FoamMelt 190 Processor - Nordsonemanuals.nordson.com/adhesives/English_Manuals/107144.pdfTo Install...

FoamMelt� 190 Processor

Customer Product ManualPart 107 144D

NORDSON CORPORATION � AMHERST, OHIO � USA

� 1999 Nordson CorporationAll rights reserved

107 144DIssued 3/99

Manual 41-190

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Address all correspondence to

Nordson Corporation11475 Lakefield Drive

Duluth, GA 30155

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1997. No partof 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, EquiBead, 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 ofValues are trademarks of Nordson Corporation.

Never Seez is a registered trademark of Bostik Corporation, Loctite is a registered trademark of LoctiteCorporation, Parker Lubricant is a registered trademark of Parker Seal, and Viton is a registered trademark of

E.I. DuPont de Nemours & Co.

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Table of Contents i


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Table of Contents

1. Operate Safely 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Symbols 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Qualified Personnel 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Installation and Electrical Connections 1-4. . . . . . . . . . . . . . . . . . . . . . .

6. Operation 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less-Obvious Dangers 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Action in the Event of Unit Malfunction 1-5. . . . . . . . . . . . . . . . . . . . .

Danger of Burns 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Maintenance/Repair 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Cleaning 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Thermoplastic Hot Melt Material 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Equipment and Material Disposal 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Intended Use 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FoamMelt Process 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional Description 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melting System 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mixing System 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Flow 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses, Guns, and Related Equipment 2-4. . . . . . . . . . . . . . . . . . .

Operator Control Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard I/O 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Modulation 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2Description

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Hydraulic Pressure Control 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Supply 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Control 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostics 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequential Start-up 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System-Ready Time Delay 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm Start 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Component Descriptions 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical and Pneumatic Components 2-8. . . . . . . . . . . . . . . . . . . . .

Light Tower (1) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Cabinet (2) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Controller (3) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure and Gas Control Panel (4) 2-9. . . . . . . . . . . . . . . . . . . .

Motor Controller or Pump RPM Display (5) 2-10. . . . . . . . . . . . . .

Pump outlet Pressure Monitor (6) 2-10. . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Control (7) 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Audible Alarms (8) 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Components 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hopper (1) 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grid (2) 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reservoir (3) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold (4) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses (5) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor (6) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly (7) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. System Controller 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Status 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT Light (1) 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING Light (2) 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIME BEFORE READY Display (3) 2-15. . . . . . . . . . . . . . . . . . . .

Description (contd.)

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READY Light (4) 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDBY Key and Light (5) 2-15. . . . . . . . . . . . . . . . . . . . . . . . . .

HEATERS Key and Light (6) 2-15. . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM OK (n) Light (7) 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Code Display (8) 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run/Program Switch (9) 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Status 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Zone Symbols (1) 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Status Lights (2) 2-18. . . . . . . . . . . . . . . . . . . . . . . . .

Zone FAULT Lights (3) 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SILENCE ALARM Key (4) 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAR FAULT Key (5) 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCAN Key (6) 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up Key (7) 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZONE Display (8) 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACTUAL TEMPERATURE Display (9) 2-20. . . . . . . . . . . . . . . . . .

Temperature Set 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZONE/SETUP Display (1) 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SET ALL Light (2) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up Key (3) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEMPERATURE Display (4) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . .

Up and Down Keys (5) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENTER Key (6) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T1 (Operating Setpoint) Key and Light (7) 2-22. . . . . . . . . . . . . .

T2 (Standby Setpoint) Key and Light (8) 2-22. . . . . . . . . . . . . . .

OVERTEMP Key and Light (9) 2-22. . . . . . . . . . . . . . . . . . . . . . . .

STORE Key and Light (10) 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

USE Key and Light (11) 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Auto Start, Auto Standby, and Auto Shutdown 2-23. . . . . . . . . . . . .

DAY Display (1) 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SET M-F (Monday-Friday) Light (2) 2-24. . . . . . . . . . . . . . . . . . . .

Up Keys (3) 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIME (HH-MM) Display (4) 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DELETE ENTRY Key (5) 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENTER Key (6) 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO START TIME Key and Light (7) 2-25. . . . . . . . . . . . . . . . . .

SET CLOCK Key and Light (8) 2-25. . . . . . . . . . . . . . . . . . . . . . . .

TIMER Key and Light (9) 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR SPEED Display (1) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . .

Up and Down Keys (2) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR Key and Light (3) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up Key (4) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guns Display (5) 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Overload Relay 2-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Pressure and Gas Control Panel 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Controls 2-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Auto Button (1) 2-28. . . . . . . . . . . . . . . . . . . . . .

MANUAL Pressure Control Potentiometer (2) 2-29. . . . . . . . . . .

GAS ON Button (3) 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Controls 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOW GAS Light (4) 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GAS FLOW Light (5) 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PURGE Button (6) 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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6. Gear-to-Line Motor Controller 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Pressure Control Mode 2-30. . . . . . . . . . . . . . . . . . . . . . . .

Motor Controller Keys and Lights 2-30. . . . . . . . . . . . . . . . . . . . . . . .

RPM/Parameter Display (1) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . .

TACH Key and Light (2) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Numeric Keys (3) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENTER Key (4) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Down Key (5) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code Display (6) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODE SELECT Key and Light (7) 2-32. . . . . . . . . . . . . . . . . . . . .

DEV Alarm Light (8) 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limit Alarm Light (9) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preset Light (10) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jog Light (11) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run Light (12) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up Key (13) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAR Key (14) 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SET SPEED Key and Light (15) 2-33. . . . . . . . . . . . . . . . . . . . . . .

7. PUMP OUTLET PRESSURE Monitor 2-34. . . . . . . . . . . . . . . . . . . . . . .

PUMP OUTLET PRESSURE Display (1) 2-34. . . . . . . . . . . . . . . . . .

SET POINT Light (2) 2-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT Light (3) 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set Pressure Alarm Button (4) 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . .

SCAN/FREEZE Button (5) 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure-Alarm Potentiometers (6) 2-35. . . . . . . . . . . . . . . . . . . . . . .

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8. Technical Data 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Current Requirements 2-38. . . . . . . . . . . . . . . . . . . . . . . . .

Pump Charts 2-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Speed 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Density Reduction 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulation to Output Ratio 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Equipment Location 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Mechanical Installation 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Processor 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Air Supply 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Automatic Guns 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Hoses 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install Supply Hoses 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install Jumper Hoses Between Guns 3-7. . . . . . . . . . . . . . . . .

To Install Return Hoses to Guns 3-8. . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Gas Supply 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Making Standard Remote Input/Output Connections 3-10. . . . . . . .

To Use Remote Outputs 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Use Remote HEATER Inputs 3-12. . . . . . . . . . . . . . . . . . . . . . .

To Use Remote EMERGENCY STOP Input 3-12. . . . . . . . . . . . .

To Use PLC Control Input 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Accessory Equipment 3-13. . . . . . . . . . . . . . . . . . . . . . . . . .


Section 3Installation

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6. Electrical Installation 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the Electrical Cabinet Door 3-14. . . . . . . . . . . . . . . . . . . . . .

Installing the Light Tower 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Incoming Service Line 3-16. . . . . . . . . . . . . . . . . . . . . .

To Install 240 Vac, Three-Phase Service 3-16. . . . . . . . . . . . . . . .

To Install 400 Vac, Four-Wire Service 3-17. . . . . . . . . . . . . . . . . .

Setting Up PUMP OUTLET PRESSURE Monitor 3-18. . . . . . . . . . .

To Enable the Pressure-Band Fault 3-18. . . . . . . . . . . . . . . . . . . .

To Change Unit of Measure to kPa 3-19. . . . . . . . . . . . . . . . . . . . .

Changing System Configuration Settings 3-21. . . . . . . . . . . . . . . . . .

To Disable Sequential Start-Up 3-23. . . . . . . . . . . . . . . . . . . . . . . .

To Change System-Ready Time Delay 3-23. . . . . . . . . . . . . . . . .

To Change Auto Standby Timer 3-24. . . . . . . . . . . . . . . . . . . . . . .

To Change Temperature Band Warning 3-24. . . . . . . . . . . . . . . . .

To Change Auto Shutdown Timer 3-25. . . . . . . . . . . . . . . . . . . . . .

To Change Low Temperature Fault 3-25. . . . . . . . . . . . . . . . . . . . .

To Change Temperature Display Units 3-26. . . . . . . . . . . . . . . . . .

To Change Maximum Temperature 3-26. . . . . . . . . . . . . . . . . . . . .

1. Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Temperature Setpoint Warnings and Recommendations 4-1. . . . . . . .

Safety Warnings 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommendations 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Initial Setup Procedures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming the System Controller 4-3. . . . . . . . . . . . . . . . . . . . . . .

To Enter Program Mode 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Create Temperature Setups 4-5. . . . . . . . . . . . . . . . . . . . . . . . .

To Store Temperature Setups 4-7. . . . . . . . . . . . . . . . . . . . . . . . . .

To Change the System Clock Settings 4-11. . . . . . . . . . . . . . . . . .

To Secure Your Settings 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4Operation

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Programming the Gear-to-Line Motor Controller 4-12. . . . . . . . . . . .

Setting the Low-Pressure Fault Setpoint 4-20. . . . . . . . . . . . . . . . . .

Preparing the Hydraulic System 4-21. . . . . . . . . . . . . . . . . . . . . . . . .

To Flush the System 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Connect Return Hoses 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Density Control 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Get a Hot Melt Sample 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Get a Foam Sample 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Determine and Adjust Density Reduction 4-30. . . . . . . . . . . . .

4. Routine Operating Procedures 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Up the System 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Complete Automatic Startup 4-33. . . . . . . . . . . . . . . . . . . . . . . .

To Perform Manual Startup 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing the System in Standby Mode 4-36. . . . . . . . . . . . . . . . . . . . .

To Use Automatic Standby Mode 4-36. . . . . . . . . . . . . . . . . . . . . .

To Use Manual Standby Mode 4-36. . . . . . . . . . . . . . . . . . . . . . . .

Removing the System from Standby Mode 4-37. . . . . . . . . . . . . . . .

Shutting Down the System 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Perform Automatic Shutdown 4-37. . . . . . . . . . . . . . . . . . . . . . .

To Perform Manual Shutdown 4-38. . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Motor Speed 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing the System in Auto Pressure Control Mode 4-39. . . . . . . . .

Placing the System in Manual Pressure Control Mode 4-39. . . . . .

Displaying Actual Temperatures 4-40. . . . . . . . . . . . . . . . . . . . . . . . .

To Scan All Zones 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Display Only One Zone at a Time 4-40. . . . . . . . . . . . . . . . . . .

Reviewing the Current System Setup 4-41. . . . . . . . . . . . . . . . . . . . .

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Changing or Selecting a Stored Set of Temperatures 4-42. . . . . . .

To Change an Existing Setup and Store the Change(s) 4-43. . .

To Select A New Setup 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the System Status 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Responding to Faults and Warnings 4-45. . . . . . . . . . . . . . . . . . . . . .

To Silence the Alarms 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Clear Warnings and Faults 4-46. . . . . . . . . . . . . . . . . . . . . . . . .

Changing Hot Melt Material 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Revised Configuration Switch Settings 4-48. . . . . . . . . . . . . . . . . . . . . .

6. Revised Auto-Start Time Settings 4-48. . . . . . . . . . . . . . . . . . . . . . . . . .

7. Stored Temperature Sets 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Gear-to-Line Motor Controller Default Settings 4-51. . . . . . . . . . . . . . .

1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. System Preparation 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 5-2. . . . . . . . . . . . . . . . . . . . . .

Resuming Normal Operation 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Maintenance Procedures 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduling Maintenance 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the Filter Assembly 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Hydraulic, Gas, and Electrical Connections 5-8. . . .

Checking and Cleaning the Filter Assembly 5-8. . . . . . . . . . . . . . . .

To Remove the Density Controller and Filter 5-9. . . . . . . . . . . . .

To Inspect the Filter Assembly 5-11. . . . . . . . . . . . . . . . . . . . . . . . .

To Clean or Replace the Filter Screen 5-12. . . . . . . . . . . . . . . . . .

To Replace the Density Controller and Filter 5-13. . . . . . . . . . . . .

Flushing the System 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Drive Belt for Signs of Wear 5-17. . . . . . . . . . . . . . . . .

To Access and Check the Drive Belt 5-17. . . . . . . . . . . . . . . . . . .

To Remove the Drive Belt 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Replace the Drive Belt 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Maintenance Record Form 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5Maintenance

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1. Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Troubleshooting Tables 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CPU Error Codes 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Controller Warning/ Fault Specifications 6-4. . . . . . . . . . . .

Mechanical 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Controller 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP OUTLET PRESSURE Monitor 6-17. . . . . . . . . . . . . . . . . . . . .

RPM Display 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Measurement Procedures 6-18. . . . . . . . . . . . . . . . . . . . . . . . . .

3. Indicators and Connectors 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Board Indicators 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Board Connectors 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface Board Indicators 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface Board Terminal Blocks and Fuses 6-27. . . . . . . . . . . . . . .

RTD Resistance vs. Temperature Charts 6-28. . . . . . . . . . . . . . . . . .

4. FM-190 Processor Schematics 6-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Component Map Legend 6-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. General Information 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation for Hydraulic System Repairs 7-1. . . . . . . . . . . . . . . . . .

Quick-Disconnect Fittings 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Disconnection 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tasks to Perform After Replacing Miscellaneous Components 7-3

Removing the Hopper Enclosure and Unit Cover 7-4. . . . . . . . . . . .

Replacing the Unit Cover and Hopper Enclosure 7-6. . . . . . . . . . . .

Removing the Corner Enclosure 7-8. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Corner Enclosure 7-9. . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6Troubleshooting

Section 7Repair

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3. Mechanical Repairs 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Motor 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Preparation 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Access and Remove the Motor 7-11. . . . . . . . . . . . . . . . . . . . .

To Replace Motor Brushes 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Motor 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Drive Assembly 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .


To Access and Remove the Drive Assembly 7-16. . . . . . . . . . . .

To Replace Drive Shaft Face Seals 7-19. . . . . . . . . . . . . . . . . . . .

To Reinstall the Drive Assembly 7-21. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Pump or Pump O-Rings 7-22. . . . . . . . . . . . . . . . . . . .

Replacing the Pressure Control Valve 7-24. . . . . . . . . . . . . . . . . . . .

Rebuilding the Pressure Control Valve 7-26. . . . . . . . . . . . . . . . . . . .

Rebuilding the Density Controller 7-29. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Hose Connector and Pipe Plug O-Rings 7-30. . . . .

Servicing the Drain Valve 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Valve Stem Assembly 7-33. . . . . . . . . . . . . . . . . .

To Reinstall the Drain Valve 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Electrical Repairs 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Controller Battery 7-35. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Circuit Boards 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting the AP1 Circuit Board to Factory Defaults 7-39. . . . . . . .

Replacing the AP2 Circuit Board 7-40. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the AP5, AP6, AP7, or AP8 Circuit Boards 7-42. . . . . . .

Calibrating Motor Speed 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Calibrate Standard Units 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Calibrate Gear-to-Line Units 7-45. . . . . . . . . . . . . . . . . . . . . . . .

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Adjusting Current Limits 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Adjust Standard Units 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Adjust Gear-to-Line Units 7-47. . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting IR Compensation 7-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the Gear-to-Line Motor Controller 7-50. . . . . . . . . . . . .

To Configure the Internal Jumpers 7-50. . . . . . . . . . . . . . . . . . . . .

To Set the Internal Voltage Switch 7-51. . . . . . . . . . . . . . . . . . . . .

To Set the 82-CP Value 7-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the RPM Display 7-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Solid-State Relays 7-54. . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove a Relay 7-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install a Relay 7-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Light Bulb 7-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Fuses 7-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Light Tower Bulbs 7-59. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Light Tower Assembly 7-60. . . . . . . . . . . . . . . . . . . . .

Configuring a Replacement Motor Overload Relay (KL1) 7-61. . . .

Replacing the Hopper Thermostat, RTD Sensor, or Heater 7-62. .


To Replace the Hopper Thermostat 7-63. . . . . . . . . . . . . . . . . . . .

To Replace the Hopper RTD 7-64. . . . . . . . . . . . . . . . . . . . . . . . . .

To Replace the Hopper Heater 7-65. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Grid Thermostat or RTD Sensor 7-67. . . . . . . . . . . .


To Replace the Grid Thermostat 7-67. . . . . . . . . . . . . . . . . . . . . . .

To Replace the Grid RTD 7-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair (contd.)

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Replacing the Reservoir Thermostat or RTD Sensor 7-69. . . . . . . .


To Replace the Reservoir Thermostat 7-70. . . . . . . . . . . . . . . . . .

To Replace the Reservoir RTD 7-71. . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Manifold Heater or RTD Sensor 7-72. . . . . . . . . . . . .


To Replace the Manifold Heater 7-73. . . . . . . . . . . . . . . . . . . . . . .

To Replace the Manifold RTD 7-74. . . . . . . . . . . . . . . . . . . . . . . . .

5. Gas/Pneumatic Repairs 7-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing the System for Gas Repairs 7-76. . . . . . . . . . . . . . . . . . . .

Replacing the Gas Pressure Regulator, Gas Gauge, or ReedexValve 7-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


To Replace the Gas Pressure Regulator 7-78. . . . . . . . . . . . . . . .

To Replace the Gas Pressure Gauge 7-80. . . . . . . . . . . . . . . . . . .

To Replace the Reedex Valve 7-81. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Gas Pressure Check Valve 7-82. . . . . . . . . . . . . . . . .

Replacing the Gas Pressure Switch 7-83. . . . . . . . . . . . . . . . . . . . . .

Replacing the I/P Transducer 7-84. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Pressure Transducer Assembly 7-86. . . . . . . . . . . . .

1. Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Base and Frame Assembly Parts List 8-2. . . . . . . . . . . . . . . . . . . . . . . .

3. Melting System Parts List 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Motor Assembly Parts List 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Routing Hardware Parts List 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Enclosures Parts List 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Hopper Assembly Parts List 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Grid Assembly Parts List 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8Parts

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9. Reservoir Assembly Parts List 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Manifold Assembly Parts List 8-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Drain Valve Assembly Parts List 8-21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. Pressure Control Valve Assembly Parts List 8-22. . . . . . . . . . . . . . . . .

13. Density Control/Filter Assembly Parts List 8-23. . . . . . . . . . . . . . . . . . .

14. Drive Assembly Parts List 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. Electrical Cabinet Front Panel Exterior Parts List 8-27. . . . . . . . . . . . .

16. Motor Controller for Gear-to-Line Parts List 8-29. . . . . . . . . . . . . . . . . .

17. RPM Display for Standard Units Parts List 8-30. . . . . . . . . . . . . . . . . . .

18. Gas Controller Parts List 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19. Pressure Display Parts List 8-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20. Pressure and Gas Control Panel Parts List 8-35. . . . . . . . . . . . . . . . . .

21. Heatsink Panel and Adjacent Main Panel Exterior Parts List 8-36. . .

22. Light Tower Assembly Parts List 8-38. . . . . . . . . . . . . . . . . . . . . . . . . . . .

23. System Controller Assembly Parts List 8-40. . . . . . . . . . . . . . . . . . . . . .

24. Main Panel Interior Parts List 8-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25. Terminal Blocks Parts List 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26. Back Panel Interior Parts List 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27. Cabinet Door Interior Parts List 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . .

28. Recommended Spare Parts 8-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Board 8-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relays 8-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Fuses 8-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface Board Fuses 8-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Controller or Drive Fuses 8-57. . . . . . . . . . . . . . . . . . . . . . . . . .

Lamps 8-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 8-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 8-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic and Gas 8-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-Rings 8-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Miscellaneous 8-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts (contd.)

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29. Available Service Kits 8-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings 8-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Coupling 8-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Pump 8-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grid 8-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold 8-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reservoir 8-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly 8-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transducer Assembly 8-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Miscellaneous 8-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30. Ship-With Kit Parts List 8-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31. Optional Parts and Equipment 8-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Installation Kit 8-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Installation Kit 8-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handgun Installation Kit 8-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extension Cords 8-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Fittings for 5/8 in. Hoses 8-67. . . . . . . . . . . . . . . . . . . . . . . . . . .

FM 190 Accessories 8-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kalrez Brand Assemblies and O-Rings 8-69. . . . . . . . . . . . . . . . . . .

32. Fuse Replacement Table 8-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 9Nordson Glossary

Section 10Index

Table of Contentsxvi


107 144DIssued 3/99

Manual 41-190


Issued 11/94 A1EN−02−[XX−SAFE]−4

Section 1

Safety

Safety1-0


Issued 11/94A1EN−02−[XX−SAFE]−4

Safety 1-1



Section 1Safety

Safety instructions contained in this section and throughout thisdocument apply to tasks that may be performed with or on the unit.Warnings related to specific safety concerns are included within the textas appropriate. It is very important that these safety instructions arealways followed. Failure to do so could result in personal injury and/ordamage to the unit or other equipment.

With this in mind, here are some basic safety recommendations:

� Read and become familiar with this Safety section prior to installing,operating, maintaining, or repairing the unit.

� Read and follow the warnings which appear within the text and arerelated to specific tasks.

� Store this document within easy reach of personnel operating ormaintaining the unit.

� Wear personal protective equipment and clothing such as safetygoggles and gloves.

� Familiarize yourself with and follow all safety instructions prescribedby your company, general accident-prevention regulations, andgovernment safety regulations.

1. Operate Safely

Safety1-2



The following symbols are used to warn against dangers or possiblesources of danger. Become familiar with them! Failure to heed awarning could lead to personal injury and/or damage to the unit or otherequipment.

WARNING: Failure to observe may result in personal injury,death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

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

CAUTION: Failure to observe may result in equipmentdamage.

CAUTION: Hot surface. Failure to observe may result inburns.

2. Safety Symbols

Safety 1-3



“Qualified personnel” is defined here as individuals who thoroughlyunderstand the equipment and its safe operation, maintenance, andrepair. Qualified personnel are physically capable of performing therequired tasks, familiar with all relevant safety rules and regulations, andhave been trained to safely install, operate, maintain, and/or repair theequipment. It is the responsibility of the company operating theequipment to see that its personnel meet these requirements.

The unit is designed and intended to be used only for the purposedescribed in the Description section. Uses not in accordance with thatsection or as described in this document are considered unintended usesand not in accordance with governing regulations.

WARNING: Use of this equipment in ways other thandescribed in this document may result in personal injury, death,or equipment damage.

The following actions of the owner or operator of the unit are some, butnot all, examples of unintended use which would permit Nordson to claimit is not responsible for personal injury or property damage arising fromsuch unintended use:

� Unapproved modifications or changes to the unit

� Failure to comply with the safety instructions

� Failure to comply with instructions concerning installation, use,operation, maintenance, or repair, or when these tasks are carried outby unqualified personnel

� Use of inappropriate or incompatible foreign materials or auxiliaryequipment

� Failure to observe workplace safety rules or regulations issued bygovernment authorities or safety councils

3. Qualified Personnel

4. Intended Use

Safety1-4



WARNING: Failure to follow the safety procedures can result ininjury or death.

� All electrical, pneumatic, gas, and hydraulic connections andinstallations of hot melt equipment may only be carried out byqualified personnel. Be sure to observe installation instructions forcomponents and accessories.

� Equipment must be properly grounded and fused according to itsrated current consumption (see ID plate).

� Cables which run outside the unit must regularly be checked for wearor damage.

� Power supply wire gauge and insulation must be sufficient to handlerated current consumption.

� Cables must never be squeezed or pinched. Do not locate cables orhoses in high traffic areas.

The unit should be operated by qualified personnel in accordance withthe instructions presented in this document.

WARNING: Failure to follow the safety procedures can result ininjury or death.

� Never allow the unit to be operated by personnel under the influenceof substances which reduce their reaction times, or who are not ableto operate the equipment for physical reasons.

� Prior to each start-up of the unit, check protection and warningdevices and make sure they are fully functional. Do not operate theunit if these devices are not functioning properly.

� When the removal of safety equipment is required for installation,maintenance, or repair of the unit, it must be re-connectedimmediately upon completion of the work.

� Prior to start-up of the unit, check to make sure all safety guards andsafety equipment are in place and functioning properly.

5. Installation and ElectricalConnections

6. Operation

Safety 1-5



� In a humid environment, only equipment featuring a correspondingclass of protection may be operated.

� Do not operate the unit in an explosive environment.

� Keep parts of the body or clothing away from rotating parts. Do notwear loose articles of clothing when operating or servicing units withrotating parts. Take off wrist watches, rings, necklaces, or similarpieces of jewelry and pin up or cover long hair before performing anywork on or with the unit.

� To carry out measurements on work pieces, switch off the unit andwait until it comes to a standstill.

� Never point hand guns or applicator nozzles at yourself or otherpersons.

WARNING: An operator or service technician working with theunit should be aware of less-obvious dangers that often cannotbe completely minimized at production sites:

� Exposed surfaces of the unit which cannot be practicallysafeguarded. They may be hot and take time to cool after the unithas been operating.

� The possibility that electrical potentials may remain in the unit afterthe unit was de-energized

� Hot melt material and vapors

� Hydraulically or pneumatically operated parts of the unit

� Parts winding something up or down which are not covered

If the unit malfunctions, switch it off immediately.

� Turn the circuit breaker or main power switch OFF.

� Have the unit repaired by qualified personnel only.

6. Operation (contd.)

Less-Obvious Dangers

Action in the Event of UnitMalfunction

Safety1-6



Contact with hot melt materials or hot areas of the unit may produce asevere skin burn.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

� Be extremely careful when using hot melt material. Even solidifiedmaterial may still be very hot.

� Always wear protective clothing which safely covers all exposed partsof the body.

In case of burns:

� Immediately cool affected skin areas using cold, clean water.

� Do not forcefully remove hot melt material from the skin.

� Immediately seek medical attention.

Allow only qualified personnel to perform the procedures described in thisdocument. When performing such tasks, wear protective clothing, andequipment.

WARNING: Even when the circuit breaker or main powerswitch is OFF, the unit is still electrically energized. Completethe following steps prior to maintenance or repair:

� Disconnect, lock out, and tag external power supply.

� To ensure the external power supply is disconnected, attempt tooperate the unit. If the unit does not energize, proceed withmaintenance or repair work.

� If the unit energizes, repeat the disconnect, lock out, and tagprocedure. Re-test the unit.

Danger of Burns

7. Maintenance/Repair

Safety 1-7



� Follow the specific instructions provided in this manual to relieve thesystem pressure in the entire unit.

� Secure pneumatically- or hydraulically-operated equipment againstuncontrolled movement.

� Only use parts which do not compromise the safety of the unit. Onlyuse genuine Nordson parts.

� Always use tools with insulated handles when removing or installingcomponents.

NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any ma-terial.

WARNING: Never clean any aluminum part or flush anysystem using halogenated hydrocarbon fluids. Examples ofcommon halogenated hydrocarbons are: dichloromethylene,1,1,1-trichloroethylene, and perchloroethylene. Halogenatedhydrocarbons may react violently with aluminum parts.

WARNING: Fire, open flame, and smoking are prohibited whencleaning fluids are used. Observe all explosion preventionregulations. Cleaning fluids may only be heated usingtemperature-controlled and explosion-protected heaters.

� Never use an open flame to clean the unit or components of the unit.

� Use only cleaning fluids designed or intended to be used with the hotmelt material being used in the unit. Never use paint fluids under anycircumstances.

� Note the flash point of the cleaning fluid used. Only use a controlledheating method to heat fluids.

� Ensure sufficient room ventilation to draw off generated vapors.Avoid prolonged breathing of vapors.

7. Maintenance/Repair (contd.)

8. Cleaning

Safety1-8



NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any hotmelt material.

� Ensure the work area is adequately ventilated.

� Do not exceed recommended processing temperatures. Doing socreates a danger to personnel due to decomposition of the material.

Dispose of equipment and materials used in operation and cleaningaccording to local regulations.

9. Thermoplastic Hot MeltMaterial

10. Equipment and MaterialDisposal


107 144DIssued 3/99

Manual 41-190

Section 2

Description

Description2-0


107 144DIssued 3/99

Manual 41-190

Description 2-1


107 144DIssued 3/99

Manual 41-190

Section 2Description

The FoamMelt 190 Series Processor (FM-190) may be used only to melt,transfer, and apply hot melt materials. The FM-190 is not intended foruse other than that described in this manual.

The FM-190 uses a process that combines hot melt material with an inertgas to produce a foam of uniform density.

4904001

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Fig. 2-1 FoamMelt 190 Processor

1. Intended Use

2. Overview

Description2-2


107 144DIssued 3/99

Manual 41-190

There are four stages in the FoamMelt process:

Stage What Happens

1 The FM-190 melts solid hot melt material.

2 The FM-190 mixes the molten hot melt material with ametered amount of inert gas.

3 The FM-190 holds the hot melt solution under pressure.

4 Upon extrusion, the hot melt solution expands toproduce foam.

See the System Logic Diagram in The Troubleshooting section for agraphic representation of system functions.

This part of the manual provides a functional description of the FM-190processor.

Melting System

A heated hopper, grid, reservoir, and manifold melt pellets, slats, or otherforms of solid hot melt material. Each of these heating components iscontrolled independently.

A drain valve located on the side of the manifold enables you to drainmolten hot melt material from the hopper.

Drive System

A two-horsepower, variable-speed DC motor is coupled to the gear pumpby a high-temperature drive belt.

Two motor controllers are available. For both types of motor controllers,a magnetic pickup senses the pump speed and displays it for monitoring.Gear-to-line processors automatically adjust output pressure to matchvariable line speeds. Motor speed and output pressure on standardprocessors must be manually adjusted.

FoamMelt Process

Functional Description

Description 2-3


107 144DIssued 3/99

Manual 41-190

Mixing System

After being melted, the hot melt material is fed into a constantdisplacement, two-stage gear pump where it is mixed with an inert gas(commonly industrial-grade carbon dioxide or nitrogen). The two-stagegear pump is similar to a pair of gear pumps that are stacked one on topof the other in a single housing.

The first stage (top portion) of the pump draws a measured amount ofmolten hot melt material into the second stage (bottom portion) of thepump.

The second stage of the pump creates a vacuum that helps draw in thegas. As the gas and molten hot melt material move toward the pumpdischarge port, hydraulic pressure in the pump increases, forcing the gasinto solution with the molten holt melt material. A series of slots cut intothe plates above and below the second-stage gear teeth also help mixthe gas with molten hot melt material.

Hydraulic Flow

As the hot melt solution leaves the pump and enters the manifold,hydraulic pressure is measured by a pressure transducer and displayedon the operator control panel.

The hot melt solution flows from the manifold through the densitycontrol/filter assembly, into supply hoses, and out to the automatic orhand-operated extrusion gun(s). Unused solution recirculates throughthe return hose(s) connected to the return port in the manifold. Thisprevents the hot melt solution from separating and improves itsconsistency.

As the holt melt solution enters the return port in the manifold, it passesthrough a pressure control valve.

Hydraulic overpressure protection is provided by a pressure relief valvemounted in the manifold. If hydraulic pressure reaches 10,343 kPa+/−690 kPa (1,500 psi +/−100 psi), the valve redirects the solution intothe pump return passage.

Description2-4


107 144DIssued 3/99

Manual 41-190

Hoses, Guns, and Related Equipment

The FM-190 is an externally recirculating system. Up to a total of sixhoses and four automatic extrusion guns can be connected to theFM-190 processor. Up to two circulating handguns can be connected.All use Resistance Temperature Detectors (RTDs) to sense and controltemperature.

Nordson conventional, automatic, and water-wash hoses can be usedwith automatic guns. Special extension cords are available to supplypower to a jumper hose that is beyond the reach of the hose electricalcord.

Zero-cavity and reduced-cavity hot melt guns are used for dispensing hotmelt solution. These guns reduce the drooling and stringing caused byexpanding gas.

Refer to your Nordson Adhesives and Sealants Equipment Catalog orcontact your Nordson representative for complete information on allFM-190 system components, including guns, hoses, and auxiliaryequipment.

Operator Control Panel

The operator control panel enables you to program system operatingvalues into the unit and provides feedback for monitored components. Allsystem operating values are stored in non-volatile memory. Therefore,you enter the values only once.

The operator control panel is divided into two sections. The uppersection provides digital readouts, temperature, motor, and timer controls,and system status indicators.

The lower section of the operator control panel contains the readouts andcontrols for pressure, motor speed, and gas. Note that pressure can bedisplayed in pounds per square inch (psi) or kilo Pascals (kPa).

Description 2-5


107 144DIssued 3/99

Manual 41-190

Standard I/O

The FM-190 processor includes input and output signals for interfacing toremote devices.

Inputs are used with isolated (potential-free) contacts and are located onconnector XP20 on the interface board (AP4). Available signals are:

Remote heater on

Remote heater off

Outputs are isolated relay contacts, both normally-open and normally-closed and are located on connector XP21 on the interface board (AP4).Available signals are:

Remote Ready Out

Remote Warning Out

Remote Fault Out

Gas Modulation

The gas (carbon dioxide or nitrogen) should be supplied to the unit from auser-supplied gas cylinder equipped with a regulator. Once connected,the gas flows through a pressure switch that signals a system errorcondition if the supply pressure falls below 207 kPa (30 psi).

The gas passes from the pressure switch through a pressure regulatorand pressure gauge which permit you to control input gas pressure to thepump. The gas then passes through a check valve located just beforethe manifold; this eliminates the possibility of material backflow into thegas line.

The amount of gas supplied to the pump is controlled by the densitycontrol/filter working in conjunction with a Reedex valve. Turning thedensity control knob clockwise adds more gas to the solution.

Hydraulic Pressure Control

Hydraulic pressure can be controlled manually or by a user-suppliedencoder that registers changes in production line speed.

When equipped with an encoder, the FM-190 processor automaticallyadjusts hydraulic pressure to maintain a constant bead thickness.

When the processor is used in manual mode, hydraulic pressure iscontrolled through manual adjustments of the pressure controlpotentiometer.

Description2-6


107 144DIssued 3/99

Manual 41-190

Air Supply

Regulated air supplied to the unit is routed to a pressure transducer (I/P).The transducer converts an electrical signal from the controls to an airpressure change that is sent to the pressure control valve actuator.

Temperature Control

The FM-190 processor maintains temperature control of systemcomponents with a microprocessor. The microprocessor controls thetemperature of system components using pulse width modulation and aproportional-integral-derivative (PID) control algorithm. Nickle RTDsmonitor temperatures.

Of the 14 temperature control channels, only those within the unit mustbe connected for system operation. While the unit is in PROGRAMmode, the operator control panel displays the setpoint of any selectedzone. While the unit is in RUN mode, the operator control panel displaysactual temperatures only for active zones.

Diagnostics

The FM-190 processor automatically performs a number of diagnosticsduring initial startup and continually during operation. Items checkedinclude:

� Overtemperature� Shorted/open RTD sensors� Shorted solid state relays (SSRs)� Open heater circuits� Low line voltage� Low gas pressure� Motor overload� Hydraulic under-pressure

If an error condition occurs, the processor displays an error code andturns on fault indicators. Depending on the type of error, the FM-190system may or may not shut down. See the Troubleshooting section fora complete list of error codes, troubleshooting procedures, and systemresponses.

Description 2-7


107 144DIssued 3/99

Manual 41-190

Sequential Start-Up

When this feature is enabled, the FM-190 processor heats one group ofzones at a time, beginning with the hopper (which is the zone furthestfrom the extrusion gun) and continuing with zones progressively closer tothe gun.

Group: Includes these zones:

One Hopper and Grid

Two Reservoir, Manifold and Hoses

Three Guns

Since different materials heat and expand at different rates, sequentialstart-up ensures that pressure stress on system components (especiallyhoses) is kept to a minimum.

NOTE: The sequential start-up feature may increase applicator warm-uptime beyond 30 to 45 minutes. For a shorter warm-up period, thesequential start-up feature can be disabled. See the Installation sectionfor the proper procedure.

NOTE: Some thermoplastic materials expand rapidly when initiallyheated. When using such materials, always employ the sequentialstart-up feature.

System-Ready Time Delay

This feature prevents operation of the motor and gear pump until allheated zones have reached their setpoints and a predetermined timeperiod has elapsed.

You set the time delay value during initial setup based on the timerequired for the adhesive to liquify. The delay period begins after alltemperature zones are within their setpoint bands.

The FM-190 control panel displays the time before ready during the delayperiod. After the delay period expires, the pump can be started.

Warm Start

The FM-190 microprocessor also features a warm start function thatallows faster system startup and operation after a brief power-down.

If the system is turned off, then on and the reservoir is within 42 �C (75 �F) of its setpoint temperature, the pump may be restarted withoutgoing through the system-ready delay sequence.

Description2-8


107 144DIssued 3/99

Manual 41-190

The major electrical, pneumatic, and mechanical components of theprocessor are briefly described in the following pages.

4904002

3

4

6

5

7

21

8

Fig. 2-2 Electrical and Pneumatic Components of the Processor

1. Light tower2. Electrical cabinet3. System controller4. Pressure and gas control panel5. Motor controller or pump RPM

display

6. PUMP OUTLET PRESSUREmonitor

7. Gas pressure control8. Audible alarms

3. Component Descriptions

Electrical and PneumaticComponents

Description 2-9


107 144DIssued 3/99

Manual 41-190

Light Tower (1)

The light tower provides a highly visible display of the system status. Itsred, yellow, and green lights correspond to the FAULT, WARNING, andREADY lights on the system controller panel. Table 2-1 lists each of theconditions that cause the light tower to turn on.

