.
 
Warning: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released under pressure.
 
1. Ensure that the unit is at operating temperature.
2. Flush the manifold filter. Refer to Flushing the Manifold Filter in this section.
Warning: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns.
3. Relieve system pressure. Refer to Relieving System Pressure in this section.
4. Loosen the filter using a wrench. A socket-type wrench is recommended.
5. Pull the filter assembly out of the manifold.
6. Remove the screw in the back of filter assembly and separate the filter screen from the assembly.
7. Use one of the following methods to clean the filter components.

Warning: Risk of fire. Do not heat Nordson Type R cleaning fluid above 246 °C (475 °F). Do not heat cleaning fluid with an open flame or in an unregulated heating device (for example, a small pan on an unregulated hot plate). A fire hazard exists if an open flame or an unregulated heating device is used to heat cleaning fluid. Use only a controlled heating device (such as a small, deep fat fryer or thermostatically-controlled hot plate) to heat the fluid above the melting temperature of the hot melt material.

  • Place the components (except for the o-ring) in a container of Type R cleaning fluid and heat the fluid until it is above the melting point of the adhesive. Scrub the components with a fine-bristled brush. Remember to scrub the filter screen inside and out. Wipe the components with a clean, dry cloth.
  • Use a flameless, electric heat gun or compressed hot air to heat thecomponents. Wipe the components with a clean, dry cloth.
  • Use an ultrasonic cleaner filled with cleaning fluid to soak the components, then wipe the components with a clean, dry cloth.
  • Caution: Do not use a metal brush to clean a manifold filter screen. Doing so can damage the screen and prevent the filter from operating properly.
8. Inspect the filter screen and o-ring for damage. A dent or break in the filter screen mesh means that
    the screen is damaged beyond repair and should be replaced.
9. Reassemble the filter.
     Caution: Ensure that the unit is at operating temperature before reinstalling the filter. Cold material
     from the filter or manifold walls can cause the filter screen to collapse if it is tightened in a cold system.
10. Ensure that the unit is at operating temperature.
11. Slide the filter assembly into the manifold and tighten it until it is finger-tight only.
12. Follow these steps to flush the manifold again:
  • Open the manifold drain valve.
  • Turn the pump on by pressing the PUMP key.
  • Allow adhesive to flow from the drain valve.
  • Turn the pump off by pressing the PUMP key.
  • Close the manifold drain valve.
13. Tighten the filter assembly until it seats. Do not overtighten.
14. Turn the pump on by pressing the PUMP key and resume normal operation.
 
 
FLUSHING THE MANIFOLD FILTER
 
Use this procedure to flush the manifold filter. Flushing the manifold filter removes excess dirt and charred material that can clog the system and cause poor system performance.
Warning: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released under pressure.
 

 1. Ensure that the unit is at operating temperature.
 2. Place containers under all guns and the manifold drain valve. If necessary, open the
     manifold filter and drain valve cover.
 3. Turn the pump off by pressing the PUMP key.
 4. Trigger the guns to relieve system pressure.
 5. Open the manifold drain valve.
 6. Turn the pump on by pressing the PUMP key.
 7. Allow adhesive to flow from the drain valve until no traces of char are present.
 8. Turn the pump off by pressing the PUMP key.
 9. Close the manifold drain valve.
10. Turn the pump back on by pressing the PUMP key and resume normal operation.

Warning: System or material pressurized. Relieve system pressure. Failure to observe may result in serious burns.

FLUSHING THE SYSTEM

Use this procedure to periodically flush the system with hot melt material, a flushing material, or Type R cleaning fluid. System flushing removes excess dirt and charred material that can clog the system and cause poor system performance. You should also flush the system when you switch to a new type of hot melt material that is incompatible with the old material. If you are unsure whether the materials are compatible, contact your material supplier.

To Prepare for Flushing the System

1.  Ensure that the unit is at operating temperature.
     Warning: System or material pressurized. Relieve system pressure. Failure to observe may result in
    serious burns.
2.  Relieve systen pressure. Refer to RELIEVING SYSTEM PRESSURE in this section.
3.  Draing the unit by pumping as much hot melt material from the tank as possible using one of the following     
     methods:

Method of Draining
Description
   
Gun/Applicator Place a suitable container under each gun nozzle. Remove each nozzle from its gun. Turn on the pump by pressing the PUMP key and pump the hot melt material out through the gun.
Manifold Pump the hot melt material out through the manifold. Refer to FLUSHING THE MANIFOLD FILTER in this section.
Hose Disconnect a hose from its gun. Replace the dust cover, which was removed during installation, over the hose electrical receptacle. Position the hose over a suitable waste container and secure it. Turn the pump on by pressing the PUMP key and pump the hot melt material out through the hose.

