Chameleon Application Head System

Transcript

CHAMELEONR Application Head System Manual P/N 409 216 C – English – NORDSON TECHNOLOGY D MAASTRICHT D THE NETHERLANDS Note This manual applies to the entire series. Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AquaGuard, Blue Box, Control Coat, Equi=Bead, FloMelt, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Porous Coat, Posi-Stop, RBX, Sure-Bond, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation. BetterBookSM, CF, Controlled Fiberization, Easy-Screen, Fibermelt, Flo-Tracker, PrintGuard, and Package of Values are trademarks of Nordson Corporation. COV_EN_409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved MANUFACTURER DECLARATION Directive 98/37/EC NORDSON TECHNOLOGY BV Bergerstraat 10 6226 BD Maastricht The Netherlands PRODUCT FAMILY: CHAMELEON® APPLICATION HEAD SYSTEM Model No.: CM 200, CM 900, CM 711, CM 800 Part No.: Serial No.: International Standards Fulfilled: (Safety of machinery) EN 292 Winfred C. Otten, General Manager – English – NORDSON TECHNOLOGY BV Date: January 13, 2000 Table of Contents I Table of Contents Congratulations on the Purchase of Your Nordson Product Nordson International Your Safety is Important to Nordson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 We Welcome Your Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-3 Distributors in Eastern & Southern Europe . . . . . . . . . . . . . . . . . . . . . . . O-3 Outside Europe / Hors d’Europe / Fuera de Europa . . . . . . . . . . . . . . . . O-4 Africa / Middle East . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-4 Asia / Australia / Latin America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-4 Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-4 North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-4 General Hot Melt Material Processing Instructions Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-5 Preparations for Material Application/Coating . . . . . . . . . . . . . . . . . . . . . O-5 Processing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-5 Danger of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-6 Mixing Hot Melt Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-6 Disposal of Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-6 Section 1 Safety 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2. Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 3. Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 4. Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 5. Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 6. Installation and Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 1-3 7. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Less-obvious Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Danger of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C II Table of Contents Section 1 Safety (contd.) 8. Maintenance / Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Liquid Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 9. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Liquid Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 10. Liquid Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 11. Thermoplastic Hot Melt Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 12. Action in the Event of a Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Section 2 Description 1. Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Unintended Use -Examples- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Current Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2. Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3. Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Adhesive Flow/Adhesive Application . . . . . . . . . . . . . . . . . . . . . . 2-3 Heating and Temperature Regulation . . . . . . . . . . . . . . . . . . . . . . 2-3 4. Core Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 5. Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 CM 900 and CM 800 (electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 CM 200 (pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CM 711 (pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 6. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Nozzle Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Substrate Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hose Connection Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Cordsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Table of Contents Section 2 Description (contd.) III 7. Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Application Head Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Position of the Control Module on the Core Manifold . . . . . . . . 2-11 Vertical and Horizontal Position of the Application Head . . . . . 2-12 Cordsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 8. Application Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Cold Glue Application Heads with Pneumatic Control Modules CM 711 . . . . . . . . . . . . . . . . . . 2-13 Application Head with Electrical Control Modules CM 900 (hot melt) or CM 800 (cold glue) . . . . . . . . . . . . . . . . . . 2-14 Hot Melt Application Head with Pneumatic Control Modules CM 200 . . . . . . . . . . . . . . . . . 2-15 Section 3 Installation 1. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 2. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Exhausting Adhesive Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 4. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 5. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 6. Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Laying Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hot Melt Application Head, Electrical Connection . . . . . . . . . . . . 3-2 Connect Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 7. Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Connect Control Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Maximum Operating Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 8. Installing Heated Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Second Open-jawed Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C IV Table of Contents Section 4 Operation 1. Switching System On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Hot Melt Application Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cold Glue Application Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 2. Switching On for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hot Melt Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Cold Glue Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 3. Switching On Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hot Melt Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Cold Glue Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4. Shutting Down Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Hot Melt Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Cold Glue Application Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 5. Emergency Switch-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 6. Activate Solenoid Valve (hot melt only) . . . . . . . . . . . . . . . . . . . . . . . 4-4 7. Activate Electrical Control Modules (hot melt only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 8. Set Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 9. Set Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Air Pressures/Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 10. Module Synchronization/Set Application Pattern (CM 200 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 11. Set Application Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 12. Change Nozzle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 13. Recording the Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Table of Contents Section 5 Maintenance V 1. Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2. Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Inspection for External Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 External Cleaning (hot melt application heads) . . . . . . . . . . . . . . 5-2 External Cleaning (cold glue application head) . . . . . . . . . . . . . . 5-3 Check Leakage Hole (CM 200) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 3. Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Check Screw Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Control Modules CM 711 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Control Modules CM 900 and CM 800 . . . . . . . . . . . . . . . . . . . . . 5-6 Control Module CM 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Nozzle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Application Head Assembly (visual inspection) . . . . . . . . . . . . . 5-11 Flushing the Hot Melt Application System . . . . . . . . . . . . . . . . . 5-11 4. Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Section 6 Troubleshooting 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 2. Fault Table (Cold Glue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 3. Fault Table (Hot Melt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Section 7 Repair 1. Change Nozzle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 2. Change Heater Cartridge(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 3. Change Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 4. Change Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 5. Disassembling and Reassembling the Control Module . . . . . . . . . 7-3 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C VI Table of Contents Section 8 Parts 1. Use of the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Updated Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 2. Application Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Cold Glue Application Head with Pneumatic Control Module CM 711 . . . . . . . . . . . . . . . . . . . . 8-2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hot Melt Application Head with Electrical Control Module CM 900 . . . . . . . . . . . . . . . . . . . . . 8-4 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Cold Glue Application Head with Electrical Control Module CM 800 . . . . . . . . . . . . . . . . . . . . . 8-6 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Hot Melt Application Head with Pneumatic Control Module CM 200 . . . . . . . . . . . . . . . . . . . 8-8 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 3. Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Diagram of the CM 711 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Diagram of the CM 800 and CM 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Diagram of the CM 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 4. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Heater Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Solenoid Valves, CM 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Solenoid Valves, CM 710 - CM 711 (cold glue) . . . . . . . . . . . . . 8-16 Cordsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Substrate Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Bleeding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 5. Length-dependent Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Table of Contents Section 8 Parts (contd.) VII 6. Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Insert CM 800 and CM 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Nozzle Stem and Seal Kit CM 800 and CM 900 . . . . . . . . . . . . 8-25 Insert CM 71x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 Spare Part Kit, Insert CM 71x (standard) . . . . . . . . . . . . . . . . . . 8-27 Seal Kit, Insert CM 71x (standard) . . . . . . . . . . . . . . . . . . . . . . . 8-27 7. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28 Section 9 Specifications 1. General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 2. Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Pneumatic Control Module CM 711 . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Electrical Control Module CM 900 . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Electrical Control Module CM 800 . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Pneumatic Control Module CM 200 . . . . . . . . . . . . . . . . . . . . . . . 9-4 3. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Hot Melt Application Head in Vertical Position up 90 with Pneumatic Control Modules CM 200 . . . . . . . . . . . . . . . . . . 9-5 Hot Melt Application Head in Vertical Position Straight with Pneumatic Control Modules CM 200 . . . . . . . . . . . . . . . . . . 9-6 Hot Melt Application Head in Horizontal Position up 90 with Pneumatic Control Modules CM 200 . . . . . . . . . . . . . . . . . . 9-7 Hot Melt Application Head in Horizontal Position Straight with Pneumatic Control Modules CM 200 . . . . . . . . . . . . . . . . . . 9-8 Hot Melt Application Head in Vertical Position with Electrical Control Modules CM 900 . . . . . . . . . . . . . . . . . . . . 9-9 Hot Melt Application Head in Horizontal Position with Electrical Control Modules CM 900 . . . . . . . . . . . . . . . . . . . 9-10 Cold Glue Application Head in Vertical Position with Electrical Control Modules CM 800 . . . . . . . . . . . . . . . . . . . 9-11 Cold Glue Application Head in Horizontal Position with Electrical Control Modules CM 800 . . . . . . . . . . . . . . . . . . . 9-12 Cold Glue Application Head in Vertical Position with Pneumatic Control Modules CM 711 . . . . . . . . . . . . . . . . . . 9-13 Cold Glue Application Head in Horizontal Position with Pneumatic Control Modules CM 711 . . . . . . . . . . . . . . . . . . 9-14 4. Cordsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 5. Electrical Connection Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . 9-16 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C VIII Table of Contents P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Introduction O-1 Congratulations on the Purchase of Your Nordson Product Nordson equipment is engineered and manufactured in accordance with strict specifications, using high-quality components and state-of-the-art technologies that assure reliable, long-term performance. Your product was thoroughly tested for proper operation prior to shipment. Data and specifications included in this manual are accurate at the time of publication. Nordson reserves the right to change the contents of this manual and/or specification without notice. Carefully read the manual first. It is your guide to safe installation, productive operation and effective maintenance. We recommend that you keep the manual available for future reference. Your Safety is Important to Nordson We Welcome Your Suggestions E 1994 Nordson Corporation All rights reserved Carefully read the Safety instructions. Your product is designed for safe operation when used according to the published instructions. However, potential hazards exist when instructions – particularly safety instructions – in this manual and all related documentation are not followed. If you have any comments or questions concerning Nordson products, spare parts or manuals, do not hesitate to contact Nordson. For addresses see Nordson International. CONG_EN_B–1294 O-2 Introduction CONG_EN_B–1294 E 1994 Nordson Corporation All rights reserved Introduction O-3 Nordson International Europe Country Phone Austria 43-1-707 5521 43-1-707 5517 Belgium 31-13-511 8700 31-13-511 3995 Czech Republic 4205-4159 2411 4205-4124 4971 Denmark Hot Melt 45-43-66 0123 45-43-64 1101 Finishing 45-43-66 1133 45-43-66 1123 Finland 358-9-530 8080 358-9-530 80850 France 33-1-6412 1400 33-1-6412 1401 Erkrath 49-211-92050 49-211-254 658 Lüneburg 49-4131-8940 49-4131-894 149 Italy 39-02-904 691 39-02-9078 2485 Netherlands 31-13-511 8700 31-13-511 3995 Hot Melt 47-23 03 6160 47-22 68 3636 Finishing 47-22-65 6100 47-22-65 8858 Poland 48-22-836 4495 48-22-836 7042 Portugal 351-22-961 9400 351-22-961 9409 Russia 7-812-11 86 263 7-812-11 86 263 Slovak Republic 4205-4159 2411 4205-4124 4971 Spain 34-96-313 2090 34-96-313 2244 Hot Melt 46-40-680 1700 46-40-932 882 Finishing 46-304-66 7080 46-304-66 1801 41-61-411 3838 41-61-411 3818 Hot Melt 44-1844-26 4500 44-1844-21 5358 Finishing 44-161-495 4200 44-161-428 6716 UV 44-1753-558 000 44-1753-558 100 Germany Norway Sweden Switzerland United Kingdom Distributors in Eastern & Southern Europe E 2001 Nordson Corporation All rights reserved Fax DED, Germany 49-211-92050 49-211-254 652 NI_EN_J–0301 O-4 Introduction Outside Europe / Hors d’Europe / Fuera de Europa S For your nearest Nordson office outside Europe, contact the Nordson offices below for detailed information. S Pour toutes informations sur représentations de Nordson dans votre pays, veuillez contacter l’un de bureaux ci-dessous. S Para obtenir la dirección de la oficina correspondiente, por favor diríjase a unas de las oficinas principales que siguen abajo. Contact Nordson Phone Fax Africa / Middle East DED, Germany 49-211-92050 49-211-254 652 Asia / Australia / Latin America Pacific South Division, USA 1-440-988-9411 1-440-985-3710 Japan Japan 81-3-5762 2700 81-3-5762 2701 North America Canada 1-905-475 6730 1-905-475 8821 Hot Melt 1-770-497 3400 1-770-497 3500 Finishing 1-440-988 9411 1-440-985 1417 USA NI_EN_J–0301 E 2001 Nordson Corporation All rights reserved Introduction O-5 General Hot Melt Material Processing Instructions NOTE: Before processing hot melt material, carefully read the material manufacturer’s Material Safety Data Sheet (MSDS) or material information sheet. Nordson supplies only general processing instructions and is not liable for hazards associated with or damage caused by the use of hot melt material. Storage Preparations for Material Application/Coating Store the material in dry areas at room temperature. Keep it in covered, dust-protected containers. Keep the substrate at room temperature, dry, and free of dust and grease. Perform tests to determine the suitable hot melt material, optimum operating conditions, and preliminary treatment of the substrate for the application. Some substrates contain plasticizers and other ingredients which dissipate over time. In some cases, surfaces are treated with waxes, anti-stick oils, etc. Without adequate pretreatment, the hot melt bond in these applications may be defective at the time of dispensing. Processing Temperature The application temperature of the hot melt material at the nozzle is crucial for effective bonds. Refer to the material manufacturer’s MSDS or material information sheet. Avoid unnecessary thermal stress. If the work is interrupted, reduce the melting temperature. Avoid heating the hot melt material above the prescribed processing temperature. Higher temperatures may cause charring of the hot melt material. This results in downtime. In addition, material may generate dangerous vapors at excessively high temperatures. Remove these vapors by using appropriate exhaust systems. E 1994 Nordson Corporation All rights reserved HMI02_EN_B–1294 O-6 Introduction Danger of Burns Be careful when using hot melt materials. These materials are solid at room temperature. For proper application, they may be heated to temperatures of up to 230 _C (450 _F). Refer to the safety instructions in the Safety section. Mixing Hot Melt Materials Avoid mixing different hot melt materials. Refer to Changing the Hot Melt Material in the Maintenance section. Disposal of Hot Melt Material Refer to the supplier’s MSDS or material information sheet. HMI02_EN_B–1294 E 1994 Nordson Corporation All rights reserved Section 1 Safety E 2000 Nordson Corporation All rights reserved SIG05_EN_A–0100 1-0 Safety SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Safety 1-1 Section 1 Safety 1. Introduction Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. 2. Qualified Personnel 3. Regulations and Approvals E 2000 Nordson Corporation All rights reserved Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. SIG05_EN_A–0100 1-2 Safety 4. Personal Safety To prevent injury follow these instructions. S Do not operate or service equipment unless you are qualified. S Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. S Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. S Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. S Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer’s instructions for safe handling and use of materials, and use recommended personal protection devices. S To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Safety 5. Fire Safety 1-3 To avoid a fire or explosion, follow these instructions. S Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. S Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly. S Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. S Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. S Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. 6. Installation and Electrical Connections S Prior to installation, check intended location and surrounding area for any potential hazards during operation. S All electrical, pneumatic, gas and hydraulic connections and installation of all system components may only be carried out by qualified personnel. Observe installation instructions for components and accessories. S Equipment must be properly grounded and fused according to the rated current consumption (see ID plate). S Cables which run outside the system must regularly be checked for wear or damage. S Power supply wire gauge and insulation must be sufficient to handle rated current consumption. S Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas. WARNING: Failure to install the system properly, and especially failure to ensure electrical, pressurized and high pressure feed connections are made correctly may result in serious injury or death. E 2000 Nordson Corporation All rights reserved SIG05_EN_A–0100 1-4 Safety 7. Operation The system should only be operated when it is in working order. It should only by operated by qualified persons following all regulations valid for liquid adhesive systems. S Never allow the system to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons. S Prior to each startup of the system, check protection and warning devices and make sure they are fully functional. Do not operate the equipment if these devices are not functioning properly. S When the removal of safety equipment is required for installation, maintenance or repair, it must be reconnected immediately upon completion of the work. S In a humid environment, only equipment featuring a corresponding protection may be operated. S Do not operate the system in an explosive environment. S Keep parts of the body and clothing away from rotating parts. Do not wear loose articles of clothing when operating or servicing equipment with rotating parts. Remove wrist watches, rings, necklaces or similar jewelry and pin up or cover long hair before performing any work on or with the equipment. The wearing of protective gloves may prove hazardous in certain circumstances where rotating parts are present and may therefore be forbidden. S To carry out measurements on the substrate or system components, switch off parent machine and/or system and wait until the equipment comes to a standstill. S Never point guns or applicator nozzles at yourself or other persons. SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Safety Less-obvious Dangers 1-5 WARNING: An operator or service technician working with the equipment should be aware of the less-obvious dangers that often cannot be completely minimized at production sites: S Pressurized system components S Exposed surfaces of the unit which cannot be practically safeguarded. They may be hot and take time to cool after the unit has been operating. S The possibility that electrical potentials may remain in the system after the system was de-energized S Liquid adhesive vapors or hot melt material and vapors S Hydraulically or pneumatically operated system components S Uncovered winding parts Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. S Be extremely careful when using hot melt material. Even solidified material may still be very hot. S Always wear protective clothing which safely covers all exposed parts of the body. In case of burns: S Immediately cool affected skin areas using cold, clean water. S Do not forcefully remove hot melt material from the skin. S Immediately seek medical attention. E 2000 Nordson Corporation All rights reserved SIG05_EN_A–0100 1-6 Safety 8. Maintenance / Repair Allow only qualified personnel to perform the procedures described in this document. Work should only be carried out on a completely depressurized system, following all safety procedures. WARNING: Some voltage is still present in the control cabinet even after equipment has been turned off at the main switch. Complete the following steps prior to maintenance or repair: S Disconnect external power supply. S Lock out external power supply. S Check no voltage is present. S Ground and short. S Cover nearby live sections. S Secure pneumatically- and hydraulically-operated equipment against uncontrolled movement. S Only use genuine Nordson parts. Liquid Adhesive NOTE: Depending on the configuration of the liquid adhesive application system, high pressure may remain between application head and pressure regulator or pump even after the system has been switched off using the main switch or the emergency stop. This especially applies to multi–hose configurations between pumps and application heads. S Prior to maintenance and repair work it is therefore essential to ensure that all liquid adhesive application system components are depressurized as follows: 1. Release input pressure in front of pump by shutting off customer compressed air supply. 2. Release any remaining system pressure behind the pumps by manually operating the application heads. S Switch off system electrically. If liquid adhesive application system is left idle for extended periods (e.g. overnight or long breaks) Nordson recommends applying Vaseline to the application head nozzles to prevent them from drying out and becoming blocked as a result. Hot Melt Material S Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit. S Always use tools with insulated handles when removing or installing components. SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Safety 9. Cleaning 1-7 NOTE: Always refer to the manufacturer’s Material Safety Data Sheet or material information sheet before working with any cleaning fluids. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-controlled and explosion-protected heaters. S Never use an open flame to clean the system or its components. S Ensure sufficient room ventilation to draw off vapors. Liquid Adhesive S Check that (warm) water can be used to clean the liquid adhesive system components, possibly with the addition of household washing–up liquid. If this is not possible, use only the cleaning fluid stated in the liquid adhesive manufacturer’s information. If the manufacturer recommends heating the cleaner, note the flash point. S Disposal must be according to the waste key in the DIN Safety Data Sheet. Liquid adhesives or residue, solvent or separating agents must not be released into open waterways. In the case of a leak or spillage, contain liquid and if necessary use an absorbant material e.g. sawdust to soak it up; then proceed according to the relevant waste disposal regulations. S If the liquid adhesive application system is to be idle for an extended period, the entire system should be flushed and outlets sealed with Vaseline. Warm water is usually used to flush application systems with which water based liquid adhesives are processed. S If the liquid adhesive manufacturer specially recommends a flushing agent, the manufacturer’s safety and disposal details must be followed. Hot Melt Material S Use only cleaning fluids designed or intended to be used with the hot melt material being used in the unit. Never use paint fluids under any circumstances. S Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids. E 2000 Nordson Corporation All rights reserved SIG05_EN_A–0100 1-8 Safety 10. Liquid Adhesives As there is a wide variety of liquid adhesives available with different compositions and characteristics, it is impossible here to give an exhaustive list of safety notes reflecting the typical characteristics of liquid adhesives. The use of liquid adhesives in Nordson’s liquid adhesive application systems therefore requires reference to the liquid adhesive manufacturer’s documents beforehand. Information relating to safety aspects e.g. concerning solvent content, hazards and countermeasures in the event of liquid adhesive coming into contact with skin or mucous membranes are contained in the technical data sheets and the DIN Safety Data Sheets from the manufacturer. NOTE: S It may be necessary to refer to the manufacturer’s notes on the use of materials from a third party. These may be required for processing a liquid adhesive, but hazards arising from their use are not necessarily mentioned by the manufacturer of the liquid adhesive. S Liquid adhesives may still give off vapors when they are processed correctly. The smell produced can cause some annoyance. This is especially true where liquid adhesives are used that contain solvent, thus requiring the use of breathing equipment e.g. a filter. S If the prescribed processing conditions are not followed, harmful decomposition products may develop. Therefore, the vapors must be removed. S Wash hands well before breaks and when work is finished. S If liquid adhesive comes into contact with eyes or mucous membranes, rinse well with water – especially the eyes. Change damp clothes, and seek medical advice if it is swallowed. S If solvents or separating agents are used to process a liquid adhesive, follow the safety and disposal information from the manufacturer. SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Safety 11. Thermoplastic Hot Melt Material 1-9 NOTE: Always refer to the material manufacturer’s Material Safety Data Sheet (MSDS) or material information sheet before working with any hot melt material. S Ensure the work area is adequately ventilated. S Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition of the material. 12. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: S Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. S Identify the reason for the malfunction and correct it before restarting the system. E 2000 Nordson Corporation All rights reserved SIG05_EN_A–0100 1-10 Safety SIG05_EN_A–0100 E 2000 Nordson Corporation All rights reserved Section 2 Description E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-0 Description P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 1999 Nordson Corporation All rights reserved Description 2-1 Section 2 Description 1. Intended Use The CHAMELEON application head system, subsequently also referred to as application head, may only be used for the bead/dot pattern application and surface application of adhesive. Any other use is considered as not intended and is carried out at the operator’s own risk. Nordson assumes no liability for personal injury or equipment damage resulting from unintended use. Intended use also includes the observance of Nordson safety instructions. Nordson recommends collecting detailed information regarding the materials to be used. The product described here may only be operated, serviced and repaired by persons familiar with the product and who have been informed of the potential dangers involved. The appropriate accident prevention regulations must be observed as well as any applicable, commonly accepted safety and industrial health regulations. Unauthorized modifications to this product annul any rights to claims for liability from the manufacturer in respect of consequential damage. Unintended Use -Examples- The application head may not be used under the following conditions: S In a defective condition S In an explosive atmosphere S With protective covers open S In environments which do not correspond to the unit’s Degree of Protection S With unauthorized modifications S When unsuitable hot melt or cold glue is used S When the values stated under Specification are not complied with. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-2 Description Unintended Use -Examples(contd.) The application head may not be used with the following materials: S Explosive and inflammable materials S Erosive und corrosive materials S Foodstuffs Safety Instructions The safety instructions must be read prior to installation of the unit and and observed when putting into operation for the first time. The general safety instructions are provided in the documentation folder or are a part of this manual. Any special safety instructions are part of the instruction manual. Current Parts List Please note that your Nordson equipment may differ slightly from the description or some informational details in the manual. Please refer to the updated Bill of Material which is packed with the equipment. In case of doubt, please contact Nordson. 2. Residual Risks All measures and precautions were taken when designing the unit to protect personnel from possible dangers. Nevertheless, some residual risks cannot be avoided. Personnel should be aware of the following points: S Risk of burns from the hot application heads: through hot adhesive, when exchanging the filter cartridge and adjustment work. S Risk of burns from the hot melt. S Inhalation of potentially hazardous adhesive fumes. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 1999 Nordson Corporation All rights reserved Description 3. Functioning 2-3 The application heads in the Chameleon product series serve to apply cold glue, hot melt or other similar thermoplastic materials. They have been conceived on a modular basis and can be assembled according to individual requirements. Standardized precision components provide high performance and enable a long service life. The application heads are basically comprised of a main body and pneumatic and/or electrical control modules. The application heads are designed for bead/dot pattern application and surface application; the modular structure enables complex application patterns to be realized. The distance to the center of the control modules is a minimum of 35 mm. Adhesive Flow/Adhesive Application The adhesive prepared in the application unit flows through a hose (feed hose) to the body of the application head. In the longitudinal hole, it is distributed to the cross holes through which it enters the upper hole of the control module. From there, it flows through the bottom hole back into the body to the nozzle plate. The control modules and body are sealed from each other around the adhesive holes by means of O-rings. Heating and Temperature Regulation When preparing hot melt, the body (Fig. 2-1) of the application head must be heated up by a heater cartridge whose length matches the length of the body. In order to improve the heat transfer of the heating elements, heat conductive paste (Nordson P/N 257 326) is applied in its holes. The integrated temperature sensor signals the temperature of the application head to the relevant temperature controller in the customer’s hot melt application system control unit or switching cabinet. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-4 Description 4. Core Manifold The core manifold (Fig. 2-1) is provided with longitudinal and cross holes for control air and adhesive, with holes to mount the heater cartridges and temperature sensor, and another larger hole to mount a connection terminal which is used for the wiring. It serves to mount the required control modules (refer to Control Modules) and components (refer to Components). 1 2 3 4 CHAM001A Fig. 2-1 Core manifold 1. Suitable for CM 900 2. Suitable for CM 200 P/N 409216C 3. Suitable for CM 800 CHAMELEON® Application Head System Issued 03/02 4. Suitable for CM 711 E 1999 Nordson Corporation All rights reserved Description 2-5 All the control modules described below can be used according to the application to be performed. A combination of different control modules is also possible. Refer to Application Heads for combining application heads. 5. Control Modules CM 900 and CM 800 (electrical) This control module is a hydraulic precision part which is used for the application of both cold glue and hot melt. The valve is opened electrically. This occurs by means of a coil which moves the valve needle upwards against the pressure exerted by a compression spring. The control modules for cold glue and hot melt only differ in the coils used. The adhesive is fed into the control module through a hole located on the rear of the module at the top. The adhesive is forced out of the application control module through the adhesive outlet, located at the bottom rear of the control module. The electrical connection to the core manifold is achieved by means of an integrated coded pin. The corresponding counterpart is located on the core manifold. CHAM003A Fig. 2-2 Control modules CM 900 and CM 800 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-6 Description 5. Control Modules (contd.) This control module is a pneumatic-hydraulic precision part and is used exclusively for the application of hot melt. It opens/closes the nozzle by raising and lowering the nozzle stem against the pressure exerted by an adjustable compression spring. CM 200 (pneumatic) The piston, to which the nozzle stem is attached, is raised by the compressed air fed in from below; as soon as the solenoid valve switches off the compressed air, the compression spring presses the piston head down, together with the nozzle stem, so that the nozzle stem is lowered exactly in the nozzle orifice and closes it. 1 The compression spring, which exerts pressure from the top onto the piston head, can be adjusted by means of a counterlocked adjustment screw (1) so that when an application head is connected to several control modules, the modules can be synchronized in respect of triggering the nozzle stem stroke and cutting off the adhesive. The upper air chamber, in which the piston moves up and down, and the lower material chamber, through which the hot melt is forced, are sealed off from each other by several special seals. CHAM004A Fig. 2-3 The adhesive is forced out of the application control module through the adhesive outlet, located at the bottom rear of the control module. Control module CM 200 The compressed air is fed into the control module through a hole located on the rear side if the control module at the top. All the control modules connected are supplied with compressed air via a central compressed air connection (2). 1 The compressed air is controlled by means of electrically powered solenoid valves (1). The complete assembly (Fig. 2-5) is mounted on the core manifold. 2 CHAM005A Fig. 2-4 Compressed air supply assembly for CM 200 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 1999 Nordson Corporation All rights reserved Description 2-7 5. Control Modules (contd.) The pneumatically controlled CM 711 control module is used exclusively for the application of cold glue. CM 711 (pneumatic) Extremely short control air paths ensure fast, extremely accurate movement of the nozzle stem. Air is applied to both sides of the working piston. A pressure spring causes a nozzle stem to close the adhesive outlet even if the control air is switched off, e.g. during a system shutdown. The compression spring is equipped to operate with an adhesive pressure of up to approx. 48 bar. 1 CHAMELEON The compressed air is controlled by means of an electrically powered solenoid valve (1).The control module is inserted in the core manifold from the top. The adhesive is fed to the control module from the core manifold and is then fed back into the core manifold from the control module. CHAM006A Fig. 2-5 Control module CM 711 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-8 Description The components described below can be mounted on the required application head according to the task to be performed. 6. Components The actual nozzle implemented in all the application heads consists of a front nozzle plate (1) and rear nozzle plate (2), and an intermediate shim if necessary. The plates are screwed to each other and then secured to the core manifold (3). Nozzle Plates 1 3 2 CHAM007A Fig. 2-6 Nozzle plates Mounting Brackets A wide range of mounting brackets is available for mounting the application heads on the production machine. Two mounting brackets are supplied which can be mounted as required by means of the corresponding rails either straight (2) or angled (1). 1 2 CHAM008A Fig. 2-7 Mounting brackets P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 1999 Nordson Corporation All rights reserved 2-9 Description 6. Components (contd.) Substrate Guides In order to position the substrate accurately during the adhesive application, guides of various lengths can be mounted on the left or right of the application heads. CHAM009A Fig. 2-8 Substrate guides Hose Connection Nipple The application heads are supplied together with a hose connection nipple and a plug. In this way, the application head can be mounted on either side (‘non-handed’) and be specified with any hose feeding equipment for installation in the production machine. Short or long hose nipples are required depending on the application head. The long hose nipples are designed for use with application heads which have electrical connection sockets. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-10 Description 6. Components (contd.) The connection lines for the heater cartridge temperature sensor (refer to Cordsets in the Section Specifications) are bundled in a cordset (Fig. 2-9). The cordsets are equipped with ready-made plugs with which they are connected to the heated hose connector. Cordsets They are set in a grooved connection slot provided on the outside of the core manifold, to the left or right, according to the position of the cordset. 1 2 3 6 4 5 CHAM010A Fig. 2-9 Cordset with temperature sensor Pt 100 or Ni 120 1. Cover plate 2. Ground connection P/N 409216C 3. Temperature sensor 4. Heater cartridge CHAMELEON® Application Head System Issued 03/02 5. Connection terminal 6. Connection plug E 1999 Nordson Corporation All rights reserved 2-11 Description 7. Configuration Fig. 2-10 illustrates the modularly constructed appication heads CM 711, CM 900, CM 800 and CM 200. These application heads are mounted on the core manifolds, control modules and components described on the previous pages. For information on the possible application heads which can be configured (including combinations), refer to Application Heads in this section. Application Head Variants Solenoid valve, horizontal position Solenoid valve, angled position Application head with electrical control module CM 900 (hot melt) or CM 800 (cold glue) Application head with pneumatic control module CM 711 (cold glue) Application head with pneumatic control module CM 200 (hot melt) CHAM011A Fig. 2-10 Application head variants Fig. 2-12 illustrates the possible positions of the control modules on the core manifold. Position of the Control Module on the Core Manifold NOTE: The maximum length of the core manifold is 610 mm. However, this length only applies to application heads with control modules CM 711. The length is limited to 365 mm for all other application heads. CM 711 only 35 35 35 35 35 35 35 35 35 35 35 35 35 35 35 25 Right 35 Left 25 X A B C D E F G H J K L M N O P R S CHAM012A Fig. 2-11 Position of the control modules on the core manifold E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 2-12 Description 7. Configuration (contd.) Vertical and Horizontal Position of the Application Head Fig. 2-12 illustrates the possible positions of the application head on the production machine. 1 2 1 2 3 5 4 3 5 6 View from the left Horizontal 6 4 View from the right Vertical CHAM013A Fig. 2-12 Vertical and horizontal positions of the application head 1. Control module 2. Core manifold 3. Front nozzle plate 4. Rear nozzle plate Cordsets Refer to Section Parts. Solenoid Valves Refer to Section Parts. P/N 409216C CHAMELEON® Application Head System Issued 03/02 5. Cold glue or hot melt 6. Substrate E 1999 Nordson Corporation All rights reserved 2-13 Description 8. Application Heads Cold Glue Application Heads with Pneumatic Control Modules CM 711 1 2 3 CHAMELEON CHAMELEON 4 11 5 10 5 5 6 9 8 7 5 CHAM014A Fig. 2-13 Cold glue application head with pneumatic control modules CM 711 1. 2. 3. 4. Solenoid valve assembly Electric connection Core manifold Flow control valve E 2002 Nordson Corporation All rights reserved 5. Plug 6. Hose nipple 7. Hose nipple CHAMELEON® Application Head System Issued 03/02 8. 9. 10. 11. Control air connection Nozzle plate (exchangeable) Bleeding valve Control module CM 711 P/N 409216C 2-14 Description 8. Application Heads (contd.) Application Head with Electrical Control Modules CM 900 (hot melt) or CM 800 (cold glue) 1 3 2 10 4 9 8 7 6 5 CHAM016A Fig. 2-14 Application head with electrical control modules CM 900 (hot melt) or CM 800 (cold glue) 1. 2. 3. 4. Core manifold Insulation plate (CM 900 only) Fixation for mounting bracket Control module P/N 409216C 5. Cover plate 6. Electrical connection (male) 7. Nozzle plate (exchangeable) CHAMELEON® Application Head System Issued 03/02 8. Cordset (CM 900 only) 9. Protection cap 10. Hose nipple E 1999 Nordson Corporation All rights reserved Description 2-15 8. Application Heads (contd.) Hot Melt Application Head with Pneumatic Control Modules CM 200 1 2 10 3 9 8 7 6 5 4 CHAM017A Fig. 2-15 Application head with pneumatic control module CM 200 1. 2. 3. 4. Solenoid valve Air distributor Deaeration Control module E 2002 Nordson Corporation All rights reserved 5. Nozzle plate (exchangeable) 6. Hose nipple (hot melt) 7. Cordset CHAMELEON® Application Head System Issued 03/02 8. Cover plate 9. Control air connection 10. Core manifold P/N 409216C 2-16 Description P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 1999 Nordson Corporation All rights reserved Section 3 Installation E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 3-0 Installation P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Unpacking Unpack the equipment carefully and check for damage caused during transport. 