Table 2-1 Light Tower Colors and System Conditions

Light Tower Color System Condition

Green System ready for operation

Yellow System pressure out of band

Low gas

Electrical cabinet temperature high

Zone temperature out of band

Open heater

Red Zone overtemperature

Zone under temperature

Zone heater short

Zone RTD fault

Motor overtemperature

Error code displayed

Electrical Cabinet (2)

The electrical cabinet contains most of the wiring, controls, and otherelectrical components for the processor.

System Controller (3)

The system controller provides most of the controls, lights, andmessages for operating the processor. It is described in detail later inthis section.

Pressure and Gas Control Panel (4)

The pressure and gas control panel provides controls for the systemhydraulic pressure and the flow of gas in the processor. It is described indetail later in this section.

Description2-10


107 144DIssued 3/99

Manual 41-190

Motor Controller or Pump RPM Display (5)

Gear-to-line processors are equipped with a motor controller that showspump RPM and provides functions for constant hydraulic pressurecontrol. It is described in detail later in this section.

Standard (non-gear-to-line) processors are equipped with a pump RPMdisplay that provides pump speed data.

PUMP OUTLET PRESSURE Monitor (6)

The PUMP OUTLET PRESSURE monitor tracks and displays themanifold hydraulic pressure in psi or kPa. It is described in detail later inthis section.

Gas Pressure Control (7)

The gas pressure control regulates the input gas pressure to the pumpand displays gas pressure.

Audible Alarms (8)

A bell and siren are audible alarms that alert you to check the systemcontroller panel for information about the condition of the processor. Thefollowing table describes each alarm.

Table 2-2 Audible Alarms

Alarm Condition Example

bell warning low gas pressure level

siren fault overtemperature

Description 2-11


107 144DIssued 3/99

Manual 41-190

4904177

1 7

6

54

3

2

Fig. 2-3 Mechanical Components

1. Hopper2. Grid3. Reservoir4. Manifold

5. Hoses6. Motor7. Pump Assembly

Hopper (1)

A one-piece cast aluminum tank and welded hopper maintain prescribedtemperatures with two cast aluminum strip heaters. The interior of thehopper is PTFE-coated. (Zone 1)

Grid (2)

The aluminum grid is independently monitored for correct temperatureand contains one cast-in heater. (Zone 2)

Mechanical Components

Description2-12


107 144DIssued 3/99

Manual 41-190

Reservoir (3)

The cast aluminum reservoir is independently monitored for correcttemperature and contains two cast-in heaters. (Zone 3)

Manifold (4)

A cast aluminum manifold provides hose ports for connecting hoses.The manifold temperature is independently monitored and is heated by acartridge heater. (Zone 4)

Hoses (5)

Two pairs of recirculating hoses and up to four guns can be connected tothe applicator. Hoses can be automatic biaxial or standard hoses withstraight, 45, or 90 angles. Optional hose installation kits fornon-circulating guns are available. (Zone 5)

Motor (6)

A two horsepower, variable-speed DC motor powers the pump assembly.(Zone 6)

Pump Assembly (7)

The pump assembly features a pump drive, a pump coupling, and atwo-stage corrosion-resistant gear pump. The pump and the pumpcoupling are available in either standard or high-output versions.(Zone 7)

Description 2-13


107 144DIssued 3/99

Manual 41-190

The system controller panel is divided into five areas:

� system status� temperature status� temperature set� auto-start timer� motor control

The controls and lights for each of these areas are described on thefollowing pages.

4904043

2

1

1

2

4

3

4

3

5

6

Fig. 2-4 Functional Areas of the System Controller Panel

4. System Controller

4710043

1

2

3

4

5

6

8 9

7

Description2-14


107 144DIssued 3/99

Manual 41-190

FAULT Light (1)

The red FAULT light turns on when any of the following conditions occur:

� A sensor (RTD) is open or shorted.

� A heater circuit is shorted.

� The motor is over temperature.

� A heating zone is over temperature.

� A heating zone is greater than 19 C (35 F) under setpointtemperature.

� A diagnostic error code appears in the error code display.

Refer to the Troubleshooting section for an explanation of the conditionsthat cause the FAULT light to turn on.

WARNING Light (2)

The yellow WARNING light turns on when the following conditions occur:

� A heating zone is out of the temperature band.

� A heater is open.

� The electrical cabinet temperature is too high.

Fig. 2-5 System Status Controlsand Lights

1. FAULT light2. WARNING light3. TIME BEFORE READY display4. READY light5. STANDBY key and light6. HEATERS key and light7. SYSTEM OK light8. Error code display9. RUN/PROGRAM switch

System Status

Description 2-15


107 144DIssued 3/99

Manual 41-190

TIME BEFORE READY Display (3)

The TIME BEFORE READY display shows the number of minutesremaining on the system-ready time delay. As the heating zones startheating up, dashes ( - - - ) appear in the display. When the temperatureson all heating zones are within their temperature band, the display showsthe total time delay, which is user adjustable, and the timer startscounting down. The time delay allows the hot melt material in the hopperto melt so that it can be pumped. When the delay is over, the READYlight turns on. When the READY light turns on, you can start the pump.

READY Light (4)

The green READY light turns on when the system-ready time delay isover, indicating that all zones are within the temperature band, the timedelay has elapsed, and no major faults exist.

STANDBY Key and Light (5)

The STANDBY key is used to place the system in the standby mode.The STANDBY light turns on, the READY light turns off, the pump turnsoff, and the system controller controls the temperatures on all zones atstandby setpoints. When you press the STANDBY key again, theSTANDBY light turns off and the system controller controls thetemperatures on all zones at operating setpoints. The time delay doesnot occur if the internal zones are within 42 C (75 F) of their operatingsetpoints. When the green READY light turns on, you can start the pumpby pressing the MOTOR key.

Placing the unit in standby mode reduces temperatures in the heatedzones to minimize heat-related degradation of the adhesive. This resultsin consistent adhesive quality on your final product.

NOTE: In the FoamMelt processor, standby also turns off the pump.When the pump is off, gas comes out of solution (because pressure isrelieved).

HEATERS Key and Light (6)

The HEATERS key turns power to the heaters on and off. When youpress the HEATERS key, the light turns on.

Description2-16


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Manual 41-190

SYSTEM OK (�) Light (7)

The SYSTEM OK (�) light is normally on except under the followingconditions:

� A ground fault exists.� An overtemperature thermostat is tripped.� The software detects a fault condition.

Error Code Display (8)

The error code display indicates system problems by displaying a code.Each code is a letter or number. A complete explanation of all errorcodes is provided in the Troubleshooting section.

RUN/PROGRAM Switch (9)

The RUN/PROGRAM switch selects either the run or program mode. Tohelp you remember which keys are active in the run mode, they arecolor-coded white.

Keys Active in Run Mode

STANDBY

HEATER

MOTOR

Zone selection

SILENCE ALARM

CLEAR FAULT

TIMER

In the run mode you can also review, but not change, all temperature andauto-start settings.

In the program mode, all keys on the system controller panel are active.

Description 2-17


107 144DIssued 3/99

Manual 41-190

4904097

1

9

8

7

6 5

4

3

2

2

1

1

2

4

3

4

3

5

6

Fig. 2-6 Temperature Controls and Lights

1. Zone symbols2. TEMPERATURE status lights3. Zone FAULT lights4. SILENCE ALARM key5. CLEAR FAULT key

6. SCAN key7. ZONE key8. ZONE display9. ACTUAL TEMPERATURE

display

Temperature Status

Description2-18


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Zone Symbols (1)

A zone symbol identifies each zone according to its type.

Zone Description Symbol

1 Hopper

2 Grid

3 Reservoir

4 Manifold

5, 7, 9, 11, 13, 14 Hoses

6, 8, 10, 12 Guns

Temperature Status Lights (2)

Three temperature status lights allow you to quickly check the status ofeach heating zone. Table 2-3 describes the function of each light.

Table 2-3 Functions of Temperature Status Lights

If this lightturns on . . . The temperature of the heating zone is . . .

NORMAL within the temperature band

HIGH above the temperature band

LOW below the temperature band

Except during sequential startup, standby operation, or when thetemperature setting is changed, the system will turn on the WARNINGlight and sound the bell when the temperature goes out of band.

Description 2-19


107 144DIssued 3/99

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Zone FAULT Lights (3)

Each temperature zone has a zone FAULT light for each of the following:

� an overtemperature (OT) condition� a faulty RTD (SENSOR)� an open or shorted heater circuit (HTR)

The alarm sounds for any fault on any zone. The following tabledescribes what else happens when one of these conditions occurs.

Table 2-4 Zone Fault Lights

FaultIndicator Zone Heaters

ZoneFAULTLight

READYLight

SENSORHTR OT

Hopper

Grid

Manifold

Reservoir

All turn offaftertwo-minutedelay

On Off

SENSORHTR

Hose

Gun

Individualzone turnsoffimmediately

On On

OT Any All turn offimmediately

On Off

SILENCE ALARM Key (4)

The SILENCE ALARM key turns off the bell or siren alarm after it hasbeen activated by a fault or warning.

CLEAR FAULT Key (5)

The CLEAR FAULT key turns off the FAULT light and silences the siren.The control system then starts a test. If the test determines that the faulthas not been corrected, the light and siren turn on again.

SCAN Key (6)

The SCAN key turns the scan function on and off. When the scanfunction is on, the actual temperature for each active zone appears insequence in the ACTUAL TEMPERATURE display. At the same time,the ZONE display shows which zone is being monitored. If a faultoccurs, the ZONE and ACTUAL TEMPERATURE displays show thefaulted zone.

When the scan function is off, the ACTUAL TEMPERATURE displayshows only the current temperature of the selected zone. The ZONEdisplay shows which zone is selected.

Description2-20


107 144DIssued 3/99

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Up Key (7)

The up key selects individual zones for monitoring.

ZONE Display (8)

The ZONE display shows which zone is currently being monitored. Itshows only active zones. A zone is considered active when its operatingtemperature is set to at least 16 �C (60 �F).

ACTUAL TEMPERATURE Display (9)

The ACTUAL TEMPERATURE display shows the current temperature ofthe zone being monitored.

4904093

1 2 4 5

6

11

3

7 8 9 10

Fig. 2-7 Temperature Set Controls and Lights

1. ZONE/SETUP display2. SET ALL light3. Up zone/set key4. TEMPERATURE display5. Up and down temperature keys6. ENTER key

7. T1 (operating setpoint) key andlight

8. T2 (standby setpoint) key and light9. OVERTEMP key and light

10. STORE key and light11. USE key and light

ZONE/SETUP Display (1)

The ZONE/SETUP display shows the currently selected zone number.When you are using the store or use function, the display shows anumber that stands for a stored set of temperatures.

Temperature Set

Description 2-21


107 144DIssued 3/99

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SET ALL Light (2)

The SET ALL light turns on when the set all function is active. The set allfunction allows you to set all active heating zones to the sametemperature. To activate the set all function, change the selected zone tozero (0) in the ZONE/SETUP display. You must press the ENTER key forthe value in the TEMPERATURE display to become effective for all activeheating zones.

Up Key (3)

The up key selects heating zones for setup or, when used with the use orstore function, selects a stored set of temperatures.

TEMPERATURE Display (4)

In the programming mode, the TEMPERATURE display shows theoperating (T1), standby (T2), or overtemperature setpoints for theselected zone.

In the run mode, it shows the operating setpoint for a zone at the sametime the zone’s actual temperature is being shown in the ACTUALTEMPERATURE display. This allows you to compare the actualtemperature of the displayed zone with its setpoint.

The following table contains additional information that theTEMPERATURE display provides during run mode.

Table 2-5 The TEMPERATURE Display During Run Mode

Condition What the Display shows

routine operation operating setpoints

standby operation standby setpoints

zone is off OFF

fault OFF

Up and Down Keys (5)

The up and down keys change the temperature shown in theTEMPERATURE display. Pressing a key once changes the temperatureby one degree. Pressing and holding a key changes the temperature infive-degree increments.

ENTER Key (6)

The ENTER key saves the values shown in the ZONE/SETUP and theTEMPERATURE displays.

Description2-22


107 144DIssued 3/99

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T1 (Operating Setpoint) Key and Light (7)

The T1 (operating setpoint) key sets the operating temperature of thezone that is shown in the ZONE/SETUP display. The T1 light turns onwhen the function is active.

T2 (Standby Setpoint) Key and Light (8)

The T2 (standby setpoint) key sets the standby temperature of the zonethat is shown in the ZONE/SETUP display. The T2 light turns on whenthe function is active.

OVERTEMP Key and Light (9)

The OVERTEMP key sets the overtemperature setpoint of the zone thatis shown in the ZONE/SETUP display. The OVERTEMP light turns onwhen the function is active.

STORE Key and Light (10)

The STORE key saves up to six sets of operating, standby, andovertemperature setpoints into memory. In the STORE mode, you canuse the up key below the ZONE/SETUP display to select the desired setnumber for temperature storage. The STORE light turns on when thefunction is active.

USE Key and Light (11)

The USE key recalls stored temperatures. In the USE mode, you canuse the up key below the ZONE/SETUP display to select a desired set oftemperatures. The USE light turns on when the function is active.

Description 2-23


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The Auto Start feature enables you to program the processor toautomatically start heaters at pre-set times any day of the week. Thisallows the system to efficiently use pre-shift time to bring material toapplication temperature.

The Auto Standby feature enables the system to automatically reducetemperatures in heated zones if no trigger signal is received after a setlength of time.

The Auto Shutdown feature enables the system to automatically turn offthe motor, pump and all heaters if no trigger signal is received within apre-set time period during standby mode.

Both the Auto Standby and Auto Shutdown features are enabled byrotary configuration switches on the Main Board (AP2) inside theelectrical cabinet and require the presence of a customer-supplied triggersignal device. Refer to Connecting the Gun Trigger Signal and ChangingSystem Configuration Settings in the Installation section for moreinformation. In addition, for Auto Standby, you must program the standbysetpoint temperature you want the system to maintain. Refer toProgramming the System Controller in the Operation section forprogramming information.

The Auto Start controls are located on the system control panel and aredescribed below.

4710180

1 2 3 4 3

5

6

7

89

Fig. 2-8 Auto Start Controls and Lights

1. DAY display2. SET M-F light3. Up keys4. TIME (HH-MM) display5. DELETE ENTRY key

6. ENTER key7. AUTO START TIME key and

light8. SET CLOCK key and light9. TIMER key and light

Auto Start, Auto Standby, andAuto Shutdown

Description2-24


107 144DIssued 3/99

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DAY Display (1)

The DAY display shows a number representing the day of the weekaccording to the following table.

Table 2-6 Key to DAY Display Numbers

Number Represents

0 Set M-F

1 Monday

2 Tuesday

3 Wednesday

4 Thursday

5 Friday

6 Saturday

7 Sunday

SET M-F (Monday-Friday) Light (2)

The SET M-F light turns on when zero is displayed in the DAY display.When the light is on, the auto-start setting (if entered) will be the same forMonday through Friday.

Up Keys (3)

Each up key increases the number shown in the display above the key.

TIME (HH-MM) Display (4)

The TIME (HH-MM) display shows the current time in hours and minuteson a 24-hour clock. When the AUTO START TIME function is active, thedisplay shows the auto-start-time setting for the selected day(s).

DELETE ENTRY Key (5)

The DELETE ENTRY key deletes the auto-start time for the selectedday(s). When you delete the time, four dashes (- - - -) appear in theTIME display and the system will not automatically start on the selectedday(s).

ENTER Key (6)

The ENTER key saves the currently displayed day and time into thetimer.

Description 2-25


107 144DIssued 3/99

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AUTO START TIME Key and Light (7)

The AUTO START TIME key activates the up keys so you can changethe auto-start time. The light turns on to show that the keys are active.

SET CLOCK Key and Light (8)

The SET CLOCK key activates the up keys so you can change the clocktime. The light turns on to show that the keys are active.

TIMER Key and Light (9)

The TIMER key turns the auto start function on and off. When you turnthe function on, the light turns on to show that the system will start upautomatically on those days for which an auto-start time has beenentered.

4710058

1

2

3

5

4

1. MOTOR SPEED display2. Up and down keys3. MOTOR key and light4. Up key5. GUNS display

Description2-26


107 144DIssued 3/99

Manual 41-190

Standard (non-gear-to-line) units are equipped with the motor controllerdescribed below. These units also have a pump RPM display that isconnected to a tachometer on the pump shafts (refer to Electrical andPneumatic Components in this section for a description and location ofthe pump RPM display).

MOTOR SPEED Display (1)

The MOTOR SPEED display shows the motor speed setting as apercentage of the full motor speed.

Up and Down Keys (2)

The up and down keys allow you to change the speed setting of themotor.

MOTOR Key and Light (3)

The MOTOR key turns the motor on and off. The MOTOR light turns onwhen the motor is on. The READY light must be on for the motor to run.

Fig. 2-9 Motor Controls and Lights

Up Key (4)

This key is not used.

GUNS Display (5)

This display indicates a motor speed code of 1 or 2. Although this codeis inoperative on FoamMelt processors, this display always shows 1.

Motor

Description 2-27


107 144DIssued 3/99

Manual 41-190

The overload relay switch, KL1, is located on the back panel in the mainelectrical cabinet. The relay monitors the motor load. When the motordraws too much current, the relay opens, interrupting power to all heatedzones and the motor controller. The system controller remains powered.The system displays P4 in the error code display on the system statuspanel when the overload relay has opened.

NOTE: An output contact of the overload relay is wired in series with theinternal zone overtemperature thermostats. The error code area displaysonly 4 for an overtemperature condition. Refer to the Troubleshootingsection for more information on identifying and correctingovertemperature conditions.

Settings on the overload relay are preset at the factory and should not bechanged. The relay should always remain in manual mode at 10 ampswith the blue reset switch set to R.

Motor Overload Relay

Description2-28


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4904094

1 2

3

4

6

5

Fig. 2-10 Pressure and Gas Control Panel

1. PRESSURE CONTROL AUTO button2. MANUAL pressure control potentiometer3. GAS ON button

4. LOW GAS light5. GAS FLOW light6. PURGE button

The pressure controls are described below.

PRESSURE CONTROL AUTO Button (1)

The PRESSURE CONTROL AUTO button, available only on gear-to-lineunits, allows you to switch between automatic and manual modes ofhydraulic pressure control. A light in the button turns on when the buttonis pressed to enter automatic mode. The light turns off when the buttonis pressed to enter manual mode. The following table describes eachmode.

Table 2-7 Pressure Control Modes

Mode Function

Automatic When used with an encoder, this feature adjusts thesystem hydraulic pressure to maintain a constant beadthickness as the encoder signal changes.

Manual The system maintains a constant hydraulic pressure.You must use the MANUAL pressure controlpotentiometer to adjust the system hydraulic pressure.

5. Pressure and GasControl Panel

Pressure Controls

Description 2-29


107 144DIssued 3/99

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MANUAL Pressure Control Potentiometer (2)

The MANUAL pressure control potentiometer allows you to manuallycontrol the system hydraulic pressure.

The gas controls are described below.

GAS ON Button (3)

The GAS ON button enables and disables the gas flow into the gearpump. A light inside the button turns on when the button is pressed toenable the gas flow. This button is disabled while the processor is in thepurge mode and when the motor is off.

LOW GAS Light (4)

The LOW GAS light turns on when the pressure switch located on theincoming gas line detects low pressure (less than 207 kPa (30 psi)) in thegas supply cylinder.

GAS FLOW Light (5)

The GAS FLOW light turns on when the gas is flowing. The light shouldturn on and off rapidly during normal operating conditions. If the lightstays on for long periods of time, the gas pressure setting is too low.

PURGE Button (6)

The PURGE button purges gas from the hot melt material. Pressing thePURGE button turns off the gas flow and turns on the motor to a fixedspeed. The PURGE button is disabled when the motor is on.

Gas Controls

Description2-30


107 144DIssued 3/99

Manual 41-190

The gas controls are described below.

Your processor may be equipped with a gear-to-line motor controller.The gear-to-line controller is operated through a control panel located onthe front of the processor.

The gear-to-line motor controller is used with a customer-suppliedencoder device that measures the line speed and sends a signal to themotor controller. In turn, the motor controller adjusts the hydraulicpressure in direct proportion to the line speed. The motor controller iscapable of operating with different types of encoder devices such as

� magnetic pickup� open collector encoder

The encoder device should be installed before the system is operational.Set up the device according to the installation instructions that came withyour device.

The keys and lights on the top part of the controller panel are used inRUN mode. The keys and lights on the bottom part of the controllerpanel, covered by the fold-down panel, are used in PROGRAM mode.All of these keys and lights are described in the following pages.

NOTE: The motor controller does not receive electric power until heatersare turned on. No digits appear in the display and no lights turn on untilthen.

6. Gear-to-Line MotorController

Automatic Pressure ControlMode

Motor Controller Keys andLights

Description 2-31


107 144DIssued 3/99

Manual 41-190

4904096

15

14

13

12

11

10

9

8

1

2

3

4

5

6

7

Fig. 2-11 Motor Controller Keys, Lights, and Displays

1. RPM/parameter display2. TACH key and light3. Numeric keys4. ENTER key5. Down key6. Code display7. CODE SELECT key and light8. Dev Alarm light

9. Limit Alarm light10. Preset light11. Jog light12. Run light13. Up key14. CLEAR key15. SET SPEED key and light

Description2-32


107 144DIssued 3/99

Manual 41-190

RPM/Parameter Display (1)

In run mode, this displays pump RPM. During program mode, theparameter display shows the parameters for the code shown in the codedisplay.

TACH Key and Light (2)

The TACH key provides a quick check of the averaged pump RPM(code 40). When you press the TACH key, the light turns on.

Numeric Keys (3)

The numeric keys allow new codes or control parameters to be keyedinto the display.

ENTER Key (4)

The ENTER key saves the displayed codes or control parameters intothe motor controller memory.

Down Key (5)

The down key decreases the number shown in the parameter display.

Code Display (6)

The code display shows the selected code.

CODE SELECT Key and Light (7)

The CODE SELECT key selects the code to be viewed or changed in thecode display. When you press the CODE SELECT key, the light turns on.

DEV Alarm Light (8)

The Dev (or Deviation) Alarm light turns on when the actual motor speeddeviates from the desired speed by more than 100 RPM. This value iscontrolled by drive parameter 10-CP. Refer to Gear-to-Line MotorController Default Settings in the Operation section.

Description 2-33


107 144DIssued 3/99

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Limit Alarm Light (9)

The Limit Alarm light turns on when one or more of the following alarmsis on:

� minimum speed� maximum speed� low RPM� high RPM� current

Preset Light (10)

The Preset light is not used.

Jog Light (11)

The Jog light is not used.

Run Light (12)

The Run light turns on when the motor controller is in RUN mode(code 53).

Up Key (13)

The up key increases the number shown in the parameter display.

CLEAR Key (14)

The CLEAR key clears the parameter display.

SET SPEED Key and Light (15)

This key is disabled. The motor speed is entered on the system controlpanel.

Description2-34


107 144DIssued 3/99

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The PUMP OUTLET PRESSURE monitor, located on the front of theprocessor, displays system hydraulic pressure. A pressure transducerinside the manifold constantly measures the hydraulic pressure. Themonitor provides a choice of two pressure fault indications: alow-pressure fault and a pressure-band fault. When the motor shaft isnot rotating, the fault alarm function is disabled.

The controls and lights on the PUMP OUTLET PRESSURE monitor aredescribed in the following pages.

4756360

1

2

3

4

6

5

Fig. 2-12 PUMP OUTLET PRESSURE Monitor Components

1. PUMP OUTLET PRESSURE display2. SET POINT light3. FAULT light

4. SET pressure alarm button5. SCAN/FREEZE button6. Pressure-alarm

potentiometers

The PUMP OUTLET PRESSURE display shows either the actual systemhydraulic pressure or the pressure-alarm setpoint.

The SET POINT light turns on when you press the SET pressure alarmbutton. The light indicates that you can change the pressure-alarmsetpoint that is shown in the display.

7. PUMP OUTLETPRESSURE Monitor

PUMP OUTLET PRESSUREDisplay (1)

SET POINT Light (2)

Description 2-35


107 144DIssued 3/99

Manual 41-190

The FAULT light (along with the WARNING light on the system controllerpanel) turns on any time the actual system hydraulic pressure goesbelow the setpoint except during startup and shutdown. If thepressure-band fault is enabled, the FAULT light turns on if the pressuregoes 1380 kPa (200 (+/− 20) psi) above the setpoint.

The SET pressure alarm button allows you to display the pressure-bandsetpoint.

The SCAN/FREEZE button is not used.

The pressure-alarm potentiometers allow you to change thepressure-band setpoint that is shown in the display.

FAULT Light (3)

SET Pressure Alarm Button (4)

SCAN/FREEZE Button (5)

Pressure-Alarm Potentiometers(6)

Description2-36


107 144DIssued 3/99

Manual 41-190

The following tables and charts contain technical data for the FM-190.

Table 2-8 Specifications Table

Specifications

Type of system Circulating gear pump

Heating elements:

Hopper

Grid

Reservoir

Manifold

Two strips

One cast-in

Two cast-in

Cartridge

Holding capacity 27 kg (60 lb)

Temperature range:

Operating

Ambient

16 C to 204 C (60 F to 400 F)

0 C to 40 C (32 F to 104 F)

Temperature stability 0.5 C ( 1 F)

Temperature band warning 3 C to 28 C ( 5 F to 50F)

Maximum continuous deliveryrate (MCDR):

At 50% density reduction:

Standard pump 25 kg/hr (55 lb/hr)

High-output pump 34 kg/hr (75 lb/hr)

Melt rate Exceeds MCDR (MaximumContinuous Delivery Rate)

Viscosity range 1,000 to 40,000 cps

Hose capacity 6

Gun capacity 4

Exterior dimensions:

Height

Depth

Width

Weight

152 cm (70 in.)

61 cm (24.00 in.)

92 cm (36 in.)

300 kg (660 lb)

8. Technical Data

Specifications

Description 2-37


107 144DIssued 3/99

Manual 41-190

Specifications

Electrical requirements:

240 Vac (+ 5%, - 10%)

400 Vac ( 10%)

3 phase Delta, up to 54 amps(nom) 63 amps (max)

3 phase Wye plus neutral,up to 34 amps (nom) 41 amps(max)

Air supply requirements:

Pressure

Type

Volume

620 to 830 kPa (90 to 120 psi)

Dry

Negligible

Gas supply requirements:

Pressure

Type

Filter

207 to 345 kPa (30 to 50 psi)

Industrial-grade Carbon Dioxideor Nitrogen

0.006 in., mesh (optional sizesavailable)

Controller:

Type

Temperature control algorithm

Temperature sensors

Temperature control channels

Microprocessor with zero-crossswitching

PID

Nickel RTD (120 ohm)

14

Enclosures:

Electrical

Mechanical

IP 54

IP 33

Noise Level 75.5 dB(A) at maximum pumpspeed, measured at a distance of1 m (39 in.) from the surface ofthe processor

Display Digital temperature, pressure, andpump speed readout. Keyedlockout of temperature setpoints.

Operator Interface Pressure-sensitive membranepanel for system control; dials forpressure.

Specifications (contd.)

Description2-38


107 144DIssued 3/99

Manual 41-190

The electrical current requirement for a FoamMelt 190 system isdetermined by internal requirements of the unit and by the currentrequired by external hoses and guns.

To determine the current requirement for external hoses and guns, totalthe requirements for each of the individual components. The current forany individual hose or gun cannot exceed 3.5 amps. Even though thefuse is set at 5 amps, this margin is necessary to prevent nuisancetripping with normal variations in line voltage, heater wattage, andambient temperature. The total current requirement for all hoses andguns should not exceed 26 amps.

For external equipment built to customer order, refer to the electricalinformation stamped on the component information plate. Use thefollowing formula to convert the stamped information to the currentrequirement:

Amps = Nameplate Wattage/Voltage

Use the following formula to convert nameplate information to heaterresistance values:

Resistance = (Voltage x Voltage)/Nameplate Wattage

The total line current requirement of the system, which is determined bythe unit and external loads, should not exceed 54 amps for 240 V units or34 amps for 400 V units. These limits will not be exceeded if the externalloads satisfy the total current of 26 amps.

Because of tolerance of line voltages and heater manufacturingtolerances, incoming power wire should be sized for maximum calculatedcurrent levels to ensure a safety margin. Calculated worst-case currentratings are 63 amps for 240 V units and 41 amps for 400 V units.

Electrical CurrentRequirements

Description 2-39


107 144DIssued 3/99

Manual 41-190

The following tables provide the electrical current, resistance, andwattage values for 240 V and 400 V unit heaters.

Table 2-9 Electrical Current, Resistance, and Wattage for 240 V Units

Description Current inAmperes at

177 C(350 F)

SeeNote

Resistance inOhms at 24 C

(75 F)

SeeNote

Power in Watts at177 C (350 F)

SeeNote

Manifold 2.5 91.2 600

Hopper 8.3 A 27.1 A 2000 A

Grid 15.0 15.2 3600

Reservoir 9.4 B 24.4 B 2244 B

NOTE A: Values are for the unit (two heaters used in parallel).

B: Values are for the unit (two heaters used in series).

Table 2-10 Electrical Current, Resistance and Wattage for 400 V Units

Description Current in Am-peres at 177 C

(350 F)

SeeNote

Resistance inOhms at 24 C

(75 F)

SeeNote

Power in Watts at177 C (350 F)

SeeNote

Manifold 2.4 91.2 551

Hopper 8.0 A 27.1 A 1837 A

Grid 14.4 15.2 3306

Reservoir 9.0 B 24.4 B 2061 B

NOTE A: Values are for the unit (two heaters used in parallel).

B: Values are for the unit (two heaters used in series).

Electrical CurrentRequirements (contd.)

Description2-40


107 144DIssued 3/99

Manual 41-190

The following charts show the maximum system output at various pumpspeeds and density reduction ratios, and the recommended maximumpump speed based on material viscosity. System output is determinedby pump speed, viscosity, density reduction, and circulation to outputratio. Each of these factors, as they relate to the charts, is explainedafter the charts.

4904095

900

800

700

600

500

400

300

200

100

10 20 30 40

50 60

70 80 90

10 20 30 40

50 60

System Output (lb/hr)

3:1 Circulation to Output Ratio


Minimum Recommended

Pump Speed

Maximum Pump Speed

Pum

p rp

m

Fig. 2-13 System Output Chart for Standard Pump

Pump Charts

Description 2-41


107 144DIssued 3/99

Manual 41-190

4904188

900

800

700

600

500

400

300

200

100

10 20 30 40

50 60

70 80 90

10 20 30 40

50 60

System Output (lb/hr)



Minimum Recommended

Pump Speed

Maximum Pump SpeedP

ump

rpm

Fig. 2-14 System Output Chart for High Output Pump

4904098

0

100

200

300

400

500

600

700

800

900

10000 20000 30000 40000

Viscosity (cps)

0

Pum

p rp

m

Standard PumpHigh Output Pump

Fig. 2-15 Recommended Maximum Pump Speed at 4137 kPa (600 psi)

Description2-42


107 144DIssued 3/99

Manual 41-190

4904099

0

100

200

300

400

500

600

700

800

900

10000 20000 30000 40000

Viscosity (cps)

0

Pum

p rp

m

Standard PumpHigh Output Pump

Fig. 2-16 Recommended Maximum Pump Speed at 6205 kPa (900 psi)

Pump Charts (contd.)

Description 2-43


107 144DIssued 3/99

Manual 41-190

Pump Speed

The motor controller is programmed for a maximum pump speed of 900rpm. The minimum recommended pump speed is 300 rpm.

Viscosity

The amount of material flowing into the pump inlet and the amount ofoutput generated by the pump is restricted by high viscosity. Additionaldata, not shown in the charts, indicates that material with a high viscosityhas a fixed maximum system output regardless of pump speed.Examples of this data are given in the following table.

Material with a viscosity of . . . Allows a maximum systemoutput of . . .

55,000 cps 50 lb/hr

40,000 cps 35 lb/hr

Density Reduction

Reduced density (increased gas content) reduces the total systemcirculation, thereby reducing the amount of material that is available forsystem output.

Circulation to Output Ratio

The circulation to output ratio indicates the amount of material circulatingthrough the system in relation to the amount of material being dispensed.

Example: At a 3:1 circulation to output ratio, the amount of materialflowing through the system with the guns closed is three timesthe amount being dispensed.

Nordson recommends a ratio of 2:1 to 3:1 to maintain optimum pressureand density control. Reduction of the ratio to below 2:1 may result inerratic pressure and density control.

Description2-44


107 144DIssued 3/99

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107 144DIssued 3/99

Manual 41-190

Section 3

Installation

Installation3-0


107 144DIssued 3/99

Manual 41-190

Installation 3-1


107 144DIssued 3/99

Manual 41-190

Section 3Installation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.

This section describes how to install the FM-190 and its components.Refer to the manuals that came with the hoses, guns, and encoder forinstallation instructions for those products.

Besides using normal care, you need no special instructions to unpackthe processor or the equipment you purchased with it. All hoses andguns are shipped in separate containers.

Perform the following steps to inspect the processor.

1. Inspect all surfaces for dents, scratches, cracks, corrosion, and otherphysical damage.

2. Inspect the hoses for broken connectors, tears in the outer cover, andother damage.

3. Inspect all fasteners and mechanical connections for tightness.

1. Introduction

2. Unpacking

3. Inspection

Installation3-2


107 144DIssued 3/99

Manual 41-190

Carefully select the location for the processor and its guns and hoses.Make sure that the location meets these requirements:

� An operator can reach all of the controls.

� Maintenance personnel have room to service and repair theprocessor.

� All doors and panels have enough clearance to open.

� The ambient temperature is above 0 �C (32 �F) and below40 �C (104 �F).

� The flooring is level.

� All hoses can be routed without bending or kinking.

See Figure 3-1 for the processor dimensions and required clearances.

4904004FRONT VIEW SIDE VIEW

55 cm(22 in.)

132 cm(52 in.)

179 cm(71 in.)

152 cm(70 in.)

92 cm(36 in.)

61 cm(24 in.)

Fig. 3-1 Processor Dimensions and Required Clearances

4. Equipment Location

Installation 3-3


107 144DIssued 3/99

Manual 41-190

Follow the procedures in this part of the manual to install andmechanically connect the different parts of the processor.

Perform the following steps to install the processor.

WARNING: Use a forklift that is rated for 300 kg (660 lb).Failure to observe can result in personal injury and equipmentdamage.

1. Move the processor to its location with a forklift.

2. Drill mounting holes in the floor according to the mounting holepattern.

NOTE: Use anchoring bolts that are at least 9.53 mm (0.375 in.) indiameter.

4904005

61.00 cm(24.00 in.)

57.20 cm(22.50 in.)

84.40 cm(33.21 in.)

89.40 cm(35.21 in.)

Fig. 3-2 Mounting Hole Pattern for FM-190 Base

3. Remove the shipping pallet and position the processor in place.

4. Place concrete anchoring bolts through the mounting holes on thebase of the processor and secure it to the floor.

5. Mechanical Installation

Installing the Processor

49040061

2

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Manual 41-190

Nordson recommends installing a customer-supplied valve in the airsupply line so that you can shut off the air to the processor duringmaintenance and troubleshooting procedures.

Connect a supply of clean, non-lubricated air to the input air fitting on theback of the processor. Nordson recommends a regulated air supplypressure of 620-689 kPa (90-100 psi). To order the appropriate filterregulator, refer to the Parts section for the part number.

Fig. 3-3 Connecting Air Supply

1. Air supply hose2. Input air fitting

Follow the instructions in your automatic gun manual to completeinstallation.

The FM-190 requires supply and return hoses to circulate the solutionfrom the manifold to the guns and back to the manifold. Refer to theinstallation card that is shipped with each hose for additional informationon how to install the hose properly.

NOTE: If automatic guns that do not have two hydraulic ports are beinginstalled with a pair of hoses, circulation fittings must be connected to theguns before connecting the hoses.

To Install Supply Hoses

Perform the following steps to install supply hoses.

1. See Figure 3-4 to determine the proper hose and gun configurationfor your processor. A (+) sign indicates a hydraulic supply port; a (-)indicates a hydraulic return port. Squares ( ) indicate electricalconnections.

Connecting the Air Supply

Installing Automatic Guns

Installing Hoses

Installation 3-5


107 144DIssued 3/99

Manual 41-190

4904007


ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ


1

2

3

4

5

6


+_ ++_ _

_

++_ _

++_ _

++_ _

123456 123456

123456123456

123456 123456

++

_

_

+



ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

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Fig. 3-4 Hose and Gun Configurations

1. 1 gun2. 2 guns

3. 2 guns4. 3 guns

5. 4 guns6. Handgun

2. Based on the configuration of your processor, remove the plug froman appropriate supply port in the manifold.

3. Attach a connector that is provided in the ship-with kit to the supplyport. See Figure 3-5.

Installation3-6


107 144DIssued 3/99

Manual 41-190

To Install Supply Hoses (contd.)

4. Apply anti-seize lubricant to the fitting threads and o-ring lubricant tothe o-rings on the supply hose.

5. Attach the supply hose to the connector in the manifold.

6. Attach the hose electrical plug to one of the electrical sockets on theprocessor.

49040091 32

4

5

Fig. 3-5 Attaching Supply Hose to Processor

1. Connector2. Supply port3. Supply hose

4. Hose electrical plug5. Electrical socket

7. If the hose is being connected to a gun, route the hose from themanifold to the gun. Follow the procedures in your gun manual forinstructions on connecting hoses to guns.

8. Repeat steps 2 through 7 if your processor requires an additionalsupply hose.

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107 144DIssued 3/99

Manual 41-190

To Install Jumper Hoses Between Guns

Perform the following steps to install hoses that connect two automaticguns.

1. Apply anti-seize lubricant to the threads of the hydraulic fitting oneach gun that the hose connects to.

2. Follow the instructions in your gun manual to attach the hose to theguns.


NOTE: If the electrical cord for the jumper hose does not reach fromthe guns to the processor, use a hose extension cord. Refer to theParts section for more information.