5. If you have not already done so, disconnect each hose in the system from its gun.
6. Clean each automatic gun and handgun as needed. Refer to the gun manual for information on gun
    disassembly, cleaning, and rebuilding.
7. Refer to Table below to determine which method of flushing the system is best for your operation.

Flushing Procedure
Time Needed
(See Note A)
Best Used for...
(See Note B)
Advantages and Disadvantages
       
Using hot melt material About 1 hour Routine cleaning when the system is relatively free of char. The advantage of this method is that it requires less downtime. However, it is not as thorough as the other two methods.
Using a flushing material recommended by your adhesive supplier and approved by your Nordson representative From 21/2 to 5 hours Occasional cleaning when there is some char buildup.

Although this method requires more downtime, it does a good job of ridding the system of char buildup. However, you may need to scrub the tank to remove all char. You will also need to purchase and store flushing material, which may have special storage and disposal requirements.

Using Type R fluid From 3 to 13 hours Thorough cleaning when there is significant char buildup. This procedure is the most thorough way to remove char. You may also need to scrub the tank to remove all char. Disadvantages are that you cannot flush Type R fluid through the hoses; accidentally doing so can cause later downtime. Type R fluid is expensive but can be reused several times if the used fluid is strained into a storage container. The fluid is considered a regulated waste.
             Note A : Time needed varies depending on how much char must be removed.
             Note B : Because operating conditions vary from plant to plant, you may find that
                            more or less frequent flushing is required.

       8. Refer to the appropriate procedure for the flushing method you have selected: 
               -  To flush the system with hot melt material
               -  To flush the system with a flushing material
               -  To flush the system with type R fluid



To Flush the System with Hot Melt Material

1. Before beginning this procedure, first complete the procedure TO PREPARE FOR FLUSHING THE SYSTEM earlier in this section.

Note: This procedure describes how to flush all hoses at once. However, for maximum cleaning of badly charred hoes, use this procedure and flush each hose Note:one at a time.

2. If you have not already done so, secure the free end of each hose to a container that will be used to collect the hot melt material.

3. Using a metal or plastic scoop, fill the tank to within 25 mm (1 in.) of the top with fresh, clean hot melt material.

4. Allow the unit to reach operating temperature.

5. When the READY light turns on, turn the pump on by pressing the PUMP key.

6. Pump hot melt material through the hoses until the material is free of char and contaminants.

7. Turn the pump off by pressing the PUMP key.

Caution: Using a metal brush or scraper can damage non-stick coated tanks. Use a stiff-bristled, nonmetal brush when cleaning a non-stick coated tank.

8. Use a stiff-bristled, non-metal brush or similar tool to scrub the tank or dislodge as much char and debris as possible. Do not use a metal brush or scraper on non-stick coated tanks.

Note: If this procedure does not remove all the charred material, you may need to replace the tank.

9. Go to the procedure To Restore the Unit to Normal Operation in this section

 

To Flush the System with a Flushing Material

Warning: Use the flushing material at the manufacturer’s recommended temperature, which will be below the hot melt material’s flash point. Failure to observe this warning can cause a fire.

Warning: Never flush your system or clean any aluminum components with halogenated hydrocarbon cleaning solutions. These cleaning solutions are extremely dangerous when used to clean aluminum components in a pressurized fluid system.

Caution: Do not use this procedure to flush your system with Type R fluid. This procedure instructs you to pump flushing material through the hoses. Flushing Type R fluid through hoses can cause large pieces of char to break off and clog the nozzles during later operation. If you plan to use
Type R fluid to flush your system, refer the procedure To Flush the System with Type R Fluid in this section.

Caution: Certain flushing materials can damage seals and o-rings, resulting in poor pump performance. Be sure that the flushing material you use has been approved by your Nordson representative. To determine the best flushing material to use, contact your adhesive supplier.

1. Before beginning this procedure, first complete the procedure To Prepare for Flushing the System earlier in this section.

Note: This procedure describes how to flush all hoses at once. However, for maximum cleaning of badly charred hoses, use this procedure and flush each hose one at a time.