2. Transport NOTE: The application head is a high precision, valuable part. Handle it with care! Protect the nozzle plate from damage. 3. Installation Install the application head at the point designed for it on the parent machine. Observe the following: S Only install the application head on a solid mounting bracket and tighten the screw fitting(s) firmly due to possible self-oscillation following activation of the compressed air to drive the control modules. S The best distance, drawn from experience and/or any eventual modifications of it, should be taken into account in respect of the intended application during assembly. It should be possible to vary the angle of incidence of the application head to the substrate later, if necessary. S Do not operate in an explosive atmosphere S Protect from humidity, vibrations, dust and drafts S Ensure easy access to parts relevant to maintenance and operation S Protect the nozzle plate from damage. Exhausting Adhesive Fumes E 2002 Nordson Corporation All rights reserved When using hot melt application heads, ensure that the vapors do not exceed the prescribed limit values. Vapors must be drawn off via an exhaust system, if necessary. Ensure sufficient ventilation at the installation site. CHAMELEON® Application Head System Issued 03/02 P/N 409216C 3-2 Installation 4. Storage Do not store outside! Protect from humidity and dust. Do not set down on the nozzle plate. Protect the nozzle plate from damage. 5. Disposal Dispose of according to the applicable laws. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, fatal injury or equipment damage. 6. Electrical Connection Laying Cable WARNING: Ensure cables are not squeezed and do not come into contact with hot parts. Check all cables regularly for signs of damage. Replace damaged cables immediately! Operating Voltage WARNING: Only operate using the operating voltage specified on the rating plate. Hot Melt Application Head, Electrical Connection When using hot melt application heads, the electrical connection is made by connecting the connection plug supplied in the cordset (3, Fig. 3-3) to the connection socket of the heated hose. In the case of special models or larger application heads, plug it into the indicated connection socket of the hot melt application system. NOTE: Secure plug connections with the safety latch. CHAM020A Fig. 3-1 Connect Solenoid Valve Depending on the system’s specific design, the solenoid valves are controlled either by an external power supply, e. g. control unit, or through the solenoid valve control leads of the heated hose. Triggering of the solenoid valve is dependent on the entire function of the hot melt application system and, therefore, cannot be described in detail here. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Installation 3-3 7. Pneumatic Connection The pneumatic connection of application heads with control module CM 200 is made at the control air connection (4, Fig. 3-2). Connect Control Air The control modules operate with unoiled, filtered, dry compressed air. NOTE: If the control air needs be oiled for a specific customer, only use resin-free, low viscosity silicone oil. Nordson recommends: P/N Lubricant Klüber Unisilkon TK 002/100 253 700 NOTE: The control air must be fed to the application head solenoid valves via a pressure regulator which can regulate a minimum pressure range between approx. 2 bar (30 psi) and 7 bar (100 psi). 1. Install the solenoid valve(s) in the application head. 2. Always seal air supply screw fittings with a suitable sealant. Nordson recommends PTFE Paste (Nordson P/N 900 236). WARNING: To prevent eye damage during operation, install the solenoid valves in such a way that the exhaust opening does not point upwards. NOTE: If possible, the solenoid valve should be installed near the body air inlet to achieve a fast switching effect of the control air. 3. Make the electrical connections for the solenoid valve(s). NOTE: Ensure that the nominal voltage of the solenoid valves corresponds to the output switching voltage of the respective controlling unit (photocell, timer, switch etc.). Failure to observe this can result in the solenoid valve being immediately destroyed. Maximum Operating Air Pressure E 2002 Nordson Corporation All rights reserved Refer to Section Specifications. CHAMELEON® Application Head System Issued 03/02 P/N 409216C 3-4 Installation 1 4 3 2 CHAM022A Fig. 3-2 1. Solenoid valve connection for control module CM 200 2. Hose connection nipple (hot melt) for control module CM 200 P/N 409216C 3. Cordset for hot melt application head CHAMELEON® Application Head System Issued 03/02 4. Control air connection for control module CM 200 E 2002 Nordson Corporation All rights reserved Installation 8. Installing Heated Hoses Connecting 1 2 3 3-5 WARNING: Hot! Risk of burns. Wear heat-protective gloves. If cold hot melt is in the hose connection nipple (2, Fig. 3-2) and/or hose connection (2, Fig. 3-3), these parts must be heated up until the adhesive becomes soft (approx. 80 _C). 1. Only make the electrical connection for the hose (3, Fig. 3-3) initially. If several hoses are used, observe the following: Each hose connection nipple is assigned to a connection socket. Do not mix them up! NOTE: When using models with return flow hoses, they must not be mixed up with the feed hoses. 2. Heat the unit and hose to approx. 80 _C (176 °F). CHAM023A 3. Screw on the heated hose. Fig. 3-3 NOTE: If several hose connection nipples are available, the last must be connected to a return flow hose or closed by means of a Nordson plug. Hose connection nipples between should be connected to the first connection in the series. WARNING: System and hot melt material are pressurized. Before disconnecting heated hoses, relieve system pressure. Failure to observe can result in serious burns. Disconnecting Relieving Pressure 1. Set the motor speed(s) to 0 min-1; switch motor(s) off and set pump to 0 bar. 2. Place a collector under the application head nozzle plate. 3. Trigger the solenoid valves electrically or manually. Repeat until hot melt material no longer flows out. 4. Re-use the hot melt material or dispose of properly according to local regulations. Second Open-jawed Wrench Using a second open-jawed wrench prevents the hose connection nipple on the unit from turning. CHAM024A Fig. 3-4 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 3-6 Installation P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Section 4 Operation E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 4-0 Operation P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Operation 4-1 Section 4 Operation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Switching System On WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. Hot Melt Application Heads The hot melt application heads with control modules CM 900 and CM 200 receive their power supply from a hot melt application system. The application heads are normally included in the stage-by-stage heating of all the hot melt application system heating zones and, therefore, are only ready for operation after the heating zone which requires the longest time has reached its set process temperature. 1. Ensure that operation of the application head complies with the applicable instructions in the hot melt application system operating manual. 2. Switch on the hot melt application system according to the applicable instructions in the hot melt application system operating manual. The control module is controlled by a pattern controller (with an internal or external pulse amplifier). Cold Glue Application Heads When cold glue application heads are used with control modules CM 800, and CM 711, the control module is controlled by a pattern controller (with an internal or external pulse amplifier). 1. Ensure that operation of the application head complies with the applicable instructions in the control module operating manual. 2. Switch on the pattern controller according to the instructions in the pattern controller operating manual. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 4-2 Operation 2. Switching On for the First Time Hot Melt Application Head 1. Switch on the hot melt application system according to the applicable instructions in the hot melt application system operating manual. 2. Position a collector underneath the head and open the compressed air supply. Set the operating air pressure (max. 6.9 bar/100 psi) on the relevant pressure regulator for the respective application head. 3. Adjust the application system so that the adhesive flows out of the application head nozzle plate evenly and without any air bubbles. 4. Carry out test gluing and check the adhesive bead. If a thicker bead is required, the adhesive pressure can be increased, but not over 60 bar (870 psi). Cold Glue Application Head 1. Set the air pressure on the pump so that the adhesive pressure does not exceed 48 bar (700 psi). NOTE: Do not exceed 48 bar (700 psi). A higher pressure may damage the application head. 2. Position a collector underneath the head and switch on the pattern controller. 3. Adjust the application system so that the adhesive flows out of the application head nozzle plate evenly and without any air bubbles. 4. Carry out test gluing and check the adhesive bead. If a thicker bead is required, the adhesive pressure can be increased but not over 48 bar (700 psi). 3. Switching On Daily Hot Melt Application Head 1. Switch on the hot melt application system or pattern controller according to the system or controller operating manual. 2. Open the compressed air supply and set the operating air pressure (max. 6.9 bar/100 psi) on the relevant pressure regulator to its optimum setting for the respective application head. Cold Glue Application Head 1. Check whether there is sufficient adhesive in the reservoir. 2. Release the air pressure for the pump. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Operation 4-3 4. Shutting Down Daily Hot Melt Application Head 1. Switch off the hot melt application system according to the system operating manual. 2. Operate the solenoid valve on all the control modules to fully relieve the system from the adhesive pressure. 3. Shut off the compressed air supply Cold Glue Application Head 1. Shut off the compressed air supply to the pump (reduce to 0 bar). 2. Seal the nozzle openings with non-drying grease. 5. Emergency Switch-OFF Familiarize yourself thoroughly in respect of behavior in emergency situations and with the location and activation of the Emergency Switch-OFF devices of your Cold Glue Application System. WARNING: Switch off the system immediately in any emergency situation. 1. Switch the main switch on the hot melt application system or pattern controller to 0/OFF or press the nearest Emergency Switch-OFF element (e.g. Emergency Off switch or main switch with emergency shutdown function). WARNING: Any fault should be eliminated by qualified personnel during shutdown and prior to starting up again. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 4-4 Operation 6. Activate Solenoid Valve (hot melt only) 7. Activate Electrical Control Modules (hot melt only) 8. Set Temperatures When using application heads with solenoid valves, only activate the solenoid valve when the application head has heated up to operating temperature! If the adhesive is still too cold, seals on the control module may be damaged. In the case of application heads with electrical control module CM 900, only activate the control module when the application head has heated up to operating temperature! If the adhesive is still too cold, seals on the control module may be damaged. The way to set the temperatures for hot melt application heads with control modules CM 900 and CM 200 is described in the operating manual for the temperature controller. Temperature controllers are not component parts of the application heads. They are located, for example, in the hot melt application system switching cabinet or a separate switching cabinet. NOTE: The maximum operating temperature of the product described here and heated system components must not be exceeded. Nordson annuls the terms of guarantee and is not liable for claims regarding damage caused through setting incorrect temperatures. Application head Standard Maximum temperature 200 °C (392 °F) NOTE: The basis for temperature selections are the values stipulated by the hot melt manufacturer. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Operation 9. Set Air Pressure 4-5 The air pressure setting only applies to the pneumatic application heads CM 711 and CM 200. 1. Open the air pressure shut-off feature on the customer compressed air supply. 2. Set the air pressure relevant to the application head solenoid valves (refer to table). Air pressure Application head CM 200 2.8 - 4.8 bar / 40 - 70 psi CM 711 4 - 5 bar / 58 - 73 psi NOTE: It may be necessary to change the air pressure setting depending on the viscosity of the adhesive used and the required switching pulse for the control module. Air Pressures/Consumption Customer compressed air supply S Before pressure regulation of the application head: approx. 4.8 - 6.9 bar (70 - 100 psi). S Operating pressure of application head: refer to table. S Air consumption of a module at 3000 switches per minute and at 2 bar (30 psi) operating pressure (refer to table): Application head E 2002 Nordson Corporation All rights reserved Air pressure CM 200 Approx. 0.47 m3/h (16.7 SCFH) CM 711 Approx. 1 m3/h (35.3 SCFH) CHAMELEON® Application Head System Issued 03/02 P/N 409216C 4-6 Operation 10. Module Synchronization/ Set Application Pattern (CM 200 only) Adjustment of the nozzle stem stroke on application heads with CM 200 control modules is carried out at the factory. In order to synchronize triggering of nozzle stems on several control modules and optimize the application pattern, it may be necessary to adjust the setting. S The nozzle stem stroke may only be adjusted when the application head has been heated up. S The adjustment screw (1) can be used to make minimal modifications to the position and length of the adhesive bead. If the nozzle plate adhesive beads/dot patterns deviate a great deal from each other, check the assigned control module as to whether the timer intervals set cause an asynchronous triggering of the nozzle stem stroke before making any adjustments to the adjustment screw. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. 1. Press the solenoid valve(s) briefly to apply a test application on the substrate currently running through. 2. Measure and note the position of the bead/dot pattern applied. 1 2 3. Loosen the counternut (2) of the adjustment screw (1) which regulates the spring pressure on the air piston/nozzle stem. 4. Turn the adjustment screw to delay or advance triggering of the nozzle stem stroke and, thus, shorten or lengthen the adhesive bead. Turn clockwise to delay the nozzle stem stroke = shorter bead Turn anticlockwise to advance the nozzle stem stroke = longer bead 5. If necessary, correct the factory setting of the other control modules for synchronization. CHAM025A 6. Tighten the counternut (2). Fig. 4-1 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Operation 11. Set Application Pattern 4-7 The application pattern is dependent on the pressure of the adhesive. For more information on the adhesive pressure, refer to the operating manuals of the hot melt application system and adhesive pump used. For information on the settings necessary to control the application head, refer to the operating manuals of the hot melt application system and pattern controller. Proceed as follows to change the nozzle plate where necessary for production reasons: 12. Change Nozzle Plate WARNING: Hot! Risk of burns! Failure to observe the pressure relief directives may lead to severe burns! WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. 