2 1

4904010

Fig. 3-6 Attaching Jumper Hose Electrical Plug to Processor

1. Hose electrical plug 2. Electrical socket

4. Repeat steps 1 through 3 if your processor requires an additionaljumper hose.

Installation3-8


107 144DIssued 3/99

Manual 41-190

To Install Return Hoses to Guns

Perform the following steps to attach return hoses to guns.

NOTE: Do not connect the return hose to the manifold at this time. Theprocessor must be flushed first. Attaching return hoses to the manifold isdescribed in Preparing the Hydraulic System in the Operation section.

1. Apply anti-seize lubricant to the thread of the hydraulic fitting on eachgun.

2. Follow the instructions in your gun manual to attach the hose to thegun.

3. Attach the gun electrical plug to the electrical socket of the hose.


5. Repeat steps 1 through 4 if your processor requires an additionalreturn hose.

2

1

4904011

Fig. 3-7 Attaching Return Hose Electrical Plug to Processor

1. Hose electrical plug 2. Electrical socket

4904044

12

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107 144DIssued 3/99

Manual 41-190

Gas cylinder installation kits are available for use with carbon dioxide andnitrogen gas. Refer to the Parts section in this manual for kit information.

WARNING: Cylinders of compressed gas are under highpressure. Observe all safety precautions that the vendor of thecompressed gas provided with the cylinder.

1. The following items are needed to connect gas to the processor:

� a gas cylinder with a pressure regulator� a gas supply hose with a male connector

NOTE: The end of the gas supply hose must be cut straight acrossso that it stops flush in the input gas fitting.

2. Push the gas supply hose firmly into the input gas fitting in the back ofthe processor.

3. Slowly open the service valve on the gas cylinder one full turn.

4. If there is an audible leak, close the service valve, correct the leak,and re-open the service valve before proceeding.

5. Adjust the gas cylinder regulator outlet pressure to 276 kPa (40 psig).

6. Apply a small amount of leak detector fluid from the ship-with kit toeach connection along the gas system.

Fig. 3-8 Connecting the Gas Supply

1. Gas supply hose2. Gas fitting

7. If bubbles form in the leak detector at any fitting, retighten andreinspect the fitting until no bubbles form.

8. When the gas system is leak-free, close the service valve on thecylinder until the processor is ready for use.

Connecting the Gas Supply

Installation3-10


107 144DIssued 3/99

Manual 41-190

The following standard remote input/output connections are available:

� READY output� FAULT output� WARNING output� HEATER STATUS output� HEATER ON and OFF input� EMERGENCY STOP input

To Use Remote Outputs

The remote READY, FAULT, and WARNING outputs have a single-poledouble-throw isolated relay contact. The remote HEATER STATUSoutput has a single pole normally open isolated relay contact. Allcontacts are rated for 30 Vdc at 1.5 A maximum. (Refer to the electricalschematic diagrams in the Troubleshooting section for more details.)

1. To use remote outputs, route leads from the remote device(s) into theelectrical cabinet. A plugged hole is provided above the heatsink forthis purpose.

2. Locate Interface Board AP4 in the upper right-hand corner of theelectrical cabinet backplate.

For the WARNING, READY, and FAULT outputs, locate terminal blockXP20 on AP4. See Figure 3-9.

For the HEATER STATUS output, locate terminal block XP15 on AP4.See Figure 3-9.

Making Standard RemoteInput/Output Connections

Installation 3-11


107 144DIssued 3/99

Manual 41-190

To Use Remote Outputs (contd.)

4904175

XP20

XP21

XP15

XP14

1 9

114

114

91

ASSY: 186024C

Fig. 3-9 Locations of XP14, XP15, XP20, and XP21 on Interface Board AP4

3. Refer to Table 3-1 to make appropriate connections.

Table 3-1 Connections for Remote OutputsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Output FunctionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Normally Open Contacts

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Normally Closed Contacts

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Warning* ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP20−1 and XP20−2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP20−2 and XP20−3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReady*

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁXP20−4 and XP20−5

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁXP20−5 and XP20−6ÁÁÁÁÁÁÁÁ


Fault*ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP20−7 and XP20−8ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP20−8 and XP20−9


Heater Status** ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP15−13 andXP15−14


Not Available

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

* These outputs are activated when the unit is in a WARNING,READY, or FAULT state.

** This output is activated when the contactors that supply power tothe heaters and motor are closed.

Installation3-12


107 144DIssued 3/99

Manual 41-190

To Use Remote HEATER Inputs

To actuate the remote HEATER inputs (on or off), use an isolate contactrated for 30 Vdc at 40 mA. The remote on and off inputs allow you toremotely perform the same functions provided by the HEATERS key onthe operator’s panel. The HEATERS OFF input is level sensitive. As longas the remote HEATERS OFF contact is closed, you cannot turn theheaters on, either remotely or at the operator’s panel.

The HEATERS ON input is edge sensitive. The action of closing theinput contact causes the function to become active. To turn the heaterson, you must open the HEATERS OFF contact, then close the HEATERSON contact for a minimum of 0.5 second. The HEATERS ON contactmay be left open or closed.

To use remote HEATER inputs:

1. Route leads from the remote device(s) into the electrical cabinet. Youcan use the same access hole that you used for the remote outputwiring.

2. Locate Interface Board AP4 in the upper right-hand corner of theelectrical backplate. See Figure 3-11 to locate XP21 on AP4.

Table 3-2 Connections for Remote HEATER InputsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Input Function ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Terminal Block PositionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Heaters On ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP21-8 and XP21-9ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Heaters OffÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XP21-6 and XP21-7

To Use Remote EMERGENCY STOP Input

To actuate the remote EMERGENCY STOP input, use contacts rated for30 Vdc at 1.5 A. The EMERGENCY STOP input allows you to turn offpower to the heaters and motor from a remote station. A closed pathbetween the terminal block positions allows the system to run. Open thecircuit to stop the system. This is a run-permissive circuit which directlycontrols internal 24 Vdc and does not depend on the microprocessor tostop the system.

To use remote EMERGENCY STOP input:

1. Route leads from the remote device(s) into the electrical cabinet. Youcan use the same access hole that you used for the remote outputwiring.

2. Locate Interface Board AP4 in the upper right-hand corner of theelectrical backplate. See Figure 3-11 to locate XP14 on AP4.

3. Remove the run-permissive jumper from XP14 terminals 13 and 14.

4. Connect the leads from the remote device to XP14 terminals 13and 14.

Installation 3-13


107 144DIssued 3/99

Manual 41-190

To Use PLC Control Input

The PLC Control Input allows you to turn off power to the heaters andmotor from a remote PLC station. To activate the PLC Control Input, usePLC output contacts rated for 30 Vdc at 1.5 A. A closed path betweenthe terminal block positions allows the system to run; open the circuit tostop the system. This is a run-permissive circuit which directly controlsinternal 24 Vdc and does not depend on the microprocessor to stop thesystem.

To use remote PLC Control Input:

1. Route leads from the PLC output contact into the electrical cabinet.You can use the same access hole that you used for the remoteoutput wiring.

2. Locate Interface Board AP4 in the upper right-hand corner of theelectrical backplate. See Figure 3-11 to locate XP14 on AP4 andrefer Table 3-4 for connections.

3. Remove the run-permissive jumper from XP14 terminals 13 and 14.

4. Connect the leads to XP14 terminals 13 and 14.

You may choose to use a line speed encoder, friction wheel, or otheraccessory equipment with your FM-190. Follow the instructions that areprovided with the accessory equipment for proper installation.

Installing Accessory Equipment

4904051

1

3

2

Installation3-14


107 144DIssued 3/99

Manual 41-190

Perform the following procedures to install the light tower and incomingservice lines to the processor electrical cabinet.

Perform the following steps to open the electrical cabinet door.

1. Use a flat-blade screwdriver to turn the slotted screw near the doorcabinet handle clockwise until the arrow on the screw points to thedoor handle.

2. Hold the screw in this position with the screwdriver and turn thehandle clockwise one-quarter turn.

3. Hold the handle in this position and remove the screwdriver from theslotted screw.

4. Push the main disconnect switch fully against the panel to release theinterlocking mechanism and pull the door open.

Fig. 3-10 Opening Electrical CabinetDoor

1. Slotted screw2. Door handle3. Main disconnect switch

6. Electrical Installation

Opening the Electrical CabinetDoor

Installation 3-15


107 144DIssued 3/99

Manual 41-190

The light tower is shipped unattached to the processor. Perform thefollowing steps to install the light tower. Install the light tower beforeinstalling incoming power.

1. Locate the light tower, gasket, and four pan head screws, which arecontained in the ship-with kit.

2. Align the gasket with the hole pattern on top of the electrical cabinet.

3. Place the light tower electrical connector and wires through the hole.

4. Align the light tower on the gasket.

5. Secure the light tower with the four screws.

6. Plug the light tower electrical connector into the four-pin connector(marked X9) near the light tower mounting hole.

4904038

4

5

1

3

2

6

Fig. 3-11 Installing Light Tower

1. Gasket2. Electrical cabinet3. Electrical connector and wires

4. Light tower5. Pan head screws (4)6. Four-pin connector

Installing the Light Tower

Installation3-16


107 144DIssued 3/99

Manual 41-190

Perform the following steps to install the incoming service line to theprocessor.

1. Route the service line through the 90� conduit fitting.

2. Make the appropriate connections to the line disconnect switch andthe PE terminal according to the following directions.

To Install 240 Vac, Three-Phase Service

WARNING: Make sure that the incoming service ground wire issecured to a reliable earth ground. Failure to observe mayresult in personal injury or death.

1. Make the following connections to install the three-phase inputservice leads and ground wire:

� phase line L1 to QS1, L1� phase line L2 to QS1, L2� phase line L3 to QS1, L3� the ground wire to the terminal marked with PE (GND)

4904013

2

4

3

1

5

Fig. 3-12 Installing 240 Vac, Three-Phase Service

1. Line disconnect switch QS12. Input service leads (3)3. Ground wire

4. Ground connector5. 90� conduit

2. Close and fasten the electrical cabinet door.

3. Do not energize input electrical power at this time.

Installing the Incoming ServiceLine

Installation 3-17


107 144DIssued 3/99

Manual 41-190

To Install 400 Vac, Four-Wire Service

WARNING: Make sure that the incoming service ground wire issecured to a reliable earth ground. Failure to observe mayresult in personal injury or death.

WARNING: Do not attempt to connect a 400 Vac, three-phase,three-wire service line (three-phase without a neutral) to theFM-190. Failure to observe may result in equipment damageand electrical shock.

1. Make the following connections to install the 4-wire input serviceleads and ground wire:

� phase line L1 to QS1, L1� phase line L2 to QS1, L2� phase line L3 to QS1, L3� the neutral to terminal N on XT1� the ground wire to the terminal marked with PE (GND)

4904014

2

5

4

1

3

6

Fig. 3-13 Installing 400 Vac, 4-Wire Service

1. Line disconnect switch2. Input service leads (3)3. Terminal block XT1

4. Ground wire5. Ground connector6. 90� conduit

2. Close and fasten the electrical cabinet door.

3. Do not energize input electrical power at this time.

Installation3-18


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Manual 41-190

Before starting the motor, perform the following procedures to

� enable the pressure-band fault (optional)� change the unit of measure from psi to kPa (optional)

To Enable the Pressure-Band Fault

The pressure monitor is capable of providing a low-pressure alarm or apressure-band alarm. The pressure-band is set at 1279 (+/− 138) kPa(200 (+/− 20) psi) above the low-pressure setpoint.

CAUTION: Risk of equipment damage. Always use anelectrostatic discharge (ESD) wrist strap when handling anyprinted circuit board. Failure to observe this caution can resultin equipment damage.

WARNING: Risk of electrical shock. Never use anyelectrostatic discharge (ESD) wrist strap when working on a unitthat is connected to any power source. Disconnect and lock outall power if you are using a wrist strap. Failure to observe thiswarning can result in equipment damage, personal injury, ordeath.

1. Make sure that the main disconnect switch is in the OFF position.

2. If the electrical cabinet door is closed, open it. Refer to Opening theElectrical Cabinet Door in this section.

3. Locate the switch S2 on the pressure readout control panel.

4. Set the right-most dip switch to the closed position.

4904079

Fig. 3-14 Setting Right-Most Dip Switch to the Closed Position

Setting Up PUMP OUTLETPRESSURE Monitor

Installation 3-19


107 144DIssued 3/99

Manual 41-190

To Change Unit of Measure to kPa

The pressure display is factory set to display pressure in psi. Perform thefollowing steps to change the unit of measure to kPa.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power may result in personal injury, death, orequipment damage.

1. Make sure that the main disconnect switch is in the OFF position.

2. If the electrical cabinet door is closed, open it. Refer to Opening theElectrical Cabinet Door in this section.

3. Remove the four nuts that secure the three-part board assembly tothe control panel. Access these four nuts through cutaways.

Refer to Replacing the Pressure Monitor in the Repair section forelectrical connections.

4756361

Fig. 3-15 Removing Nuts that Secure Board Assembly

4. Pull the board assembly away from the panel so that you have roomto work.

5. Remove the four screws that hold the printed front panel to theassembly.

Installation3-20


107 144DIssued 3/99

Manual 41-190

To Change Unit of Measure to kPa (contd.)

CAUTION: With the four screws removed from the panel, thePUMP OUTLET PRESSURE monitor is not secured to theprocessor. Use care when setting switch S5 so that you do notdamage the monitor.

6. Locate switch S5. To change the unit of measure to kPa, push in thebottom part of the dip switch on S5.

4756362

S5 PSI

kPa

Fig. 3-16 Accessing Dip Switch S5

7. Reassemble the front panel and secure the assembly to the controlpanel.

WARNING: Risk of electrical shock. Never use an electrostaticdischarge (ESD) wrist strap when working on a unit that isconnected to any power source. Disconnect the wrist strapfrom the unit before restoring power. Failure to observe thiswarning can result in equipment damage, personal injury, ordeath.

8. Restore power and continue system set-up as needed.

Installation 3-21


107 144DIssued 3/99

Manual 41-190

Your processor comes with a factory-set configuration that determineshow it will operate under various conditions. Table 3-3 lists the factorysettings for the AP2 (main) circuit board. Each setting is explained indetail on the following pages. Review the factory settings at this time andchange them as needed according to the instructions provided. Recordany changes you make in the appropriate table at the end of theOperation section.

System configuration switches are located on the AP2 circuit board,which is mounted to the back of the system controller assembly insidethe electrical cabinet. Refer to System Controller Assembly Parts List inthe Parts section for the exact location of the AP2 board.

If you change any of the configuration settings with power applied to theprocessor, the system controller will not recognize the changes until youdo either of the following:

� Press the reset button (S1) on back of the system controller panel.

� Turn the main disconnect switch off and back on.

In either case, operation will be interrupted briefly while the systemcontroller performs a self-test.

NOTE: Do not change the position of any switches except thosementioned in the following pages.

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when changing switch settings and donot come into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

Changing SystemConfiguration Settings

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107 144DIssued 3/99

Manual 41-190

Table 3-3 Configuration Switch Options and Factory Settings

Configuration Switch Range or Options Factory Setting

Sequential Start-up (S2-1) ON or OFF ON

System-ready Time Delay (S4) 0 to 180 minutes 12 minutes

Auto Standby Timer (S5) 10 to 150 minutes F (Disabled)

Temperature Band Warning (S6) 3 �C to 28 �C ( 5 �F to 50 �F) 6 �C ( 10 �F)

Auto Shutdown Timer (S7) 0 to 160 minutes 9 (Disabled)

Low Temperature Fault (S8) 19 �C to 44 �C (35 �F to 80 �F)

(Below Operating Setpoint)

19 �C (35 �F)

Temperature Display Units (S2-3) �C or �F �C (for symbolsonly) �F (for English)

Maximum Temperature (S3-2, S3-3):

Hopper 66 �C to 171 �C (150 �F to 340 �F) 171 �C (340 �F)

Grid, Reservoir, Manifold, Hoses, and Guns 66 �C to 204 �C (150 �F to 400 �F) 204 �C (400 �F)

4904059

S312

34

56

78

910

1112

S212

34

XP2

XP1

XP4 J6 J7 XP16XP7

XP8

XP5

S14

S1

DS4

XP3

J1

S4 S5 S6 S7

S8S16

Fig. 3-17 Location of Configuration Switches on AP2 (Main Board)

Changing SystemConfiguration Settings (contd.)

Installation 3-23


107 144DIssued 3/99

Manual 41-190

To Disable Sequential Start-Up

Sequential start-up is controlled by the S2-1 dipswitch on the AP2 circuitboard. Set the dipswitch to the OFF position to disable sequentialstart-up.

To Change System-Ready Time Delay

CAUTION: The system-ready time delay protects theequipment from damage due to cold adhesive. Setting thedelay time to less than the factory setting can damage theequipment.

The position of the system-ready time delay switch (S4) determines thelength of the time delay. The system-ready time delay allows the hot meltmaterial to melt sufficiently for pumping.

Example: If you keep the factory setting of 12 minutes, the time delaywill start when the temperatures on all zones are within thetemperature band. The delay will last for 12 minutes and thenthe READY light will turn on.

If the system is heating up from a warm start instead of a cold start, itoverrides the time delay.

Table 3-4 Encoder Switch S4 Positions for System-Ready Time Delay

Position = Minutes

0 = 0 4 = 48 8 = 96 12 or C = 144

1 = 12 5 = 60 9 = 108 13 or D = 156

2 = 24 6 = 72 10 or A = 120 14 or E = 168

3 = 36 7 = 84 11 or B = 132 15 or F = 180

The factory setting is 12 minutes.

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107 144DIssued 3/99

Manual 41-190

To Change Auto Standby Timer

The position of the auto standby timer switch (S5) determines the lengthof time the system waits for a trigger signal before automatically enteringthe standby mode.

Example: If you set the timer to position 2, the system goes into standbyafter 30 minutes pass without a gun being triggered.

Table 3-5 Encoder Switch S5 Positions for Auto Standby Time Delay

Position = Minutes

0 = 10 4 = 50 8 = 90 12 or C = 130

1 = 20 5 = 60 9 = 100 13 or D = 140

2 = 30 6 = 70 10 or A = 110 14 or E = 150

3 = 40 7 = 80 11 or B = 120 15 or F = Disabled

The factory setting is Disabled.

To Change Temperature Band Warning

The position of the temperature band warning switch (S6) determineshow much the temperature of a zone can deviate from the operatingsetpoint before the yellow WARNING light turns on and the warning bellsounds.

Example: If you keep the factory setting of 6 �C ( 10 �F), the warningwill occur at 6 �C (10 �F) above or below the operatingsetpoint for the hopper, grid, reservoir, and manifold.

Table 3-6 Encoder Switch S6 Positions for Temperature Band Warning

Position = Degrees

0 = 3 �C (5 �F) 5 = 17 �C (30 �F)

1 = 6 �C (10 �F) 6 = 19 �C (35 �F)

2 = 8 �C (15 �F) 7 = 22 �C (40 �F)

3 = 11 �C (20 �F) 8 = 25 �C (45 �F)

4 = 14 �C (25 �F) 9 = 28 �C (50 �F)

The factory setting is 6 �C (10 �F).

Installation 3-25


107 144DIssued 3/99

Manual 41-190

To Change Auto Shutdown Timer

The position of the auto shutdown timer switch (S7) determines thelength of time the system waits for a trigger signal before automaticallyshutting down while in the auto standby mode.

Example: If you change the setting to 60 minutes, the system will shutdown if no gun is triggered within 60 minutes of having goneinto the auto standby mode.

To calculate the total number of minutes between a gun trigger signal andauto shutdown, add the auto shutdown setting (in minutes) to the autostandby setting (in minutes).

NOTE: Auto shutdown is disabled anytime the auto standby feature isdisabled, regardless of S7 settings.

Table 3-7 Encoder Switch S7 Positions for Auto Shutdown Timer

Position = Minutes

0 = 0 5 = 100

1 = 20 6 = 120

2 = 40 7 = 140

3 = 60 8 = 160

4 = 80 9 = Disabled

The factory setting is Disabled

To Change Low Temperature Fault

The position of the low temperature fault switch (S8) determines howmuch the temperature of a zone can drop below the operating setpointbefore a temperature fault occurs.

Example: If you keep the factory setting of 19 �C (35 �F), the fault willoccur at 19 �C (35 �F) below the operating setpoint. The redFAULT light will turn on and the siren will sound.

Table 3-8 Encoder Switch S8 Positions for Low Temperature Fault

Position = Degrees

0 = 19 �C (35 �F) 5 = 33 �C (60 �F)

1 = 22 �C (40 �F) 6 = 36 �C (65 �F)

2 = 25 �C (45 �F) 7 = 39 �C (70 �F)

3 = 28 �C (50 �F) 8 = 42 �C (75 �F)

4 = 31 �C (55 �F) 9 = 44 �C (80 �F)

The factory setting is 19 �C (35 �F).

Installation3-26


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Manual 41-190

To Change Temperature Display Units

The position of the temperature display units switch (S2-3) determineswhether the system controller displays temperatures in Celsius orFahrenheit units.

Table 3-9 DIP Switch S2-3 Positions for Temperature Display Units

Position = Temperature Display Units

ON = �C OFF = �F

The factory setting is ON for only non-English language units and OFF for only English language units.

To Change Maximum Temperature

The positions of the maximum temperature switches (S3-2 and S3-3)determine the maximum operating, standby, and overtemperaturesetpoint you can enter on any zone.

Table 3-10 DIP Switch S3-2 and S3-3 Positions for Maximum TemperatureÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SwitchPositions


MaximumOperatingSetpoint


Maximum Standby Setpoint

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

MaximumOvertemperature

Setpoint


Note

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

S3-2 = ON

S3-3 = ON

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

66 �C

(150 �F)


66 �C

(150 �F)


93 �C

(200 �F)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

S3-2 = OFF

S3-3 = ONÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

121 �C

(250 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

121 �C

(250 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

149 �C

(300 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


S3-2 = ON

S3-3 = OFFÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

177 �C


177 �C

(350 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

204 �C


A


S3-2 = OFF

S3-3 = OFF


204 �C

(400 �F)


204 �C

(400 �F)


218 �C

(425 �F)


A

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The factory setting is 204 �C (400 �F).ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE A: The software overrides the maximum operating and standby setpoints for the hopper. If you use theseDIP switch settings, the maximum temperature for the hopper setpoints is 171 �C (340 �F).


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Manual 41-190

Section 4

Operation

Operation4-0


107 144DIssued 3/99

Manual 41-190

Operation 4-1


107 144DIssued 3/99

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Section 4Operation


This section describes how to program the system controller and how toperform routine operating procedures. For more information on systemcontroller setup, refer to Changing System Configuration Settings in theInstallation section. For more information on how the system controllerworks, refer to System Controller in the Description section.

Review the warnings and recommendations that are provided herebefore setting the operating, standby, and overtemperature setpoints foryour processor.

WARNING: Do not set the operating or overtemperaturesetpoints without first consulting your hot melt materialmanufacturer and the Material Safety Data Sheet (MSDS)concerning the storage, handling, and use of the hot meltmaterial. Failure to follow the recommendations that areprovided in the MSDS can lead to personal injury.

WARNING: The overtemperature setpoint must be below theflash point of the hot melt material that you are using. Failure toobserve may cause personal injury or equipment damage.

1. Introduction

2. Temperature SetpointWarnings andRecommendations

Safety Warnings

Operation4-2


107 144DIssued 3/99

Manual 41-190

Follow these recommendations when setting temperatures:

� Set the operating setpoint at the application temperature that isrecommended in the MSDS.

� Do not exceed the maximum temperature limits set by theconfiguration switches when you set the operating, standby, andovertemperature setpoints.

� Observe the previous recommendation on all active zones whenusing the SET ALL function.

The following procedures describe how to complete the initial setup ofyour processor. Initial setup consists of:

� Programming the system controller

� Programming the gear-to-line motor controller (if your applicator isequipped with this type of motor controller)

� Setting the low-pressure fault setpoint

� Preparing the hydraulic system

� Adjusting density control

Recommendations

3. Initial Setup Procedures

Operation 4-3


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Your applicator was shipped with factory settings programmed into thesystem controller. You can retain or override the factory settings asdesired. The following table provides factory as well as valid rangesettings for programmable temperatures and the auto-start feature.

NOTE: All maximum temperatures are dependent on appropriatedipswitch settings. Refer to To Change Maximum Temperature in theInstallation section for dipswitch settings.

Table 4-1 Programmable Temperature and Auto-Start Functions

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Function and Description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory Setting ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Valid Range

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Operating Setpoint (T1). The desiredtemperature of a zone during normaloperation.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Zone 1

Zones 2−4

Zone 5−14

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

32 �C (90 �F)

32 �C (90 �F)

OFF (less than 16 �C (60 �F)


OFF to 171 �C (340 �F)

OFF to 204 �C (400 �F)

OFF to 204 �C (400 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standby Setpoint (T2). Temperature at whicha zone will be controlled when system is instandby mode.


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Zone 1

Zones 2−14





OFF to 171 �C (340 �F)

OFF to 204 �C (400 �F)


Overtemperature Setpoint. Temperature atwhich an overtemperature fault occurs on azone.




Zone 1

Zones 2−14


66 �C (150 �F)

66 �C (150 �F)


29 �C (85 �F) to 185 �C (365 �F)

29 �C (85 �F) to 218 �C (425 �F)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Auto Start. The day of the week for whichyou want to specify an auto-start time.*



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1 = Monday

2 = Tuesday

3 = Wednesday

4 = Thursday

5 = Friday

6 = Saturday

7 = Sunday


06:00

06:00

06:00

06:00

06:00

− − − − **

− − − −


− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59

− − − − or 00:00 to 23:59ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

* Time is expressed in 24-hour format. For example, 2:30 p.m. is expressed as 14:30.

** Four dashes (− − − −) indicate the auto-start function is turned off for that weekday.

Before creating your own temperature setups, review TemperatureSetpoint Warnings and Recommendations earlier in this section anddetermine the temperatures you want for each active heating zone. Youmust set at least operating and overtemperature setpoints for each zone.If you use the standby function, you must also set standby setpointtemperatures.

Programming the SystemController

4904041

Operation4-4


107 144DIssued 3/99

Manual 41-190

Use the forms at the end of this section to plan temperature setups youwant to create, then proceed with instructions below that tell you how to

� enter program mode.

� create and store up to six sets of operating, overtemperature, andstandby temperatures customized to your operating requirements.

� change the auto-start time (optional).

� change the system clock day and time values.

� secure your settings.

To Enter Program Mode

1. Apply input power to the processor.

2. Place the main disconnect switch in the ON position.

� The system controller performs a self-test of lights and displays.� The WARNING light turns on.� The GAS LOW light turns on.

Fig. 4-1 Turning On DisconnectSwitch

Programming the SystemController (contd.)

4710035

Operation 4-5


107 144DIssued 3/99

Manual 41-190

3. Insert the key into the RUN/PROGRAM switch and turn the switch tothe PROGRAM position.

The system displays information for the current setup, which is alwaysSetup 1 during initial setup of the unit. Now follow instructions for ToCreate Temperature Setups.

Fig. 4-2 Turning RUN/PROGRAMSwitch to PROGRAM

To Create Temperature Setups

You can create and store up to six customized temperature setups to useas your FoamMelt requirements change. A temperature setup consistsof operating, standby, and overtemperature setpoints for one or moreheating zones. Your unit was shipped with factory default settingsalready programmed into Setup 1. Setups 2 through 6 are leftunprogrammed. You can:

� retain the factory settings for Setup 1� overwrite the factory settings for Setup 1� create settings for Setups 2 through 6

Program operating, standby, and overtemperature setpoints for eachzone you will use, following instructions below. Store each set oftemperatures under a setup number.

NOTE: To effectively use standby mode, you must enter standbytemperature setpoints. If you don’t, the standby setpoint for each zonedefaults to OFF and the heaters turn off during standby mode. If youmake the standby setpoint equal to the operating setpoint, the heatersremain on but the READY light goes off and the motor is disabled duringstandby mode.

Operation4-6


107 144DIssued 3/99

Manual 41-190

To Create Temperature Setups (contd.)

1. Depending on which type of setpoint you are programming, press theT1 (operating temperature), T2 (standby temperature), orOvertemperature key.

3

14904112

2

4

Fig. 4-3 Setting Temperature Setpoints

1. USE key2. Up key

3. ENTER key4. Setpoint key

2. Press the up key beneath the ZONE/SETUP display to select a zonefor which you want to set the temperature.

NOTE: To set all zones to the same temperature, select 00 (zero) inthe display. The SET ALL function has no affect on zones that areOFF. To turn a zone ON, you must enter an operating setpointspecifically for that zone. The processor is shipped with externalzones (hoses and guns) OFF.

3. Use the up and down keys beneath the TEMPERATURE display toselect the temperature you want.

NOTE: The overtemperature setpoint must be at least 14 C (25 F)higher than the operating and standby setpoints.

4. Press ENTER to save the temperature for that zone.

Operation 4-7


107 144DIssued 3/99

Manual 41-190

5. If you did not use the SET ALL (Zone 00) function, repeat steps 2through 4 to enter a setpoint for each additional zone you will use.For Overtemperature setpoints, repeat steps 2 through 4 even forzones that are not used.

6. To exit setpoint programming mode, press the T1 (operatingtemperature), T2 (standby temperature), or Overtemperature key,depending on which type of setpoint you were programming.

7. Return to Step 1 and program the next type of setpoint or, if you haveprogrammed all three types of setpoints, proceed with To StoreTemperature Setups.

To Store Temperature Setups

1. Press the STORE key. The display shows the first unused setupnumber.

2 3

1 4710037

Fig. 4-4 Storing Temperature Settings

1. STORE key2. UP key3. ENTER key

Operation4-8


107 144DIssued 3/99

Manual 41-190

To Store Temperature Setups (contd.)

2. Press the up key beneath the ZONE/SETUP display to select a setupnumber. The system does not allow you to skip any unused number.(For example, if only Setup 1 exists, you can select only 1 or 2.Setup 3 is not a choice because Setup 2 does not exist yet.) If youselect a number for an existing setup, you will overwrite temperaturesstored for that setup.

3. Press ENTER to save current setpoints to the setup number youselected.

4. Press STORE to exit the store temperature function.

5. To create and store another set of temperatures, return to To CreateTemperature Setups.

If you are finished storing setups, proceed with To Change theAuto-Start Time.

Operation 4-9


107 144DIssued 3/99

Manual 41-190

To Change the Auto-Start Time

The auto-start function is enabled for any day that has a valid startuptime (00:00−23:59) programmed. The auto-start function is disabled forany day for which the startup time has been deleted. The FM-190processor arrives from the factory with a Monday-Friday startup time of06:00 and with auto-start disabled for Saturday and Sunday. To changethe factory set startup times, perform the following steps. Record yourrevised settings in the appropriate table at the end of this section.

1. Press the AUTO START TIME key.

4710038

2

3

5

1

4

Fig. 4-5 Changing Auto-Start Settings

1. AUTO START TIME key2. Up key for changing day3. Up keys for changing time

4. DELETE ENTRY key5. ENTER key

Operation4-10


107 144DIssued 3/99

Manual 41-190

To Change the Auto-Start Time (contd.)

2. Press the up key beneath the DAY display to select the day(s) forwhich you want to set an auto-start time.


Setting ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SelectÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The same time for Mondaythrough Friday


0.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The time for a single day ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The number for that day:

1. Monday

2. Tuesday

3. Wednesday

4. Thursday

5. Friday

6. Saturday

7. Sunday

3. Press the up keys beneath the TIME display until the desiredauto-start hour and minutes appear on the display. To turn theauto-start feature off for a particular day, press DELETE ENTRY tochange the display to four dashes (− − − −).

NOTE: Time is displayed in 24-hour format. For example, 1:30 p.m.is expressed as 13:30.

4. Press the ENTER key to save the values.

5. Press the AUTO START TIME key to exit the auto-start function.

6. Proceed with To Change the System Clock Settings.

Operation 4-11


107 144DIssued 3/99

Manual 41-190

To Change the System Clock Settings

Perform the following steps to change the current DAY and TIMEdisplays when necessary.

1. Press the SET CLOCK key.

4904019

2

3

4

1

Fig. 4-6 Changing Day and Time Settings

1. SET CLOCK key2. Up key for changing day

3. Up keys for changing time4. ENTER key

2. Press the key beneath the DAY display until the correct day is shown.

3. Press the keys beneath the TIME displays until the correct hour andminutes are shown on the display.

NOTE: Time is displayed in 24-hour format. For example, 1:30 p.m.is expressed as 13:30.

4. Press the ENTER key to save the values.

5. Press the SET CLOCK key to exit the set-clock function.

4904020

Operation4-12


107 144DIssued 3/99

Manual 41-190

To Secure Your Settings

After you have completed all setup procedures, perform the followingsteps to secure your settings.

1. Turn the switch to the RUN position.

2. Remove the key.

Fig. 4-7 Turning Switch to RUN

The gear-to-line motor controller settings are pre-programmed at theNordson factory prior to shipping. Typically the only parameters that mayrequire changing are code 81-CP, code 82-CP, and code 83-CP. All threeare explained in the table below.

Table 4-2 Selected Gear-to-Line Motor Controller Code Defaults

Code Factory Setting

81-CP Default value is 2000 Hz. Thiscode defines the maximum linespeed in units of frequency (Hz).When the line speed input is atthe value defined by this code,the output is at the value definedin 83-CP.

82-CP Set to provide 4 mA into the I/Ptransducer to give (near) zeropressure. This value is theminimum value from which thesystem will start from.

83-CP Default value is 2048. Set toprovide 14 mA to the I/Ptransducer, which results in about6895 kPa (1000 psi) with Type Rfluid when the frequency of theline speed sensor is 2000 Hz.

Other factory settings are provided and explained in Gear-to-Line MotorController Default Settings later in this section.

Programming the Gear-to-LineMotor Controller

4904042

4110132

Operation 4-13


107 144DIssued 3/99

Manual 41-190

This part of the Operation section tells you how to:

� prepare the motor controller for adjustment� program the parameter for code 81-CP, 82-CP, and 83-CP� replace the jumper

NOTE: For further details about the controller, refer to the separate mo-tor controller manual that is shipped with your processor.

To Remove the Keypad Lockout Jumper and Install anAmmeter

Remove the keypad lockout jumper and install an ammeter before youattempt to program the motor controller.

Follow procedures below for these tasks.


1. Place the main disconnect switch in the OFF position.

Fig. 4-8 Turning Off MainDisconnect Switch

2. Disconnect and lock out the input power line to the main disconnectswitch.

Fig. 4-9 Locking Out Input Power

Operation4-14


107 144DIssued 3/99

Manual 41-190

To Remove the Keypad Lockout Jumper and Install anAmmeter (contd.)

3. Open the electrical cabinet door. Refer to Opening the ElectricalCabinet Door in the Installation section.

4. Locate connector J4 on the back of the motor controller.

5. Use a screwdriver to loosen the screws that secure the jumper atpositions 1 and 2 and pull the jumper out of the connector.

4904052

123456789

10111213141516

J1

J3

J4

J2

123456789

10111213141516

1234567

123456789

101112131415161718

Fig. 4-10 Removing Keypad Lockout Jumper

6. Connect the ammeter probes to J4, pins 17 and 18.

7. Unlock and reconnect the input power line to the processor maindisconnect switch.

8. Close the electrical cabinet door.


Operation 4-15


107 144DIssued 3/99

Manual 41-190

To Program the Motor Controller

While it may not be necessary to program the gear-to-line motorcontroller, these instructions enable you to customize this feature to yourapplication if required.

Table 4-3 Selected Gear-to-Line Motor Controller Code Field Settings

Code Field Settings

81-CP Adjust to provide the proper adhesive output when the line speed is at maximum. The value for 81-CPin the parameter display is in Hertz (Hz). This value should match the frequency of the full-scale linespeed input for the encoder and gearing being used and then adjusted if required. For instance, if themaximum frequency input is 3200 Hz at maximum line speed, then the value for 81-CP should be set to3200 and possibly adjusted further, depending on observed adhesive output. This feature is especiallyuseful for the output pressures well below the maximum capability of the FM-190. For example, 81-CPcan be adjusted to produce a maximum of only 2758 kPa (400 psi) at maximum line speed, eventhough the unit may be capable of pressures in excess of 6205 kPa (900 psi). In the rare case thatsufficient pressure can not be achieved by adjusting 81-CP, 83-CP can be increased.

82-CP Adjust for the desire pressure at zero line speed, then adjusted to produce the required output at anyline speed. Usually the factory adjustment zero pressure is correct.

83-CP While 81-CP sets the upper limit, adjusting 83-CP can set the maximum hydraulic pressure from about50% to 100%, with 83-CP values of 2048−4095. If 50% pressure is too high (83-CP at minimum of2048), the adjustment should definitely be made using the 81-CP parameter. For higher pressure, ifsetting 83-CP is set to 4095 does not yield enough pressure, then 81-CP can be adjusted as well.However, if this is the case, the unit may have a malfunctioning component.

Follow these instructions to check or change the codes for 81-CP, 82-CP,and 83-CP.

1. Bring the production/packaging line up to maximum speed.

2. Turn down the lower panel on the motor controller to access theprogramming keys.

Operation4-16


107 144DIssued 3/99

Manual 41-190

To Program the Motor Controller (contd.)

4106268

5

3

4

2

1

Fig. 4-11 Programming Motor Controller

1. CODE SELECT KEY2. Code display3. Numeric Keys

4. ENTER key5. Parameter display

3. Press the CODE SELECT key. The current code appears in the codedisplay.

4. Use the numeric keys to enter 81, then press ENTER.

� 81 appears in the code display.

� The existing value for 81-CP appears in the parameter display.This value should match the frequency of the full-scale line speedinput for the encoder and gearing being used. If not, use eitherthe numeric keys or the up or down keys to enter the new value,then press ENTER.