2. If you have not already done so, secure the free end of each hose to a container that will be used to collect the hot melt material

3. Set the tank and hose temperature to the recommended temperature of the flushing material.

4. Pour the flushing material into the empty tank to within 25 mm (1 in.) of the top of the tank.

5. When the unit reaches the preset temperature (at which point the READY light will turn on), turn the pump on by pressing the PUMP key.

6. Pump material through the hoses until the flushing material starts to come out.

7. Turn the pump off by pressing the PUMP key.

8. Allow the remaining material to drain from the hoses.

9. Remove the hoses from the collection container, place them over the tank, and secure them.

10. Turn the pump on by pressing the PUMP key.

11. Allow the flushing material to circulate through the system for 11/2 to 4 hours.

12. Turn the pump off by pressing the PUMP key.

13. Wait for any remaining material to drain from the hoses.

14. Remove the hoses from the tank, secure them over a waste container, and drain the flushing material from the tank into the container.

Caution: Using a metal brush or scraper can damage non-stick coated tanks. Use a stiff-bristled, nonmetal brush when cleaning a non-stick coated tank.

15.Use a stiff-bristled, nonmetal brush or similar tool to scrub the tank or dislodge as much char and debris as possible. Do not use a metal brush or scraper on non-stick coated tanks.

Note: If this procedure does not remove all the charred material, you may need to replace the tank.

16. Using a metal or plastic scoop, fill the tank to within 25 mm (1 in.) of the top with fresh, clean hot melt material.

17. Set the temperature of the tank to the lowest temperature that the adhesive can be pumped at.

18. Wait for the unit to reach the preset temperature, then drain 3/4 of the adhesive through the hoses into the waste container.

19. After you have drained 3/4 of the material, turn the pump off by pressing the PUMP key.

20. Place a container under the manifold drain valve, open the valve, and drain the remaining adhesive

21. Clean the manifold filter. Refer to Cleaning the Manifold Filter in this section.

22. Go to the procedure To Restore the Unit to Normal Operation in this section.

To Flush the System with Type R Fluid

1. Before beginning this procedure, first complete the procedure To Prepare for Flushing the System
    earlier in this section.

2. Set the tank temperature 14--17 °C (25--30 °F) higher than the recommended application temperature
    of the adhesive.

3. Pour Type R fluid into the empty tank to within 25 mm (1 in.) of the top of the tank.

4. Use a clean paint brush or similar tool to apply fluid to areas not submerged in the fluid.

5. Allow the fluid to heat in the tank for 2 -12 hours.

6. As needed, use a wooden or plastic strainer to skim off the char and adhesive that floats to the top
    of the tank.

Caution: Do not pump Type R fluid through hoses. Fluid absorbed by char in the hoses may leach out or cause large pieces of char to break off and clog a nozzle during later operation.

7. Place a container under the manifold drain valve, open the valve, and drain the fluid from the manifold

Note: You can reuse the fluid if you place a strainer on the top of the container used to collect it.

8. Close the manifold drain valve.

9. Using a metal or plastic scoop, place several pounds of fresh, clean hot melt material into the empty
    tank.

10. Set the temperature of the tank and hoses to the lowest temperature that the adhesive can be pumped
    at.

11. Secure the free end of the hose to a container that will be used to collect the hot melt material When
     the tank and hoses reach their setpoint temperatures (at which point the READY light will turn on), turn
     the pump on by pressing the PUMP key.

12. Pump adhesive into the containers until a clean, steady stream of material flows from each hose.

13.When material has finished draining, turn the pump off by pressing the PUMP key.

14. Go to the procedure To Restore the Unit to Normal Operation in this section.

To Restore the Unit to Normal Operation

After flushing your system with hot melt material, a flushing material, or Type R fluid, follow this procedure to restore your unit to normal operation:

1. Disconnect and lock out electrical power to the unit.
2. Reconnect each gun to its hose both electrically and mechanically. Remove the
    lock-out and restore power to the unit.
3. If you have changed the unit's temperature setpoint or if the recommended operating
    temperature of the new adhesive is different from the previous adhesive, reprogram
    the temperature settings. Refer to the appropriate procedure as directed by the table
    below.

To reprogram this setting Follow this procedure
Overtemperature setpoint PROGRAMMING SYSTEM SETTINGS CONTROLS in Section A 4, Operation
Setpoint or standby temperature PROGRAMMING TEMPERATURE CONTROLS in Section A 4, Operation

1. Use a metal or plastic scoop to fill the tank with adhesive.

2. When the READY light turns on, turn the pump on by pressing the PUMP key.

3. Resume normal operation.