1. Loosen the retaining screws (1), remove the nozzle plate from the application head and disassemble into the two halves (and intermediate shim, if present). 2. Remove hot melt or cold glue with a cleaning agent and/or soft cloth. NOTE: When using cleaning agents, observe the manufacturer’s information! Read the Manufacturer’s Safety Data Sheet (MSDS) and product information concerning the cleaning agent thoroughly. 3. Assemble the new nozzle plate, mount on the application head and tighten firmly. 2 1 4 6 7 1 5 3 NOTE: If an intermediate shim (2) must be inserted between the front and rear nozzle plate, screw in the screws (3 and 7) loosely in the nozzle plates first of all. To align the shim, the nozzle plates have a recess (4 and 6) on both sides. Position the nozzle plate on the nozzle side (5). Align the shim by simultaneously pressing it from the top in the area of the recesses. Finally, tighten the screws (3 and 7) and mount the entire nozzle plate. NOTE: For assembly, ensure that the screws (3 and 7) are loosened sufficiently. CHAM026A Fig. 4-2 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 4-8 Operation 13. Recording the Settings The form below can be used to enter the system settings and specifications on production, and adhesive and cleaning agents used. Entries should be made in pencil, if possible or make copies of the form for future use. Production information Adhesive Manufacturer Max. processing temperature Viscosity Cleaning agent Manufacturer Flash point Basic settings Application weight (grammage) Application width Substrate speed Adhesive quantity Flow quantity Processing temperatures Application head heating zone Hose heating zone Under temperature Over temperature Air pressure at application head Control air Pump speed / Pump pressure Application unit Pump Adhesive pressure Application unit Pump Comments Form filled out by: Name P/N 409216C Date CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Section 5 Maintenance E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-0 Maintenance P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-1 Section 5 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Maintenance is an important preventive measure for maintaining operating safety and extending the service life of the equipment. It should not be neglected under any circumstances. 1. Relieving Pressure WARNING: The system and adhesive are pressurized. Before disconnecting any hoses, relieve the system pressure. Shut off the adhesive supply. Switch off the compressed air supply. Failure to observe can result in serious burns. WARNING: Do not carry out any work without wearing heat-protective gloves (hot melt). WARNING: Hot! Risk of burns. Wear safety goggles. WARNING: Disconnect power supply! 1. When using a hot melt application head: Set the motor speed of the hot melt feeding unit to 0 min-1 Switch motor(s) off and set pump to 0 bar. When using a cold glue application head : Depressurize the pressure and material supply. 2. Place a collector under the application head nozzle plate. 3. Trigger the solenoid valves or control modules electrically or operate manually. Repeat this process until no more adhesive escapes. 4. Re-use hot melt material or dispose of it properly according to local regulations. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-2 Maintenance 2. Daily Maintenance Unit Part Application head assembly All control modules Activity Interval Refer to Inspection for damage Daily - External cleaning Daily - Inspection for damage Check leckage hole (CM 200) Daily Daily - Inspection for External Damage External Cleaning (hot melt application heads) WARNING: When damaged parts pose a risk to the operational safety of the unit and/or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. External cleaning prevents pollution created during production from causing unit malfunctions. When cleaning agents are used, it is essential to observe the manufacturer’s notes! 1. Heat up the cold application heads electronically or with a hot air blower until the adhesive becomes liquid. WARNING: Hot! Risk of burns. Wear heat-protective gloves. 2. Remove the warm adhesive with a cleaning agent and/or a soft cloth thoroughly. CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-3 2. Daily Maintenance (contd.) External Cleaning (cold glue application head) It is not necessary to clean the application head if air is prevented from entering into the hydraulic system and coming into contact with the glue. If this occurs, however, the glue starts to solidify after approx. 30 minutes. The precise time varies according to the adhesive used. Blocked nozzle orifices can be cleaned easily at any time. NOTE: Do not disassemble an application head in which glue has solidified! It is highly likely this would damage sensitive components. We recommend immersing the core manifold and control module in warm water for 1 - 2 days to loosen the glue. Repeat this process, if necessary. If the application head still cannot be disassembled, return it to us for repair. Check Leakage Hole (CM 200) If hot melt escapes from the leakage hole, the internal O-rings have worn and the control module must be replaced. Nordson recommends keeping control modules in stock. A defect control module can then be replaced by a functional one, and serviced and cleaned later. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-4 Maintenance 3. Regular Maintenance The application heads should always be kept clean, residue glue and dirt being removed daily. Activity Unit part Interval Refer to Screw fittings Check and tighten, if necessary According to operating conditions - Control modules Check, disassemble and clean According to operating conditions - Nozzle plate Disassemble and clean When the application pattern becomes poor - Complete hot melt application system (also when cold glue is used) Flush On changing the adhesive used - Check Screw Fittings The application head screw fittings must be checked for tightness at regular intervals, determined from operation experience, because they may become loose as a result of intermittent operation. This particularly applies to the firm fitting of the application head mounting bracket, control modules and nozzle plates. Control Modules CM 711 Disassembling and Cleaning WARNING: Disconnect the power supply. WARNING: The system and material are pressurized. Shut off the compressed air supply! Otherwise, there is a considerable risk of injury. 1. Set the compressed air being applied to the solenoid valve(s) to 0. 2. Place a collector under the application head nozzle plate and trigger the control modules to relieve any system pressure which may have accumulated. 3. Ensure that the working area and all the tools are clean. NOTE: Foreign bodies can damage seals and seal kits causing leaks. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-5 3. Regular Maintenance (contd.) Control Modules CM 711 (contd.) 4. Unscrew and remove the connector (1, Fig. 5-1). 5. Loosen the retaining screws (2, Fig 5-1) and remove the control module from the core manifold. 1 6. Remove the adhesive thoroughly using a cleaning agent and/or a soft cloth. NOTE: When using cleaning agents, observe the manufacturer’s information! Read the Manufacturer’s Safety Data Sheet (MSDS) and product information concerning the cleaning agent thoroughly. 2 CHAM027A Fig. 5-1 Control module CM 711 7. Always replace all O-rings (also refer to Control Modules in the Section Parts) 8. Mount the control modules on the core manifold again and tighten. NOTE: Before inserting screws, always apply a little copper paste to the threads. 9. Dispose of cleaning agents according to applicable laws. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-6 Maintenance 3. Regular Maintenance (contd.) Control Modules CM 900 and CM 800 Disassembling and Cleaning WARNING: Disconnect the power supply. WARNING: The system and material are pressurized. 1. Heat up the application head with control module CM 900 to processing temperature according to the operating manual of the hot melt application unit. 2. Reduce the adhesive pressure generated by the adhesive pressurizing unit to 0 according to the operating manual. WARNING: Hot! Risk of burns! Failure to observe the pressure relief directives may lead to severe burns! 3. Place a collector under the application head nozzle plate and trigger the control modules to relieve any system pressure which may have accumulated. 3 4. Switch off the hot melt application system or pattern controller. 5. Ensure that the working area and all the tools are clean. 2 1 NOTE: Foreign bodies can damage seals and seal kits causing leaks. CHAM029A Fig. 5-2 Control module CM 900 WARNING: The following applies to hot melt application heads: Hot! Risk of burns. Wear goggles and heat-protective gloves. 6. Loosen the retaining screws (1) and remove the control module from the core manifold. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-7 3. Regular Maintenance (contd.) Control Modules CM 900 and CM 800 (contd.) NOTE: Be sure not to damage contacts on the core manifold and control module. Place protective caps on both contacts. NOTE: When the electrical cable is unplugged from the electrical connection (2) on the core manifold, install a protective cap (3) immediately. 7. Remove the adhesive with a cleaning agent and/or a soft cloth thoroughly. NOTE: When using cleaning agents, observe the manufacturer’s information! Read the Manufacturer’s Safety Data Sheet (MSDS) and product information concerning the cleaning agent thoroughly. 8. Always replace all O-rings (also refer to Control Modules in the Section Parts). 9. Mount the control module on the core manifold again and tighten. NOTE: Before inserting screws, always apply a little copper paste to the threads. 10. Dispose of cleaning agents according to applicable laws. NOTE: If the protective cap needs to be removed, always use the cord provided. This is especially important in the case of hot melt application heads. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-8 Maintenance 3. Regular Maintenance (contd.) Inspect Leakage Hole Control Module CM 200 1 The leakage hole (1) serves as an inspection hole to detect leaks in the nozzle stem seal. Check whether adhesive escapes from the hole on a weekly basis. If adhesive does escape, there is a leak in the nozzle stem seal. In this case, Nordson recommends replacing the entire control module. If a leak should be repaired, use the explosion diagram and parts lists in the Section Parts to identify the spare parts required. CHAM030A Fig. 5-3 Disassembly and Cleaning 1. Heat up the application head to processing temperature according to the operating manual of the hot melt application unit. 2. Reduce the adhesive pressure generated by the adhesive pressurizing unit to 0 according to the operating manual. 3. Place a collector under the application head nozzle plate and trigger the control modules to relieve any system pressure which may have accumulated. 4. Reduce the compressed air applied to the solenoid valve(s) to 0 on the pressure regulator. 5. Switch off the power supply to the application head. (Refer to the power supply unit operating manual). WARNING: Failure to observe the pressure relief directives may lead to severe injury! WARNING: Hot! Risk of burns. Wear goggles and heat-protective gloves. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-9 3. Regular Maintenance (contd.) Control Module CM 200 (contd.) 6. Loosen the retaining screws (1) and remove the control module from the warm application head. 7. Remove the warm hot melt thoroughly using a cleaning agent and/or a soft cloth. NOTE: When using cleaning agents, observe the manufacturer’s information! Read the Manufacturer’s Safety Data Sheet (MSDS) and product information concerning the cleaning agent thoroughly. 8. Always replace all O-rings. 1 9. Mount the control module on the warm application head and tighten. NOTE: Before inserting screws, always apply a little copper paste to the threads. 10. Dispose of cleaning agents according to the applicable laws. CHAM031A Fig. 5-4 Nozzle Plate Disassembling and Cleaning 1. Heat up the application head to processing temperature according to the operating manual of the hot melt application unit (only applies to hot melt application heads). 2. Reduce the adhesive pressure generated by the adhesive pressurizing unit to 0 according to the operating manual. WARNING: Failure to observe the pressure relief directives may lead to severe injury! 3. Place a collector under the application head nozzle plate and trigger the control modules to relieve any system pressure which may have accumulated. 4. Reduce the compressed air applied to the solenoid valve(s) to 0 on the pressure regulator (only applies to application heads with pneumatic control modules). E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-10 Maintenance 3. Regular Maintenance (contd.) 5. Switch off the power supply to the application head. (Refer to the power supply unit operating manual). WARNING: The following applies to hot melt application heads: Hot! Risk of burns. Wear goggles and heat-protective gloves. 6. Loosen the retaining screws, remove the nozzle plate from the application head and disassemble into the two halves. 7. Remove the adhesive thoroughly using a cleaning agent and/or a soft cloth. NOTE: When using cleaning agents, observe the manufacturer’s information! Read the Manufacturer’s Safety Data Sheet (MSDS) and product information concerning the cleaning agent thoroughly. 8. Reassemble the nozzle plate, mount on the application head and tighten. NOTE: Before inserting screws, always apply a little copper paste to the threads. NOTE: If an intermediate shim is inserted between the front and rear nozzle plate, refer to Change Nozzle Plate in the Section Operation. CHAM032A 9. Dispose of cleaning agents according to the applicable laws. Fig. 5-5 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Maintenance 5-11 3. Regular Maintenance (contd.) Application Head Assembly (visual inspection) The application head must be checked every six months for internal faults because vibrations and the effects of heating/cooling can cause screw fittings to become loose or damage wiring. 1. Unscrew the cover plate from the core manifold. 2. Check the wiring for signs of wear or damaged insulation; replace any damaged parts. 