Operation 4-17


107 144DIssued 3/99

Manual 41-190

5. Press the CODE SELECT key.



� The existing value for 83-CP appears in the parameter display.This value should cause the ammeter to display 20 mA. If not,use either the numeric keys or the up or down keys to enter thenew value, then press ENTER.

� The new value appears in the parameter display.

7. Stop the production/packaging line.

8. Press the CODE SELECT key.



� The existing value for 83-CP appears in the parameter display.This value should cause the ammeter to display 4 mA. If not, useeither the numeric keys or the up or down keys to enter the newvalue, then press ENTER.

� The new value appears in the parameter display.

10. Observe the adhesive output at various line speeds. Repeat steps 1through 9 until the desired adhesive output is achieved at all linespeeds.

11. Flip up the lower panel on the motor controller to prevent access tothe programming keys.

4904042

4110132

Operation4-18


107 144DIssued 3/99

Manual 41-190

To Remove the Ammeter and Reinstall the Keypad LockoutJumper

After you finish programming the motor controller, remove the ammeterand replace the keypad lockout jumper.

Follow procedures below for both these tasks.




2. Disconnect and lock out the input power line to the main disconnectswitch.

Fig. 4-13 Locking Out Input Power

Operation 4-19


107 144DIssued 3/99

Manual 41-190

3. Open the electrical cabinet door. Refer to Opening the ElectricalCabinet Door in the Installation section.

4. Locate connector J4 on the back of the motor controller.

5. Remove the ammeter probes from pins 17 and 18

6. To replace the jumper, insert the jumper in positions 1 and 2, then usea screwdriver to tighten the screws that secure the jumper to theconnector.

7. Unlock and reconnect the input power line to the main disconnectswitch.



Operation4-20


107 144DIssued 3/99

Manual 41-190

NOTE: If you want to use the pressure-band fault feature and did notenable it during installation procedures, do so now before setting alow-pressure fault setpoint. Refer to Setting Up PUMP OUTLETPRESSURE Monitor in the Installation section.

Set the low-pressure fault setpoint for your processor after powering upthe unit, but before starting the motor. The FAULT light on the pressurereadout panel and the WARNING light on the control panel turn on anytime the pressure goes below the setpoint, except during startup andshutdown. If the pressure-band fault is enabled, you also get a faultindication if the pressure goes approximately 200 psi (1380 kPa) abovethe setpoint.

1. If the electrical cabinet door is open, close it.

2. Unlock and reconnect the input power line to the processor maindisconnect switch.

3. Place the main disconnect switch in the ON position to restore powerto the processor.

� The PUMP OUTLET PRESSURE display shows the actualpressure, which should be 0000.

� The number 1 light turns on.

4. Press the SET button to display the low-pressure setpoint.

5. Adjust the number 1 setpoint potentiometer until the desiredlow-pressure setpoint is shown in the display.

6. Press the SET button to save the setting.

4904080

3

1

2

Fig. 4-14 Setting Low-pressure Fault Setpoint

1. SET button2. Number 1 setpoint potentiometer3. PUMP OUTLET PRESSURE display

Setting the Low-Pressure FaultSetpoint

4904034

1

2

Operation 4-21


107 144DIssued 3/99

Manual 41-190

After you have completed all setup procedures, follow these instructionsto prepare the hydraulic system for routine operation.

WARNING: Hot! Risk of burns. Hot processor parts andsplashed hot melt material can cause severe burns. Wearlong-sleeved, heat-protective clothing, safety goggles, andheat-protective gloves.

To Flush the System

Perform the following steps to remove air from the hydraulic system ofthe processor.

1. Place the end(s) of the return hose(s) into a waste container.

Fig. 4-15 Preparing to PurgeHydraulic System

1. Return hose2. Waste container

Preparing the Hydraulic System

4904023

4104058

Operation4-22


107 144DIssued 3/99

Manual 41-190

To Flush the System (contd.)

2. Fill the hopper with clean hot melt material to a maximum of 25 mm (1 in.) below the top of the hopper.

3. Press the HEATERS key.

4. Wait for the SYSTEM READY light to turn on.

Fig. 4-16 Turning Heaters On

5. Press the PURGE button.

� The gas flow is disabled.

� The motor turns on and increases to a set speed.

� Hot melt material forces the air from the hydraulic system of theprocessor.

6. Allow approximately half of the material in the hopper to flow throughthe system and into the waste container.

7. Press the PURGE button again. The motor turns off.

Fig. 4-17 Starting Purge

4904063

4904046

Operation 4-23


107 144DIssued 3/99

Manual 41-190

To Connect Return Hoses

Perform the following steps to connect the return hoses to the manifold.Refer to the installation card that is shipped with each hose for additionalinformation on how to install the hose properly.

1. Loosen the thumb screw that locks the manifold cover.

2. Open the manifold cover.

Fig. 4-18 Opening Manifold Cover

3. Place a waste container beneath the drain valve.

4. Use a flat-blade screwdriver to open the drain valve to relieve systemhydraulic pressure.

Fig. 4-19 Opening Drain Valve

Operation4-24


107 144DIssued 3/99

Manual 41-190

To Connect Return Hoses (contd.)

5. Based on the configuration of your processor, remove the plug froman appropriate return port in the manifold. (Refer to Installing Hosesin the Installation section for configurations.)

6. Attach a connector that is provided in the ship-with kit to the returnport.

7. Apply Never Seez to the fitting threads and o-rings on the returnhose.

8. Attach the return hose to the connector on the manifold.

9. Repeat steps 5 through 8 for each return hose.

49040361 2

Fig. 4-20 Attaching Return Hose

1. Connector 2. Return hose

4904058

Operation 4-25


107 144DIssued 3/99

Manual 41-190

10. Press the PURGE button.

� The motor turns on and increases to a set speed.� Molten hot melt material flows from the open drain valve.

11. Wait until the molten hot melt material flowing from the drain valve isfree of debris.


13. Use a flat-blade screwdriver to close the drain valve.

14. Close the manifold cover.

15. Tighten the thumb screw to lock the manifold cover.

Fig. 4-21 Starting and StoppingPurge

Adjusting the density control means changing the ratio of hot meltmaterial to gas in the foam. You may need to adjust the density control inthe following instances:

� after initial setup� after changing from one type of hot melt material to another� after changing the motor speed� after changing the operating temperature setpoint

During this procedure, you must get both a hot melt and a foam sampleto weigh. Be sure to use identical containers for collecting samples. Theweights of the samples are used to calculate the density reduction. Thedensity reduction refers to the amount of hot melt material being replacedby gas to produce foam.


Adjusting Density Control

4904033

Operation4-26


107 144DIssued 3/99

Manual 41-190

To Get a Hot Melt Sample

1. Make sure that the system is on and the temperature of each zone isat its operating setpoint.




CAUTION: Do not adjust the density control knob when thesystem is cold. Failure to observe may result in equipmentdamage.

4. Turn the density control knob counterclockwise until the edge of theknob lines up with position 1 on the index plate (approximately halfway out).

4904054

Fig. 4-23 Adjusting Density Control Knob Counterclockwise

4904058

4904022

Operation 4-27


107 144DIssued 3/99

Manual 41-190

5. Press the PURGE button. The MOTOR turns on and increases to aset speed.

6. Manually trigger a gun to obtain a measured sample of hot meltmaterial in a small heat-proof container.

7. Weigh the sample of hot melt material.



To Get a Foam Sample

1. Open the valve on the gas cylinder one full turn.

� The WARNING light turns off.� The LOW GAS light turns off.

2. Set the outlet pressure regulator on the gas cylinder to 207−345 kPa(30−50 psi).

3. Press the MOTOR key. The motor turns on.

4. Adjust the motor speed to suit your application needs. Refer to PumpCharts in the Description section.

Fig. 4-25 Turning On Motor

1 2

4904048

4904040

Operation4-28


107 144DIssued 3/99

Manual 41-190

To Get a Foam Sample (contd.)

5. If the processor is in automatic pressure control mode (the AUTObutton light is on), press the PRESSURE CONTROL AUTO button toenter the manual mode.

6. Use the MANUAL pressure control potentiometer to adjust the systemhydraulic pressure to 2758−3447 kPa (400−500 psi).

Fig. 4-26 Adjusting System HydraulicPressure

1. PRESSURE CONTROL AUTObutton

2. MANUAL pressure controlpotentiometer

7. Press the GAS ON button.

8. Set the gas pressure regulator on the processor to 21 kPa (3 psi).The pressure regulator is located next to the PUMP OUTLETPRESSURE monitor on the front of the processor.

Fig. 4-27 Turning On Gas

Operation 4-29


107 144DIssued 3/99

Manual 41-190

9. Turn the density control knob clockwise until the GAS FLOW lightturns on, then turn the knob another full turn.

NOTE: You achieve the best foam density control with as low a gaspressure as possible. We recommend 21 kPa (3 psi).

4904055

Fig. 4-28 Adjusting Density Control Knob Clockwise

10. Wait 3 to 5 minutes for the system to stabilize.

11. Manually trigger a gun to obtain a measured sample of foam in ashallow heat-proof container.

NOTE: Make sure that the hot melt and foam samples fill thecontainers to the same level.

12. Weigh the sample of foam.

Operation4-30


107 144DIssued 3/99

Manual 41-190

To Determine and Adjust Density Reduction

The following table describes the density reduction range available on theFM-190.

Table 4-4 Density Reduction and OperationÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

% Density ReductionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Operation


50% ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Ideal


40%− 60% ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Normal rangeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

30%−70%ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Full range

Perform the following steps to determine and adjust the densityreduction.

1. Perform the following calculation:

% Density Reduction = 1 -Hot Melt Weight

Foam Weightx 100

2. Compare the density reduction to your application needs.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDensity Reduction

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁActionÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

CorrectÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed to step 8.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Too low ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� Turn the density control knobclockwise to increase theamount of gas and proceed tostep 4.

or

� If you cannot turn the densitycontrol knob, proceed to step 3.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Too high ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� Turn the density control knobcounterclockwise to decreasethe amount of gas and proceedto step 4.

or

� If you cannot turn the densitycontrol knob, proceed to step 3.

NOTE: Turn the density control knob a maximum of two turns at atime to adjust the density reduction gradually. This practice mayprevent you from overadjusting at a given time.

Operation 4-31


107 144DIssued 3/99

Manual 41-190

3. Check the density control knob for the following conditions:

NOTE: Refer to Pump Charts in the Description section forrecommended output levels.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Density Control Knob Position ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Motor Speed ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Action

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Turned completely clockwise ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Below maximum RPM ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1. Increase the motor speed.

2. Reposition the density controlknob to position 1 on the indexplate (approximately half wayout).

3. Begin again from step 10 of ToGet a Foam Sample.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Turned completely clockwise ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

At maximum RPM ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace the existing density controlwith a low viscosity density control.

Refer to FM 190 Accessories in theParts section for service kitinformation.


Turned completely counterclockwiseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Above minimum RPM ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1. Decrease the motor speed.

2. Reposition the density controlknob to position 1 on the indexplate (approximately half wayout).

3. Begin again from step 10 of ToGet a Foam Sample.


Turned completely counterclockwiseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

At minimum RPM ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace the existing density controlwith a high viscosity density control.

Refer to FM 190 Accessories in theParts section for service kitinformation.

4. Wait 3 to 5 minutes for the system to stabilize.

5. Manually trigger a gun to obtain a measured sample of foam in asmall heat-proof container.

6. Weigh the sample of foam.

7. Repeat steps 1 through 6 until you obtain the density reductionrequired by your application.

8. Make sure the processor is running at its normal output for yourapplication needs.

9. Adjust the gas pressure setting until the GAS FLOW light turns onand off intermittently.

Operation4-32


107 144DIssued 3/99

Manual 41-190

This part of the Operation section tells you how to perform the followingroutine operating procedures:

� Start up the system

� Enter or exit the standby mode

� Shut down the system

� Change the motor speed

� Use automatic or manual pressure control

� Display actual temperatures

� Review the current temperature and auto-start setup

� Change or select temperature setups

� Check the system status

� Silence the alarms and clear faults and warnings

4. Routine OperatingProcedures

4904022

4904040

Operation 4-33


107 144DIssued 3/99

Manual 41-190

You can start up the system automatically or manually. The followingprocedures describe both methods of startup.

NOTE: The system controller retains the settings in use when thesystem was last shut down.

To Complete Automatic Startup

If a valid startup time exists for the week day(s) when you want auto-startenabled, the processor automatically begins heating at the specified time.

NOTE: Refer to To Change the Auto-Start Time earlier in this section fordetailed instructions for changing auto-start times.

After all zones reach operating setpoint temperature, the READY lightcomes on. Follow the steps below to finish system startup.

1. Turn on the inert gas at the cylinder.

2. Press the MOTOR key to start the motor.


3. Press the GAS ON button. The GAS FLOW light begins flashing.

4. Allow the system to stabilize 3−5 minutes before continuing.


Starting Up the System

4904041

4904023

Operation4-34


107 144DIssued 3/99

Manual 41-190

To Perform Manual Startup

You must perform a manual startup in the following instances:

� if you do not use the auto-start feature

� before it is time for automatic startup to occur

� on a day when the auto-start feature is turned off

� after the main disconnect switch was turned off and the auto-startfeature was not activated

Perform the following steps to start up the system manually.

1. If the main disconnect switch is off, turn it on.

Fig. 4-31 Turning On MainDisconnect Switch

2. Press the HEATERS key.

3. Turn on the inert gas at the cylinder.

Fig. 4-32 Turning Heaters On

4904022

4904040

Operation 4-35


107 144DIssued 3/99

Manual 41-190

4. Wait for the READY light to turn on and then press the MOTOR key tostart the motor.

5. Check the motor speed. Reset the speed if necessary.


6. Press the GAS ON button to enable the gas flow.

7. Allow the system to stabilize 3−5 minutes before continuing.


4904025

12

Operation4-36


107 144DIssued 3/99

Manual 41-190

You can configure the system to enter standby mode either automaticallyor manually.

To Use Automatic Standby Mode

You must have Auto Standby enabled and have an externalcustomer-supplied gun trigger signal. (Refer to Connecting the GunTrigger Signal and Changing System Configuration Settings in theInstallation section for more information.) The system goes into standbymode automatically when no trigger signal is received within theuser-selected time delay.

To Use Manual Standby Mode

Purge the processor before manually entering standby mode if youexpect standby mode to last 60 minutes or less. (Refer to Preparing theHydraulic System earlier in this section for more information.) Purgingthe processor before manually entering standby mode prevents erraticpressure swings when the unit is restarted.

To place the system in standby mode manually, press the STANDBY key.

� The STANDBY light turns on.� The READY light turns off.� The GAS ON light turns off.� The motor is disabled.� Auto-shutdown is disabled.� The temperatures are maintained at standby setpoints.

NOTE: If you entered OFF for standby setpoints, the heaters turn offduring standby mode. However, the HEATERS light remains on.

Fig. 4-35 Placing System in StandbyMode

1. STANDBY key2. STANDBY light

Placing the System in StandbyMode

4904022

Operation 4-37


107 144DIssued 3/99

Manual 41-190

Perform the following steps to remove the system from standby mode.

1. Press the STANDBY key.

2. Wait for the READY light to turn on, then press the MOTOR key.

3. Press the GAS ON button. The GAS FLOW light begins flashing.

4. Allow the system to stabilize for 3−5 minutes before continuing.


You can shut down the system automatically or manually. The followingprocedures describe both methods of shutdown.

To Perform Automatic Shutdown

You must have Auto Standby and Auto Shutdown enabled and have anexternal customer-supplied gun trigger signal. (Refer to Connecting theGun Trigger Signal and Changing System Configuration Settings in theInstallation section for more information.) When no trigger signal isreceived within the user-selected time delay, the system automaticallyenters standby mode. The motor and pump turn off and the heaters goto a user-defined lower temperature. After another user-selected timedelay, the system automatically turns off the heaters.

Turn off the inert gas at the cylinder to prevent loss of gas in case of aleak in the gas supply line.

Removing the System fromStandby Mode

Shutting Down the System

4904023

1

2

4904026

Operation4-38


107 144DIssued 3/99

Manual 41-190

To Perform Manual Shutdown

Perform the following steps to shut down the system manually.

1. Press the HEATERS key to turn off the heaters.

2. Turn off the inert gas at the cylinder.

Fig. 4-37 Turning Heaters Off

Press the up and down keys under the MOTOR SPEED display tochange the motor speed. The setting is displayed as a percentage of fullspeed.

NOTE: The motor speed is correct when a 2:1 or 3:1 circulation to outputratio is reached. See Pump Charts in the Description section.

After you change the motor speed, you must readjust the density control.Refer to Adjusting Density Control in this section.

Fig. 4-38 Changing Motor Speed

1. Up and down keys2. MOTOR SPEED display

Changing the Motor Speed

4904049

1 2

4904048

Operation 4-39


107 144DIssued 3/99

Manual 41-190

NOTE: This option is effective only with gear-to-line processors.

If the PRESSURE CONTROL AUTO light is off, press the PRESSURECONTROL AUTO button to place the system in the automatic pressurecontrol mode.

Fig. 4-39 Placing System in AutoPressure Control Mode

NOTE: Processors with standard motor controllers always use manualpressure control.

1. If the PRESSURE CONTROL AUTO light is on, press thePRESSURE CONTROL AUTO button to place the system in themanual pressure control mode.

2. Control the hydraulic pressure with the manual potentiometer.

Fig. 4-40 Placing System in ManualPressure Control Mode

1. PRESSURE CONTROL AUTObutton

2. MANUAL potentiometer

Placing the System in AutoPressure Control Mode

Placing the System in ManualPressure Control Mode

4904027

490402812

3

Operation4-40


107 144DIssued 3/99

Manual 41-190

The system controller displays the temperatures of all zones in sequenceor displays the temperature of a single zone continuously (to hold).

To Scan All Zones

When the system controller is holding on a single zone, press the SCANkey.

� The system controller scans all active zones.

� The zone number appears in the ZONE display.

� The actual temperature appears in the ACTUAL TEMPERATUREdisplay.

� The setpoint temperature appears in the TEMPERATURE display.

Fig. 4-41 Placing System in ScanMode

To Display Only One Zone at a Time

1. When the system controller is scanning all zones, press the SCANkey. The system controller displays the actual and setpointtemperatures for the zone identified in the ZONE display.

2. Press the up key below the ZONE display to see information for thenext zone.

Fig. 4-42 Displaying One Zone at aTime

1. SCAN key2. Up key3. ZONE display

Displaying ActualTemperatures

Operation 4-41


107 144DIssued 3/99

Manual 41-190

Perform the following steps to review system settings for the currentsetup.

1. Use the keys in the AUTO START and TEMPERATURE SET areas ofthe system controller panel to review your system settings.

4904029

Fig. 4-43 Reviewing System Settings


Setting to Review ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Key to Press


Auto-start time ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AUTO START


Operating setpoint ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Operating setpoint (T1)


Standby setpoint ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standby setpoint (T2)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Overtemperature setpoint ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

OVERTEMP

2. Press the key beneath ZONE/SETUP to display setpointtemperatures for other zones in the current setup.

Press the key beneath DAY to display the auto-start time for otherdays.

3. If you want to change the setpoint temperatures for an existing setup,refer to Changing or Selecting a Stored Set of Temperatures later inthis section.

If you want to change auto-start times, refer to To Change theAuto-Start Time earlier in this section.

Reviewing the Current SystemSetup

4710035

Operation4-42


107 144DIssued 3/99

Manual 41-190

Stored sets of temperatures enable you to quickly change systemsettings. You can change setpoints for any zone in a setup and save thechange or you can select another setup to use.

1. Place the key in the RUN/PROGRAM switch on the system controlpanel and turn the switch to the PROGRAM position.

Fig. 4-44 Turning Switch toPROGRAM

2. ZONE/SETUP displays Zone 1 for the current setup. TEMPERATUREdisplays the operating, standby, or overtemperature setpoint for thatzone, depending on which setpoint is currently selected for display.(A light in the temperature setpoint key indicates which temperature isbeing displayed.)

3

14904112

2

4

Fig. 4-45 Viewing Temperatures

1. USE key2. Up key

3. ENTER key4. Temperature setpoint keys

Changing or Selecting a StoredSet of Temperatures

Operation 4-43


107 144DIssued 3/99

Manual 41-190

3. Follow instructions below to change an existing setup or to select anew setup.

To Change an Existing Setup and Store the Change(s)

1. Press the key beneath ZONE/SETUP to select the zone for which youwant to change setpoint temperatures.

2. Press T1, T2, or OVERTEMP to select the type of setpointtemperature you want to change.

3. To change the temperature setpoint, press the keys below theTEMPERATURE display.

4. Change other temperatures for this zone or select another zone.

5. After you change all zone temperatures you want to change, pressSTORE. ZONE/SETUP displays the first unused setup number. If nounused setup number exists, the display defaults to Setup 1.

6. Press the key beneath ZONE/SETUP to select a setup number tosave your changes to.

7. Press ENTER.

8. Press STORE again to exit the Store function.

9. Turn the RUN/PROGRAM switch to the RUN position and remove thekey.

10. Resume normal operation.

To Select A New Setup

1. Press USE. ZONE/SETUP defaults to Setup 1.

2. Press the key beneath ZONE/SETUP to select the setup number youwant.

3. Press ENTER.

4. Press USE again to exit the Use function.

5. Turn the RUN/PROGRAM switch to the RUN position and remove thekey.

6. Resume normal operation.

4710043

1

2

3

4

5

6

8 9

7

Operation4-44


107 144DIssued 3/99

Manual 41-190

Look at the SYSTEM STATUS area of the system controller panel tocheck

� for warnings or faults� if the system is READY� the time remaining before the READY light turns on� if the system is in STANDBY� if the HEATERS are on� if the SYSTEM OK light is on� for error codes� if the controller is in the RUN or PROGRAM mode

Fig. 4-46 Checking System Status

1. FAULT light2. WARNING light3. TIME BEFORE READY display4. READY light5. STANDBY light6. HEATERS light7. SYSTEM OK light8. Error code display9. RUN/PROGRAM switch

Checking the System Status

4904031

Operation 4-45


107 144DIssued 3/99

Manual 41-190

The error code display on the system control panel shows any unclearedCPU error codes for system faults and warnings.

Some faults and warnings require your immediate attention. Others donot. With each warning or fault, the system controller takes action, ifnecessary, to prevent equipment damage or dangerous operatingconditions.

Refer to the Troubleshooting section in this document for additionalinformation on identifying and correcting problems.

To Silence the Alarms

Press the SILENCE ALARM key any time the siren sounds for faults orthe bell sounds for warnings. Perform appropriate troubleshootingprocedures.

Fig. 4-47 Silencing Alarms

Responding to Faults andWarnings

4904030

Operation4-46


107 144DIssued 3/99

Manual 41-190

To Clear Warnings and Faults

During routine system tests, the controller automatically turns off theWARNING light if the problem causing the warning has been corrected.In the case of an open heater warning, however, you can clear thewarning before a system test (if the problem has been corrected).

Correct the problem that caused the fault or warning, then press theCLEAR FAULT key.

� The FAULT light turns off.

� The alarm turns off.

� The system performs a self-test.

Fig. 4-48 Clearing Faults

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁProblem

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁResultÁÁÁÁÁÁÁÁÁÁÁÁ


YesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� The FAULT light turns on.

� The ALARM turns on.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NoÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The SYSTEM OK light turns on.

Operation 4-47


107 144DIssued 3/99

Manual 41-190

Before changing from one type of hot melt material to another, contactyour hot melt material supplier to find out if the two hot melt materials arecompatible. Ask your supplier for an acceptable flushing material (tothoroughly clean the system) if the new material is not compatible withthe old one.

Perform the following steps to introduce the new hot melt material to thesystem.

1. Pump as much of the old hot melt material as possible from thesystem.

2. Flush the system with a flushing material recommended by your hotmelt material supplier. Refer to Flushing the System in theMaintenance section.

3. If the new hot melt material has a different recommendedtemperature for application, follow instructions provided in InitialSetup Procedures in this section to set new temperatures.

4. Trigger the gun(s) to obtain a sample of the foam made from the newhot melt material.

5. Inspect the sample.


Density Reduction ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Not adequateÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Follow the instructions provided inAdjusting Density Control in thissection of the manual.


Adequate ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Resume normal operation.

Changing Hot Melt Material

Operation4-48


107 144DIssued 3/99

Manual 41-190

Configuration Switch Factory Setting Revised Setting

Sequential Start-up (S2-1) ON

System Ready Time Delay (S4) 12 minutes

Auto Standby Timer (S5) F (Disabled)

Temperature Band Warning (S6) 6 �C ( 10 �F)

Auto Shutdown Timer (S7) 9 (Disabled)

Low Temperature Fault (S8) 19 �C (35 �F)

Temperature Display Units (S2-3) �C (for symbols only) �F (for English)

Maximum Temperature (S3-2, S3-3):

Hopper 171 �C (340 �F)

Grid, Reservoir, Manifold, Hoses, and Guns 204 �C (400 �F)


Day ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Revised Setting


0 = Monday through Friday ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ1 = Monday ÁÁÁÁÁÁÁÁÁÁÁ


2 = Tuesday ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ3 = Wednesday ÁÁÁÁÁÁÁÁÁÁÁ


4 = Thursday ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ5 = Friday ÁÁÁÁÁÁÁÁÁÁÁ


6 = Saturday ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ7 = Sunday ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

5. Revised ConfigurationSwitch Settings

6. Revised Auto-Start TimeSettings

Operation 4-49


107 144DIssued 3/99

Manual 41-190

Use copies of the forms below to record temperatures of stored sets youcreate.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Setpoints for Set 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Setpoints for Set 2ÁÁÁÁÁÁÁÁ

ZoneÁÁÁÁÁÁÁÁÁÁÁÁ

Operating ÁÁÁÁÁÁÁÁÁÁÁÁ

Standby ÁÁÁÁÁÁÁÁÁÁÁÁOvertemperatureÁÁÁÁÁÁ

ÁÁÁÁÁÁOperatingÁÁÁÁÁÁ

ÁÁÁÁÁÁStandby ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁOvertemperature

ÁÁÁÁÁÁÁÁ

1 ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁ2ÁÁÁÁÁÁÁÁÁÁÁÁ




































ÁÁÁÁÁÁÁÁ

8ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ





ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁ9 ÁÁÁÁÁÁÁÁÁÁÁÁ





































Setpoints for Set 3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Setpoints for Set 4

ÁÁÁÁÁÁÁÁ



Standby ÁÁÁÁÁÁÁÁÁÁÁÁOvertemperatureÁÁÁÁÁÁ

ÁÁÁÁÁÁOperatingÁÁÁÁÁÁ

ÁÁÁÁÁÁStandby ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁOvertemperature

ÁÁÁÁÁÁÁÁ















































































ÁÁÁÁÁÁÁÁ







7. Stored Temperature Sets

Operation4-50


107 144DIssued 3/99

Manual 41-190


Setpoints for Set 5 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Setpoints for Set 6

ÁÁÁÁÁÁ



Standby ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

OvertemperatureÁÁÁÁÁÁÁÁÁÁÁÁ


Standby ÁÁÁÁÁÁÁÁÁÁÁÁOvertemperature

ÁÁÁÁÁÁ






ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁ2 ÁÁÁÁÁÁÁÁÁÁÁÁ




































ÁÁÁ8ÁÁÁÁÁÁÁÁÁÁÁÁ




































ÁÁÁÁÁÁ







Stored Temperature Sets (contd.)

Operation 4-51


107 144DIssued 3/99

Manual 41-190

The following table describes the Nordson factory settings of thegear-to-line motor controller for the FM-190. Typically, the only settingsyou may need to change are 81-CP (the Analog Output Range) and83-CP (the Analog Output Span). Refer to Programming theGear-to-Line Motor Controller earlier in this section.

NOTE: The motor controller is programmed by Nordson especially forthe FM-190. These settings are not the same as the originalmanufacturer’s settings. If the controller requires replacement, programand verify that all parameters match the following table.


Code TypeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

DescriptionÁÁÁÁÁÁÁÁÁÁÁÁ

MinimumÁÁÁÁÁÁÁÁÁÁÁÁ

MaximumÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory SettingÁÁÁÁÁÁÁÁÁÁ

UnitsÁÁÁÁÁÁÁÁÁÁÁÁ

1-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Primary Setpoint 1ÁÁÁÁÁÁÁÁÁÁÁÁ

0ÁÁÁÁÁÁÁÁÁÁÁÁ

9999ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

0-900ÁÁÁÁÁÁÁÁÁÁ

Eng.ÁÁÁÁÁÁÁÁÁÁÁÁ2-CP

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁPrimary Setpoint 2

ÁÁÁÁÁÁÁÁÁÁÁÁ0


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ0

ÁÁÁÁÁÁÁÁÁÁEng.ÁÁÁÁÁÁ

ÁÁÁÁÁÁ3-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSecondary Setpoint 1





ÁÁÁÁÁÁ4-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSecondary Setpoint 2





ÁÁÁÁÁÁ5-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁJog Setpoint




ÁÁÁÁÁÁÁÁÁÁRPMÁÁÁÁÁÁ


6-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Output SetpointÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


+100ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

0ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

%


10-CP ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Minimum Limit ÁÁÁÁÁÁÁÁÁÁÁÁ


9999 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

0 ÁÁÁÁÁÁÁÁÁÁ

RPM



Maximum Limit ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



Low Alarm ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



High Alarm ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



Error Alarm 1 ÁÁÁÁÁÁÁÁÁÁÁÁ




RPMÁÁÁÁÁÁÁÁÁÁÁÁ


Error Alarm 2 ÁÁÁÁÁÁÁÁÁÁÁÁ






Acceleration Time ÁÁÁÁÁÁÁÁÁÁÁÁ

0.0 ÁÁÁÁÁÁÁÁÁÁÁÁ

600.0 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5.0 ÁÁÁÁÁÁÁÁÁÁ

SecondsÁÁÁÁÁÁÁÁÁÁÁÁ


Deceleration Time ÁÁÁÁÁÁÁÁÁÁÁÁ

0.0 ÁÁÁÁÁÁÁÁÁÁÁÁ

600.0 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5.0 ÁÁÁÁÁÁÁÁÁÁ

SecondsÁÁÁÁÁÁÁÁÁÁÁÁ


Lag Pulse Limit ÁÁÁÁÁÁÁÁÁÁÁÁ




PulsesÁÁÁÁÁÁÁÁÁÁÁÁ


Lead Pulse LimitÁÁÁÁÁÁÁÁÁÁÁÁ



0ÁÁÁÁÁÁÁÁÁÁ

PulsesÁÁÁÁÁÁÁÁÁÁÁÁ


Eng. Units-Pri. Sp.ÁÁÁÁÁÁÁÁÁÁÁÁ

0.000ÁÁÁÁÁÁÁÁÁÁÁÁ


900ÁÁÁÁÁÁÁÁÁÁ

Eng.ÁÁÁÁÁÁÁÁÁÁÁÁ21-CP

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEng. Units-Sec. Sp.

ÁÁÁÁÁÁÁÁÁÁÁÁ0.000


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ1.0


ÁÁÁÁÁÁ22-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEng. Units-Pri. Dsp.





ÁÁÁÁÁÁ23-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁEng. Units-Sec. Dsp.



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ1.0


ÁÁÁÁÁÁ29-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRecovery Multiplier




ÁÁÁÁÁÁÁÁÁÁ—ÁÁÁÁÁÁ


30-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

PPR-Ext. ReferenceÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


9999ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

60ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

PPR



PPR-Feedback ÁÁÁÁÁÁÁÁÁÁÁÁ




PPR



PPR-Auxiliary ÁÁÁÁÁÁÁÁÁÁÁÁ




PPR



RPM-Ref.-Pri. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



RPM-Fdbk.-Pri. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



RPM-Aux.-Pri. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM



RPM-Ref.-Sec. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ






RPM-Fdbk.-Sec. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ






RPM-Aux.-Sec. Max. ÁÁÁÁÁÁÁÁÁÁÁÁ




RPM

8. Gear-to-Line MotorController DefaultSettings

Operation4-52


107 144DIssued 3/99

Manual 41-190


Code Type ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Minimum ÁÁÁÁÁÁÁÁÁÁÁÁ

Maximum ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory Setting ÁÁÁÁÁÁÁÁ

UnitsÁÁÁÁÁÁÁÁÁÁÁÁ

60-CP ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Current Limit ResponseÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



20 ÁÁÁÁÁÁÁÁ

CodedÁÁÁÁÁÁÁÁÁÁÁÁ


Scaling Mode-Pri. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



1 ÁÁÁÁÁÁÁÁ



Scaling Mode-Sec. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



2 ÁÁÁÁÁÁÁÁ



Display Mode-Pri. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



1 ÁÁÁÁÁÁÁÁ


64-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Display Mode-Sec.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



2ÁÁÁÁÁÁÁÁ



GainÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



9000ÁÁÁÁÁÁÁÁ

—ÁÁÁÁÁÁÁÁÁÁÁÁ66-CP

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁReset

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ0



ÁÁÁÁÁÁÁÁ—ÁÁÁÁÁÁ

ÁÁÁÁÁÁ67-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRate




ÁÁÁÁÁÁÁÁ—ÁÁÁÁÁÁ

ÁÁÁÁÁÁ68-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁTrim Authority




ÁÁÁÁÁÁÁÁ%ÁÁÁÁÁÁ

ÁÁÁÁÁÁ69-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRate Threshold




ÁÁÁÁÁÁÁÁHzÁÁÁÁÁÁ


70-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Device AddressÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




—



Baud Rate ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



6 ÁÁÁÁÁÁÁÁ

Coded



Character Format ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



2 ÁÁÁÁÁÁÁÁ

Coded



Control Mask ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ

Coded



Zero Speed Logic ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ

Coded



Positive Offset, Pri. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ

HzÁÁÁÁÁÁÁÁÁÁÁÁ


Negative Offset, Pri. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ



Positive Offset, Sec. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ



Negative Offset, Sec. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



0 ÁÁÁÁÁÁÁÁ



Setpoint Mask ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



1 ÁÁÁÁÁÁÁÁ



Analog Output Allocat.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



41ÁÁÁÁÁÁÁÁ



Analog Output RangeÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



2000ÁÁÁÁÁÁÁÁ

HzÁÁÁÁÁÁÁÁÁÁÁÁ82-CP

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAnalog Output Zero



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSee Note A

ÁÁÁÁÁÁÁÁCodedÁÁÁÁÁÁ

ÁÁÁÁÁÁ83-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAnalog Output Span





ÁÁÁÁÁÁ84-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAnalog Input Allocat.





ÁÁÁÁÁÁ85-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAnalog Input Zero






86-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Analog Input SpanÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



See Note AÁÁÁÁÁÁÁÁÁÁÁÁ

Coded


NOTE A: These settings vary with individual processor calibration.

8. Gear-to-Line MotorController DefaultSettings (contd.)


107 144DIssued 3/99

Manual 41-190

Section 5

Maintenance

Maintenance5-0


107 144DIssued 3/99

Manual 41-190

Maintenance 5-1


107 144DIssued 3/99

Manual 41-190

Section 5Maintenance



This section describes maintenance procedures that help maintain theoverall performance of your processor. For information on automatic gunor handgun maintenance, refer to the automatic gun or handgun manual.

The following procedures describe how to prepare the system formaintenance and for normal operation after maintenance.

1. Introduction

2. System Preparation

4904022

1 2

4904048

Maintenance5-2


107 144DIssued 3/99

Manual 41-190

Perform the following steps to relieve system hydraulic pressure.

1. If the motor is on, press the MOTOR key to turn off the motor.

Fig. 5-1 Turning Off Motor


2. If the processor is in the auto pressure control mode (indicated by alighted AUTO button), press the AUTO PRESSURE CONTROLbutton to place in manual mode.

3. Use the manual potentiometer to set the hydraulic pressure to 0 kPa(0 psi).

Fig. 5-2 Setting Hydraulic PressureManually

1. AUTO PRESSURE CONTROLbutton

2. Manual potentiometer

Relieving System HydraulicPressure

4904058

4904033

Maintenance 5-3


107 144DIssued 3/99

Manual 41-190

4. Press the PURGE button. The motor turns on and increases to a setspeed.

5. Allow pump outlet pressure to drop and stabilize.




7. Remove the gun nozzle(s).

8. Trigger the gun(s) into a waste container to ensure the hydraulicpressure in the system is relieved.




4904046

4904022

Maintenance5-4


107 144DIssued 3/99

Manual 41-190

11. Place a waste container under the drain valve.

12. Use a flat-blade screwdriver to open the drain valve as a final safetycheck before breaking any hydraulic connection.

Fig. 5-5 Opening Drain Valve

Perform the following steps to resume normal operation after relievingsystem hydraulic pressure and performing maintenance.

1. Replace the gun nozzle(s).

2. Make sure the system is on and that the READY light is on, whichindicates that all zones are at operating temperature.

3. Press the MOTOR key. The motor turns on. Adjust motor speed tosuit your application needs. Refer to Pump Charts in the Descriptionsection.


Relieving System HydraulicPressure (contd.)

Resuming Normal Operation

4904040

Maintenance 5-5


107 144DIssued 3/99

Manual 41-190

4. Press the GAS ON button.

5. Allow the system to stabilize 3−5 minutes before resuming normaloperation.


Maintenance5-6


107 144DIssued 3/99

Manual 41-190

Performing routine maintenance can extend the life of your unit anddecrease downtime caused by extensive repairs. The procedures in thissection will help you keep your unit running properly and reducedowntime.

The following table lists a recommended schedule for preventivemaintenance. Use the table to develop a maintenance schedule for yournew processor. Keep in mind that you may need to adjust how often youperform procedures because of conditions specific to your operations.You may find that more or less frequent maintenance is required forsome procedures.

Table 5-1 Recommended Maintenance ScheduleÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFrequency

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDescription of MaintenanceÁÁÁÁÁÁÁÁ


DailyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean the exterior surfaces of the processor and guns. Keep adhesive supply clean andfree of contaminants to prevent poor pump performance or clogged nozzles.

Check the o-rings and gaskets on hose connectors and plugs for leaks. Refer toReplacing the Hose Connector and Pipe Plug O-rings in the Repair section.

Flush the manifold filter. Refer to Flushing the Filter Assembly later in this section.

Check for gas leaks. Refer to Connecting the Gas Supply in the Installation section.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

WeeklyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check the hydraulic, gas, and electrical connections. Refer to Checking the Hydraulic,Gas, and Electrical Connections later in this section.


Semi-annuallyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Install a new density controller and filter assembly by following the procedures in Checkingand Cleaning the Filter Assembly later in this section.

Flush the system. Refer to Flushing the System later in this section.

Check the drive belt for wear. Refer to Checking the Drive Belt for Signs of Wear later inthis section.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

As Needed ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

If you use carbon dioxide with your processor, inspect the fiber washer seal between thegas cylinder valve and the inlet to the main gas regulator any time you change the gascylinder. Replace the washer if it is badly worn or damaged. (No washer seal exists onprocessors that use nitrogen.)

Check and clean the filter assembly if problems are evident. Refer to Checking andCleaning the Filter Assembly later in this section.

Clean inside the electrical cabinet.

Check electrical connections and terminal blocks.

3. Maintenance Procedures

Scheduling Maintenance

4904058

Maintenance 5-7


107 144DIssued 3/99

Manual 41-190

The gas in the system dissipates overnight, so you may want to flush thefilter assembly each morning before you turn on the gas. Doing soreduces the amount of time it takes for the purge cycle to work.


1. Relieve system hydraulic pressure as described in SystemPreparation in this section.



3. Allow hot melt material to flow from the drain valve until the material isfree of debris.



Flushing the Filter Assembly

4904045

Maintenance5-8


107 144DIssued 3/99

Manual 41-190


6. Resume normal operation as described in System Preparation in thissection.

Fig. 5-9 Closing Drain Valve

1. Check the following hydraulic connections for leaks and damage:

� all hose connections and fittings at the manifold� all fittings between hoses and guns

2. Check all hoses for cuts, kinks, and fraying.

3. Check all gas tubes for bends, kinks, or other damage.

4. Check all electrical connections to the hoses for fraying, broken wires,and damaged connectors.

5. Refer to the Parts section to replace any of the equipment that isdamaged.

Make sure the processor is at operating temperature before beginningthis procedure. To check and clean the filter assembly, you must:

� Remove the density controller and filter� Inspect the filter assembly� Clean or replace the filter screen if necessary� Replace the density controller and filter

Flushing the Filter Assembly(contd.)

Checking the Hydraulic, Gas,and Electrical Connections

Checking and Cleaning theFilter Assembly

Maintenance 5-9


107 144DIssued 3/99

Manual 41-190

To Remove the Density Controller and Filter


WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves.


2. Turn the unit off.

3. Note the index number position of the density controller knob.

4. Turn the knob counterclockwise for access to the screw that securesthe ground wire to the density controller.

4904054

Fig. 5-10 Adjusting Density Controller Knob Counterclockwise

Maintenance5-10


107 144DIssued 3/99

Manual 41-190

To Remove the Density Controller and Filter (contd.)

5. Remove the wire retainer clip.

6. Remove the screw that secures the ground wire and lift the wire awayfrom the density controller.

4904066

213

Fig. 5-11 Disconnecting the Wire from the Density Controller

1. Wire retainer clip2. Screw

3. Ground wire

CAUTION: Apply torque to the inner portion of the densitycontroller and filter assembly only. Failure to observe mayresult in equipment damage.

7. Use a wrench to turn the density controller and filter assemblycounterclockwise to remove it from the manifold.

4904068

ÎÎÎÎÎÎ

Fig. 5-12 Removing Density Controller and Filter Assembly

Maintenance 5-11


107 144DIssued 3/99

Manual 41-190

To Inspect the Filter Assembly

1. If it has been 6 months since you last changed the filter assembly,proceed with To Replace the Density Controller and Filter and replacethe existing assembly with a new one.

2. Inspect the o-ring and filter screen.

4904072


21

Fig. 5-13 Inspecting O-ring and Filter Screen

1. O-ring 2. Filter screen

Problem Action

O-ring is damaged 1. Remove the damaged o-ringfrom the filter assembly.

2. Place a new o-ring onto thefilter assembly.

Filter screen is clogged ordamaged

Proceed with To Clean orReplace the Filter Screen.

Filter screen is clean andundamaged

Proceed with To Replace theDensity Controller and Filter.

Maintenance5-12


107 144DIssued 3/99

Manual 41-190

To Clean or Replace the Filter Screen

1. Remove the bolt from the end of the filter assembly.

2. Remove the support from the end of the filter assembly.

4904070

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

1

2

3

4

Fig. 5-14 Disassembling Filter Assembly

1. Bolt2. Support

3. Screen4. Filter core

3. Slide the filter screen off the filter core, then select a task:

Task Proceed to

Cleaning the filter screen Step 4

Replacing the filter screen Step 7

4. Place the filter screen in a container of Nordson Type R fluid or othercleaning agent recommended by your hot melt material supplier.

5. Use a regulated hot plate or similar device to heat the fluid slightlyabove the application temperature of the hot melt material.

CAUTION: Do not use a metal bristle brush to clean the filterscreen. Failure to observe may result in equipment damage.

6. Scrub the screen with a fiber bristle brush until it is free of depositsand char.

7. Slide the new or cleaned filter screen onto the filter core.

8. Place the support on the end of the filter assembly.

9. Replace and tighten the bolt into the end of the filter assembly.

Maintenance 5-13


107 144DIssued 3/99

Manual 41-190

To Replace the Density Controller and Filter

1. Turn the unit and the heaters on. Wait until the NORMAL indicator onthe TEMPERATURE status panel lights up for Zone 4 (the manifold).

2. Place and finger-tighten the density controller and filter assembly inthe manifold.

3. If you cleaned the filter screen, allow the filter assembly to heatenough to melt any hardened material clinging to it.

CAUTION: Apply torque to the inner portion of the densitycontroller and filter assembly only. Failure to observe mayresult in equipment damage.

4. Use a wrench to tighten the filter until it seats. Do not overtighten.

4904069


Fig. 5-15 Replacing Density Controller and Filter

Maintenance5-14


107 144DIssued 3/99

Manual 41-190

To Replace the Density Controller and Filter (contd.)

5. Attach the ground wire to the density controller and filter assembly.

6. Insert the screw into the fork lug to secure the wire.

7. Install the wire retainer clip.

4904067

132

Fig. 5-16 Replacing Wire and Clip

1. Screw2. Ground wire

3. Wire retainer clip

8. Turn the density controller knob clockwise to the previous setting.

4904055

Fig. 5-17 Adjusting Density Controller Knob Clockwise

4904045

4904032

4904034

1

2

Maintenance 5-15


107 144DIssued 3/99

Manual 41-190


10. Remove the waste container from under the drain valve.

Fig. 5-18 Closing Drain Valve

11. Close the manifold cover.

12. Tighten the thumb screw that locks the manifold cover.

13. If you installed a new filter assembly, proceed with Flushing theSystem before resuming normal operation.


Fig. 5-19 Closing Manifold Cover

Perform the following steps to flush the system.



2. Disconnect the return hose(s) from the manifold.

3. Place the disconnected end(s) of the hose(s) into a waste container.

Fig. 5-20 Preparing to PurgeHydraulic System

Flushing the System

4904058

Maintenance5-16


107 144DIssued 3/99

Manual 41-190


5. Pump hot melt material into the waste container until the top of thegrid is visible.


7. Cover the grid with fresh hot melt material.

8. Wait for the material to melt.



10. Pump hot melt material into the waste container until new hot meltmaterial begins to flow from the hose.


12. Reconnect the return hose(s) to the manifold.

4904062

Fig. 5-22 Reconnecting Return Hose

13. Fill the hopper with fresh hot melt material.

14. Wait for the material to melt.


Flushing the System (contd.)

4904022

4904023

Maintenance 5-17


107 144DIssued 3/99

Manual 41-190

Perform the following procedures to check the drive belt for signs of wear.

To Access and Check the Drive Belt

1. If the motor is on, press the MOTOR key to turn off the motor.


2. Press the HEATERS key to turn off the heaters.

Fig. 5-24 Turning Off Heaters

Checking the Drive Belt forSigns of Wear

4904042

Maintenance5-18


107 144DIssued 3/99

Manual 41-190

To Access and Check the Drive Belt (contd.)


4. Remove the belt cover. Refer to Removing the Hopper Enclosureand Unit Cover in the Repair section as needed.

If you are adjusting the motor speed sensor gap, slightly loosen thescrews that hold the L-bracket and sensor to the belt plate, thenproceed with Step 9 in To Replace the Drive Belt later in this section.

If you are checking the drive belt for wear, look for missing ordamaged teeth and for cracks in the belt.

Belt Condition Action

Damaged Proceed with To Remove theDrive Belt.

Not damaged Replace the drive belt cover.Refer to Replacing the UnitCover and Hopper Enclosure inthe Repair section as needed.


Maintenance 5-19


107 144DIssued 3/99

Manual 41-190

To Remove the Drive Belt

1. Remove the two screws that secure the L-bracket and sensor to thebelt plate.

2. Pull the sensor and L-bracket away from the sprocket.

4904073

2

1

Fig. 5-26 Removing Sensor

1. Screws (2) 2. L-bracket and sensor

3. Remove the three hex head cap screws and split lockwashers fromthe clearance holes on the sprocket that is coupled to the pump driveshaft.

4. Set aside the lockwashers.

5. Place the three screws into the three tapped holes in the sprocket.

Maintenance5-20


107 144DIssued 3/99

Manual 41-190

To Remove the Drive Belt (contd.)

49040761 2 3

Fig. 5-27 Using Hex Head Cap Screws to Remove Sprocket

6. Tighten the screws into the holes to raise the sprocket off the taperedbushing on the pump drive shaft.

4904074

Fig. 5-28 Removing Sprocket

7. Lift the sprocket off the pump drive shaft.

8. Remove the old drive belt.

Maintenance 5-21


107 144DIssued 3/99

Manual 41-190

To Replace the Drive Belt

1. Place the new drive belt onto the sprockets.

2. Place the sprocket onto the pump drive shaft.

3. Loosen the screws to lower the sprocket onto the tapered bushing onthe pump drive shaft.

4904075

Fig. 5-29 Replacing Sprocket

NOTE: Align the drive and motor sprockets so that the belt does notrub against the edges of either sprocket. That is, the belt should belevel to avoid rubbing.

4. Remove the three hex head screws from the tapped holes on thesprocket that is coupled to the pump drive shaft.

5. Place the three screws and split lockwashers into the clearance holeson the sprocket.

6. Apply 6.78−8.13 N�m (5−6 lb-ft) of torque to the screws to secure thesprocket.

49040771 2 3

Fig. 5-30 Securing Sprocket

Maintenance5-22


107 144DIssued 3/99

Manual 41-190

To Replace the Drive Belt (contd.)

7. Replace the sensor and L-bracket onto the belt plate.

8. Replace and snug the two screws that secure the L-bracket andsensor, but do not tighten.

9. Adjust the sensor so that it is 0.31−0.56 mm (0.012−0.22 in.) awayfrom the sprocket teeth. Measure when the gap between the sensorand sprocket teeth is at a minimum. Rotate the pulley by hand to findthe proper spot.

4904078

1

2

Fig. 5-31 Replacing Sensor

1. L-bracket and sensor 2. Screws (2)

WARNING: Risk of personal injury. Do not allow clothing orother items to become entangled in the drive belt. Failure toobserve may result in equipment damage or personal injury.

10. Restore power.

11. Run the unit and verify proper speed. If necessary, turn off the unitand re-adjust the sensor gap. Proceed to the next step when thesensor gap is correct.

NOTE: If you have just installed the motor as a result of servicing orreplacing the existing motor, observe the direction of motor shaftrotation. The shaft should rotate counter-clockwise.

12. Replace the belt cover. Refer to Replacing the Unit Cover andHopper Enclosure in the Repair section as needed.

13. Reconnect power and resume normal operation.

Maintenance 5-23


107 144DIssued 3/99

Manual 41-190

Use this form to keep a record of the performed maintenance. Makecopies before using this form the first time.


Task ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Name ÁÁÁÁÁÁÁÁÁÁ

Date ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Name ÁÁÁÁÁÁÁÁÁÁ

Date


Clean and inspect processor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ
















ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁFlush filter assembly ÁÁÁÁÁÁÁÁ

















Check connectionsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

















Check and clean filter assembly ifnecessary


















ÁÁÁÁÁÁÁÁÁÁÁÁFlush system ÁÁÁÁÁÁÁÁ








ÁÁÁÁÁÁÁÁÁÁÁÁCheck drive beltÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ










Install new density controller andfilter assembly









4. Maintenance RecordForm

Maintenance5-24


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Section 6

Troubleshooting

Troubleshooting6-0


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Troubleshooting 6-1


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Section 6Troubleshooting


This section contains troubleshooting procedures. These procedurescover only the most common problems that you may encounter. If youcannot solve the problem with the information given here, contact yourlocal Nordson representative for help.

The CPU error codes, board indicators, and test measurementprocedures are used with the mechanical and system controller tables.

The system status area of the controller panel includes an error codedisplay for internal diagnostics. This display shows any uncleared CPUerror codes.

1. Introduction

2. Troubleshooting Tables

CPU Error Codes

Troubleshooting6-2


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To clear an error code, correct the problem indicated on the followingchart, then power the unit off then on again.

Table 6-1 Codes Shown on Left Side of the DisplayÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

CodeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Explanation


8ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Lamp test. An “8” is normal during a lamp test, whichoccur during power up reset, when the heaters are turnedon, and when faults are cleared.


C


Corrupt RAM memory data. Reset factory defaults usingAP2 S3−12 according to procedure in the Repair section,Resetting the AP1 Circuit Board to Factory Defaults. Ifproblems persists, a replacement of the CPU (AP1), themain board (AP2), or the entire system controllerassembly may be required.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

HÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

High internal cabinet temperature. Investigate and resolvecause of high temperature.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

F

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Failure. Try the following:

� Check AP2 S2 and S3. Cycle power to the unit.

� Check the +12 Vdc and −12 Vdc power supplied toAP2 terminal block XP17. Refer to the systemschematics in this section. Examine all wiring, fusesand connections between power supply GS1 andAP2−XP17 for open or intermittent connections.Verify the voltage at the terminals of GS1.

� Attempt to reset the factory defaults using theprocedure in the Repair section, Resetting the AP1Circuit Board to Factory Defaults.

If problem persists, replace CPU module.


LÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Low battery voltage, Replace battery according toprocedure in the Repair section, Replacing the ControllerBattery, in order to preserve user settings.


P4ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Motor overload relay tripped. Check for excessive motorload and reset overload relay KL1 after it cools.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NOTE: 0 may appear on the right side of display.

CPU Error Codes (contd.)

Troubleshooting 6-3


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Table 6-2 Codes Shown on the Right Side of the Display


Code ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Explanation


1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Ground fault*. This is usually due to a faulty powercomponent (heater, motor, etc.) or wiring. Most often,the component is an external device such as a hose orgun. Locate and correct the faulty device.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

2

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Watchdog timer fault*. A “watchdog timer” detectsfailure of the microprocessor or software to executetasks in a timely manner. Specific causes are:

� Electrical noise or intermittent connections to thecontrol assembly or a faulty power supply (GS1).

� Incorrect or missing voltage at AP2−XP15.

� Holding the reset button on AP2 down too long.

Refer to the system schematics in the Troubleshootingsection.



Ground and watchdog timer faults.


4


Emergency thermostat fault*. Refer to theTroubleshooting section to determine the cause of theovertemperature. A contact from the motor overloadrelay (KL1) is also part of this circuit. A “P4” displayindicates a motor overload.



Emergency thermostat and ground faults



Emergency thermostat and watchdog timer faults


7ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Emergency thermostat, watchdog timer, and groundfaults


* Single faults

Troubleshooting6-4


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Some warnings and faults require your immediate attention. Others donot. With each warning or fault, the system controller takes action, ifnecessary, to prevent equipment damage or dangerous operatingconditions.

Refer to Tables 6-3 and 6-4 for a description of actions the systemcontroller takes for each warning or fault condition.

Perform the following steps to find the cause of the warning or fault.

1. Observe the various control system lights and temperature displays.

2. If necessary, refer to the Troubleshooting tables in this section forproblem resolution.

Table 6-3 Temperature Status Warning and Fault ConditionsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Condition1


Temp.StatusLight


Ready Light


WarningLight


Fault Light


OT FaultLight


Alarm


Turns OffPump


Shuts DownHeaters


Zone under temperatureby less than low tempfault setting


LOW ÁÁÁÁÁÁÁÁÁÁÁÁ

NO CHANGEÁÁÁÁÁÁÁÁÁÁÁÁ

YESÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



RepetitiveBELL ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Zone over temperatureand less thanovertemperature setpoint


HIGH ÁÁÁÁÁÁÁÁÁÁÁÁ

NO CHANGEÁÁÁÁÁÁÁÁÁÁÁÁ

YESÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



RepetitiveBELLÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Major zone2 undertemperature by morethan low temp faultsetting


LOW ÁÁÁÁÁÁÁÁÁÁÁÁ

NO(after a 2-minute

delay)



YES ÁÁÁÁÁÁÁÁÁÁÁÁ


SIREN ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

YES(after a 2-minute

delay)



Minor zone3 undertemperature by morethan low temp faultsetting


LOWÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NO CHANGEÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


YESÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


SIRENÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Zone reachesovertemperature setpoint


HIGHÁÁÁÁÁÁÁÁÁÁÁÁ

NO(immediately)



YESÁÁÁÁÁÁÁÁÁÁÁÁ


SIRENÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

YES(immediately)


YES(immediately)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1 Customer-specified temperature value2 Major zone − hopper, grid, reservoir, manifold3 Minor zone − hose and gun

System Controller Warning/Fault Specifications

Troubleshooting 6-5


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Table 6-4 General Warning and Fault Conditions


Condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Ready Light ÁÁÁÁÁÁÁÁÁ

WarningLightÁÁÁÁÁÁÁÁÁÁÁÁ

FaultLightÁÁÁÁÁÁÁÁÁ

HTRFaultLight


RTDFaultLight


AudibleAlarmÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Turns OffPump


Shuts OffIndividual

Zone


ShutsDown

Heaters


Zone heater or circuitfault (defined as inabilityto turn off heater)


NO(after a 2-minute

delay)

ÁÁÁÁÁÁÁÁÁ


YES ÁÁÁÁÁÁÁÁÁ




YES(after a

2-minute delay)



YES(after a

2-minutedelay)


Zone heater open circuitfault


ÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁ



RepetitiveBELL





Major zone1 RTD fault ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NO(after a 2-minute

delay)



YES ÁÁÁÁÁÁÁÁÁÁÁÁ


YES ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SIRENÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

YES(after a

2-minute delay)



YES(after a

2-minutedelay)


Minor zone2 RTD fault ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

YES ÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

YES ÁÁÁÁÁÁÁÁ

SIRENÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

YES(immediately)ÁÁÁÁ


Motor overload3,4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NO(immediately)

ÁÁÁÁÁÁÁÁÁ


YESÁÁÁÁÁÁÁÁÁ




YES(immediately)



ÁÁÁÁÁÁÁÁHydraulic pressure outof band


ÁÁÁÁÁÁ

YESÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

RepetitiveBELLÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ



Gas lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁ



SingleBell



ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

1 Major zone − hopper, grid, reservoir, and manifold2 Minor zone − hose and gun3 Also opens the motor overload relay, which must be reset.4 System OK light off, P4 displayed on error code display.

Troubleshooting6-6


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The following table provides general troubleshooting information formechanical problems. You may need to refer to maintenance anddisassembly procedures for additional troubleshooting information.

Table 6-5 Troubleshooting Mechanical Problems

Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Little or no hot meltmaterial output at gun


Low level of hot melt materialÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Add hot melt material to hopper.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Processor in purge modeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check PURGE light. If light is on, pressPURGE button to exit purge mode.



System not up to temperature ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check READY light on system controllerpanel. Wait for ready time delay tolapse.



Low hydraulic pressureÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check PUMP OUTLET PRESSUREreadout. Adjust hydraulic pressure to2069−8964 kPa (300−1300 psi).



Motor speed too lowÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check pump charts for appropriate RPMsetting. Increase percent of motorspeed at control panel.



Incorrect temperature settingsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check operating setpoints for hopper,grid, reservoir, hoses, and guns. Adjustsetpoints as needed.



Clogged nozzle on gun ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean nozzles.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Clogged or damaged filterÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean or replace filter. Refer toChecking and Cleaning the FilterAssembly in the Maintenance section.



Clogged or damaged pressure controlvalve


Clean or replace pressure control valve.Refer to Replacing the Pressure ControlValve in the Repair section.



Incorrect gear-to-line settings ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check motor controller settings.Change as necessary according toGear-to-Line Motor Controller DefaultSettings in the Operation section.

Continued on next page

Mechanical

Troubleshooting 6-7


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Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Little or no hot melt materialoutput at gun (contd.)


Excessive foam density reductionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Adjust density reduction. Refer toAdjusting Density Control in theOperation section.



Damaged or missing pump o-ringseals


Replace o-ring seals. Refer toReplacing Pump or Pump O-Rings inthe Repair section..



Pump or motor not running ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Refer to Pump not operating or Motorstops or fails to start in this table.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


KA-1, KA-2, or KA-3 relay notfunctioning correctly


Check circuit operation of these relaysusing the system schematic.

Examine for loose connections.

Test for bad relay.



Problem with shop air supply ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check that air is supplied to the unit atthe proper pressure.

Troubleshooting6-8


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Little or no gas in the hotmelt deposit


Gas not onÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check GAS ON light. If not lit, pressGAS ON button.



Low level of input gasÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check GAS LOW light. If on, increasegas supply pressure to 207−267 kPa(30−40 psi). Refer to Replacing the GasPressure Switch in the Repair section.



Low gas pressure at the pumpÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check gauge on gas pressure controlpanel. Increase pressure setting to21−34 kPa (3−5 psi).



Processor in purge mode ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check PURGE light. If on, pressPURGE button to exit purge mode.



Incorrect density control setting ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check original setup records. Refer toAdjusting Density Control in theOperation section to reset densityreduction.



Clogged or damaged density controland filter assembly


Check filter. Refer to Checking andCleaning the Filter Assembly in theMaintenance section.



Open circuit on density control wireÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Repair or replace density control wire.



Open circuit between reedex valveand interface board


Repair or replace reedex valve wire.



Incorrect reedex valve connection tointerface board


Reconnect reedex valve. Traceconnections per schematic.



Clogged or kinked gas line or leakinggas fittings


Check gas line, check valve, and fittings.Replace damaged parts.



Worn or damaged o-rings betweenpump and manifold


Replace o-rings. Refer to Replacing thePump or Pump O-rings in the Repairsection.

Worn out pump Check PUMP OUTLET PRESSURE andthe amount of foam. If normal operatingoutput pressure and normal amount offoam cannot be maintained, the pump isworn. Refer to Replacing the Pump orPump O-rings in the Repair section.

Motor speed too low Adjust the speed. Recommendedminimum is 300 rpm.

Mechanical (contd.)

Troubleshooting 6-9


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Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Little or no gas in the hotmelt deposit (contd.)


Problem with relay KA-6ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify the functioning of the relay andassociated wiring. Correct asappropriate.



Fuse FU22 open ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check fuse. Replace if open.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Problem with diode V1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check that diode is not shorted orinstalled backwards. Correct asappropriate.



Problem with reedex valve SP2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Gas should flow when the coil isenergized. Replace SP2 if faulty.



Problem with BP3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check wire to density control/filterassembly. Also, refer to the chart in theOperation section, To Determine andAdjust Density Reduction.


Motor stops or fails to startÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No power to processor ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Restore power. Ensure that maindisconnect switch is on.



System not up to temperature ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check READY light on system controllerpanel. Wait for ready time delay tolapse.



System in fault condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check FAULT light and error code onsystem controller panel. Refer toSystem Controller troubleshooting tablein this section.



Worn or damaged motor brushesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and replace brushes. Refer toServicing the Motor in the Repairsection.



Worn or damaged motor bearingsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and replace motor bearings.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Faulty motorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Measure resistance across motorwindings. If open, replace motor. Referto Servicing the Motor in the Repairsection.



Motor is turned offÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Press motor on/off button on usercontrol panel.



Unit in standby modeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Exit standby mode. When unit is ready(temperatures reach setpoints), motorcan be started.



Speed setpoint is zero ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and correct speed setpoint if setto zero.



Motor Control fuses or malfunctionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check fuses and replace if necessary.Check motor control and replace iffailed.

Troubleshooting6-10


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Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Motor stops or fails to start(contd.)


Gear-to-line motor controller linespeed input signal is zero


Ensure that the production line is notstopped. Check for a disconnectedcable. Check for a failed encoder.



Motor Overload relay has tripped ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check the overload relay (KL1). Verifycurrent setting. If tripped, find cause ofexcessive load on motor.


Pump not operating (motorrunning)


Broken drive belt ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace drive belt. Refer to Checkingthe Drive Belt for Signs of Wear in theMaintenance section.



Driveshaft coupling worn or damagedÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace driveshaft coupling. Refer toServicing the Drive Assembly in theRepair section.


Pump not operating(driveshaft turning)


Sheared driveshaft key on pumpÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace key. Refer to Servicing theDrive Assembly in the Repair section.


Pump speed erraticÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Misaligned or faulty sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Realign or replace the sensor. Thesensor should be 0.31−0.56 mm(0.012−0.022 in.) from the sprocketteeth.



Worn or damaged motor bearings ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and replace motor bearings.



Worn or damaged motor brushes ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and replace brushes. Refer toServicing the Motor in the Repairsection.ÁÁÁÁÁÁÁÁÁÁ



Standard drive in current limitÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check the red LED on the motor control(AP8). If on, find the source ofexcessive motor load.



Intermittent problem in the wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check the wires and connectorsbetween the motor and the drive. Alsocheck the wires between the drive andthe main board (AP2) as well as the ACline connections to the drive.


Motor runs below set speedÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

GTL motor controller in current limitÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check the red Limit Alarm LED on themotor controller (also, CP−52displays 07). If on, find the source ofexcessive motor load.


Motor runs at high speed ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Feedback sensor mis-adjusted ordisconnected (gear-to-line controlleronly)


Make sure the feedback sensorconnections are intact. Adjust the gapbetween the sensor and the drive beltsprocket to 0.31−0.56 mm(0.012−0.022 in.).

Mechanical (contd.)

Troubleshooting 6-11


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Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pump works but speed notadjustable


Processor in purge modeÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check PURGE light. Press PURGEbutton to exit purge mode.



Worn or damaged motor brushesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and replace brushes. Refer toServicing the Motor in the Repairsection.



Incorrect motor control mode ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pump in manual mode when auto orgear-to-line is intended.


Bead size does not trackline speed change


Processor in manual pressure controlmode


Check AUTO PRESSURE CONTROLlight. Press AUTO PRESSURECONTROL button to place processor inauto mode.



Low level of hot melt materialÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Add hot melt material to hopper.



Low level of input air ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Increase air pressure to 621-690 kPa(90-100 psi).



Open pressure relief valve (excessivefoam seeping into reservoir)


Reduce system hydraulic pressure sothat it is below 10,343 kPa (1,500 psi).



Damaged or clogged pressure reliefvalve (excessive foam seeping intoreservoir)


Replace valve. Refer to Replacing thePressure Relief Valve in the Repairsection.



Clogged nozzle on gun ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clean nozzles.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Faulty I/P transducerÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace I/P transducer. Refer toReplacing the I/P Transducer in theRepair section.



Problem in relay logic ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check circuit operation of relays KA-1,KA-2 and KA-3 using the systemschematic.

Troubleshooting6-12


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The following table provides general troubleshooting information for thesystem controller. You may need to refer to the wiring schematics foradditional troubleshooting information. Refer to the Repair section forrepair or replacement procedures.

Table 6-6 Troubleshooting the System Controller


Illuminated fault lightÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

A faulty resistance temperaturedetector (RTD)


Refer to Resistance TemperatureDetector (RTD) Fault in this table.



An overtemperature condition in aheater


Refer to Heater Overtemperature Faultin this table.



An overtemperature condition in themotor, indicated by a P4 in the errorcode display


Refer to Motor Overtemperature Fault inthis table.



A solid-state relay (SSR) that is notturning off completely, indicated byone or more illuminated heater faultlights


Refer to Shorted Solid-State RelayFaults in this table.



A ground fault ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Find path where current is flowing inground wires and correct ground fault.Fault most likely located in an externalcomponent (hose or gun) showingconsiderable wear and damage.



An emergency thermostat fault asindicated by a 4 on the right side ofthe error code display


Refer to Emergency Thermostat Fault inthis table.


Emergency ThermostatFault


The zone’s setpoint is set too close tothe emergency thermostat’s triptemperature


Adjust temperature setpoint.



Faulty overtemperature thermostat ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Identify and replace thermostat causingfault. Refer to Test MeasurementProcedures, Procedure 6.



Shorted heater controlÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Identify and replace shorted solid-staterelay. Refer to Test MeasurementProcedures, Procedure 4.



Faulty RTD or RTD wiringÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Inspect RTD wiring and test RTD. Referto RTD Resistance vs. TemperatureCharts later in this section.

System Controller



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Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Illuminated heater fault LEDand illuminated yellowwarning light (Heater openfault)


Blown fuse or fusesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replace blown fuse(s).



Loose wiring connections on heatercircuit


Tighten wiring connections.



Faulty heater ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Measure heater resistance. Replaceheater or component if bad.



Faulty ribbon cable ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check 26 pin and 16 pin (if used) ribboncables between interface board(AP4-XP27, AP4-XP35) and main board(AP2-XP1, AP2-XP2). Replace if bad.ÁÁÁÁÁÁÁÁÁÁÁ



Faulty solid-state relay (SSR)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Identify bad SSR and replace. Refer toTest Measurement Procedures,Procedures 1 and 2.



Faulty interface boardÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Troubleshoot problem to board level.Replace board if bad. Refer to TestMeasurement Procedures, Procedure 7.



Faulty main boardÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Illuminated heater fault LEDand illuminated red faultlight. (Heater short fault)


Faulty solid-state relay

Faulty interface board

Faulty main board


Identify bad relay and replace. Refer toTest Measurement Procedures,Procedure 4.

A ground fault Find path where current is flowing inground wires and correct ground fault.Fault most likely located in an externalcomponent (hose or gun) showingconsiderable wear and damage.

Troubleshooting6-14


107 144DIssued 3/99

Manual 41-190


Zone fails to heat or underheats


Insufficient or no power to unitÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Resolve problem with line voltage tounit.



Open fuseÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check all fuses. Replace bad fuses.



Open heater ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Refer to Heater Open Fault in this table.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Faulty interface board (AP4)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




Faulty main board (AP2) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ




External zone heater undersized ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Zone heater may be undersized for theambient conditions. This is more likelywith non-standard equipment.



Faulty wiring ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check wiring from the interface board(AP4) to the solid-state relay (SSR).


Motor Overload Fault(Indicated by a P4 in the errorcode display)


Ambient temperature abovemaximum ambient temperatureallowed for unit


Resolve problem with work areaambient temperature.



Improper clearance around unitÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Clear area around unit.



Foreign object lodged in the pump ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Change the pump. Refer to Replacingthe Pump or Pump O-rings in the Repairsection.



Material viscosity is too high ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Adjust the pump speed and/or hydraulicpressure. Refer to Pump Charts in theDescription section.



Binding in drive/pump systemÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Examine drive system (motor, motorbrushes, pulleys, drive belt, bearingsand pump). Correct the cause of bind-ing or wear.


Heater OvertemperatureFault


Heater operating setpoint too close tothe overtemperature setpoint


Correct operating setpoint orovertemperature setpoint.



Bad or intermittent connection to RTDÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check connections for all RTDsassociated with zone at fault.

System Controller (contd.)



107 144DIssued 3/99

Manual 41-190

Problem Possible Cause Corrective Action

Processor fails to turn onwhen main disconnectswitch activated

Loose cable to controller Check all wire connections to thecontroller.

Open fuse or fuses Check all fuses. Replace bad fuses.

Power supply failure Check the output of power supply GS1.If fuses are intact and wiring is correct,replace GS1.

Resistance TemperatureDetector (RTD) Fault

1. Loose RTD connection (can causean overtemperature condition)

Check RTD connections.

2. Resistance vs. Temperatureresponse bad for RTD

Verify RTD response. Refer to RTDResistance vs. Temperature Charts laterin this section. Replace faulty RTD.

3. Bad RTD cable Verify continuity of wire betweeninterface board (AP4) and RTD.Replace faulty cable.

4. Bad conductor ribbon cablebetween interface board and mainboard

Check ribbon cable between AP4-XP24and AP2-XP6 and replace if bad.

5. Bad trace on interface board (AP4) Replace interface board.

6. Disrupted controller settings Perform a system reset according to theinstructions in the Repair section,Resetting the AP1 Circuit Board toFactory Defaults. If this fails, areplacement of the CPU (AP1), the mainboard (AP2), or the entire systemcontroller assembly may be required.

Troubleshooting6-16


107 144DIssued 3/99

Manual 41-190

Problem Possible Cause Corrective ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Controller appears to gothrough power up cyclesrandomly during normaloperation, shutting offheaters and pump

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Glitches or drop outs on the incomingAC power


Resolve problem with external powerlines.



Faulty wiring between power supply(GS1) and main board (AP2-XP17)


Inspect wiring and check continuity.Replace or repair any defectivecomponents.



Faulty wiring between controltransformer (TC1) and main boardpower detect connect (AP2-XP15)


Inspect wiring and check continuity.Replace or repair any defectivecomponents.



Faulty power supply or controllerboard


Replace power supply GS1 and/orcontroller assembly.


Cabinet ambient airtemperature too high(indicated by an H in the errorcode display)


Ambient temperature aroundprocessor too high


Resolve problem with ambienttemperature around processor.


DC motor fails to turn on oroperates at less than fullRPM rating in a transferpump system


No power to motor controller,insufficient or no power to motor, orincorrect control signals to motorcontroller


Diagnose problem. Refer to TestMeasurement Procedures, Procedure 3or 5.


Processor displays “L” inthe left-hand side of thediagnostic display


Corrupt memory. Back up battery islow


Replace back up battery. Refer to theRepair section for Replacing theController Battery.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Processor displays “C” inthe left-hand side of thediagnostic display


Corrupt memory. Hardware failure onCPU board or main board


Perform a system reset according to theinstructions in the Repair section,Resetting the AP1 Circuit Board toFactory Defaults. If this fails, areplacement of the CPU (AP1), the mainboard (AP2), or the entire systemcontroller assembly may be required.


Motor speed does notmatch the setting


Incorrect motor speed sensorspacing. Speed may be zero or twicethe desired speed


Check the alignment and spacing of themotor speed sensor gap.

System Controller (contd.)



107 144DIssued 3/99

Manual 41-190

Table 6-7 Troubleshooting the Monitor



FAULT light oncontinuously


Actual pressure is too high or low ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check alarm pressure setpoint vs.actual pressure. Adjust hydraulicpressure.



Dip switch S2 on pressure monitorcontrol board not set correctly (aninactive zone being monitored)


Check dip switch S2. The right-mostswitch should be closed; all othersshould be open. Refer to Setting UpPUMP OUTLET PRESSURE Monitor inthe Operation section.


FAULT light never turns on ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pressure within band ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No action needed.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Motor not turningÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No action needed. Pressure alarm isdisabled when motor is not turning.



Loose wiring connectionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check wires for proper connection andcontinuity. Tighten wiring connections.


Display does not scan allzones


Only one manifold in system ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No action needed. The display alwaysmonitors zone 1.


Pressure displayed doesnot match actual pressure


Faulty wiring between I/P transducerand pressure monitor assembly


Check wires for proper connection andcontinuity.


Pressure display value isfixed and does not vary


Displaying setpoint instead of actualsystem pressure


Check the SET light. If on press theSET button to exit the setpoint mode.



Pressure transducer is disconnectedfrom the monitor board


Check and re-connect the transducer.

Table 6-8 Troubleshooting the RPM Display



Speed display value isincorrect


Inaccurate motor speed calibration ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check that the calibration is correct.Re-enter the calibration constant. Referto Calibrating Motor Speed in theRepair section.


Display value is zero ortwice actual actual speed(standard motor controlonly)


Misaligned or faulty feedback sensorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Check and correct the motor speedfeedback sensor gap. The sensorshould be 0.31−0.56 mm(0.012−0.22 in.) from the drive beltsprocket teeth.

PUMP OUTLET PRESSUREMonitor

RPM Display

Troubleshooting6-18


107 144DIssued 3/99

Manual 41-190

Several of the components are protected by a shield. Holes are providedin the shield for access to the test points. If the shield does not haveholes for testing, remove the shield and replace as soon as the testing iscompleted.

WARNING: Removing the protective shields or guardsexposes you to electrical shock. Replace shield or guardsimmediately after performing test procedures or maintenancetasks.

Table 6-9 Test Measurement Procedures

ProcedureTest Points to Measure Voltage

(+) (−)Correct Reading

(Nominal)

1. Identifying Open Heaters on an Internal Zone

Verify all line fuses are not blown. If any of the fusesfail this test, replace them.

Measure the voltage across the following fuses:

F1, F2, F3, F4, F5, F6

0 Vac

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify Solid-State Relay (SSR) control is on for allSSR’s used with that heater. If test fails, verify wirecontinuity between the SSR control and the interfaceboard. If the wiring is good, go to Diagnosing HeaterControl Problems to the Interface Board or MainBoard.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NKxx-3


NKxx-4


> 3.0 Vdc


Verify all SSRs used with that heater are turning on.If test fails, replace SSR.