3. Check electrical connections are firmly fitted. Flushing the Hot Melt Application System E 2002 Nordson Corporation All rights reserved The application heads should be flushed according to instructions in the hot melt application system operating manual. CHAMELEON® Application Head System Issued 03/02 P/N 409216C 5-12 Maintenance 4. Maintenance Report This serves to protocol the regular maintenance work. Make copies of the form before completing it. Unit part Task Screw fittings g Check and tighten, g if necessary Leakage g hole Check if adhesive escapes Control module Check, disassemble and clean l Nozzle plate p Disassemble and clean Application pp head Disassemble and carry y out visual i l iinspection ti Hot melt application pp system t Flush Filter, hot melt application li ti system t Change g Filter, cold g glue li ti t application system Change g P/N 409216C Date Name CHAMELEON® Application Head System Issued 03/02 Date Name E 2002 Nordson Corporation All rights reserved Section 6 Troubleshooting E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-0 Troubleshooting P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Troubleshooting 6-1 Section 6 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: The system and adhesive are pressurized. Relieve the system pressure. WARNING: Dangerous electrical voltage. Failure to observe this warning may lead to fatal or severe personal injury. WARNING: Disconnect unit from the power supply. WARNING: Wear goggles and heat-protective gloves! S Please note, it is essential that the material to be applied is processed in a clean, filtered state. S A minimum amount of maintenance and upkeep must be performed according to individual operating conditions and varying application materials. S Ensure both the working area and the unit to be repaired are in a clean condition for all repair and maintenance work. S The unit to be repaired should not remain installed for extensive repair work but be disassembled from the machine. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-2 Troubleshooting 1. Introduction Troubleshooting tables serve as a general orientation help for qualified personnel but cannot replace a targeted search for errors using circuit diagrams and measuring instruments, for example. They do not contain all possible errors but those which may typically occur. The following faults are not normally included in the troubleshooting tables: S Installation faults S Operating errors S Defective cables S Loose plug and/or screw connections The column Corrective Action normally dispenses with the instruction to replace defect parts. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Troubleshooting 6-3 2. Fault Table (Cold Glue) Problem Control modules do not open (no adhesive application) Possible Cause Corrective Action Refer to Fault in solenoid valve. Depressurize system completely. Unscrew and clean (valve) seat in control module. Sections Operation, Maintenance Compressed air supply to solenoid valve not correct. Depressurize system completely and remove control module from body. - Damaged piston seal(s) in the control module air chamber. Check pressure of air supply to the respective solenoid valve on the pressure regulator and adjust to correct setting, if necessary. Section Repair Change control module or replace seal(s). Section Repair Cold glue escapes from inspection/ leakage hole in control module Damaged seal(s) in the material chamber. Depressurize system completely and replace or repair control module. Section Repair Control modules do not open simultaneously Switching interval setting incorrect on the control module. Correct switching interval on control module. - Sensor for solenoid valve switching defect. Replace sensor. - Reservoir is empty. Fill reservoir. Applicable sections of hot melt application system operating manual. Air motor does not run Check air motor. - Solenoid valve on application head does not switch. Check solenoid valve power supply, control air supply and coils. - Hose is fully or partially blocked through adhesive accummulation. Remove hose from application head; with system at low pressure, check whether adhesive flows from the hose. - No, or too little, adhesive flows from the nozzle plate E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-4 Troubleshooting Problem Possible Cause Wave-shaped bead Nozzle plate distance to substrate too great. Reduce distance. Section Installation Thickening of bead at start Nozzle plate distance to substrate too great. Reduce distance. Section Installation Nozzle plate partially blocked. Clean nozzle plate. Section Maintenance Compressed air feed to application head too low. Increase compressed air feed. Section Operation Fill level in reservoir too low. Fill adhesive. - Adhesive viscosity too high. Check whether adhesive is suitable for the intended application. - Adhesive drips from nozzle plate Control module needle or ball seat worn. Clean or replace. Section Maintenance Adhesion opens after passing pressing station Break in cohesion. Check pressing station is correctly aligned. - Contact adhesive manufacturer. - Special surface quality of substrate Contact adhesive manufacturer, if necessary use different adhesive. Section Description, Parts Adhesive viscosity too high. Check whether adhesive is suitable for the intended application. - Air/Vapor bubbles in adhesive application Adhesive penetration insufficient P/N 409216C Corrective Action CHAMELEON® Application Head System Issued 03/02 Refer to E 2002 Nordson Corporation All rights reserved Troubleshooting Problem Possible Cause Corrective Action 6-5 Refer to Beads not even below each other Nozzle plate blocked. Clean nozzle plate. Section Maintenance Adhesive beads not parallel or not identical Nozzle plate blocked. Clean nozzle plate. Section Maintenance Foreign bodies in application head. Remove nozzle plate from application head, flush the head and operate it several times. - System pressure too low. Increase pump pressure or temperature Section Operation Nozzle plate distance to substrate too great. Reduce distance. Section Installation Adhesive viscosity too high. Check whether adhesive is suitable for the intended application. - Threads appear E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-6 Troubleshooting 3. Fault Table (Hot Melt) Problem Possible Cause Control modules do not open (no adhesive application) Incorrect temperature setting. Set temperature according to the hot melt application system operating manual. Section Operation Nozzle plate blocked. Check processing temperature of the hot melt manufacturer. Section Maintenance Solenoid valve faulty. Depressurize system completely. Unscrew and clean (valve) seat in control module. Sections Operation, Maintenance Compressed air supply to solenoid valve not correct. Depressurize system completely and remove control module from body. - Defect piston seal(s) in control module air chamber. Check pressure of air supply to the respective solenoid valve on the pressure regulator and adjust to correct setting, if necessary. Section Repair Change control module or replace seal(s). Section Repair Damaged seal(s) in the material chamber. Depressurize system completely and replace or repair control module. Section Repair Adjustment screws are incorrectly set. Correct the setting. Section Operation Switching interval incorrectly set on control module. Correct the switching interval on the control module. - Sensor for solenoid valve switching defect. Replace sensor. - Hot melt escapes from inspection/ leakage hole in control module Control modules do not open simultaneously P/N 409216C Corrective Action CHAMELEON® Application Head System Issued 03/02 Refer to E 2002 Nordson Corporation All rights reserved Troubleshooting Problem Possible Cause Corrective Action 6-7 Refer to Fuse on hot melt application head blown. Check fuses and replace, if necessary. Applicable sections of hot melt application system operating manual Short circuit in application head. Check application head by means of resistance measurements between ground conductor and other feed lines; following throughput or low resistance, localize short circuit and eliminate. - Defect heater cartridge. Measure cold resistance of heater cartridge feed lines; replace heater cartridge. Use heat conductive paste if the resistance is not within the standard range specified. - Application head overheats Incorrect temperature settings for application head or upstream heating zones. Check temperature settings carefully, particularly for heated hose for adhesive feed; correct them if necessary. Sections Description, Operation, Repair No, or too little adhesive flows from nozzle plate Reservoir is empty. Fill reservoir. Applicable sections of hot melt application system operating manual Unit, hose, application head have not reached the correct temperature. Reservoir, low melt, high melt, hose or application head do not heat up or do so insufficiently. - Application head is not or insufficiently heated E 2002 Nordson Corporation All rights reserved Motor does not run. - Air motor does not run. - Solenoid valve on application head does not switch. Check solenoid valve power supply, control air supply and coils. - Hose is fully or partially blocked through adhesive accummulation. Unscrew application head from hose; run pump at slow speed or low system pressure and check if adhesive flows from the hose. - CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-8 Troubleshooting Problem Pump runs, but no or too little adhesive Adhesive cracked in reservoir Wave-shaped bead Thickening of bead at start Thickening of bead at end P/N 409216C Possible Cause Corrective Action Refer to Fault on safety valve/ distribution block. – Applicable sections of Safety Valve manual Fault on pump. – Applicable sections of Pump manual Feed hole to pump is blocked. Screw off pump; if hole is blocked, clean it without damaging the non-stick coating. - Reservoir temperature too high. Lower temperature, Refer to temperature specifications of adhesive manufacturer. Applicable sections of hot melt application system operating manual Reservoir fill level too low. Keep reservoir approx. half full. - Adhesive oxidizes in reservoir. Keep reservoir lid closed. Contact adhesive manufacturer. - Adhesive in reservoir too cold. Set correct temperature. * Ambient temperature below 0°C / 32°F. Raise ambient temperature. - Nozzle plate is exposed to a draft . Prevent draft. - Temperature set for application head too low. Set correct temperature. * Nozzle plate distance to substrate too great. Reduce distance. Section Installation Nozzle plate distance to substrate too great. Reduce distance. Section Installation Partially blocked nozzle plate. Clean nozzle plate. Section Maintenance Compressed air supply to application head insufficient. Increase compressed air supply. Section Operation Adhesive too cold. Set correct temperature. * Compressed air supply to application head insufficient. Increase compressed air supply. Section Operation CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Troubleshooting Problem Possible Cause Corrective Action 6-9 Refer to Reservoir fill level too low. Fill adhesive. * Adhesive viscosity too high. Compare set temperature adhesive manufacturer’s specifications. - Check whether adhesive is suitable for the intended application. - Substrate is damp. Preheat the substrate again. - Adhesive drips from nozzle plate Control module needle or ball seat is worn. Clean or replace. Section Maintenance Adhesion opens after passing pressing station Adhesive cools too slowly. Reduce adhesive quantity or temperature. * Adhesive exposed too long. Contact adhesive manufacturer. - Adhesive cools too quickly. Increase adhesive quantity or temperature. Protect application heads from drafts. - Adhesive exposed too briefly. Contact adhesive manufacturer. - Break in cohesion. Check pressing station is correctly aligned. - Contact adhesive manufacturer. - Change to an adhesive which is compatible with the sort initially used. Drain off adhesive and clean the system. Section Maintenance Adhesive heated too long. Contact adhesive manufacturer regarding thermal stability. - Adhesive too hot. Set correct temperature. * Adhesive too hot. Set correct temperature. * Pump pressure too high. Lower the speed of the hot melt application head or the pump pressure. * Adhesive viscosity too high. Compare the set temperature with that specified by the adhesive manufacturer. - Check whether adhesive is suitable for the intended application. - Air/Vapor bubbles in adhesive application Adhesive gels Adhesive splashes away from substrate E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-10 Troubleshooting Problem Possible Cause Corrective Action Refer to Adhesive too cold. Set correct temperature. * Special surface quality of the substrate. Contact adhesive manufacturer or use different adhesive. Sections Description, Parts Insufficient amount of adhesive applied. Increase temperature or pump pressure. - Adhesive viscosity too high. Compare set temperature with that specified by the adhesive manufacturer. - Check whether adhesive is suitable for the intended application. - System temperature too high. Reduce temperature. Check temperature specifications of the adhesive manufacturer. * Adhesive quality unstable. Keep reservoir lid closed. Contact adhesive manufacturer. * Beads not evenly under each other Nozzle plate blocked. Clean nozzle plate. Section Maintenance Adhesive beads not parallel or not identical Nozzle plate blocked. Clean nozzle plate. Section Maintenance Foreign bodies in application head. Remove control module from application head, flush head and operate several times. - System pressure too low. Increase pump pressure or temperature. Section Operation Nozzle plate distance to substrate too great. Reduce distance. Section Installation Adhesive viscosity too high. Compare set temperature with that specified by the adhesive manufacturer. * Check whether adhesive is suitable for the intended application. * Adhesive too cold. Increase temperature. * Adhesive too old. Never let adhesive heat up too long. * Adhesive penetration insufficient Smoke from adhesive Threads appear P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Troubleshooting Problem Circular indent in adhesive dot Possible Cause Corrective Action Refer to Adhesive too hot. Set correct temperature. * Adhesive viscosity too low. Compare set temperature with that specified by the adhesive manufacturer. * Check whether adhesive is suitable for the intended application. * Reduce application speed. * Application speed extremely high. 6-11 NOTE: *Corresponding sections in the hot melt application system operating manual. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 6-12 Troubleshooting P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Section 7 Repair E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 7-0 Repair P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Repair 7-1 Section 7 Repair WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Only use original spare parts. 1. Change Nozzle Plate 2. Change Heater Cartridge(s) In order to change the nozzle plate, proceed as described in Disassembling and cleaning in the Section Maintenance, Chapter Nozzle Plate. WARNING: Disconnect equipment from the line voltage. 1. Unscrew the cover plate of the application head used (also refer to Section Description or Parts) and remove it from the core manifold complete with heating cartridge and temperature sensor. 2. Disconnect the old heater cartridge and remove it from its hole. 3. Insert the new heater cartridge applying a little heat conductive paste. Using the heat conductive paste achieves a much improved heat transfer which increases the service life of the heater cartridge. 