NKxx-1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

NKxx-2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

< 2 Vac

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify power is getting to the SSR AC inputs. If not,trace signal back (using schematic) to determinewhere power is being lost. Use schematic todetermine which fuse to measure from to giveline-to-line voltage readings.


NKxx-1


F4, F5, or F6


230 Vac

2. Identifying Open Heaters on a External Zone (Refer to the schematic during the following.)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Disconnect the cordset from the hose/gun connectorabove the hose hydraulic ports. Measure theresistance of the heater at the pins of the cordset −NOT on the unit. Reconnect cordset after taking themeasurement.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Pin 6 (Hose)Pin 2 (Gun)


Pin 4 (Hose)Pin 1 (Gun)


Depends on heater.Typically tens ofohms to 1k ohm.Open circuitindicates a problem.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify SSR control is on for that heater. If test fails,verify wire continuity between the SSR control andthe interface board. If the wiring is good, go todiagnosing Heater Control Problems to the InterfaceBoard or Main Board.


Nkxx−3(xx=5−14)


Nkxx−4(xx=5−14)


> 3.0 Vdc


Verify that AC voltage is available for the heaters ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

XT8−1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


230 VacÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify wiring is good to one side of the SSRÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Nkxx−1(xx=5−14)


XT8−7ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

230 Vac


Verify that SSR is turning on ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Nkxx−2(xx=5−14)


XT8−7 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

230 Vac


Verify that the wire between the SSR and fuse isgood


FUxx−1(xx=12−21)


XT8−7 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

230 Vac


Verify that the fuse is good ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

FUxx−2(xx=12−21)



230 Vac

Test Measurement Procedures



107 144DIssued 3/99

Manual 41-190



(Nominal)


3. Diagnosing DC Motor Controller Problems for Standard Motor Controller Systems


Verify receiving 230 Vac. If not receiving power, tracepower wires back (using schematic) to determinewhere power is being lost.


AP8-TB1-L1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AP8-TB1-L2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

230 Vac, and greenlight on motor driveshould beilluminated

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify motor controller is receiving RUN signal. If it isnot receiving signal, go to Diagnosing Heater ControlProblems on the Interface Board or Main Board tofurther diagnose the problem to the main board or theinterface board. The motor on/off control signal worksexactly like one of the heater control signals.


AP8-TB3-1


AP8-TB3-2


0 Vdc, and yellowlight on motor driveshould beilluminated


Verify motor controller is receiving valid speedcommand


AP8-TB3-4


AP8-TB3-5


Will vary from 0 toapproximately 8.5Vdc, depending onpercentage speedset on front panelÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Verify motor controller is supplying high voltage toDC motor


AP8-TB2-A1


AP8-TB2-A2


Will vary from 0 Vdcto 180 Vdcdepending onpercentage speedset on the frontpanel


Verify motor controller is not being current limited.The current limit is factory set to the rated output ofthe motor controller. If current limiting occurs, themotor is trying to draw more current than the motordrive can reliably supply.




Red LED on motordrive should not beilluminated. If it ischeck for adhesivecuring in pump orbinding in themechanical systemÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ4. Identifying Shorted Heater Zone Solid-State RelaysÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

With unit powered up and heater zones energized,compare actual temps to setpoint temps for all zones.




Failed SSR probablyin zone with higheractual temp thansetpoint

No heater faultLEDs illuminated

Switch unit off, open electrical cabinet door, removePlexiglas panel over SSR’s, hold door interlock pindown and switch unit back on, press heaters key, waitfor the self−checks to complete, and observe controlinput indicator (see Fig. 6-3).

Indicator for faultyzone should stay offwhen actualtemperature isabove setpointtemperature.

Use voltmeter to test suspected SSR. Note that “xx”in Test Points columns refers to SSR number asfound on either Fig. 6-11 or Fig. 6-12. For example,SSR for faulty channel 6 (Gun 1) is NK6; test pointsfor this step would be NK6−3 and NK6−4.

NKxx-3 NKxx-4 Less than 3.0 Vdc isnormal when zonetemperature isabove setpoint.

Verify that Vac voltage across output of all SSR’s inthis heater control circuit is at line potential (230 Vac).If test fails, replace SSR.

NKxx-1 NKxx-2 Normal reading isline voltage.

NOTE: If an SSR isnot shorted, thisreading would be 0VAC for all SSR’sused for that heater.

Troubleshooting6-20


107 144DIssued 3/99

Manual 41-190



(Nominal)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5. Diagnosing DC Motor Controller Problems for Gear-to-Line SystemsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify receiving 230 Vac. If not receiving power, tracepower wires back (using schematic) to determinewhere power is being lost.


AP5-J2-5


AP5-J2-6


230 Vac


Verify motor controller is receiving RUN signal. If it isnot receiving signal, go to Diagnosing Heater ControlProblems on the Interface Board or Main Board tofurther diagnose the problem to the main board or theinterface board. The motor on/off control signal worksexactly like one of the heater control signals.


AP5-J3-14


AP5-J3-15


0 Vdc


Verify motor controller is receiving valid speedcommand


AP5-J4-16


AP5-J4-17


Will vary from 0 toapproximately 8.5Vdc, depending onpercentage speedset on front panel


Verify motor controller is supplying high voltage toDC motor


AP5-J2-3


AP5-J2-4


Will vary from 0 Vdcto 180 Vdcdepending onpercentage speedset on the frontpanel

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Verify motor controller is not being current limited.The current limit is factory set to the rated output ofthe motor controller. If current limiting occurs, themotor is trying to draw more current than the motordrive can reliably supply.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ



Red limit alarm LEDon motor driveshould not beilluminated. If it ischeck for adhesivecuring in pump orbinding in themechanical system

Test Measurement Procedures (contd.)



107 144DIssued 3/99

Manual 41-190



(Nominal)


6. Identifying Tripped Emergency Overtemperature Thermostats

NOTE: These measurements must be made while the unit is hot and the overtemperature thermostat is still open.Periodically check to make sure the thermostat is still open by re-connecting all thermostats and looking at the SYSTEM OKlight above the diagnostic displays. If the SYSTEM OK light is still OFF, the thermostat is still open. If the SYSTEM OK lightis back on, you must re-heat the unit until the thermostat opens again, then resume testing thermostats.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

With a voltmeter, measure the voltage across eachthermostat. Work systematically so no thermostatsare skipped. If the zone cools enough to cause thethermostat contacts to close, cycle power andre−heat the unit to reactivate the tripped conditionand provide additional time to check all thermostats.




<1 volt: Contactsclosed, thermostatnot tripped.

>20 volts: Contactsopen, thermostattripped.

1−20 volts: Checkthat voltage supplyis 24 V. If not,check/replacethermostat oradjacent wiring.


7. Diagnosing Heater Control Problems to the Interface Board (AP4) or Main Board (AP2)

NOTE: The following tests assume that the heaters are turned on and the system is set up so that the heater in question isalways being turned on. For example, its set point would need to be at least 50 degrees F above its actual temperature forthe controller to try to turn it on continuously.ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Verify that the 24 Vdc and the 24 Vdc_A indicatorsare illuminated indicating that the system has 24 Vdc(24 Vdc indicator) and that the contactors are turnedon (24 Vdc_A indicator)




24 Vdc indicator andthe 24 Vdc_Aindicator areilluminated


Verify that the indicator on AP4 corresponding to theheater (or motor) in question is illuminated. If it is, theinterface board is faulty (assuming the SSRs havebeen tested as described in Identifying Open Heaterson a Major Zone or Identifying Open Heater on aMinor Zone.)




Heater controlindicator illuminated


Verify the 26 pin and 16 pin (if used) heater controlribbon cables between interface board (AP4-XP27,AP4-XP25) and main board (AP2-XP1, AP2-XP2)are good. Replace if bad.





Verify that the main board is trying to turn on theheater (or motor). If the ribbon cables tested goodand the main board is not trying to turn on the heater,then replace the main board.


Wire #219 on thecontroller powersupply, GS1 or the+5 Vdc test point onthe interface board


Heater control testpoint on theinterface board forthe heater inquestion


0 Vdc: heatercontrolled OFF

+5 Vdc: heatercontrolled ON


8. Diagnosing Motor Overload Relay Problems

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Remove wires from contact points and measureresistance. If resistance is infinite, the relay is openand the visual indicator is faulty. A faulty indicator willnot prevent the unit from operating normally. Ifresistance is ohms, the relay is not open. Makesure that both ends of all wire connections feedinginto the relay contacts (KL1−95, −96, −97, and −98)are securely attached.


KL1−95


KL1−96


Infinite resistance:open relay

ohms resistance:closed relay

Troubleshooting6-22


107 144DIssued 3/99

Manual 41-190

Use the following figures to locate and identify board indicators.

4756224

+

+++

+

+

+

++

++

+

++

+

++

1

2

3

4

5

7

6

Fig. 6-1 Main Board Indicator Status When Illuminated

1. AC power is applied to the heaters and motor circuits (DS6)2. 24 Vdc power supply is operational (DS5)3. Software programmable for level sensing calibration (DS4)4. Watchdog timer fault has occurred (DS3)

5. Ground fault has occurred (DS1)6. System reset has occurred (DS2)7. No emergency thermostats have tripped (DS7)

3. Indicators andConnectors

Main Board Indicators



107 144DIssued 3/99

Manual 41-190

4756253

+

+++

+

+

+

++

++

+

++

+

++

XP

1X

P2

XP

3

XP

6

Fig. 6-2 Main Board Connectors

Main Board Connectors

Troubleshooting6-24


107 144DIssued 3/99

Manual 41-190

Use the following figure to locate the control input indicators and testpoints.

4756474

(Hop

per

Hea

ter)

CH

1

(Grid

) C

H 2

(Res

ervo

ir) C

H 3

(Man

ifold

1)

CH

4

(Hos

e 1)

CH

5

(Gun

1)

CH

6

(Hos

e 2)

CH

7

(Gun

2)

CH

8

Unu

sed

CH

22

(Hos

e 3)

CH

9

(Gun

3)

CH

10

(Mot

or 1

ON

/OF

F)

CH

23

D1

D2

D3

D4

D5

D6

D7

D8

D9

D10

D11

D12+5V

DC

+5V

DC

INDICATORTP

TP

D33

D34

D35

D36

D29

D30

D31

D32

D25

D26

D27

D28

+5VDC

+5VDC

CH 19 Unused

CH 20 Unused

CH 21 Unused

CH 24 Unused

CH 15 Unused

CH 16 Unused

CH 17 Unused

CH 18 Unused

CH 11 (Hose 4)

CH 14 (Hose 6)

CH 12 (Gun 4)

CH 13 (Hose 5)

INDICATOR

TP

Fig. 6-3 Control Input Indicators and Test Points (Channel is energized when indicator is illuminated.)

Interface Board Indicators



107 144DIssued 3/99

Manual 41-190

Use the following figure to locate the motor drive speed control andsystem control voltage indicators and test points. Motor drive speedcontrol is not used on gear-to-line units.

4756394

+12V

D53

D64

−12V

12V COM

Motor Drive Speed Control

INDICATOR TP

TPINDICATOR

D50 D49

V C

OMINDICATOR

System Control Voltage

INDICATOR

Fig. 6-4 Motor Drive and System Control Indicators and Test Points (Channel is energized when indicator is illuminated.)

Troubleshooting6-26


107 144DIssued 3/99

Manual 41-190

Use the following figure to locate the relay coil indicators and test points.

4756395

K4 COIL K12 COIL K8 COIL K10 COIL K9 COIL K11 COIL K14 COIL K15 COIL K13 COIL K5 COIL K6 COIL K7 COIL

INDICATOR

TP

D68 D93 D76 D83 D79 D86 D101 D97 D70 D69 D74

K2

CO

IL

K1

CO

IL

D55

D51K3 COIL

D57INDICATOR

TPINDICATORTP

TP

INDICATOR

D109

Fig. 6-5 Relay Coil Indicators and Test Points (Channel is energized when indicator is illuminated.)

Interface Board Indicators (contd.)



107 144DIssued 3/99

Manual 41-190

Use the following figure to locate fuses and terminal blocks on theinterface board.

4756526

XP32

XP31

XP

15

XP

14

XP26

XP

18

XP

19

XP

6

XP

7

XP16

XP17

XP20

XP21

XP22

XP23

FU9

XP

25X

P35

XP

27

XP61

XP62

XP59

XP60

XP57

XP58

XP56XP53

XP54

XP51

XP52

FU

1

FU

2

FU

17

XP3

XP2

29

30XP

1

Fig. 6-6 Terminal Blocks and Fuses

Interface Board TerminalBlocks and Fuses

Troubleshooting6-28


107 144DIssued 3/99

Manual 41-190

4103413

77 93 110 127 143 160 177 193 210 227 243 260

400

380

360

340

320

300

280

260

240

220

200

180

160

170 200 230 260 290 320 350 380 410 440 470 500

RE

SIS

TAN

CE

(O

HM

S)

TEMPERATURE (DEGREES F)

TEMPERATURE (DEGREES C)

MAX

MIN

Fig. 6-7 Reservoir, Grid, Hopper, Manifold RTD Resistance vs. Temperature

RTD Resistance vs.Temperature Charts



107 144DIssued 3/99

Manual 41-190

4103412

77 99 121 143 166 188 210 232360

340

320

300

280

260

240

220

200

180

160

170 210 250 290 330 370 410 450

RE

SIS

TAN

CE

(O

HM

S)

TEMPERATURE (DEGREES F)

TEMPERATURE (DEGREES C)

MAX

MIN

Fig. 6-8 Hose RTD Resistance vs. Temperature

Troubleshooting6-30


107 144DIssued 3/99

Manual 41-190

4904180

260

250

240

230

220

210

200

190

180

170170 180 190 200 210 220 230 240 250 260 270 280 290 300 310

GUN RTD RESISTANCE VS. TEMPERATURER

TD

RE

SIS

TAN

CE

(O

HM

S)

TEMPERATURE (DEGREES F)RANGE: 170−310 DEGREES F

MaxMin

Fig. 6-9 Gun RTD Resistance vs. Temperature

RTD Resistance vs.Temperature Charts (contd.)



107 144DIssued 3/99

Manual 41-190

The following pages contain wiring diagrams and schematics for yourFM-190 processor.

MO

TO

R S

ET

PO

INT

DISABLE

ENABLE

MECHANICAL COUPLING

MOTOR CONTROLLER

IN OUT

RUNUP AUTO/MANUAL MODE

EXTERNAL

FE

ED

BA

CK

KA5

CONTROLDENSITY

PCAPCAPCAINTERFACEMAINLED/DISPLAY

AUTORUNUP

RUNUP

PRESSURE XDUCERCURRENT TO

COM

NO

NC

INPUTLINE SPEED

GAS/AIR PATH

MANIFOLD

ANALOG I/O

ADHESIVE PATH

ELECTRICAL PATH

PUMP

LOW GAS PRESSURE DETECT

GA

S C

YLI

ND

ER

(SA3)

(SA1)

(HL4)

POTENTIOMETERMANUAL RUNUP

GAS ON/OFF

MODE LAMPRUNUP AUTO

4−20mA

0−10 VOLTS

SHOP AIR

MO

TO

R O

N/O

FF

SP

EE

D S

ET

PO

INT

(H/W)

(LAMP TEST)LAMP CONTROLGAS FLOW

LAMP CONTROLGAS FLOW

24VDC

MO

TO

R O

N/O

FF

PANELMEMBRANE LEGEND:

LAMP TEST

(HL7)LAMP

GAS LOW

(HL6)GAS ON LAMP

(SA2)PURGE MODE

(HL5)LAMP

PURGE

(HL8)LAMP

GAS FLOW

REGULATORPRESSURE

SWITCHPRESSURE

GAUGEPANEL

VALVEREEDEX

VALVECHECK

CONTROLVALVE

PRESSURE

RESERVOIR

HOSES AND GUNS

MOTOR

KA1 / KA2

COM

NO

NC

KA4

COM

NO

NC

KA3

COM

NO

NC

KA6

COM

NO

NC

GAS FLOW CONTROL

24V

DC

GAS FLOWENABLE

4904092

*

*

* FOR GEAR TO LINE PROCESSORS ONLY

Fig. 6-10 System Logic Diagram

4. FM-190 ProcessorSchematics

Troubleshooting6-32


107 144DIssued 3/99

Manual 41-190

XT8−24

1

AP6−J1−2

22

2. DASH−DOT−DASH LINES ( ) DENOTE

1

1

2

2

2

KM312A

12A

1KM1

50A5

1

5

XT8−6 XT8−5

2

2

10

11

9

17

16

152

6

2

6

4

88+

87−

NK131

3

115V

0VESS

XT3−3

N

6

4

2

1

( )

55

54

FU6

FU5

5

1KM2

50AFU1

50AFU4

50AFU3

FU2

L3

L2

L1

1

1

2

3TA3

TA2

52 5350 51

48A

P2−

XP

9−3

AP

2−X

P9−

449

AP

2−X

P9−

1

AP

2−X

P9−

2

AP

2−X

P10−

1

AP

2−X

P10−

2

2

3

XT3−1

XT3−2

200A:1ATA1

QS1 100ASWITCH

DISCONNECT

TRANSFORMER

0V

18V

18V

0V

18

0V100V115V

100V

20

19

FU11

10A

2223(+)

23

VC

(−)

562

RECTIFIER

AP2-XP15-1

AP2-XP15-2

TC1

61

22

61

VC1BRIDGE

XT8−12 XT8−11

+ −

+ −

+ −

RE

D

BLK

RE

D

BLK

18

19

1 2

1

1

2

1

5

62

XP

1

24VDC COMMON

UNREGULATED +24VDC

1 XP

2

1

4

4

1 XP61

XP6214

4 11

HOSE #5HOSE #6

XT8−16 XT8−15

1

2

2

11

33

3

3

1

2

2

3

1

7

8

6

14

13

12

7 6 4

46

125A

36

FU

20

2

FU

21

7 46

47

12NK1489

5A37

90

5

0V

56 24VSUPPLYPOWER

GS2

24VN

L1

21

2

FU

9

11

FU

103

XT55

55

5

XT2 5

CHASSISGROUND

AP

5−J2−

7

55 0V

54 5V POWERSUPPLY

GS3

5V

L1

55KA2−2

AP6−J1−4

R2−2 18

19

19

18

18

19

19

5

19

18

18

19

18

18

1918

18

19

19

5

5

MOTOR12V

5

XT7−1

1. DASHED LINES ( ) DENOTE COMPONENTS THAT CAN BE CONNECTED TO THE FM190 UNIT BUT ARE NOT PART OF THE UNIT, IE: HOSES.

PHYSICAL GROUPING OF ELECTRICAL COM− PONENTS, IE: SWITCHES.

3. THICK LINES ( ) DENOTE BUSBAR CONNECTIONS OF CONDUCTORS.

NOTES:

2

6

55

SEE SHT 6

5 13 5 13

X5X6

1313

XT3

12A

12A

PE

55

1212

XT9−9

XT9−9

XT9−10

XT9−10

(XT10)

(XT10)

22

61 10

9

8

75

1

3

XT7−2

XT7−3

XT7−4

XT7−5

XT7−6

XT7−7

XT7−8

XT7−9

21

21

240V, 3 WIRE

4904081

( )

GROUND FAULTCURRENT

TRANSFORMER

XP

3

XP59

XP60

4

+

− 1

3 2

A

B

C

D

E

FG

H

I

61

6

6

5AFU1

FU17

5

1

FU26

59

58

1

5V

18L2/N195

B

12V L1

60

5859

55

57

A12V55

55

1

XT6-3

XT6-2

5A

XT6-7

60

60

FU24

2

- OUT

- SENSE

+ SENSE

- SENSE

+ SENSE

+ OUT

- SENSE

- OUT

+ OUT

- OUT

+ SENSE

GS1

POWER

55

+ OUT

AP3-X1A-1

219

AP6-J1-1

AP2-XP17-1

218

220

582 1A

XT6-5

5555

2 1A

FU255755

SUPPLY

CONTROLLER

AP2-XP17-5AP2-XP17-4


AP3-X1A-2

AP6-J1-3

219

21960

55

220

218

5522055

(ON

LY W

/GT

L)

16

17

XT8−23

MOTORDRIVE

DENSITYCONTROLLER

Fig. 6-11 Sheet 1 Input Power and Heat Zone Switching for 240 V Processors



107 144DIssued 3/99

Manual 41-190

4904082

4

+

− 1

3 2

NK5714

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

HEATER HEATER

4

+

− 1

3 2

4

+

− 1

3 2

NK6

X1

73

74 72

GUN #113

HOSE #1

29

13

28

GUN #4 HOSE #4

XT8−11

XT8−5

XT8−10

XT8−4

XT8−10

XT8−4

XT8−9 XT8−8 XT8−8

12 12

XT8−9

XT8−3

(INTERFACE BOARD)(CONTINUED ON SHEETS 2 & 3)

AP4

9XP31 1XP32 1 9

4

4

XP571

1 XP584 1 XP56 4

4

7874 727773 7176 66

XP53

XP541

1 4

75

4

70 65 69 64 68XP511

1 XP5263 67

XT8−7

GUN #2 HOSE #2GUN #3 HOSE #3

7980818286 85 8384 87888990

XT8−1XT8−2XT8−2XT8−3

5A

FU

12

38

XT8−15 XT8−14 XT8−14

FU

13

395

15HOPPER

15

64

24

NK163 14

GRID

66

25

65 NK2 14

XT8−17 XT8−18

XT8−21XT8−20

15

RESERVOIR

26

XT8−22

NK367

68

14

XT8−19

15

MANIFOLD

27

XT8−22

NK469

70

14

XT8−19

HEATER

HEATER

4627 1

5A

7 12 6 4

3112NK8

77

78

75NK7

FU

155A

76

FU

145A

3012

84

83NK1285 12

86

5A

FU

19

35 3312NK11 12 NK10

81

5A34

FU

18

82

79 NK9

FU

175A

80

FU

165A

3212

13

12

14

15

EH1 EH3

EH4

EH6

X2

5 13 41 13 40

12121212

1313

55

13

5 13 45 13 44 5 13 43 13 42

46127X4

46127X3

13131313

12 12 12 12

55

15 15 15 15

24 25 26 27

14 14 14 14

XT9−1

XT9−1

XT9−2

XT9−2

XT9−3

XT9−3

XT9−4

XT9−4

XT9−5

XT9−5

XT9−6

XT9−6

XT9−7

XT9−7

XT9−8

XT9−8

5 13

122

1

21

211

221

21

21

EH2

EH5

A

B

C

D

E

FG

H

I

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

XT

8−13

XT16−3 XT16−1

Troubleshooting6-34


107 144DIssued 3/99

Manual 41-190

4904083

55

XP

2XT7−8

2

2

1

4

4

1

KM3

12A

1

KM1

5

XT8−6 XT8−5

2

211 17

2

6

4

88+

87−

NK131

3

XT3−3

N

55

54

FU6

1

KM2

50A

FU1

50A

FU3

L3

L2

L1

1

1

2

3

TA3

TA2

52 5350 51

48A

P2−

XP

9−3

AP

2−X

P9−

449

AP

2−X

P9−

1

AP

2−X

P9−

2

AP

2−X

P10−

1

AP

2−X

P10−

2

2

3

XT3−1

XT3−2

200A:1ATA1

QS1 100ASWITCH

DISCONNECT

XT8−12 XT8−11

+ −

+ −

+ −

RE

D

BLK

RE

D

BLK

1 2

1

HOSE #5HOSE #6

XT8−16 XT8−15

33

3

1

2 8

6

14

7 6 4

46

125A

36

FU

20

2

FU

21

7 46

47

12NK1489

5A37

90

5

0V

56 24VSUPPLYPOWER

GS2

24VN

L1

21

FU

103XT5

555

5

XT25

CHASSISGROUND

AP

5−J2−

7

55 0V

54 5V POWERSUPPLY

GS3

5V

L1

55KA2−2

AP6−J1−4

R1−2AP6−J1−2

18

19

19

18

18

19

19

5

19

18

18

19

419

4

4

19

19

5

5

XT7−1

55

SEE SHT 6

5 13 5 13

X5X6

1313

XT3

12A

PE

55

1212

XT9−9

XT9−9

XT9−10

XT9−10

(XT10)

(XT10)

XT7−2

XT7−3

XT7−4

XT7−5

XT7−6

XT7−7

XT7−9

21

21

400V, 4 WIRE

GROUND FAULTCURRENT

TRANSFORMER

4

+

− 1

3 2

AB

C

D

E

FG

H

I

XT44

XT1N 4

4

22

2. DASH−DOT−DASH LINES ( ) DENOTE

115V

0VESS

6

4

2

1

( )

TRANSFORMER

0V

18V

18V

0V

18

0V100V115V

100V

20

19

FU11

10A

2223(+)

23

VC

(−)

562

RECTIFIER

AP2−XP15−1

AP2−XP15−2

TC1

61

22

61

VC1BRIDGE

18

19

2

1

5

62

XP

1

24VDC COMMON

UNREGULATED +24VDC

1

1

4

4

1 XP61

XP6214

4 11

MOTOR12V

5

1. DASHED LINES ( ) DENOTE COMPONENTS THAT CAN BE CONNECTED TO THE FM190 UNIT BUT ARE NOT PART OF THE UNIT, IE: HOSES.

PHYSICAL GROUPING OF ELECTRICAL COM− PONENTS, IE: SWITCHES.

3. THICK LINES ( ) DENOTE BUSBAR CONNECTIONS OF CONDUCTORS.

NOTES:

22

61 10

9

8

75

1

3

( )

XP

3

XP59

XP60

61

66

5AFU1

FU17

5

5

1

FU26

59

58

1

5V

18L2/N195

B

12V L1

60

5859

55

57

A12V55

55

1

XT6-3

XT6-2

5A

XT6-7

60

60

FU24

2

- OUT

- SENSE

+ SENSE

- SENSE

+ SENSE

+ OUT

- SENSE

- OUT

+ OUT

- OUT

+ SENSE

GS1

POWER

55

+ OUT

AP3-X1A-1

219

AP6-J1-1

AP2-XP17-1

218

220

582 1A

XT6-5

5555

2 1A

FU25 5755SUPPLY

CONTROLLER



AP3-X1A-2

AP6-J1-3

219

21960

55

220

218

55220

(ON

LY W

/GT

L)

12

XT8−2317

16

XT8−24

MOTORDRIVE

17

4

DENSITYCONTROLLER

Fig. 6-12 Sheet 2 Input Power and Heat Zone Switching for 400 V Processors



107 144DIssued 3/99

Manual 41-190

4904084

4

+

− 1

3 2

NK5714

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

HEATER HEATER

4

+

− 1

3 2

4

+

− 1

3 2

NK6

X1

73

74 72

GUN #1

13

HOSE #1

29

13

28

GUN #4 HOSE #4

XT8−11

XT8−5

XT8−10

XT8−4

XT8−10

XT8−4

XT8−9 XT8−8 XT8−8

12 12

XT8−9

XT8−3

(INTERFACE BOARD)(CONTINUED ON SHEETS 2 & 3)

AP4

9XP31 1XP32 1 9

4

4

XP5711 XP58

4 1 XP56 4

4

7874 727773 7176 66

XP53

XP5411 4

75

4

70 65 69 64 68

XP5111 XP52

63 67

XT8−7

GUN #2 HOSE #2GUN #3 HOSE #3

7980818286 85 8384 87888990

XT8−1XT8−2XT8−2XT8−3

5AF

U12

38

XT8−15 XT8−14 XT8−14

FU

13

395

15

HOPPER

15

64

24

NK163 14

GRID

66

25

65 NK2 14

XT8−17 XT8−18

XT8−21XT8−20

15

RESERVOIR

26

XT8−22

NK367

68

14

XT8−19

15

MANIFOLD

27

XT8−22

NK469

70

14

XT8−19

HEATER

HEATER

4627 1

5A

7 12 6 4

3112NK8

77

78

75NK7

FU

155A

76

FU

145A

3012

84

83NK1285 12

86

5AF

U19

35 3312NK11 12 NK10

81

5A34

FU

18

82

79 NK9

FU

175A

80

FU

165A

3212

4

12

14

EH1 EH3

EH4

EH6

X2

5 13 41 13 40

12121212

1313

55

13

5 13 45 13 44 5 13 43 13 42

46127X4

46127X3

13131313

12 12 12 12

55

15 15 15 15

27

14 14 14 14XT9−1

XT9−1

XT9−2

XT9−2

XT9−3

XT9−3

XT9−4

XT9−4

XT9−5

XT9−5

XT9−6

XT9−6

XT9−7

XT9−7

XT9−8

XT9−8

5 13

122

1

21

211

221

21

21

EH2

EH5

AB

C

D

E

FG

H

I

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

4

+

− 1

3 2

XT

8−18

4

XT16−3 XT16−1

Troubleshooting6-36


107 144DIssued 3/99

Manual 41-190

4904087

HL11

108

L2 C

UR

RE

NT

TR

AN

SF

OR

ME

R

SB1

X1 X1A

X3

X2A

X2

HL3 REDFAULT

HL2 AMBERWARNING

HL1 GRNREADY

+ MOTOR #1− SPEED

XP6 XP3 XP5 XP1

XP

18X

P17

XP

15X

P4

XP7

XP11

XP14 XP13

−+

5VDC COMMON

+5VDC

−12VDC12VDC COMMON+12VDC

(18VAC)

WARNINGHL10AMBER

READYHL9GRN

FAULTRED

SIRENBELL

9192

1

TC1−8

22TC1−761

GSI−5(−)OUT

220

11

GSI−5(+)OUT

55GSI−(−)12(−)OUT 218

GSI−(−)12(−)OUT

219

GSI−(+)12(+)OUT

60

1 FLASHMEMORYSUPPLY

123

124

125

126

11

XP24 XP25 XP26

3

1

11

SPARE ANALOGINPUTS

ME

MB

RA

NE

TO

WE

RP

AN

EL

939495969798

1

107

11

108109110

1

11

AP3

(LED BD)

111

112

219

60

111AP4−XP29−2112

219FU24−2 (5V+)60XT6−2 (5V−)

AP4−XP29−1

121122

SUPERVISOR

1XP27

+ − + −

AP1(CPU MODULE)

GAS LOW PRESSURE

HL7

24V

DC

CO

MM

ON

+24

VD

C

+5V

DC

5VD

C C

OM

MO

N

J3

XP8

XP12

J2

ALTERNATE

11

X4D

X4C

X4B

KEY LOCK

XP10

10V

RE

F

L1 C

UR

RE

NT

TR

AN

SF

OR

ME

R

GR

OU

ND

FA

ULT

SE

NS

E

LOA

D L

EV

EL

+

LOA

D L

EV

EL −

11

ANALOG COM.

XP9

TA3

(+)

TA2

(+)

TA3

(−)

TA2

(−)

TA1

(+)

TA1

(−)

52 5048 53 5149

(INTERFACE BOARD)(CONTINUED ON SHEET 1,2 & 4)

AP4

(MAIN BD)

AP2

RIBBON RIBBON2

RIBBON1

RUN−UP AUTO MODEHL4

HL5PURGE MODE

GAS ONHL6

1

POWER FAILWARNING

99100101102103104105106

120

119

118

117

116

115

114

113

105 106

103 104

10210110099

RUN−UP AUTO MODE

PURGE MODE

GAS ON

GAS LOW PRESSURE

1−31−4

21

XP

22X

P31

50 PIN 34 PIN 26 PIN

127

128

129

130

131

132

133

HA1 HA2

107 110

109107

107

120

117

119

118

116115

114113

127

129

128

130

132

131

133

1−31−4

1−3 1−4

SA1

SA2

SP1

SA3

X4A

BOARD TO BOARDINTERCONNECT

II I :

I I I :

I I I :

I I I :X12 1

2

3

4

XP2

XP35

RIBBON4

16 PIN

MOTOR DRIVE

(GTL)

Fig. 6-13 Sheet 3 Lamp and Control Wiring



107 144DIssued 3/99

Manual 41-190

4904085

XP23

RUN UPAUTO MODE

176

124

217

158

159

160

161

24 1

11

XP22

DISABLE

(INTERFACE BOARD)AP4

(CONTINUED ON SHEETS 1,2 & 3)

11 XP14

XP1514

14

177

169

168

A1 A2

KM1

A1 A2

KM2

170

171

172

173

A1 A2

KM3

24V

DC

MA

JOR

ZO

NE

CO

NTA

CT

OR

CO

NT

RO

L

157

156

155

154

153

152

151

150

149

148

147

146

145

144

143

142

167

24V

DC

165

ST1

164

XT15−1

165

ST3ST2

166

166

XT15−4

167

THERMOSTAT

140

141

139

138

136

137

135

134

GUN−4

ot ot

HOSE−4

to ot

HOSE−3GUN−3 GUN−2

ot to

HOSE−2

to ot

GUN−1 HOSE−1

ot

HOSE−5

to

HOSE−6

to

RT1HOPPER

t

RT2GRID

ot

RESERVOIRRT3

o

RT4MANIFOLD

to

(RES.) (GRID) (HOPPER)

TO

CO

NT

RO

LLE

R

TO

CO

NT

RO

LLE

R

TO

CO

NT

RO

LLE

R

1

24V

TO

CO

NT

RO

LLE

R

TO

CO

NT

RO

LLE

R

TO

CO

NT

RO

LLE

R

12 XP28

NO CONNECTIONS PERMITTED

8935

9 8 9 8X4

89X3

35 89X2

35 5 3 9 8X1

RTD’S

164

167

XT15−2 XT15−3

ON XP14, XP15 AND XP28IN THIS UNIT. KA2

5 1

177

176

MAJORZONE

MINORZONE

MOTORDRIVER

172

173

170

171

168

169

X5X6

161

160

159

158

134

135

136

137

138

139

140

141

142

147

149

148

146

145

144

143

156

157

155

154

153

151

152

150

5 1

176 KA1

177

(XT11)

24V

XT

15−

13

XT

15−

12

XT

15−

11

XT

15−

10

XT

15−

9

XT

15−

8

XT

15−

7

XT

15−

6

A

RUN PERMISSIVE

(E−STOP)JUMPER

ZONE 12 ZONE 11 ZONE 10 ZONE 9 ZONE 8 ZONE 7 ZONE 6 ZONE 5ZONE 4 ZONE 3 ZONE 2 ZONE 1

ZONE 14 ZONE 13

95 96

217

KL1

Fig. 6-14 Sheet 4 RTD, Thermostat, and Relay Control Wiring

Troubleshooting6-38


107 144DIssued 3/99

Manual 41-190

4904086

XP29 9 1XP209 1XP21

XP1616XP1716

XP191 XP18

12424

187

186

11

66 XP7

XP6

178

180

175

181

1616

184

221

MOTOR #1ON/OFF

MOTOR #2ON/OFF

ON/OFFMOTOR DRIVER

24V

DC

DENSITYCONTROLLER

ENABLE

GASFLOWDIAG.

5

KA5

1

174

179

RUN

DISABLEUP

5 1

KA3

1

111

112

AP

3−X

1−3

AP

3−X

1−1

AP

6−J8−

3

AP

6−J8−

2

182

183

TO

CO

NT

RO

LLE

R

REMOTEREADY OUT

RM

T H

TR

OF

F (

+)

RM

T O

FF

(−

)

RM

T O

N (

+)

RM

T H

TR

ON

(−

)

FAULT OUTREMOTE

REMOTEWARNING OUT

0.5A

24VDC COMMON

24VDC UNREGULATEDF4

CUSTOMER CONNECTION

24VDC

111

112

0V

24V

DC

24V

DC

0V

XP301

162

163

SE

E D

EN

SIT

Y C

ON

TR

OLL

ER

SC

HE

MA

TIC

SH

EE

T 8

ALARMPRESSURE

LOW

182

183

184

185

179

178

180

181

174

175

(AP6)(XT11) (XT11)

(XT11)

24V

24V

24V

KA6

5 1

A

222

222

221

DISPLAYRPM

(AP7)(NON GTL)

185

FU

16

3A

STANDARD I/O

98 97

KL1 (FOR AP5 OR AP8)

22



107 144DIssued 3/99

Manual 41-190

4904088

XT6-9XT6-11

198

AP4-XP18-15

AP4-XP18-14

10

13

15

16

14

12

11

3

8

9

7

5

6

4

2

1

XT8-23

15

18

17

16

17

192

191

J2

AP5CONTROLLER

MOTOR

13

14

12

11

9

10

8

7

4

6

5

2

3

1

J4

16

15

MOTOR

PICKUP

X8

A1(+) A2(-)M1

BR1

MOTOR SPEED

J1

12

13

14

10

11

184

9

8

7

6199

1

3

5

4

2

198

J3193

5

184

185

195

196

KEY PAD LOCKOUT

202

AP2-XP4-1

AP2-XP4-292

91

203

92

17

3 4 2 1

191

192

191

192

191

192

XT8-2416 16

MOTOR OTST4

THERMOSTAT

#1

AP6-J15-1

AP6-J15-2

189

MTR SP REF INPUT +

MTR SP REF INPUT -

AUTO PRESSURE CONTROL -

AUTO PRESSURE CONTROL +

6 4 2

135 9897

9695 FOR WIRING

SEE SHEETNO. 4 OF 7AT LOCATIONA2 & A8

KL1

191

CHASSISGROUND

X7

2

1

3BLACK

RED

WHITE

3

7

5

6

4

2

1

190

CHASSISGROUND

199

190

198

190

198

XT6-8XT6-10

199

190

190

198

5

AP5CHASSIS

198

AB

D

E

C

190

Fig. 6-15 Sheet 5 Motor Controller Wiring

Troubleshooting6-40


107 144DIssued 3/99

Manual 41-190

4904089

2063

24 2

4

3

24

207

208

KA220520454

GS3 − 5V

92

203

GS3 − 0V

55

55

54

KA1

KA3

100MA.+12VDC (100MA. MAX.)

SIGNAL

GROUND

SHIELD

F2321 XT12−2194

XT12−3

XT12−4

XT12−5

XT12−1

CW

BP2

21

208

207

X9

2 3

1W 2K

BLACK

WHITE

I/P TRANSDUCER

EXTERNAL LINESPEED INPUT

(CUSTOMER SUPPLIED)

RUN UP DISABLEAUTO/MANUALRUN UP SELECTION

AUTO/MANUALRUN UP SELECTION

(5VDC)

R2 R1

ABC

D

E

197

CHASSISGROUND

(XT11)



107 144DIssued 3/99

Manual 41-190

4904114

A2

A1TB2

1617

AP6−J15−1

KL1

12

3

5

4

6

AT

LO

CA

TIO

NN

O. 4

OF

7S

EE

SH

EE

TF

OR

WIR

ING

9698 97 95

A2

& A

8

43

X8

21

THERMOSTATMOTOR OT

A2(−)

ST4

A1(+)M1

192

MOTOR

191

#1

192

191

191 192

192

191

192

186

187

164

217

RUN UP SELECTIONAUTO/MANUAL

KA2

206

GS3 − 5V

R21W

CW

54 2

(5VDC)

55

54

GS3 − 0V

3

55

2

204

2K

3R1

RUN UP SELECTION

205

4

2

3

AUTO/MANUALKA1

4

2082

I/P TRANSDUCER

WHITE208

(XT11)

RUN UP DISABLE

2

4 207 1

KA3

BP2

BLACK207

XT8−24XT8−23

92

91

184

185

AP2−XP4−2

AP2−XP4−1

AP4−XP18−14

AP4−XP18−15

AP8MOTOR DRIVE

L1L2TB1

F1F2

2

1

4

3

5

TB3

6

BR1

ENCODERSPEEDMOTOR

BLACK

RED

WHITE

3

1

2 198

190

199

AP6−J15−2

190

198

X7

1

2

3

6

7

8

(−)

(+)

GND

COM

Acc +

SIG A

198

190

XT6−11 XT6−9 XT6−8 XT6−10199

190

198198

190

CHASSISGROUND

CHASSISGROUND

AP4−XP18−16

AP4−XP18−13DISPLAY

AP7RPM

�

CHASSISGROUND

AP9 SPEED

ON/OFF

−

+FERRITECOREC1

C2

1 2

X9

5

GNDSTUD

NOTE:ALL TERMINALS OF TB3 ARE ATPOWER LINE POTENTIAL.

5

Fig. 6-16 Sheet 6 Standard Motor Controller

Troubleshooting6-42


107 144DIssued 3/99

Manual 41-190

4904090

AP

4−X

P18−

12

AP

4−X

P18−

1118

2

1

183

2 3

FU25−2 (+12)

XT6−5

4

10

7

5 6

8

11

9

12

J8

1 J1

XT

6−9

XT

6−8

198

190

BLA

CK

RE

DW

HIT

E

J4

MODULE

DISPLAY

PRESSURE

AP6

J15J16 J7 J6 J5 J3

209

210

211

GS3−5V+

GS3−0V55

55

54

220

1 1

BP1

1

LOWPRESSURE

ALARM

3

X10

PRESSURESENSOR

ADHESIVE

CHASSISGROUND

FERRITECORE

5

MOTORSPEEDPICKUP 2

Fig. 6-17 Pressure Display



107 144DIssued 3/99

Manual 41-190

4904091

KA5KA4

LAMPTESTRELAY

GAS FLOW LAMP

HL8

(24VDC COM)AP4-XP30-2

162

3

216

1

2

216

4

163

163

(24VDC)AP4-XP30-1

DENSITY CONTROLLER

BP3

XT15-5

214

2

1

A

K

1

5

SP2REDEXVALVE

KA4 V1(XT11)

214

213

213

213

214 214

5621

2

2

(XT11)

2

F22

1

ENABLECONTROLLERDENSITY

3

KA64

100M

A

(24VDC)GS2 V+

RELAYFLOWGAS

2

3

24

Fig. 6-18 Sheet 8 Density Controller

Troubleshooting6-44


107 144DIssued 3/99

Manual 41-190

4904113

Fig. 6-19 Component Map Label



107 144DIssued 3/99

Manual 41-190


Board and module ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁAP1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁCPU Board (Proset)


AP2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Main Board (Proset)



LED Board (Proset)



Interface Board (Proset)



Motor Drive (M-Drive with I/O option; for gear-to-line units only)



Adhesive Pressure Display



RPM Display (for standard units only)



Motor Drive (for standard units only)



Capacitor Assembly (for standard units only)ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁTerminal BlockÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁXT1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDirect Neutral connection by userÁÁÁÁÁÁ

ÁÁÁÁÁÁXT2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁDirect PE connection by userÁÁÁÁÁÁ

ÁÁÁÁÁÁXT3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁL1, 2, 3 distribution blockÁÁÁÁÁÁ

ÁÁÁÁÁÁXT4


Neutral distribution blockÁÁÁÁÁÁÁÁÁÁÁÁ

XT5ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

PE distribution blockÁÁÁÁÁÁÁÁÁÁÁÁ


Major zone distribution blockÁÁÁÁÁÁÁÁÁÁÁÁ


Control AC power distribution blockÁÁÁÁÁÁÁÁÁÁÁÁ

XT8 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Minor zone distribution blockÁÁÁÁÁÁÁÁÁÁÁÁ


Minor zone fuseÁÁÁÁÁÁÁÁÁÁÁÁ


Power supplies GS2 and GS3ÁÁÁÁÁÁÁÁÁÁÁÁ


Relays and fusesÁÁÁÁÁÁÁÁÁÁÁÁ


Customer encoder connection (for gear-to-line units only)ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁSensors and Transducers


SP2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reedex valveÁÁÁÁÁÁÁÁÁÁÁÁ


5. Component Map Legend

Troubleshooting6-46


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Fuses ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁFU1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMajor zone in 240 V, 400 V system


FU2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Major zone in 240 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Minor zone in 240 V, 400 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Minor zone in 240 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Motor in 240 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Motor in 240 V, 400 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Control power in 240 V systemÁÁÁÁÁÁÁÁÁÁÁÁ


Control power in 240 V, 400 V system



24 V secondary transformer


FU12−FU21 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

SSR protection; mounted on XT9



PELV 24 Vdc to Density control logic



12 V to external line; mounted on XT12



+15 V to power supply GS1; mounted on XT6



+12 V to power supply GS1; mounted on XT6


FU26 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ−12 V to power supply GS1; mounted on XT6


Power Supply ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁGS1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ5, +/− 12 Vdc SMPS for control circuit


GS2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

24 V 3W SMPS for PELV


GS3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5 Vdc 7W for AP6 and manual I/P operation



ÁÁÁÁÁÁÁÁÁÁSignaling device ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


HA1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Audible Bell (Warning)


HA2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Audible Siren (Fault)


HL4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Run-up Auto mode Lamp (White) at FM unique panel


HL5 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Purge mode Lamp (White) at FM unique panel

ÁÁÁÁÁÁHL6 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁGas on Lamp (White) at FM unique panelÁÁÁÁÁÁÁÁÁÁÁÁHL7

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁGas Low pressure Lamp (Amber) at FM unique panelÁÁÁÁÁÁ

ÁÁÁÁÁÁHL8ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁGas Flow Lamp (White) at FM unique panelÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5. Component Map Legend(contd.)



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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁContactor and Relay

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁQS1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ100A AC 3 pole main disconnectorÁÁÁÁÁÁ

ÁÁÁÁÁÁKM1


85A AC 3 pole contactor for Major zone heatersÁÁÁÁÁÁÁÁÁÁÁÁ

KM2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

85A AC 3 pole contactor for Minor zone heatersÁÁÁÁÁÁÁÁÁÁÁÁ

KM3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

33A AC 3 pole contactor for Motor driveÁÁÁÁÁÁÁÁÁÁÁÁ

KA1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Run-up Auto/Manual controlÁÁÁÁÁÁÁÁÁÁÁÁ


Run-up Auto/Manual controlÁÁÁÁÁÁÁÁÁÁÁÁ


Run-up DisableÁÁÁÁÁÁÁÁÁÁÁÁ


Gas Flow Lamp drive in DiagÁÁÁÁÁÁÁÁÁÁÁÁ


Gas Flow Lamp drive in hardwareÁÁÁÁÁÁÁÁÁÁÁÁ


Density controller enableÁÁÁÁÁÁÁÁÁÁÁÁ

KL1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Motor Overload RelayÁÁÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁÁÁÁResistors ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


R1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Resistor; mounted on XT11ÁÁÁÁÁÁÁÁÁÁÁÁ

R2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Manual Pressure Control Potentiometer



ÁÁÁÁÁÁÁÁÁÁÁSolid-State Relay ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


NK1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Maximum Load 25A 400 Vac, 24 Vdc control SSR for Hopper



Maximum Load 25A 400 Vac, 24 Vdc control SSR for Grid



Maximum Load 25A 400 Vac, 24 Vdc control SSR for Reserver



Maximum Load 40A 400 Vac, 24 Vdc control SSR for Manifold



Maximum Load 40A 400 Vac, 24 Vdc control SSR for External Hose #1



Maximum Load 25A 400 Vac, 24 Vdc control SSR for External Gun #1













ÁÁÁÁÁÁNK11 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMaximum Load 25A 400 Vac, 24 Vdc control SSR for External Hose #4ÁÁÁÁÁÁÁÁÁÁÁÁNK12

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMaximum Load 25A 400 Vac, 24 Vdc control SSR for External Gun #4ÁÁÁÁÁÁ

ÁÁÁÁÁÁNK13ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMaximum Load 25A 400 Vac, 24 Vdc control SSR for External Hose #5ÁÁÁÁÁÁ

ÁÁÁÁÁÁNK14ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMaximum Load 25A 400 Vac, 24 Vdc control SSR for External Hose #6ÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

5. Component Map Legend(contd.)

Troubleshooting6-48


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Switches ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁSA1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁRun-up auto mode SW at FM unique panel (Momentary push type)


SA2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Purge Mode SW at FM unique panel (Momentary push type)


SA3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Gas on SW at FM unique panel (Momentary push type)


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁTransformersÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


TA1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Ground fault CT 200:1A


TA2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Major zone current 200:1A

ÁÁÁÁÁÁTA3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMinor Zone Current 200:1AÁÁÁÁÁÁÁÁÁÁÁÁTC1

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ400W Single Phase Transformer 200/230 Vac: 18 Vac For 24 VdcÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁSemiconductorsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁVC1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ24 Vdc Bridge rectifierÁÁÁÁÁÁ

ÁÁÁÁÁÁV1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClamp diode; mounted on XT11


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Section 7

Repair

Repair7-0


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Repair 7-1


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Section 7Repair


This section contains instructions for repairing or replacing various partsof the FM-190 unit, including disassembly of the unit in order to gainaccess to a particular component, repair or replacement of thecomponent and reassembly of the unit. Hoses are not field-repairableand are not included here. Extrusion gun procedures are covered in theirown service manuals.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

If the pump is operable, flush the system before disassembly. If thepump is not operable but the heating system is functional, bring the unitto operating temperature to facilitate disassembly. Otherwise, use a heatgun or other flameless heating device to melt solidified hot melt materialon system components.

To disconnect a flexible air line from a quick-disconnect fitting, simplycompress the metal or plastic retaining collar against the fitting, then pullthe flexible tubing away.

Installation is the reverse: compress the retaining collar against the fittingand press the flexible tubing into place. Pull the tubing firmly to ensurethat it is locked in place by the retaining collar.

NOTE: The ends of the tubing should be cut cleanly and squarely toensure a leak-free connection.

1. Introduction

2. General Information

Preparation for HydraulicSystem Repairs

Quick-Disconnect Fittings

Repair7-2


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Before disconnecting the power, you should power down the unit in anorderly fashion, which includes relieving hydraulic pressure, stopping themotor, purging gas lines, and other procedures that may be unique to therepair task you are performing.

Power to your processor is controlled at two locations: the maindisconnect switch on the cabinet door and the input power source (suchas a wall-mounted breaker box).

Many mechanical repairs can be performed after you place the maindisconnect switch in the OFF position. Most electrical repairs require thatyou also disconnect and lock out the input power source that feeds intothe processor.

49041301 2

Fig. 7-1 Power Disconnect

1. Main disconnect switch in OFF position2. Input power source in locked out OFF position

Power Disconnection

Repair 7-3


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The following table lists tasks you should perform after replacing certainunit components. Review this list to ensure you perform necessaryauxiliary tasks.

Table 7-1 Auxiliary Tasks for Replacement Components

Component Auxiliary Tasks

Motor overload relay (KL1) � Ensure that the motor rotatesCCW. You must remove the drivebelt cover to observe the directionof motor rotation. Refer toRemoving the Hopper Enclosureand Unit Cover later in this section.

� Adjust the settings on KL1. Referto Configuring a Replacement KL1Relay later in this section.

Motor speed sensor (BR1) � Adjust the gap between the sensorand the drive belt sprocket. Youmust access the drive beltassembly. Refer to Checking theDrive Belt for Signs of Wear in theMaintenance section for moreinformation.

Resistor R1 or the manualpressure controlpotentiometer (R2)

Power supply (GS3)

� Check the adjustment of R2 toachieve the proper systempressure

Current transformer (TA1) � For 400 V units, ensure that 3wires plus the neutral wire passthrough the center of TA1

� For 240 V units, ensure that 3wires pass through the center ofTA1

Change a major heatingzone, casting or pump

� Check to ensure there are no fluidleaks

Tasks to Perform AfterReplacing MiscellaneousComponents

Repair7-4


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Perform the following procedures to remove the belt cover, hopperenclosure, and unit cover.

WARNING: Hot! Risk of burns. Hot applicator parts andsplashed adhesive can cause severe burns. Wearlong-sleeved, heat-protective clothing, safety goggles, andheat-protective gloves.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power can result in personal injury, death, or equipmentdamage.

1. Disconnect and lockout power.

2. Remove the screws that hold the belt cover to the hopper enclosure.

3. Loosen the four captive screws that secure the hopper enclosure tothe hopper and lift the enclosure off the hopper.

4. Remove and set aside the gasket from the top rim of the hopper.

5. Remove the hopper insulation and set aside.

6. Disconnect any hose cordsets.

7. Loosen the screws that secure the unit cover to the corner enclosureand to the back of the frame.

NOTE: The following step may require two people. The unit cover islarge and may be difficult for one person to lift over the hopper andelectrical plugs.

8. Lift the unit cover off the unit.

9. Remove any insulation and set aside.

Removing the HopperEnclosure and Unit Cover

Repair 7-5


107 144DIssued 3/99

Manual 41-190

4904131

1

2

5

6

7

43

Fig. 7-2 Removing Hopper Enclosure and Unit Cover

1. Screws2. Hopper enclosure3. Truss head screws4. Belt cover

5. Unit cover6. Hose cordsets7. Corner enclosure

Repair7-6


107 144DIssued 3/99

Manual 41-190

Perform the following procedures to replace covers and enclosures.

1. Replace the unit insulation and secure it with tape.

2. Slide the unit cover onto the unit and replace and tighten the screwsthat secure it to the unit.

3. Reconnect any hose cordsets.

4. Replace the gasket on the top rim of the hopper.

5. Replace the hopper insulation and secure it with tape.

6. Slide the hopper enclosure onto the hopper and tighten the fourcaptive screws that secure it to the hopper.

7. Replace and tighten the screws that secure the belt cover to thehopper enclosure. If you removed the belt cover from the unit cover,replace the belt cover and all screws that secure it to the unit.

8. Reconnect power and restore the unit to normal operation (refer toRoutine Operating Procedures in the Operation section).

Replacing the Unit Cover andHopper Enclosure

Repair 7-7


107 144DIssued 3/99

Manual 41-190

4904132

7

2

1

54

6

3

Fig. 7-3 Replacing Hopper Enclosure and Unit Cover

1. Hopper enclosure2. Screws3. Truss head screws4. Belt cover

5. Unit cover6. Hose cordsets7. Truss head screws

Repair7-8


107 144DIssued 3/99

Manual 41-190

Perform the following procedures to remove the corner enclosure foraccess to the grid, reservoir, and manifold.

WARNING: System or material pressurized. Pressure must berelieved. Failure to observe can result in serious burns.

1. Relieve system hydraulic pressure (refer to Relieving SystemHydraulic Pressure in the Maintenance section).


2. Disconnect and lock out power.

WARNING: Hot! Risk of burns. Hot applicator parts andsplashed adhesive can cause severe burns. Wearlong-sleeved, heat-protective clothing, safety goggles, andheat-protective gloves.

3. Remove the hopper enclosure and unit cover. Refer to Removing theHopper Enclosure and Unit Cover earlier in this section.

4. Disconnect any hoses.

5. Remove the truss screws that secure the corner enclosure to the unitand remove the corner enclosure.

Removing the CornerEnclosure

Repair 7-9


107 144DIssued 3/99

Manual 41-190

4904133

1

2

2

2

Fig. 7-4 Removing Corner Enclosure

1. Corner enclosure 2. Truss screws

6. Remove any insulation and set aside.

Perform the following procedures to replace the corner enclosure.

1. Replace the insulation and secure it with tape.

2. Place and hold the corner enclosure in position on the unit.

3. Insert and tighten the truss screws that secure the corner enclosureto the unit.

4. Reconnect hoses.

5. Replace the unit cover, hopper enclosure, and belt cover. Refer toReplacing the Unit Cover and Hopper Enclosure earlier in thissection.


Replacing the CornerEnclosure

Repair7-10


107 144DIssued 3/99

Manual 41-190

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles and heat-protective gloves.

Servicing the motor includes replacing motor brushes or installing a newmotor.

You must remove the belt cover, hopper enclosure and unit cover as wellas the drive belt plate to remove the motor.

General Preparation


1. Relieve system hydraulic pressure. Refer to Relieving SystemHydraulic Pressure in the Maintenance section.


2. Disconnect and lock out input power from the unit.

3. Remove the hopper enclosure and unit cover (refer to Removing theHopper Enclosure and Unit Cover earlier in this section).

4. Remove the drive belt and sprocket. Refer to To Remove the DriveBelt in the Maintenance section for full details.

3. Mechanical Repairs

Servicing the Motor

Repair 7-11


107 144DIssued 3/99

Manual 41-190

To Access and Remove the Motor

1. Remove the screws and washers that hold the belt plate to the motor.Also remove the screws that hold the plate to the belt base ringclamp.

2. Disconnect the sensor wire at the quick-disconnect terminal. Lift thebelt plate from the unit.

3. Loosen the set screw in the motor sprocket and lift the sprocket offthe motor. Place the lock key aside with the sprocket.

4904134

1

2

3

4

5

Fig. 7-5 Accessing the Motor

1. Belt drive plate2. Sensor wire quick-disconnect3. Lock key, motor sprocket, and set

screw

4. Screw and washer5. Belt base ring clamp

Repair7-12


107 144DIssued 3/99

Manual 41-190

To Access and Remove the Motor (contd.)

4. Quick-disconnect the power and pressure control wire leads from themotor.

WARNING: Heavy equipment. Failure to secure may result inpersonal injury or equipment damage.

5. Screw I-bolts into the threaded holes in the top of the motor body andconnect a hoist to the I-bolts. Tighten the hoist chain enough to takeup any slack and create tension on the chain.

6. Remove the four hex head bolts and lockwashers that secure themotor to the frame.

7. Carefully hoist the motor away from the unit and place it on a worksurface.

8. Refer to the following table for further instructions.


Action ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InstructionsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replacing the motor brushesÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed with To Replace MotorBrushes.


Replacing the motorÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed with To Install theMotor.

Repair 7-13


107 144DIssued 3/99

Manual 41-190

To Replace Motor Brushes

Two motor brushes reside in the fan-end of the motor.

1. Remove the screws that hold the fan shield to the motor and removethe shield.

2. Remove the screw and nut from the protective shroud that surroundsthe motor housing. Allow the shroud to spring open, then remove itfrom the motor to expose access openings to the brushes.

4904171

3

4

1

2

Fig. 7-6 Removing the Fan Shield and Housing Shroud

1. Fan shield2. Shield screw

3. Housing shroud4. Shroud screw and nut

3. Inside the motor housing, loosen the screw that secures the brushterminal connector to the brush mounting bracket and remove theu-shaped terminal connector.

4. Pry the retaining spring off the brush and hold it away from the brushwith your finger.

Repair7-14


107 144DIssued 3/99

Manual 41-190

To Replace Motor Brushes (contd.)

5. Remove the brush from the mounting bracket. Repeat the procedurefor the other motor brush.

6. Install new brushes, reversing the foregoing procedures.

7. Replace the shroud and the fan shield.

8. Reinstall the motor.

To Install the Motor

1. Hoist the motor into place with the fan end down and align the boltholes on the mounting plate with those in the frame. Insert andtighten the mounting bolts and washers.

2. Reconnect the power and pressure control wire leads.

3. Place the motor sprocket onto the motor shaft, aligning the lock keyholes. Replace the lock key and the sprocket set screw.

4. Reinstall the drive belt plate and reconnect the magnetic sensor wireat the quick-disconnect terminal. (See Figure 7-5.)

5. Reinstall the drive sprocket and belt, adjust belt tension, andrecalibrate the magnetic sensor. Refer to To Replace the Drive Belt inthe Maintenance section to complete this procedure.

IMPORTANT! After replacing the motor, you must perform thefollowing tasks:

� Make the following motor speed adjustments:

- Potentiometer R52 (speed) on AP2. Refer to CalibratingMotor Speed later in this section.

- MIN and MAX potentiometer on AP8 (speed). Refer toCalibrating Motor Speed later in this section.

� Adjust the current limit potentiometer on AP5 or AP8. Refer toAdjusting Current Limits later in this section.

� Adjust the IR COMP potentiometer on AP8. Refer to Adjusting IRCompensation later in this section.

Repair 7-15


107 144DIssued 3/99

Manual 41-190

6. Reinstall the unit cover and hopper enclosure. Refer to Replacingthe Unit Cover and Hopper Enclosure earlier in this section.


Servicing the drive assembly includes replacing o-rings, replacing seals,or installing a new drive assembly.

You must remove the hopper enclosure and unit cover as well as thedrive belt plate to reach the drive assembly.

General Preparation





3. Remove the hopper enclosure and unit cover (refer to Removing theHopper Enclosure and Unit Cover earlier in this section).

4. Remove the drive belt and sprocket. Refer to To Remove the DriveBelt in the Maintenance section for full details.

Servicing the Drive Assembly

Repair7-16


107 144DIssued 3/99

Manual 41-190

To Access and Remove the Drive Assembly

1. Remove the four screws and washers that hold the belt plate to themotor.

2. Sufficiently loosen the screw in the belt base ring clamp to allow theclamp to slip off the drive shaft.

3. Disconnect the sensor wire at the quick-disconnect terminal. Lift thebelt plate from the unit.

4. Remove the tapered bushing from the drive shaft.

4904148

1

23

4

5

Fig. 7-7 Accessing the Drive Assembly

1. Belt plate2. Tapered bushing3. Screws and washers (4)

4. Sensor wire quick-disconnectterminal

5. Belt base ring clamp

Repair 7-17


107 144DIssued 3/99

Manual 41-190

5. Remove the hex head cap screws and lockwashers that secure thedrive assembly to the drive support. Then remove the drive assemblyand the spacers.

4904135

1

2

3

4

2

4

Fig. 7-8 Removing the Drive Assembly

1. Drive assembly2. Spacer

3. Drive support4. Screw and washer

Repair7-18


107 144DIssued 3/99

Manual 41-190

To Access and Remove the Drive Assembly (contd.)

NOTE: Perform this step only if you want to access the gear pump;otherwise, proceed with Step 6. Remove the hex head bolts andwashers that secure the drive support to the reservoir, then remove thedrive support to expose the pump.



ActionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

InstructionsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Replacing drive shaft face sealsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed with To Replace DriveShaft Face Seals.


Replacing the drive assemblyÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed with To Reinstall theDrive Assembly and RestoreNormal Operation.


Replacing the pump or pumpo-rings


Proceed with Replacing thePump and Pump O-rings, Step 2.

4904136

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÏÏÏÏÏÏÎÎÎÉÉÉ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÎÎÎÎÎÎ

ÏÏÏÏÏÏÏÏÏÏ

1

2

3 6

5

4

Repair 7-19


107 144DIssued 3/99

Manual 41-190

To Replace Drive Shaft Face Seals

1. With the drive assembly out of the unit, remove the pan head screwthat secures the retaining sleeve to the coupling. Remove the sleeve.

2. Push the exposed dowel pin out of the coupling and remove thecoupling.

3. Remove the external retaining ring and flat washer from the driveassembly.

4. Remove the face seal components from the drive shaft.

NOTE: The face seal is composed of a spring retainer, compressionspring, ceramic rings and Viton seal elements. See Figure 7-10 foran exploded view of the face seal assembly.

NOTE: Ensure that the ceramic rings are not chipped or broken andthat all face seal components are oriented properly.

Fig. 7-9 Removing the Face Seal

1. Drive coupling2. Pan Screw3. Retaining sleeve4. Face seal5. External retaining ring6. Flat washer

4904137

1

2

3

4

5

6

7

8

Repair7-20


107 144DIssued 3/99

Manual 41-190

To Replace Drive Shaft Face Seals (contd.)

5. Installation of the face seal components is the reverse ofdisassembly. Use an o-ring lubricant or Never-Seez to lubricate theViton components for installation.

6. Reinstall the face seal, the coupling and its dowel pin, the retainingsleeve, and the pan screw that secures the retaining sleeve. Thenreinstall the drive assembly.

Fig. 7-10 Face Seal Components

1. Viton housing seal2. Face seal seat (orient groove as

shown)3. Face seal ring4. Viton shaft seal5. Shaft seal housing6. Shaft seal retainer7. Spring8. Spring retainer

Repair 7-21


107 144DIssued 3/99

Manual 41-190

To Reinstall the Drive Assembly

1. Replace the drive spacers and set the drive assembly onto the drivesupport. (See Figure 7-8 if needed.)

2. Insert the cap screws and lockwashers to secure the drive assemblyto the drive support and tighten evenly.

3. Reinstall the tapered bushing, the drive belt plate, and the belt basering clamp screw, and reconnect the sensor wire at thequick-disconnect terminal. (See Figure 7-7 if needed.)

4. Reinstall the drive sprocket and belt and recalibrate the magneticsensor. Refer to To Replace the Drive Belt in the Maintenancesection.

5. Reinstall the unit cover and hopper enclosure. Refer to Replacing theUnit Cover and Hopper Enclosure earlier in this section.


Repair7-22


107 144DIssued 3/99

Manual 41-190

FoamMelt equipment pumps are manufactured with tolerances thatrequire the use of special tools and methods. These pumps contain nofield-serviceable parts and must be replaced as a unit. Use the pumpremoval tool included in the unit’s Ship-with Kit to lift the pump out of thereservoir.

NOTE: Ensure that the hot melt material surrounding the gear pump ismolten and the surface of the manifold is free of debris before attemptingto replace the gear pump.

1. To access the pump, follow instructions for Servicing the DriveAssembly earlier in this section.

2. After the pump is exposed, remove the hex nuts and washers thatsecure it to the manifold studs.

NOTE: To ease gear pump removal, it may be helpful to first removethe pressure control valve from the manifold.

4904138

1

2

3

4

Fig. 7-11 Removing the Pump

1. Hex nuts, split lockwashers, andflat washers

2. Gear pump

3. Gear pump o-ring4. Manifold o-rings

Replacing the Pump or PumpO-Rings

Repair 7-23


107 144DIssued 3/99

Manual 41-190

3. Lift the gear pump up and out of the reservoir using the pumpremoval tool.

4. The gear pump o-ring and manifold o-rings are located beneath thepump and can be replaced. Be sure to lubricate the o-rings witho-ring lubricant, then lower the pump back into place.

If you are replacing the pump, be sure to lubricate the new o-ringswith o-ring lubricant, then lower the new pump into place.

5. Insert the pump screws and tighten to 14−16 N�m (10−12 ft-lb) oftorque.

6. Replace the drive support and tighten the cap screws. (SeeFigure 7-8 if needed.)

Use the drive/pump alignment tool when installing the drive support.This will prevent unnecessary oscillating loads on the drive bearings.

7. Reassemble the unit. Refer to To Reinstall the Drive Assembly earlierin this section.

Repair7-24


107 144DIssued 3/99

Manual 41-190

Solidified hot melt material on the valve surface or inside the manifoldblock may make it difficult to install the valve. To ease installation andavoid damage to the o-rings, bring the applicator to operatingtemperature before attempting to replace the valve.




2. Disconnect and lock out input power.


4. Remove the flexible tubing at the quick-disconnect fitting on thepressure control valve.

Replacing the Pressure ControlValve

Repair 7-25


107 144DIssued 3/99

Manual 41-190

5. Turn the hex nut nearest the manifold counterclockwise to thread thevalve out of the manifold block.

4904139

1

3

2

Fig. 7-12 Removing the Pressure Control Valve

1. Pressure control valve2. Hex nut

3. Quick-disconnect fitting

6. Lubricate the new valve’s threads with Never Seez and the o-ringswith o-ring lubricant.

7. Install the new valve in the manifold and tighten firmly. Do notovertighten.


Repair7-26


107 144DIssued 3/99

Manual 41-190

Solidified hot melt material inside the manifold block may make it difficultto reinstall the valve. To ease installation and avoid damage to theo-rings, bring the applicator to operating temperature before attempting toreinstall the valve.





3. Remove the pressure control valve. (Refer to the previous topic,Replacing the Pressure Control Valve, Steps 4 and 5.)

NOTE: In the following steps, it may be necessary to heat thepressure control valve to accomplish disassembly. Never use a torchor other open flame to heat a component. Use only an electric ovenwith forced air circulation or a flameless electric heat gun.

4. Unscrew the valve actuator assembly from the valve body.

5. Carefully remove and discard the exterior o-ring from the actuatorassembly.

Rebuilding the PressureControl Valve

4904140

1

2 3

4

4904141

ÇÇÇÇÇÇÇÇÇÇÇÇ

ÉÉÉÉÉÉÉÉÉÉÉÉ

ÎÎ

ÎÎÎÎ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÌÌÌÌÌÌÌÌÌ

1 2 3

Repair 7-27


107 144DIssued 3/99

Manual 41-190

6. Remove and discard the exterior o-rings from the valve body andremove the lapped valve seat.

Fig. 7-13 Separating the ActuatorAssembly from the ValveBody

1. Valve actuator assembly2. External o-rings3. Lapped valve seat4. Valve body

7. Push the spring and ball carrier out of the valve body from the seatend. The stop ring may come out of the valve body with the ballcarrier and spring or it may have to be lifted out.

Fig. 7-14 Removing the Valve Spring

1. Ball carrier2. Spring3. Stop ring

Repair7-28


107 144DIssued 3/99

Manual 41-190

8. Carefully inspect all components for damage or wear. If visibledamage is evident, replace the component(s). Spring free lengthdimension should be 31−32.5 mm (1.22−1.28 in.). If the spring isoutside this range, replace the spring.

NOTE: Before attempting to clean the valve components, check withthe hot melt material supplier to determine whether the hot meltmaterial in use is compatible with Nordson Type R fluid. If thematerials are incompatible, ask the hot melt material supplier for arecommended cleaning agent.

WARNING: Risk of explosion or fire. Fire, open lights andsmoking prohibited.

9. Place the valve components in a container of Nordson Type R fluid orother recommended cleaning agent. Heat the fluid slightly above theapplication temperature of the hot melt material on a regulated hotplate or similar device. Then scrub the components with a fiberbristle brush. DO NOT use a metal bristle brush, as it may damagethem.

10. Reinstall the stop ring, then the ball carrier and spring inside the valvebody.

11. Reinstall the lapped valve seat onto the valve body. (Torque: 13−20N�m/10−15 ft-lb.)

12. Install new exterior o-rings onto the valve body.

13. Install a new o-ring onto the actuator assembly, then screw theactuator into the valve body and tighten. (Torque: 40−47 N�m/30−35 ft-lb.)

14. Lubricate the valve threads and o-rings with Never Seez.

NOTE: Remove any solidified hot melt material from valve threadsby first heating with a flameless electric heat gun.

15. Reinstall the valve in the manifold and tighten firmly. Do notovertighten.


Rebuilding the PressureControl Valve (contd.)

4904190A

1

2

3

4

Repair 7-29


107 144DIssued 3/99

Manual 41-190

This procedure tells you how to disassemble the density controller toinspect and replace serviceable components. To service only the filterscreen, refer to Checking and Cleaning the Filter Assembly in theMaintenance section and follow all steps.

1. Remove the density controller assembly. Refer to Checking andCleaning the Filter Assembly in Section 5 and follow procedures onlythrough To Clean or Replace the Filter Screen, Step 3. Then returnto this topic and continue with Step 2 below.

2. Screw the filter core out of the bung.

3. Remove the slug and spring from the core.

4. Carefully inspect all components for damage or wear. If damage isevident, replace the component(s). Spring free length is62.5−64.5 mm (2.47−2.54 in.). If the spring is outside this range,replace the spring.

5. Reinstall the spring and the slug into the core. Screw the core intothe bung. (Torque: 14−16 N�m/10−12 ft-lb.)

6. Slide the filter screen over the core and install the support and its bolton the end of the core. (Refer to To Clean or Replace the FilterScreen in the Maintenance section as needed.)

7. Replace the density controller assembly. Refer to To Replace theDensity Control and Filter in the Maintenance section and perform allsteps.

NOTE: You should also check density reduction. Refer to AdjustingDensity Control, To Determine and Adjust Density Reduction in theOperation section for instructions.

Fig. 7-15 Disassembling the DensityController

1. Bung2. Slug3. Spring4. Core

Rebuilding the DensityController

Repair7-30


107 144DIssued 3/99

Manual 41-190

Replace hose connector and pipe plug o-rings whenever there isevidence of leakage or whenever these fittings are removed from a gunor manifold. The hose connector is used to couple the hose to themanifold and, at the delivery end, to the gun service block. An o-ringpipe plug is used on the manifold or gun service blocks to block offunused fluid ports.




2. Remove the pipe plug or the hose connector from the manifold orgun.

4904143

2 31

Fig. 7-16 Hose Connectors and Pipe Plugs

1. Pipe plug2. Hose connector

3. Hose

Replacing the Hose Connectorand Pipe Plug O-Rings

Repair 7-31


107 144DIssued 3/99

Manual 41-190

3. Remove the o-ring from the connector or plug.

4. Ensure that the new o-ring and its groove are free of foreign particles,then lubricate the o-ring with Never Seez.

NOTE: Use only Nordson o-rings. The use of other o-rings mayresult in leakage.

5. Stretch the o-ring only so it can be carefully rolled over the threadsand into the hose connector or pipe plug groove. Do not stretch theo-ring any more than necessary.

6. Hand-thread the fitting into the manifold or gun.

7. Tighten the fitting only enough to seat, stopping when the body of themetal fitting contacts the manifold surface. Between 9.5−13.6 N�m(7 and 10 ft-lbs) of torque is enough force to create an effective seal.

8. Restore the unit to normal operation (refer to Routine OperatingProcedures in the Operation section).

Servicing the drain valve includes replacing the exterior o-ring, internalo-ring, back-up ring, or stem assembly. Repair or replace the valve whenthere is evidence of leakage at the manifold.

NOTE: If the unit is cool, heat it to operating temperature to meltadhesive material in the drain valve before proceeding.




Servicing the Drain Valve

Repair7-32


107 144DIssued 3/99

Manual 41-190



3. Remove all enclosures and covers. Refer to Removing the HopperEnclosure and Unit Cover and Removing the Corner Enclosure earlierin this section.

4. Remove the hex head screws and flat washers that secure the drainvalve to the manifold, then remove the drain valve and exterior o-ring.

NOTE: The o-ring will stick to either the valve or the manifold.

4904144

1

23

Fig. 7-17 Removing the Drain Valve

1. Hex head screws and washers2. Drain valve

3. Manifold


ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁAction

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁInstructionsÁÁÁÁÁÁÁÁÁÁÁÁ


Replacing the external o-ringÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Proceed with To Reinstall theDrain Valve, using a new o-ringin Step 1.


Replacing the internal o-ring,back-up ring, or stem assembly


Continue with To Remove theValve Stem Assembly.

Servicing the Drain Valve (contd.)

4904145

1

2

1. Internal retaining ring2. Drain valve stem

4904146

1

2

3

4

Repair 7-33


107 144DIssued 3/99

Manual 41-190

To Remove the Valve Stem Assembly

1. Remove the retaining ring with retaining ring pliers.

2. Use a screwdriver and screw the stem assembly out of the drainvalve body. (The valve spacer comes out with the assembly.)

Fig. 7-18 Removing the RetainingRing

3. To replace the stem o-ring or back-up ring, remove the old part andcarefully fit the replacement part on the valve and coat with o-ringlubricant.

To replace the stem assembly, be sure the new assembly is equippedwith an o-ring and back-up ring that are coated with o-ring lubricant.

4. Screw the stem assembly into the valve body, replace the spacer, andsecure the assembly with the retaining ring.

5. Reinstall the drain valve.

Fig. 7-19 Stem Assembly

1. Back-up ring2. Spacer3. Stem4. Internal o-ring

4904147

Repair7-34


107 144DIssued 3/99

Manual 41-190

To Reinstall the Drain Valve

1. Ensure that the drain valve is equipped with an exterior o-ringpositioned between the manifold and drain valve. Coat the o-ring witho-ring lubricant.

2. Secure the drain valve to the manifold using the hex head screws andflat washers. (Torque: 6.8−9.5 N�m/5−7 ft-lbs.)

3. Replace all insulation and covers. (Refer to Replacing the CornerEnclosure and Replacing the Unit Cover and Hopper Enclosureearlier in this section.)