4. Connect the electrical lines to the heater cartridge. 5. Slide the cover plate complete with heating cartridge and temperature sensor in the core manifold and screw tight. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 7-2 Repair 3. Change Temperature Sensor WARNING: Disconnect equipment from the line voltage. 1. Unscrew the cover plate of the application head used (also refer to Section Description or Parts) and remove it from the core manifold complete with heating cartridge and temperature sensor. 2. Disconnect the temperature sensor connection lines. 3. Insert the new temperature sensor with heat conductive paste. Using the heat conductive paste achieves a much improved heat transfer. 4. Connect the electrical lines to the temperature sensor. 5. Slide the cover plate complete with heating cartridge and temperature sensor in the core manifold and screw tight. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Repair 4. Change Control Module 7-3 Refer to Regular Maintenance in the Section Maintenance. WARNING: The following applies to hot melt application heads: Hot! Risk of burns. Wear goggles and heat-protective gloves. NOTE: Control modules are high-precision, fine engineering parts. If these parts become defect, Nordson recommends replacing them completely. NOTE: However, if a defect control module should be repaired, refer to the explosion diagrams and parts lists in the Section Parts to identify the spare parts required. WARNING: The system and adhesive are pressurized. Relieve the system pressure. Failure to observe this point may lead to severe injury. NOTE: Before inserting screws, always apply copper paste to the threads. NOTE: All residue adhesive must be removed from the core manifold, particularly in the area of the module seat. Only use soft cloths for this, never hard instruments. In the case of hot melt application heads, the core manifold must be warm. NOTE: O-rings between the control module and application head body must always be renewed; prior to installation; apply PTFE paste (Nordson P/N 900 236) to the new O-rings. 5. Disassembling and Reassembling the Control Module NOTE: Control modules are high-precision, fine engineering parts. If these parts become defect, Nordson recommends replacing them completely. However, if a defect control module should be repaired, it must first be disassembled. Refer to Regular Maintenance in the Section Maintenance. All the individual parts of the control module used can be identified in the Chapter Control Modules in the Section Parts. NOTE: When changing the coils, always replace all O-rings. NOTE: In addition, all the information in the Chapter Change Control Modules also applies and must be observed in this section. E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 7-4 Repair P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Section 8 Parts E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-0 Parts P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Parts 8-1 Section 8 Parts NOTE: Defective or worn-out parts must be replaced by original Nordson parts. When in doubt contact us. All available spare parts are listed in this section. 1. Use of the Illustrated Parts List 1. Study the illustration to find the specific part you want to identify. Note the item number associated with it. 2. Locate the item number of the part in the item number column. 3. The subsequent columns indicate the part number and description. When the item is not listed, the required part is not a regular spare part. Updated Bill of Material E 2002 Nordson Corporation All rights reserved Please observe that your Nordson equipment may slightly differ from description or some informational details in the manual. Please refer to the updated Bill of Material which is packed with your equipment. CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-2 Parts 2. Application Heads Cold Glue Application Head with Pneumatic Control Module CM 711 6 3 7 5 LOCTITE 542 LOCTITE 542 4 8 9 10 2 17 11 6 1 15 16 9 7 14 13 12 18 CHAM033A (A0439B) Fig. 8-1 Cold glue application head with pneumatic control module CM 711 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-3 Parts Parts List Item Part 1 Description Quantity Note Application head, complete 1 - Core manifold 1 - AR - 2 374 186 CM 711 module (refer to Control Modules) 3 313 995 Grease nipple M6 1 - 4 372 865 Grease tube 1 - 5 374 301 Screw, Set, M5 x 6, DIN 915-A2-70 AR - 6 311 072 Plug 1/8 BSP W/Head with O-ring AR - 7 374 752 Plug 9/16-18 UNF AR - 8 374 498 Bleeding valve 9/16-18 UNF AR - 9 311 495 O-ring AR - 10 374 593 Gasket ring 1/8 BSP aluminium AR - 11 374 505 Flow control valve 1/8 BSP AR - 12 374 401 Nut, flange M6, DIN 6923 4 - 13 373 641 Stud M6x20, DIN 938 4 - 14 372 570 Hose nipple 1/8 BSP-1/2-20 UNF AR - 15 374 631 Hose nipple 9/16-18 UNF-1/2-20 UNF (JIC 37) AR - 16 374 998 Elbow 8-1/8 BSP AR - 17 311 052 Screw, allenhead M6x16, DIN 912-A2-70 4 - 18 311 045 Screw, allenhead M5x25, DIN 912-A2-70 AR - AR: As Required E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-4 Parts Hot Melt Application Head with Electrical Control Module CM 900 1 2 4 3 5 6 7 2 23 8 20 22 9 21 20 19 10 18 17 16 15 14 2 13 12 11 CHAM035A (A0416A) Fig. 8-2 Hot melt application head with electrical control module CM 900 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-5 Parts Parts List Item Part Description Application head, complete Quantity Note 1 - 1 373 934 Triax connector assembly AR - 2 311 031 Screw, allenhead, M4x8, DIN 912 AR - 3 372 910 Insulation plate 2 - 4 374 401 Nut, flange M6, DIN 6923 4 - 5 373 641 Stud, M6 x 20 DIN 939 4 - 6 973 574 Plug 9/16-18 UNF 1 - 7 373 937 Plug M18x1 AR - 8 311 468 Plug PG9 AR - 9 373 527 Side cover 2 - 10 373 284 CM 900 module (refer to Control Modules) AR - 11 Core Mainifold CAM/B AR - 12 Heating element (refer to Heating Elements) AR - 13 311 788 Ceramic terminal AR - 14 313 630 Adapter PG9-3/8-32 UNF AR - Cordset (refer to Cordsets) AR - 15 16 373 938 Protection cap AR - 17 373 936 Connector 12 pole AR - 18 311 045 Screw, allenhead, M5x25, DIN 912-A2-70 AR - 1 - AR - 19 Gasket brass (refer to Length-dependent Parts) 20 313 526 Screw. allenhead, M2.5x5, DIN 912 21 972 628 Hose fitting 9/16-18 UNF 1 - Rear cover 1 - Ground wire 1 - 22 23 375 024 AR: As Required E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-6 Parts Cold Glue Application Head with Electrical Control Module CM 800 1 3 2 4 5 6 2 18 7 17 16 8 15 9 14 13 12 11 7 2 10 CHAM036A (A0417A) Fig. 8-3 Cold glue application head with electrical control module CM 800 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-7 Parts Parts List Item Part Description Application head, complete Quantity Note 1 - 1 373 934 Triax connector assembly AR - 2 311 031 Screw, allenhead, M4x8, DIN 912 AR - 3 374 401 Nut, flange M6, DIN 6923 4 - 4 373 641 Stud, M6x20, DIN 939 4 - 5 374 752 Plug 9/16-18 UNF 1 - 6 373 937 Plug M18x1 AR - 7 311 468 Plug PG9 2 - 8 374 527 Side cover 2 - 9 374 399 CM 800 module (refer to Control Modules) AR - 1 - 10 Core manifold 11 373 936 Connector 12 pole AR - 12 373 938 Protection cap AR - 13 311 045 Screw, allenhead, M5x25, DIN 912 AR - 1 - AR - 1 - AR - 1 - 14 Gasket mylar (refer to Length-dependent Parts) 15 374631 16 Hose nipple 9/16-18 UNF-1/2-20 UNF (JIC37) Rear cover 17 313 526 Screw, allenhead, M2.5x25, DIN 912 18 375 024 Ground wire AR: As Required E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-8 Parts Hot Melt Application Head with Pneumatic Control Module CM 200 1 2 3 4 6 5 7 8 9 9 24 10 24 28 22 3 23 25 21 11 26 27 12 20 19 18 17 9 16 15 14 13 CHAM037A (A0425A) Fig. 8-4 Hot melt application head with pneumatic control module CM 200 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-9 Parts Parts List Item Part Description Application head, complete Quantity Note 1 - AR - 1 Solenoid operated valve (refer to Solenoid Valves) 2 Air manifold 1 - 3 374 595 Gasket ring 1/2 BSP aluminum 2 - 4 373 649 Plug 1/2“ BSP 1 - 5 372 910 Insulation plate 2 - 6 374 401 Nut, flange M6, DIN 6923 4 - 7 373 641 Stud, M6x20, DIN 939 4 - 8 373 937 Plug M18x1 AR - 9 311 031 Screw, allenhead, M4x8, DIN 912 AR - 10 311 468 Plug PG9 AR - 11 973 574 Plug 9/16-18 UNF, O-ring AR - 12 222 484 CM 200 module (refer to Control Modules) AR - 13 Core manifold CAM/A 1 - 14 Heating element (refer to Heating Elements) 1 - AR - 2 - 15 311 788 Ceramic terminal 16 373 527 Side cover 17 313 630 Adapter PG9-3/8-32 UNF AR - Cordset (refer to Cordsets) AR - Screw, allenhead, M5x25, DIN 912-A2-70 4 - Gasket brass (refer to Length-dependent Parts) 1 - AR - 1 - 18 19 311 045 20 21 374 593 Gasket ring 1/8“ BSP aluminum 22 373 648 Hose nipple 1/2“ BSP-18 23 311 635 Silencer 1/4“ BSP AR - 24 373 640 Banjo fitting 10-1/4“ BSP AR - 1 - 25 Rear cover 26 313 526 Screw, allenhead, M2.5x5, DIN 912 AR - 27 972 628 Hose fitting 9/16-18 UNF AR - 28 372 911 Stand pipe adapter AR - AR: As Required E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-10 Parts 3. Control Modules Diagram of the CM 711 1 2 3 11, 12 4 10 9 5 8 6 7 CHAM038A (O0111A) Fig. 8-5 Control module CM 711 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-11 Parts Parts List Item Part Description Quantity Note - 374 186 CM 711, module - - 1 311 035 Screw, allenhead, M4x16 stainless 2 - Solenoid (refer to Solenoid Valves) 1 - 2 3 312 538 Ring, copper, 5.5x8x1 1 - 4 313 541 Screw, allenhead, M5x6 1 - Cartridge CM 71x (refer to Spare Parts Kits) 1 - 5 6 313 721 Quad ring 1 - 7 372 791 Flow nipple 1 - 8 372 785 Gun body 1 - 9 313 830 Set screw 1 - 10 372 792 Gasket 1 - 11 313 531 Screw, allenhead 2 - 12 313 610 Spring washer 2 - E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-12 Parts Diagram of the CM 800 and CM 900 1 2 12 3 4 11 5 6 10 7 8 9 CHAM040A Fig. 8-6 Control modules CM 800 and CM 900 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-13 Parts Parts List Item Part Description Quantity Note - 374 399 CM 800 module (cold glue) 1 L – TYPE - 378 434 CM 800 module (cold glue) 1 F – TYPE - 373 284 CM 900 module (hot melt) 1 L – TYPE - 378 436 CM 900 module (hot melt) 1 F – TYPE 1 311 033 Screw, allenhead SS, M4 x 10 DIN 912 4 - 2 940 111 O-ring 2 - 3 374 393 CM 800 coil assy (cold glue) 1 L – TYPE 3 377 257 CM 800 coil assy (cold glue) 1 F – TYPE 3 374 392 CM 900 coil assy (hot melt) 1 L – TYPE 3 377 256 CM 900 coil assy (hot melt) 1 F – TYPE 4 374 387 O-ring-housing/core manifold, 13 x 3,5 1 - 5 374 904 Connector protection cap 1 - 6 374 396 Cartridge assembly 1 - 7 940 111 O-ring 1 - 8 374 391 Protection cap, hydraulic 2 - 9 311 039 Screw, allenhead SS, M4 x 35 DIN 912 3 - 10 374 261 Lower manifold 1 - 11 373 524 Housing 1 - 12 372 997 Upper manifold 1 - L–TYPE F–TYPE 3mm 2mm 4mm IMPORTANT NOTE: There are 2 different connectors see drawing. Check connector type from module or coil assy before ordering!!! L – TYPE – includes white insulation sleeve – center pin and sleeve are at the same level – small slots are visible in the innner sleeve F – TYPE – does not have insulation sleeve – center pin is shorter than sleeve – there are no small slots visible in the sleeve E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-14 Parts Diagram of the CM 200 1 2 13 8 3 4 14 5 15 12 16 6 7 8 9 15 17 12 18 16 19 11 10 CHAM041A Fig. 8-7 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-15 Parts Parts List Item Part Description Quantity Note - 222 484 CM 200 module - - - 272 818 Seal kit complete AR - 1 272 289 Nut, locking 1/2 - 28 1 - 2 272 288 Screw, loading 1 - 3 987 022 Spring, compression 1 - 4 981 758 Screw with lockwasher 2 - 5 276 112 Air cap, adjuster 1 - 6 150 170 Needle with piston, H200 1 - 7 986 502 Retaining ring 1 - 8 983 012 Disc, seal, support 1 - 9 - Seal, hat, unformed 4 - 10 - Body, module 1 - 11 238 716 Screw, skt, cap, 10 - 32 W/O-ring 2 - 12 940 111 O-ring 3 - 13 - Seal, spring 1 - 14 144 892 Spring, compression 1 - 15 940 121 O-ring 1 - 16 222 485 Adapter, integrated, SPCL 1 - 17 981 516 Screw, skt, cap, 8 - 32 x 1.12 2 - 18 981 069 Screw, skt, cap, 8 - 32 x .50 2 - 19 981 132 Screw, skt, cap 10 - 32 x .62 1 - E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-16 Parts 4. Components Heater Cartridges Item Part Description Quantity Note - 373 651 Heating element 250 W / 38 mm / 1 1/2“ AR - - 373 652 Heating element 315 W / 63 mm / 2 1/2“ AR - - 373 653 Heating element 400 W / 102 mm / 4“ AR - - 373 654 Heating element 630 W / 133 mm / 5 1/4“ AR - - 373 655 Heating element 800 W / 165 mm / 6 1/2“ AR - - 373 656 Heating element 630 W / 203 mm / 8“ AR - Quantity Note Solenoid Valves, CM 200 Item Part Description - 771 114 5/2-port solenoid valve 24 VDC - 5.4 W AR - - 771 115 5/2-port solenoid valve 24 VDC - 12.7 W AR - - 771 266 5/2-port solenoid valve 115 VAC AR - - 771 267 5/2-port solenoid valve 230 VAC AR - Quantity Note Solenoid Valves, CM 711 (cold glue) Item Part Description - 771 137 5/2-port solenoid valve 24 VDC - 5.4 W AR - - 771 138 5/2-port solenoid valve 24 VDC - 12.7 W AR - - 771 139 5/2-port solenoid valve 115 VAC AR - - 771 142 5/2-port solenoid valve 230 VAC AR - P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-17 Parts Cordsets Item Part Description Quantity Note - 274 685 Nordson Cordset Ni 120 AR - - 252 092 Meltex Cordset Pt 100 AR - - 254 331 Meltex Cordset Fe-CuNi (FE/KO) AR - Substrate Guides 1 2 5 3 5 4 CHAM042A (O0114A) Fig. 8-8 Item Part - Description Quantity Note Substrate guides, right, horizontal - - 1 374 401 Nut, flange M6 1 - 2 374 267 PPT / GS-Bl-H 1 - 3 374 675 PPT / GS-BR-H 1 - PPT / GSR 1 - Screw, allenhead, M5x16 stainless steel 2 - 4 5 E 2002 Nordson Corporation All rights reserved 311 043 CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-18 Parts Substrate Guides (contd.) 1 2 5 3 3 4 CHAM043A (O0115A) Fig. 8-9 Item Part - Description Quantity Note Substrate guide, left, horizontal - - 1 374 267 PPT / GS-Bl-H 1 - 2 374 401 Nut, flange M6 1 - 3 311 043 Screw, allenhead, M5x16 stainless steel 2 - PPT / GSR 1 - PPT / GS-BL-H 1 - 4 5 P/N 409216C 374 676 CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-19 Parts Substrate Guides (contd.) 1 2 5 3 5 4 CHAM044A (O0116A) Fig. 8-10 Item Part Description Quantity Note - 373 520 Substrate guide, right, vertical - - 1 374 401 Nut, flange M6 1 - 2 374 266 PPT / GS-Bl-V 1 - 3 374 677 PPT / GS-BR-V 1 - PPT / GSR 1 - Screw, allenhead, M5x16 stainless steel 2 - 4 5 E 2002 Nordson Corporation All rights reserved 311 043 CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-20 Parts Substrate Guides (contd.) 1 5 2 4 2 3 CHAM045A (O0117A) Fig. 8-11 Item Part - Description Quantity Note Substrate guide, left, vertical - - 1 374 401 Nut, flange M6 1 - 2 311 043 Screw, allenhead, M5x16 stainless steel 2 - PPT / GSR 1 - 3 4 374 678 PPT / GS-BL-V 1 - 5 374 266 PPT / GS-Bl-V 1 - P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-21 Parts Mounting Brackets 1 2 13 2 12 11 3a 10 9 4 3b 5 8 7 6 CHAM046A (O0112A) Fig. 8-12 Item Part Description Quantity Note - 373 369 Fixation with mounting bracket, vertical and horizontal - - 1 313 523 Screw M6x30 stainless steel 1 - 2 311 051 Screw, allenhead, M6x12 stainless steel 2 - 3a 373 341 PPT Gun mounting bracket single vertikal 1 - 3b 373 346 PPT Gun mounting bracket single horizontal 1 - 4 372 819 Slide nut 1 - 5 313 738 Compression spring 1 - 6 372 830 Pin, spirol 1 - 7 372 822 Main mounting block 1 - 8 372 818 Lever M6x50 1 - 9 372 821 Lever M6x30 1 - 10 313 293 Clamp, bar, hex 1 - 11 372 823 Hinged guide 1 - 12 374 262 PPT mounting bracket 1 - 13 313 592 Nut hex M6 stainless steel 1 - E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-22 Parts Bleeding Valve 1 4 2 3 CHAM048A (A0422A) Fig. 8-13 Item Part Description Quantity Note - 374 498 Bleeding valve - - 1 374 494 Needle 1 - 2 374 499 Housing 1 - 3 374 495 Nut 9/16-18 UNF 1 - 4 311 495 O-ring 1 - Flow Control Valve 1 2 3 CHAM049A (A0423A) Fig. 8-14 Item Part Description Quantity Note - 374 505 Flow control valve - - 1 313 721 Quad ring 2.9x1.78 1 - 2 374 507 Needle 1 - 3 374 506 Housing 1 - P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Parts 5. Length-dependent Parts 8-23 Some parts are dependent on the number of control modules used and, thus, on the length of the body. Gaskets Max. no. control modules Body width 1 50 mm 374 531 374 532 - 2 85 mm 374 277 374 268 - 3 120 mm 374 278 374 269 - 4 155 mm 374 279 374 270 - 5 190 mm 374 280 374 271 - 6 225 mm 374 281 374 272 - 7 260 mm 374 282 374 273 - 8 295 mm 374 283 374 274 - 9 330 mm 374 284 374 275 - 10 365 mm 374 285 374 276 - E 2002 Nordson Corporation All rights reserved Gasket brass P/N CHAMELEON® Application Head System Issued 03/02 Gasket mylar P/N Note P/N 409216C 8-24 Parts 6. Spare Parts Kits Insert CM 800 and CM 900 1 2 3 4 5 6 CHAM050A (A0430A) Fig. 8-15 Item Part Description Quantity Note - 374 396 Cartridge, 800 & 900 Series - - 1 374 391 Protection cap 1 - 2 374 779 O-ring 1 - 3 940 111 O-ring 1 - 4 372 990 Armature sleeve 1 - 5 311 495 O-ring 1 - 6 371 752 Needle and seat kit 1 - P/N 409216C (nozzle stem and seal kit CM 800 and CM 900) CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 8-25 Parts Nozzle Stem and Seal Kit CM 800 and CM 900 1 2 3 4 CHAM051A (A0258B) Fig. 8-16 Item Part Description Quantity Note - 371 752 Needle and seat kit complete - - 1 311 196 Compression spring 1 - Needle 1 - O-ring 1 - Seat 1 - 2 3 313 451 4 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 8-26 Parts Insert CM 71x 2 1 3 4 4 5 6 13 7 8 9 4 10 12 11 CHAM052A Fig. 8-17 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Parts 8-27 Spare Part Kit, Insert CM 71x (standard) Item Part Description Quantity 372 180 Cartridge cpl. (standard) 1 1 372 796 Dubo retaining ring 1 2 374 084 Hex nut with plastic insert, M4 1 3 372 790 Plunger 1 4 377 186 O-ring 3 5 377 213 O-ring 1 6 372 795 Compression spring 1 7 372 789 Spring retainer 1 8 313 722 Quadring 1 9 372 787 Nozzle stem 1 10 372 794 Seat 1 11 372 791 Flow nipple 1 12 377 214 O-ring 1 13 372 788 Seal adapter 1 Note Seal Kit, Insert CM 71x (standard) Item Part Description Quantity 372 800 Seal kit (standard) 1 1 372 796 Dubo retaining ring 1 2 374 084 Hex nut with plastic insert, M4 1 4 377 186 O-ring 3 5 377 213 O-ring 1 6 372 795 Compression spring 1 8 313 722 Quadring 1 10 372 794 Seat 1 11 372 791 Flow nipple 1 12 377 214 O-ring 1 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 Note P/N 409216C 8-28 Parts 7. Accessories 1 2 4 3 5 CHAM053A Item Part Description Quantity - 377 266 Extraction tool for crimp contacts AR 1 375 026 Cable gundriver to junctionbox AR 2 377 255 Junctionbox AR 3 377 253 Cable junctionbox to cam gun, 3 m AR 3 377 254 Cable junctionbox to cam gun, 6 m AR 4 - Cam gun AR 5 375 027 Cable WM 408 to junctionbox AR Note Before 2001 Item Part Description Quantity - 374 977 Extraction tool for crimp contacts AR 1 375 026 Cable gundriver to junctionbox AR 2 374 751 Junctionbox AR 3 374 749 Cable junctionbox to cam gun, 3 m AR 3 374 750 Cable junctionbox to cam gun, 6 m AR 4 - Cam gun AR 5 375 027 Cable WM 408 to junctionbox AR P/N 409216C CHAMELEON® Application Head System Issued 03/02 Note E 2002 Nordson Corporation All rights reserved Section 9 Specifications E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 9-0 Specifications P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Specifications 9-1 Section 9 Specifications NOTE: The specifications only apply to standard application heads. In the case of special models, for which this operating manual also applies, the actual measurements in the technical drawings are valid. Refer to the freight bill for the actual weight. 1. General Data Product Identifier Cold glue or hot melt application head. Product Name CHAMELEON® Control Module Refer to Control Modules Operating Voltage Refer to ID plate Total Power Consumption Refer to ID plate E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 9-2 Specifications 2. Control Modules Pneumatic Control Module CM 711 Type: CM 711 (suitable for cold glue) Operating air pressure 4 - 5 bar (58 - 73 psi) Max. operating adhesive pressure 48 bar (700 psi) Solenoid valve Control voltage / Power 24 VDC / 5,4 or 12.7 W / 115 VAC or 230 VAC Minimal up-time *1 4.5 ms Minimal down-time *1 7 ms Degree of protection IP 50 NOTE: *1 These times were measured with: Adhesive viscosity: 700 mPa s Control air pressure: 5 bar Solenoid valve: 24 VDC / 5.4 W NOTE: 1 bar = 14.5 psi = 105Pa NOTE: 25.4 mm = 1 in. NOTE: 0.45 kg = 1 lbs NOTE: 9 x °C/5 +32 = °F NOTE: 1 cP = 1 mPa s = 1 mNs/m2 P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved Specifications Electrical Control Module CM 900 Electrical Control Module CM 800 Type: CM 900 (suitable for hot melt) Retaining current Peak current 0.4 A 1.8 A Max. operating pressure 48 bar (700 psi) Minimal up-time *1 1.8 ms Minimal down-time *1 3.0 ms Degree of protection IP 50 Type: CM 800 (suitable for cold glue) Retaining current Peak current 0.4 A 1.8 A Max. operating pressure 48 bar (700 psi) Minimal up-time *1 1.5 ms Minimal down-time *1 1.5 ms Degree of protection IP 50 9-3 NOTE: *1 These times are heavily dependent on the adhesive used and only serve as guideline values: Up-time determines: Adhesive bead length Down-time determines: Length between two adhesive beads Viscosity (800 mPas): Measures using the Brookfield method E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 9-4 Specifications Pneumatic Control Module CM 200 Type: CM 200 (suitable for hot melt) Operating air pressure 0.5 bis 6 bar (7.25 - 87 psi) Max. operating pressure 60 bar (870 psi) Solenoid valve Control voltage / Power 24 VDC / 5.4 or 12.7 W / 115AC V or 230 VAC Minimal up-time *1 5 ms Minimal down-time *1 10 ms Degree of protection IP 50 NOTE: *1 These times were measured with: Adhesive viscosity: 1000 mPas Control air pressure: 5 bar Solenoid valve: 24 VDC / 5.4 W P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved 30 (1.18”) 136.1 (5.36”) CHAMELEON® Application Head System Issued 03/02 66.8 (2.63”) 118.1 (4.65”) 155.8 (6.13”) PRODUCT TRAVELING DIRECTION. 10.1 (0.40”) 97.4 (3.83”) 162.1 (6.38”) M6 317.9 (12.52”) *Example: L=120 (4.72”) n=1 L=155 (6.10”) n=2 L=190 (7,48”) n=3 L=225 (8,86”) n=4 etc. 78.5 (3.1”) 68 (2.68”) Hose nipple Ø18 (0.71”) 53 (2.09”) 9/16 – 18 UNF 34.5 (0.18”) L L+30 (L+1.18”) 42.5 (1.67”) REV. A 05–DEC–2001 CM200 CAM–A/V XXXU CM200–VER–UP90 23 (0.91”) 8 (0.31”) 45 (1.77”) L n x 35* (n x 1.38”)* 35 (1.38”) M6 9 (0.35”) 27 (1.06”) E 2002 Nordson Corporation All rights reserved 48.1 (1.89) 42.5 (1.67”) Specifications 9-5 3. Dimensions Hot Melt Application Head in Vertical Position up 90 with Pneumatic Control Modules CM 200 CHAM054A Fig. 9-1 P/N 409216C 210.1 (8.27”) 25 (0.98”) 234.1 (9.22”) CHAMELEON® Application Head System Issued 03/02 76 (2.99”) 65.9 (2.59”) 10%%d 48.1 (1.89”) 78.5 (3.1”) 10.1 (0.39”) 68 (2.68”) 53 (2.09”) 9/16 – 18 UNF Hose nipple Ø18 (0.71”) 202.7 (7.98”) P/N 409216C 34.5 (0.18”) 42.5 (1.67”) L 35 (1.38”) L L+30 (L+1.18”) M6 (n x 35)* (n x 1,38”)* 42.5 (1.67”) 9 (0.35”) 45 (1.77”) M6 23 (0.91”) 92.4 (3.64”) Max .210 (8.28”) *Example: L=120 (4.72”) n=1 L=155 (6.10”) n=2 L=190 (7,48”) n=3 L=225 (8,86”) n=4 etc. PRODUCT TRAVELING DIRECTION. 48.2 (1.9”) 8 (0.31”) 27 (1.06”) 30 (1.18”) 25 (0.98”) REV. A 05–DEC–2001 CM200 CAM–A/V XXXS CM200–VER–STRAIGHT 9-6 Specifications Hot Melt Application Head in Vertical Position Straight with Pneumatic Control Modules CM 200 CHAM054A Fig. 9-2 E 2002 Nordson Corporation All rights reserved Max 146 (5.75”) Min 136 (5.35”) 118.1 (4.65”) 291.1 (11.46”) 25 (0.98”) CHAMELEON® Application Head System Issued 03/02 52.5 (2.07”) 10.6 (0.42”) 78 (3.1”) 30 (1.18”) Min. 108 (4.25”) – Max. 118 (4.65”) PRODUCT TRAVELING DIRECTION. 293.1 (11.54”) 3 (0.12”) 304.2 (11.97”) 204.6 (8.06”) 119.1 (4.69”) 49.1 (1.93”) 85.1 (3.35”) n=1 n=2 n=3 n=4 34.5 (1.36”) 9/16 – 18 UNF Hose nipple Ø18 (0.71”) 53 (2.09”) 42.5 (1.67”) M6 L n x 35* – (n x 1.38”)* 35 (1.38”) L+30 (L+1.18”) 42.5 (1.67”) 15 (0.59”) 8 (0.31”) REV. A 05–DEC–2001 CM200 CAM–A/H XXXU CM200–HOR–UP90 45 (1.77”) 9 (0.35”) 102.1 (4.02”) 25 (0.98”) E 2002 Nordson Corporation All rights reserved 27 (1.06”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. Specifications 9-7 Hot Melt Application Head in Horizontal Position up 90 with Pneumatic Control Modules CM 200 CHAM055A Fig. 9-3 P/N 409216C 126.1 (4.96”) CHAMELEON® Application Head System Issued 03/02 25 (0.98”) 52.5 (2.07”) 10.6 (0.42”) 78 (3.1”) 30 (1.18”) Min. 108 (4.25”) – Max. 118 (4.65”) 3 (0.12”) 235 (9.25”) 211 (8.31”) PRODUCT TRAVELING DIRECTION. 119.1 (4.69”) 49.1 (1.93”) 85.1 (3.35) 245.6 (0.42”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. n=1 n=2 n=3 n=4 34.5 (1.36”) 9/16 – 18 UNF Hose nipple Ø18 (0.71”) 53 (2.09”) 42.5 (1.67”) M6 L n x 35* – (n x 1.38”)* 35 (1.38”) L + 30 (L+1.18”) 42.5 (1.67”) 15 (0.59”) 8 (0.31”) 9 (0.35”) 27 (1.06”) 144.3 (5.68”) 233.3 (9.19”) P/N 409216C 45 (1.77”) REV. A 05–DEC–2001 CM200 CAM–A/H XXXS CM200–HOR–STRAIGHT 9-8 Specifications Hot Melt Application Head in Horizontal Position Straight with Pneumatic Control Modules CM 200 CHAM054A Fig. 9-4 E 2002 Nordson Corporation All rights reserved 25 (0.98”) CHAMELEON® Application Head System Issued 03/02 93.5 (3.68”) 83.4 (3.28”) 45 (1.77”) 78.5(3.09”) 3 (0.12”) 108.1(4.26”) 10.1(0.39”) 9/16 –18 UNF 34.5 (1.36”) 42.5 (1.67”) 35 (1.38”) M6 L+38 (L+1.49”) 18 (0.71”) L n x 35* – (n x 1.38”)* 42.5 (1.67”) 9 (0.35”) Max. 227 (8.28”) M6 137.2 (5.4”) E 2002 Nordson Corporation All rights reserved 10 (0.39”) n=1 n=2 n=3 n=4 Max .172 (6.77”) PRODUCT TRAVELING DIRECTION. 27 (1.06”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. 30 (1.18”) CM900–VER REV. A 03–DEC–2001 Specifications 9-9 Hot Melt Application Head in Vertical Position with Electrical Control Modules CM 900 CHAM056A Fig. 9-5 P/N 409216C Max 146 (5.75”) 25 (0.98”) Min 136 (5.35”) 121.1(4.78”) CHAMELEON® Application Head System Issued 03/02 95.5 (3.76”) 174.2 (3.76”) 10.6 (0.42”) PRODUCT TRAVELING DIRECTION. 129.7 (5.12”) 109.1 (4.29”) 79.4 (3.13”) 19.1 (0.75”) Min. 226 (8.9”) – Max. 236 (9.3”) *Example: L=120 (4,72”) n=1 L=155 (6,10”) n=2 L=190 (7,48”) n=3 L=225 (8,86”) n=4 etc. 30 (1.18”) 104.5 (4.11”) 25 (0.98”) 22.5 (0.89”) 30 (1.18”) P/N 409216C 34.5 (1.36”) 9/16 – 18 UNF 42.5 (1.67”) L+38 (L+1.49”) L n x 35* (n x 1.38”)* 35 (1.38”) M6 42.5 (1.67”) 9 (0.35”) 27 (1.06”) CM900–HOR REV. A 03–DEC–2001 9-10 Specifications Hot Melt Application Head in Horizontal Position with Electrical Control Modules CM 900 CHAM057A Fig. 9-6 E 2002 Nordson Corporation All rights reserved 45 (1.77”) M6 CHAMELEON® Application Head System Issued 03/02 93.5 (3,68”) 83.4 (3,28”) 10%%d 27 (1.06”) 45 (1.77”) 108.1 (4,26”) 8 (0,31”) 10.1 (0,39”) 118.1 (4,65”) 22 (0.87”) 42.5 (1.67”) L+26 (L+1.02”) 18 (0,71”) L n x 35* – (n x 1.38”)* 35 (1.38”) 42.5 (1.67”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. MAX 224 (8,82”) E 2002 Nordson Corporation All rights reserved 78.5 (3,09”) 9 (0,35”) 1/2” – 20 UNF n=1 n=2 n=3 n=4 PRODUCT TRAVELING DIRECTION. 92.4 (3,64”) Max.172 (6,77”) 30 (1.18”) CM800–VER REV. A 03–DEC–2001 Specifications 9-11 Cold Glue Application Head in Vertical Position with Electrical Control Modules CM 800 CHAM058A Fig. 9-7 P/N 409216C 25 (0.98”) Max 143 (5.63”) Min 133 (5.24”) 137.2 (5,40”) CHAMELEON® Application Head System Issued 03/02 95.5 (3.76”) 174.2 (3.76”) 10.6 (0.42”) PRODUCT TRAVELING DIRECTION. 129.7 (5.12”) 109.1 (4.29”) 79.4 (3.13”) 19.1 (0.75”) Min 226 (8.9”) – Max 236 (9.3”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. n=1 n=2 n=3 n=4 30 (1.18”) 104.5 (4.11”) 25 (0.98”) 22.5 (0.89”) 30 (1.18”) P/N 409216C 22 (0.87”) 1/2 – 20 UNF 42.5 (1.67”) L+26 (L+1.02”) L (n x 35)* (n x 1.38”)* 35 (1.38”) M6 42.5 (1.67”) 9 (0.35”) 27 (1.06”) CM800–HOR REV. A 03–DEC–2001 9-12 Specifications Cold Glue Application Head in Horizontal Position with Electrical Control Modules CM 800 CHAM059A Fig. 9-8 E 2002 Nordson Corporation All rights reserved 45 (1.77”) Min. 186.1 (7.32”) – Max. 196.1 (7.72”) 27.6 (1.09”) Min. 149.3 (5.88”) – Max. 159.3 (6.27”) 9.7 (0.38”) 42.5 (1.67”) 25.3 (0.99”) 25 (0.98”) 25 (0.98”) M6 CHAMELEON® Application Head System Issued 03/02 L n x 35* (n x 1.38”)* 35 (1.18”) L+57 (L+2.24”) 42.5 (1.67”) 25 (0.98”) 1/2 – 20 UNF 31.7 (1.25”) n=1 n=2 n=3 n=4 42.1 (1.66”) 59.4 (2.34”) PRODUCT TRAVELING DIRECTION. 73.4 (2.89”) 53.4 (2.1”) 10%%d 43 (1.69”) 7.5 (0.29”) CM711–VER REV. A 03–DEC–2001 10.1 (0.39”) 36.9 (1.45”) 69.1 (2.72”) 30 (1.18”) 116.4 (4.58”) 25 (0.98”) E 2002 Nordson Corporation All rights reserved 49.1 (1.93”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. Specifications 9-13 Cold Glue Application Head in Vertical Position with Pneumatic Control Modules CM 711 CHAM062A Fig. 9-9 P/N 409216C CHAMELEON® Application Head System Issued 03/02 67.2 (2.65”) 7.5 (0.3”) 50.1 (1.97”) 70.1 (2.76”) 62.6 (2.46”) *Example: L=120 (4,72”) L=155 (6,10”) L=190 (7,48”) L=225 (8,86”) etc. 49 (1.93”) 18 (0.71”) 91.3 (91.3”) 10.6 (0.42”) PRODUCT TRAVELING DIRECTION. 176.4 (6.94”) 43 (1.69”) 25 (0.98”) n=1 n=2 n=3 n=4 30 (1.18”) 80.5 (3.7”) P/N 409216C 9.7 (0.38”) 25 (0.99”) 25 (0.99”) 25.2 (0.99”) 42.5 (1.67”) L+57 (L+2.24”) L n x 35* – (n x 1.38”)* 35 (1.38”) 35 (1.38”) M6 31.7 (1.25”) 42.5 (1.67”) 25 (0.99”) 1/2 – 20 UNF CM711–HOR REV. A 03–DEC–2001 9-14 Specifications Cold Glue Application Head in Horizontal Position with Pneumatic Control Modules CM 711 CHAM063A Fig. 9-10 E 2002 Nordson Corporation All rights reserved 161.4 (6.35”) 9-15 Specifications 4. Cordsets 8 Green/Yellow 2 Blue 3 Brown Ground conductor Heater 4 Black 5 Black Pin insert HAN 7D KWU 6 Red Thermo lead + 7 Blue Thermo lead CHAM064A Fig. 1 Meltex Cordset Fe-CuNi (FE/KO) 8 Green/Yellow 2 Blue 3 Brown Ground conductor Heater 4 Black 5 Black 6 Red 7 White Pin insert HAN 7D KWU Temperature sensor Pt 100 CHAM066A Fig. 2 Meltex Cordset Pt 100 1 Black 2 Black Heater 3 Temperature sensor Ni 120 5 Green/Yellow Ground conductor CHAM067A Fig. 3 Nordson Cordset Ni 120 E 2002 Nordson Corporation All rights reserved CHAMELEON® Application Head System Issued 03/02 P/N 409216C 9-16 Specifications 5. Electrical Connection Pin Assignment 0 0 L1 Left L2 L3 L4 L5 R2 R1 Right 1 2 3 4 5 6 7 8 9 10 CHAM068A PIN 4 12 5 1 6 11 7 10 3 2 9 8 CHAM069A Cable 1 Cable 2 1 Control module L1 Control module R1 2 Control module L1 Control module R1 3 Control module L2 Control module R2 4 Control module L2 Control module R2 5 Control module L3 Control module R3 6 Control module L3 Control module R3 7 Control module L4 Control module R4 8 Control module L4 Control module R4 9 Control module L5 Control module R5 10 Control module L5 Control module R5 11 Not connceted Not connected 12 Ground Ground Fig. 9-11 NOTE: Refer to Accessories in the Section Parts for the special tools required to remove the crimp contacts. P/N 409216C CHAMELEON® Application Head System Issued 03/02 E 2002 Nordson Corporation All rights reserved