Fig. 7-20 Reinstalling the Drain Valvewith Exterior O-ring


When performing electrical repairs, be sure to note the position of allwires and cables prior to their removal from their circuit boards orterminal positions.

CAUTION: Risk of equipment damage. Always use anelectrostatic discharge (ESD) wrist strap when handling anyprinted circuit board. Failure to observe this caution can resultin equipment damage.

WARNING: Risk of electrical shock. Never use an electrostaticdischarge (ESD) wrist strap when working on a unit that isconnected to any power source. Disconnect and lock out allpower if you are using a wrist strap. Failure to observe thiswarning can result in equipment damage, personal injury, ordeath.

4. Electrical Repairs

Repair 7-35


107 144DIssued 3/99

Manual 41-190

Follow this procedure to replace a low battery on the system controller.Replace the battery when the letter L appears in the error code displayon the system status panel.


CAUTION: Failure to observe may result in equipmentdamage. Unplugging the old battery before plugging in the newbattery erases the system memory.


2. Open the electrical cabinet door (refer as needed to Opening theElectrical Cabinet Door in the Installation section). The battery isattached by a velcro strip near the upper left-hand corner on the backof the control panel assembly.

4710255

XP4 J6

J7

XP16

1 2 3

Fig. 7-21 Battery Location on Control Panel Assembly

1. Old battery2. Connector on old battery

3. Board AP2

Replacing the ControllerBattery

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Manual 41-190

3. Plug a new battery into the available connection before removing theold battery.

4710254

XP4 J6

J7

XP16

1

2

Fig. 7-22 Connecting a New Battery

1. New battery2. Connector on new battery

4. Unplug the old battery and pull it off the board.

5. Secure the new battery to the board.

6. Close the electrical cabinet door and restore power to the unit.

7. Check the error code display on the system controller. The letter Lshould no longer appear in the display.

8. Return to routine operation.

Replacing the ControllerBattery (contd.)

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Manual 41-190

Follow this procedure to replace any of the circuit boards in the electricalcabinet.

CAUTION: The static electricity carried in your body candestroy circuit boards, making your processor inoperable.Certain conditions, such as dry weather or walking across afloor, cause static electricity to build up in your body. When youtouch a circuit board, the discharge of this electricity candamage or destroy it. The damage will not be apparent until theboard is placed in service and is not always immediatelynoticeable.

1. Transport the board to your workstation in the static-safe container itwas shipped in.

WARNING: Risk of electrical shock. Never use an electricaldischarge (ESD) wrist strap when working on a unit that isconnected to any power source. Disconnect and lock out allpower if you are using a wrist strap. Failure to observe thiswarning can result in equipment damage, personal injury, ordeath.

2. Disconnect and lock out input power to the processor, includingpower to all remote input/output devices.

3. Ground yourself by one or more of the following methods:

� Wrap the copper end of a wrist strap around the ground lug at thetop of the electrical cabinet, or attach it to some other unpaintedmetal surface in the cabinet. Wrap the other end of the strapsnugly around your wrist.

� Use a static-dissipating work mat.

� Use conductive tools.

4710261

Fig. 7-23 Using a Wrist Strap

Replacing Circuit Boards

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Manual 41-190

4. Open the electrical cabinet door. Refer as needed to Opening theElectrical Cabinet Door in the Installation section.

5. Remove each wiring harness, ribbon cable, or other connector fromthe defective board.

6. Remove the mounting hardware that holds the board in place andthen remove the board. Keep the hardware to install the new board.

7. Remove the new board from its static-safe container, making sure tohandle the board by its edges without touching pins, leads, orcircuitry.

8. Set all rotary, toggle, and switches on the new board to the correctsettings. Refer to the old board for correct settings, or refer to tableson the following page(s) for the board you are replacing.

9. Install the new board in the unit with the hardware removed earlier inthis procedure.

10. Plug all wiring harnesses, ribbon cables, or other connectors backinto the new board. Refer to the electrical schematic in theTroubleshooting section, FM-190 Processor Schematic, as needed.

WARNING: Risk of electrical shock. Never use an electricaldischarge (ESD) wrist strap when working on a unit that isconnected to any power source. Disconnect the wrist strap fromthe unit before restoring power. Failure to observe this warningcan result in equipment damage, personal injury, or death.

11. If you used a wrist strap to ground yourself, remove the wrist strapfrom the ground and your wrist. Avoid touching any pins, leads, orcircuitry.



Replacing Circuit Boards (contd.)

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Manual 41-190

Use the following procedure to reset factory defaults only when theleft-hand side of the system status diagnostic display shows an errorcode of “C” or in other rare circumstances.

This procedure resets all parameters to the values for a newlymanufactured CPU (AP1) board. You must then re-enter alluser-programmed information (such as setpoints).

NOTE: If this procedure fails, replace the AP1 board. If the error codepersists, replace the entire system control board assembly (AP1, AP2,and AP3).

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when changing DIP switch settingsand do not come into contact with any other components insidethe electrical cabinet. Failure to observe may result inequipment damage, personal injury, or death.

1. Open the electrical cabinet and locate AP2 on the right-hand side ofthe cabinet. (AP1 default settings are reinstated by manipulating DIPswitches on the AP2 circuit board.) Refer to Component Map Legendin the Troubleshooting section if necessary.

2. Move DIP switch S3−12 on the AP2 board to ON.

3. Turn the unit on. Wait at least 30 seconds while the system resets allparameters to factory defaults.


5. Move DIP switch S3−12 on the AP2 board to OFF.

6. Close the cabinet.

7. Turn the unit on and re-enter all user-programmable parameters,such as setpoints. Follow instructions in the Installation section andin the Operation section for programming the unit.

NOTE: If you fail to put DIP switch S3−12 in the OFF position inStep 5, all user-programmable parameters, such as setpoints, will belost the next time the unit is turned on.

Resetting the AP1 Circuit Boardto Factory Defaults

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1. Follow procedures for Replacing Circuit Boards described earlier inthis section. To configure the new circuit board to reflect factorysettings, refer to the table below for proper AP2 switch settings.Otherwise, refer to your old board.

Table 7-2 Switch Settings for AP2 Circuit Board


S2 DIP switches


Position ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory State ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Meaning


1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ON ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Sequential start-up




FM190 Unit


3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

OFF (for English languagecontrol panel)

ON (for Symbols-only controlpanel)


Degree Fahrenheit

Degree Celsius



OFF ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

FM190 UnitÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

S3 DIP switchesÁÁÁÁÁÁÁÁÁÁ

Position ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory State ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

MeaningÁÁÁÁÁÁÁÁÁÁ



Watchdog EnabledÁÁÁÁÁÁÁÁÁÁ



Max Setpoint = 400 �FÁÁÁÁÁÁÁÁÁÁ



Max Setpoint = 400 �F




FM190 Unit




FM190 Unit




Nickel RTD




FM190 Unit




Continuous MotorControlÁÁÁÁÁ

ÁÁÁÁÁ9ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁOFF

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁFM190 UnitÁÁÁÁÁ

ÁÁÁÁÁ10ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁON


ÁÁÁÁÁ11ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁOFF


ÁÁÁÁÁ12ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

OFFÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Save SettingsÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Rotary Switches (at 12:00 position)ÁÁÁÁÁÁÁÁÁÁ

SwitchÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory StateÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


S4ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


Ready Delay 12 MinutesÁÁÁÁÁÁÁÁÁÁ

S5 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

15 or F ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Auto Standby DisabledÁÁÁÁÁÁÁÁÁÁ



Temperature Band 6 �CÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

S7 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

9 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Auto Shutdown Disabled




Low Temp 19 �C




(not used)


Toggle Switches


Switch ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory State


15 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Normal

Replacing the AP2 CircuitBoard

Repair 7-41


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Manual 41-190

2. After replacing the AP2 circuit board, complete the following tasks:

� Record the version of software displayed during the power-on selftest (lamp test).

� Re-enter all desired temperature control information (setpoints,overtemperature, etc.). Refer to Initial Setup Procedures in theOperation section.

� Set the clock. Refer to Initial Setup Procedures in the Operationsection.

� Make the following motor speed adjustments:

- Potentiometer R52 (speed) on AP2. Refer to CalibratingMotor Speed later in this section.

- MIN and MAX potentiometer on AP8 (speed). Refer toCalibrating Motor Speed later in this section.

� Adjust the current limit potentiometer on AP5 or AP8. Refer toAdjusting Current Limits later in this section.

� Adjust the IR COMP potentiometer on AP8. Refer to Adjusting IRCompensation later in this section.

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Manual 41-190

1. Follow procedures for Replacing Circuit Boards described earlier inthis section. To configure the new circuit board to reflect factorysettings, refer to the tables below for AP6, AP7, and AP8 switchsettings and potentiometer adjustments. Otherwise, refer to your oldboard(s).

Table 7-3 Switch Settings for AP6 (Pressure Display)


S2 DIP Switch


Position ÁÁÁÁÁÁÁÁÁÁÁÁ

Factory StateÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Meaning



Open ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Zone 4 Disabled




Zone 3 Disabled




Zone 2 Disabled



Closed ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Zone 1 Enabled

Table 7-4 Switch Settings for AP7 (RPM Display)


DIP Switch*(for Standard Units Only)ÁÁÁÁÁÁ


PositionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Factory State


1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

DOWN/OFF



DOWN/OFF



DOWN/OFF



DOWN/OFF


* Only one DIP switch appears on AP7.

Table 7-5 Potentiometer Adjustments for AP8 (Standard Motor Control)


Potentiometers


Type ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Value


MIN ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Full Counter-clockwise


MAX ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Full Clockwise

Replacing the AP5, AP6, AP7,or AP8 Circuit Boards

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Manual 41-190

2. After replacing the AP5, AP6, AP7, or AP8 circuit board withappropriately set switches or potentiometers, complete the tasksidentified in the following table.

Table 7-6 Additional Tasks to Perform After Replacing AP5, AP6, AP7, or AP8ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Circuit Board ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Tasks to PerformÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AP5 (Gear-to-LineMotor Controller)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� Open the drive. Check and adjust the jumpers, voltage switch, and 82−CP value. Referto Configuring the Gear-to-Line Motor Controller later in this section.

� Ensure that the motor rotates counter-clockwise. You must remove the drive belt coverto observe the direction of motor rotation. Refer to Removing the Hopper Enclosure andUnit Cover earlier in this section.

� Re-program the drive parameters. Refer to Initial Setup Procedures in the Operationsection.

� Adjust the R52 (speed) potentiometer on AP2. Refer to Calibrating Motor Speed later inthis section.

� Adjust the current limit potentiometer on AP5. Refer to Adjusting Current Limits later inthis section.ÁÁÁÁÁÁÁÁ


AP6 (PressureDisplay)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Refer to Initial Setup Procedures in Section 4 for these tasks:

� Adjust the pressure alarm setpoint on AP6.

� Set the DIP switch for the desired display units.


AP7 (RPM Display)ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� Re-program the calibration constant in AP7. Refer to Configuring the RPM Display laterin this section.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AP8 (StandardMotor Controller)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

� Ensure that the motor rotates counter-clockwise. You must remove the drive belt coverto observe the direction of motor rotation. Refer to Removing the Hopper Enclosure andUnit Cover earlier in this section.

� Make the following motor adjustments:

− R52 (speed) potentiometer on AP2. Refer to Calibrating Motor Speed later in thissection.

− MIN and MAX potentiometers (speed) on AP8. Refer to Calibrating Motor Speedlater in this section.

� Adjust the current limit potentiometer on AP8. Refer to Adjusting Current Limits later inthis section.

� Adjust the IR COMP potentiometer on AP8. Refer to Adjusting IR Compensation later inthis section.

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Manual 41-190

After replacing the AP2, AP5, or AP8 circuit boards, recalibrate the motorspeed control using the procedure appropriate for your motor controller(standard or gear-to-line).

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when setting potentiometers and donot come into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

To Calibrate Standard Units

1. Ensure there is material in the tank. Do not run the motor for anylength of time with the tank empty.

2. Open the electrical cabinet and locate AP8 on the left-hand side ofthe cabinet.

3. Visually check AP8 MIN and MAX potentiometers. The MINpotentiometer should be set fully counter-clockwise; the MAXpotentiometer should be set fully clockwise.

4. Turn the unit on.

5. After the READY light comes on, press the MOTOR on/off key to turnthe motor on. Check to be sure the motor rotates counter-clockwise.

NOTE: You must remove the drive belt cover to check the direction ofmotor rotation. Refer to Removing the Hopper Enclosure and UnitCover earlier in this section for detailed instructions.

6. Press the up key on the motor control panel to set motor speed to100%.

7. Inside the cabinet, locate AP2 on the right-hand side of the cabinet.Adjust R52 on the AP2 board to achieve a pump RPM reading (on thefront of the unit) of 900 (+/− 10) at 100% motor speed. If 900 cannotbe achieved, turn the R52 potentiometer fully counter-clockwise untilthe adjustment makes a clicking noise as it is rotated.

Note the RPM reading here: __________________________

8. Press the down key on the motor control panel to set motor speedto 3%.

Calibrating Motor Speed

Repair 7-45


107 144DIssued 3/99

Manual 41-190

9. Inside the cabinet, adjust the MIN potentiometer on AP8 to achieve apump RPM reading (on the front of the unit) of 5−10 RPM at 3%.

Note the RPM reading here: _________________________

10. Re-check the RPM at 100% motor speed and record the RPM here:__________________________________

11. Close the electrical cabinet and resume normal operation, or performother adjustment tasks as needed.

To Calibrate Gear-to-Line Units

1. Ensure there is material in the tank. Do not run the motor for anylength of time with the tank empty.

2. Turn the unit on.

3. After the READY light comes on, press the MOTOR on/off key to turnthe motor on. Check to be sure the motor rotates counter-clockwise.

NOTE: You must remove the drive belt cover to check the direction ofmotor rotation. Refer to Removing the Hopper Enclosure and UnitCover earlier in this section for detailed instructions.

4. Press the up key on the motor control membrane panel to set motorspeed to 100%.

5. Open the electrical cabinet.

6. Inside the cabinet, locate AP2 on the right-hand side of the cabinet.Adjust R52 on the AP2 board to achieve a pump RPM reading (on thefront of the unit) of 900 (+/− 10) at 100% motor speed. If 900 cannotbe achieved, turn the R52 potentiometer fully counter-clockwise untilthe adjustment makes a clicking noise as it is rotated.

Note the RPM reading here: __________________________

7. Check the readout with a hand-held tachometer. This verifies thefunctioning of the drive and the RPM display as well as properpositioning of the pump speed sensor.


Repair7-46


107 144DIssued 3/99

Manual 41-190

After replacing the motor or the AP2, AP5, or AP8 circuit board, adjustthe current limit potentiometer (I-LIM pot) on AP8 or AP5 using theprocedure appropriate for your motor controller (standard or gear-to-line).

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when adjusting potentiometers anddo not come into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

To Adjust Standard Units

1. Start with a cold unit that has the material solidified around the pumpin order to lock the pump shaft (and motor shaft).

If the unit has been in use, turn it off and allow it to cool to at leastroom temperature.

2. Open the electrical cabinet and locate the AP8 circuit board on theleft-hand side of the cabinet. Refer to Component Map Label in theTroubleshooting section if necessary.

3. Visually inspect the I-LIM potentiometer on AP8. It should be set atabout the 1 o’clock position.

4. Attach an air supply of 95 +/− 5 psi to the air inlet port.

5. Attach a DC current clamp around the motor armature wires.

6. Turn the power on. Adjust operating temperature setpoints to justabove ambient temperature.

7. Press the HEATERS ON/OFF key to turn on the heaters. Heat toready.

8. After the READY light comes on, set the motor speed to 25% on themotor control membrane panel, then turn the motor on.

NOTE: Because operating temperatures are set near the ambienttemperature, viscosity remains high and the drive and motor shaftsremain locked.

9. Inside the cabinet, adjust the I-LIM potentiometer on AP8 to achieve areading of 11.5 Amps DC. Turn the motor off as soon as theadjustment is correct.

Adjusting Current Limits

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11. Remove the current clamp.


A simpler, but much less accurate method of setting the current limit(I-LIM) potentiometer, is to visually inspect the I-LIM potentiometer onAP8 and set it to about the 1 o’clock position. Use this method onlyas a last resort.

To Adjust Gear-to-Line Units


2. Open the electrical cabinet and locate the AP5 circuit board on theright-hand side of the cabinet. Refer to Component Map Label in theTroubleshooting section if necessary.

3. Visually inspect the I-LIM potentiometer on AP5. It should be set atabout the 4 o’clock position.

4. Attach a DC current clamp around the motor armature wires.

5. Attach an air supply of 95 +/− 5 psi to the air inlet port.

6. Turn the unit on. Press the HEATERS ON/OFF key to turn on theheaters. Heat to ready.

7. After the READY light comes on, change the motor speed to 100% onthe motor control membrane panel, then turn the motor on.

8. Try to draw 11 Amps DC by adjusting the following:

� Motor RPM.

� Pressure control. However, do not increase pressure so high thatthe relief valve trips (usually 10135−10549 kPa [1470−1530 psi]).

� Operating temperature setpoints. Decrease temperature toincrease viscosity (thereby increasing load on the motor).

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To Adjust Gear-to-Line Units (contd.)

9. Remove the keypad lockout jumper. Refer to Programming theGear-to-Line Motor Controller in the Operation section forinstructions.

10. On the gear-to-line motor control panel, press the following keys todisplay the alarms:

CODE SELECT52ENTER

11. Turn the I-LIM potentiometer on AP5 fully clockwise. Then turn thepotentiometer counter-clockwise to decrease the setting until thegear-to-line controller panel displays “7” (current limit).

12. Turn the I-LIM potentiometer 1/8 turn clockwise from the point where“7” appeared. (Seven will no longer display.)

13. Turn the motor off as soon as the adjustment is correct.


15. Remove the current clamp.

16. Re-install the keypad lockout jumper. Refer to Programming theGear-to-Line Motor Controller in the Operation section forinstructions.


A simpler but much less accurate method of setting the current limitpotentiometer is to visually inspect the I-LIM potentiometer on AP5and set it to about the 4 o’clock position.

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After replacing the motor or the AP2 or AP8 circuit board, adjust the IR(current * resistance) compensation on AP8 using the followingprocedure. The IR compensation adjustment ensures that the motorspeed remains fairly constant as the load on the motor changes.

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when adjusting potentiometers anddo not come into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

1. Turn the power on.

2. Set hydraulic pressure to a low value such as 2068−2758 kPa (300−400 psi) using the MANUAL pressure control potentiometer onthe pressure and gas control panel.

Note the pump RPM here: __________________________

3. Set the pressure to as high a value as practical (such as 6895 kPa(1000 psi)) using the MANUAL pressure control potentiometer.

4. Open the electrical cabinet and locate the AP8 circuit board on theleft-hand side of the cabinet.

5. Adjust the IR COMP potentiometer on AP8 until the pump RPMequals the RPM obtained at low pressure. Record the RPM in thetable below.


PressureÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

RPM DisplayÁÁÁÁÁÁÁÁÁÁÁÁÁÁHIGH


ÁÁÁÁÁÁÁLOWÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


RPM DifferenceÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

6. Reset hydraulic pressure to the low value used in Step 1. Check andrecord the RPM value. This value may be greater than or equal tothe value obtained in Step 3.

The IR COMP setting is properly adjusted when the speed betweenlow and high pressure varies by no more than 10 RPM. Typically, it isnecessary to repeat Steps 2−4 a few times. However, do notovercompensate. The speed at high pressure should be less than orequal to the speed at low pressure.

7. After adjusting the IR compensation, close the electrical cabinet andresume normal operation, or perform other adjustment tasks asneeded.

Adjusting IR Compensation

4904181

J4 RN3

TOP

4904182

P5

Q2

BOTTOM

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Before installing a replacement gear-to-line motor controller, you mustconfigure the replacement drive to operate as expected. You must:

� Configure internal jumpers� Check and set the internal voltage switch� Set the 82-CP value

To Configure the Internal Jumpers

1. Remove the back plate from the replacement gear-to-line motorcontroller.

2. Set the jumpers for the frequency inputs:


JumperÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

PositionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Meaning



1−2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Open collector




Open collector




Open collector

The jumpers should look like Figure 7-24.

Fig. 7-24 Frequency Input Jumpers

3. Set the jumpers for the analog I/O:


JumperÁÁÁÁÁÁÁÁ

PositionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


1ÁÁÁÁÁÁÁÁ

1−2ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

0 −10V inÁÁÁÁÁÁÁÁÁÁ

2ÁÁÁÁÁÁÁÁ

5−6ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

0 − 10 V inÁÁÁÁÁÁÁÁÁÁ3

ÁÁÁÁÁÁÁÁ11−12

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ4 − 20 mA out

The jumpers should look like Figure 7-25.

Fig. 7-25 Analog I/O Jumpers

Configuring the Gear-to-LineMotor Controller

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To Set the Internal Voltage Switch

1. With the back plate removed from the replacement gear-to-line motorcontroller, check the following:

� Voltage switch is set for 230 Vac� Continuity is good for both fuses mounted in clips on the PCB

2. Re-install the back plate.

WARNING: Risk of electrical shock. Disconnect equipmentfrom the line voltage. Failure to observe may result inequipment damage, personal injury, or death.

3. Place the main disconnect switch in the OFF position. Disconnectand lockout power to the unit.

4. Install the motor controller drive in the unit.

5. Remove the jumper to disable the keypad lockout. Refer toProgramming the Gear-to-Line Motor Controller in the Operationsection for instructions.

6. Restore power and program the following CP values to match yourpreviously recorded data or to match the default table in theOperation section.


81-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Full scale depends on user maximum encoder/tachfrequency. Refer to Programming the Gear-to-LineMotor Controller in the Operation section forinstructions.


82-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Initially set to 485 (starting point for 4 mA low end).Refer to To Set the 82-CP Value below forinstructions.


83-CPÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Initially set to 2048 (starting point for the maximumpressure). This value gives about 14 mA (about1000 psi). Refer to Programming the Gear-to-LineMotor Controller in the Operation section forinstructions.

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To Set the 82-CP Value

After replacing the AP5 circuit board, use the following procedure to setthe 82-CP value if you do not know the value used by the old board.

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when checking circuits and do notcome into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

1. Turn the power off.


3. Insert a Digital Multimeter (DMM) set to the mA scale in series withthe circuit at KA1-3.

4. Attach an air supply to the air inlet port.

5. Turn the power on.

6. Set the pump RPM to 50%.

7. After the READY light comes on, press MOTOR ON/OFF to turn themotor on.

8. Press the AUTO button to put the unit in auto pressure control mode.

9. Press the GAS ON button to turn the gas on.

10. With the line stopped (input frequency = zero), verify the frequency iszero on the drive display by pressing the following keys on thegear-to-line motor controller panel:

CODE SELECT41ENTER

The drive displays the incoming line speed as a frequency:

11. Now read the DC current on the DMM.

12. On the gear-to-line motor controller panel, press the following keys:

CODE SELECT82ENTER

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13. Adjust parameter 82-CP as required to achieve a reading of 4.00 mA+/− .02 mA. Record the value of 82-CP in the chart at the end of theOperation section.

14. Re-install the keypad lockout jumper. Refer to Programming theGear-to-Line Motor Controller in the Operation section forinstructions.

15. Close the cabinet and resume normal operation, or perform otheradjustment tasks as needed.

Use the following procedure after replacing the AP7 circuit board toproperly configure the RPM display.

WARNING: Risk of electrical shock. This equipment containselectrical components with potentials that could be fatal.Exercise extreme caution when changing dipswitch settings anddo not come into contact with any other components inside theelectrical cabinet. Failure to observe may result in equipmentdamage, personal injury, or death.

1. Open the electrical cabinet and locate the AP7 circuit board on theright-hand side of the cabinet.

2. Set the right-hand DIP switch to down (off) to enable programmingmode. Verify that all other DIP switches are down (off).

3. Set the calibration factor using the following procedure:

NOTE: The following is a condensed description of the calibrationprocedure. Refer to the MAXjr Tach 2 Technical Manual, Part Number16D250−44 included with your unit (or available from DYNAPARCorporation, P.O. Box 368, Elizabethtown, NC, 28337) for completeinstructions.

� Press RUN/PGM to enter Program Mode.

� Press the down arrow until “CAL” shows on the display.

� Set the calibration factor to 2.1429 using the right arrow andINC/DEC buttons.

� Press the down arrow until the lamp test feature is active.

� Verify the integrity of all the LED segments on the RPM display.

� Press RUN/PGM to enter Run Mode.

Configuring the RPM Display

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4. Set the right-hand DIP switch to up (on) to disable programmingmode.

5. Check the readout with a hand-held tachometer (if possible) to verifyfunctioning of the RPM display and proper positioning of the pumpspeed sensor.

6. Close the cabinet and resume normal operation, or perform otheradjustment tasks as needed

Follow this procedure to replace any of the solid-state relays in theprocessor electrical cabinet.

To Remove a Relay

WARNING: Risk of electrical shock. Failure to disconnect andlock out power electrical safety procedures may result inpersonal injury or death.

1. Disconnect and lock out input power to the processor.

2. Open the electrical cabinet door. Refer to Opening the ElectricalCabinet Door in the Installation section as needed.

3. Remove the clear protective shield that covers the relays.

4. Locate the relay you want to replace. All relays are located on theheat sink panel on the left side of the electrical cabinet.

CAUTION: Be certain to properly wire the relay(s). Do notcross-connect low-voltage DC input with high-voltage ACoutput. Failure to observe may result in equipment damage.

5. Make a note of the wire numbers of the wires attached to terminal 1,2, 3, and 4 of the relay.

6. Make a note of the position of the relay. Some relays are positionedso that terminals 1 and 2 are on top. Others are positioned so thatterminals 3 and 4 are on top.

Configuring the RPM Display (contd.)

Replacing Solid-State Relays

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7. Remove the four wires from their terminals on the relays. Save thefour screws.

4710231

Fig. 7-26 Removing the Wires from a Relay

8. Remove the two screws that secure the relay to the heat sink. Savethe screws.

9. Using a screwdriver or some other flat-bladed tool, remove the relayfrom the heat sink.

4710230

Fig. 7-27 Removing a Relay from the Heat Sink

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To Install a Relay

1. Thinly cover the back of the new relay with heatsink compound.

NOTE: Make sure that the new relay is the same rating (25 A or 40 A) as the old one.

4710232

Fig. 7-28 Applying Heatsink Compound to Relay

2. Attach the relay to the heat sink in the same position that the old relaywas in.

3. Secure the relay to the heat sink with the two mounting screws.Torque the screws to 1.1 N�m (10 in-lb).

4. Reconnect the four wires to terminals 1, 2, 3, and 4 on the relay.

5. Secure the wires with the four screws.

6. Torque the screws on terminals 1 and 2 to 1 N�m (9 in-lb).

7. Torque the screws on terminals 3 and 4 to 2 N�m (18 in-lb).

8. Replace the clear protective shield that you removed earlier in thisprocedure.

WARNING: Replace protective shields immediately after testprocedures or maintenance. Removing protective shieldspermanently exposes you to electrical shock.



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Manual 41-190

Follow this procedure to replace any of the light bulbs in the unit exceptone of the bulbs in the optional warning light tower. If you need toreplace a light bulb in the optional warning light tower, refer to ReplacingLight Tower Bulbs in this section.



2. Unscrew the lens of the light that is not working by turning the lenscounterclockwise.

NOTE: If the whole bulb assembly turns when you turn the lens,open the electrical cabinet and hold the back of the light socket whileturning the lens. Refer to Opening the Electrical Cabinet Door in theInstallation section as needed.

3. Remove the lens. If you are replacing one of the light bulbs on themechanical control panel, you may need to remove one or moreadditional parts as well.

4. Remove the old light bulb from the socket by pulling it straight out.

4710233

Fig. 7-29 Removing a Lens and Bulb

Replacing a Light Bulb

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Manual 41-190

5. Install a new bulb in the socket.

6. Replace the lens and any other parts you removed earlier in thisprocedure.


Follow this procedure to replace any of the fuses in your unit’s electricalcabinet.

NOTE: Before replacing any fuse, determine what caused the fuse toblow. A blown fuse is the result of some problem in the unit. Refer toFuse Replacement Table in the Parts section as needed for replacementpart numbers.

WARNING: Risk of electrical shock. Failure to disconnect andlock out power can result in personal injury or death.

1. Disconnect and lock out input power to the unit.

2. Open the electrical cabinet door. Refer as needed to Opening theElectrical Cabinet Door in the Installation section.

3. Remove the clear Lexan covers.

4. Remove the blown fuse. Fuses FU-1—FU-26 are contained in fuseblocks on the back panel of the electrical cabinet. Any of the boardfuses on boards AP2 and AP4 can be removed by pulling the fusestraight out from the board.

5. Determine the correct replacement fuse from the Fuse ReplacementTable in the Parts section.

6. Install the replacement fuse.

7. Reinstall the clear Lexan covers.



Replacing a Light Bulb (contd.)

Replacing Fuses

4904117

2

1

3

4

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Manual 41-190



2. Using a flat blade screw driver, remove the screw from the light towercover and pull the cover off the tower. Lift out the washer that rests inthe first lens and place it with the cover.

3. Remove the screw from the lens, then gently pull the lens off thetower. (Continue removing lenses until you have removed the lenswith the burned-out bulb.)

4. Invert the lens to see the bulb. Press the bulb down and twist itcounterclockwise so that it pops out of its socket.

NOTE: If you determine that the light tower assembly (instead of abulb) should be replaced, refer to Replacing the Light TowerAssembly later in this section.

Fig. 7-30 Accessing Light TowerBulbs

1. Cover screw2. Cover3. Washer4. Lens screw

Replacing Light Tower Bulbs

4904118

1

2

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5. Insert a new bulb by pressing it into the socket and turning itclockwise.

6. To replace the lens, align the feedthrough contacts with slots in theadjoining base (or lens) and press it into place. Insert and tighten thelens screw. (Continue replacing all lenses you removed.)

7. After you replace the top lens, replace the washer, place the towercover over the top lens, and replace and tighten the cover screw.


Fig. 7-31 Inserting a Bulb

1. Bulb2. Feedthrough contacts

WARNING: Risk of electrical shock. Failure to observe mayresult in equipment damage, personal injury, or death.

1. Place the main disconnect switch in the OFF position. Disconnectand lock out power.


3. Inside the cabinet, disconnect the light-tower electrical connector fromthe four-pin connector (marked X−9) near the light-tower mountinghole.

4. Remove the screws that secure the light tower to the cabinet and liftthe assembly off the unit.

5. Install the new light tower assembly according to instructions in theInstallation section, Installing the Light Tower.

6. Close the electrical cabinet.

7. Restore power and resume normal operation.

Replacing Light Tower Bulbs (contd.)

Replacing the Light TowerAssembly

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Manual 41-190

If you replace the motor overload relay (KL1), ensure the following valuesare set according to the table below.

Table 7-7 Overload Relay (KL1) SettingsÁÁÁÁÁÁÁÁÁÁÁÁ

Dial ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ValueÁÁÁÁÁÁÁÁÁÁÁÁ

AmpÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

10 AmpsÁÁÁÁÁÁÁÁÁÁÁÁReset Method

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMANÁÁÁÁÁÁ


ResetÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

R (the dial points to 9:00; blue part should protrudefrom the surface of the relay)

4904183

1

2

3

Fig. 7-32 KL1 Overload Relay Settings

1. Amp dial2. Reset method dial

3. Reset button

Configuring a ReplacementMotor Overload Relay (KL1)

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Manual 41-190

Perform these procedures to replace the hopper thermostat, RTD sensor,or heater.

General Preparation

WARNING: Allow only qualified personnel to perform electricalrepairs. Observe the safety instructions.



2. Remove the hopper enclosure and corner enclosure. Refer toRemoving the Hopper Enclosure and Unit Cover and Removing theCorner Enclosure earlier in this section.

NOTE: Remove only the hopper enclosure if you are replacing onlythe heater.

3. Now follow instructions below for the component you are replacing.

Replacing the HopperThermostat, RTD Sensor, orHeater

4904149

2

1

3

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To Replace the Hopper Thermostat

1. Remove the two fillister head screws that secure the thermostat to thehopper.

2. At the XT-15 terminal block, note which numbered block thethermostat leads are connected to. Then disconnect the thermostatleads.

3. Coat the mounting surface of the new thermostat with heat sinkcompound and secure the thermostat to the hopper with the fillisterhead screws.

4. Connect the new thermostat leads at the XT-15 terminal block.

5. Replace all insulation and enclosures.


Fig. 7-33 Removing the Old HopperThermostat

1. Thermostat2. Fillister head screws3. XT-15 terminal block

4904150

2

1

3

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To Replace the Hopper RTD

1. Remove the pan head retaining screw from the RTD mounting blockon the side of the hopper and remove the RTD.

2. At the XT-15 terminal block, note which numbered block the RTDleads are connected to. Then disconnect the RTD leads.

3. Coat the new RTD with heat sink compound and insert it into themounting block. Replace the retaining screw.

4. Connect the new RTD wire leads to the XT-15 terminal block.



Fig. 7-34 Removing the Old HopperRTD Sensor

1. RTD sensor2. Pan head retaining screw3. XT-15 terminal block

4903009

1

234

1. Spot welds2. Spring3. Nut4. Heater

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To Replace the Hopper Heater

1. Loosen the nut on each T-bolt clamp assembly until the clamp isloose.

2. Remove the ceramic terminal covers and disconnect the heater leadsat the heater.

Fig. 7-35 Loosening the ClampAssemblies

3. Remove the nuts and washers from the pan screws that secure theheater to the side of the hopper. Carefully remove the heater.

4904151

43

1

2

98 7

5

6

Fig. 7-36 Removing the Old Hopper Heater

1. Pan head screw2. Heater3. Flat washer4. Hex jam nut5. Heater leads (2)

6. Terminals (2)7. Washers (2)8. Nuts (2)9. Ceramic terminal covers (2)

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To Replace the Hopper Heater (contd.)

4. Align the slotted hole in the new heater with the exposed pan headscrews on the hopper and mount the heater onto the hopper. Makesure that the two terminals for the heater leads are near the bottom ofthe hopper.

NOTE: Coat the screws with Loctite adhesive.

5. Use a flat washer and hex jam nut from the kit and finger-tighten theheater to the hopper.

6. Attach the heater leads to the terminals of the new heater.

7. Replace the washers and nuts that secure the leads to the heater,and replace the two ceramic covers onto the heater terminals.

8. Reposition each clamp assembly in its place, adjusting the clampassembly so that the spot welds that secure the T-bolt are as close tothe corner of the hopper as possible. Tighten the nuts on the T-boltsto snug the assembly against the hopper.

NOTE: Make sure that the spot welds are facing away from thehopper.

NOTE: Alternately tighten each nut of the clamp assembly so thatpressure is applied equally. Otherwise, one side of the clampassembly will fit tighter than the other against the hopper and mayresult in the heater not making full contact with the hopper.

9. Apply 1.69 Nm (15 in-lb) of torque to each nut on the clampassembly. A visible gap should remain between the coils of thespring to provide room for the aluminum hopper to expand whenheated.

10. Replace the hopper insulation and enclosure.


4904152

2

1

3

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Manual 41-190

Follow the procedures below to replace the grid thermostat or RTDsensor.

General Preparation




2. Remove the hopper enclosure, the unit cover, and the cornerenclosure. Refer to Removing the Hopper Enclosure and Unit Coverand Removing the Corner Enclosure earlier in this section.


To Replace the Grid Thermostat

1. Remove the two fillister head screws that secure the thermostat to thegrid.


3. Coat the mounting surface of the new thermostat with heat sinkcompound and secure the thermostat to the grid with the fillister headscrews.

4. Connect the thermostat leads at the XT-15 terminal block.



Fig. 7-37 Removing the Old GridThermostat

1. Thermostat2. Fillister screws3. XT-15 terminal block

Replacing the Grid Thermostator RTD Sensor

3

1

4

2

4904153

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Manual 41-190

To Replace the Grid RTD

1. Remove the pan head screw that secures the strap for the RTD leadsto the grid.

2. Slide the RTD out of the grid.


4. Coat the new RTD with heat sink compound and insert it into the grid.Replace the strap that secures the RTD lead wires to the grid.

5. Connect the RTD wire leads to the XT-15 terminal block.



Fig. 7-38 Removing the Old GridRTD

1. RTD sensor2. Pan head screw3. Strap4. XT-15 terminal block

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Follow the procedures below to replace the reservoir thermostat or RTDsensor.

General Preparation




2. Remove the hopper enclosure, the unit cover, and the cornerenclosure. Refer to Removing the Hopper Enclosure and Unit Coverand Removing the Corner Enclosure earlier in this section.


Replacing the ReservoirThermostat or RTD Sensor

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To Replace the Reservoir Thermostat

1. Remove the two fillister head screws that secure the thermostat to thereservoir.


4904154

21

3

Fig. 7-39 Removing the Old Reservoir Thermostat

1. Thermostat2. Fillister head screws3. XT-15 terminal block

3. Coat the mounting surface of the new thermostat with heat sinkcompound and secure the thermostat to the reservoir with the fillisterhead screws.

4. Connect the thermostat leads at the XT-15 terminal block.



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To Replace the Reservoir RTD

1. Lift the old RTD out of the reservoir.


1

2 4904155

Fig. 7-40 Removing the Old Reservoir RTD

1. RTD sensor2. XT-15 terminal block

3. Coat the new RTD with heat sink compound and insert it into thereservoir.




Repair7-72


107 144DIssued 3/99

Manual 41-190

Follow the procedures below to replace the manifold heater or RTDsensor.

General Preparation




2. Remove all enclosures and covers and insulation. Refer to Removingthe Hopper Enclosure and Unit Cover and Removing the CornerEnclosure earlier in this section.

3. Now follow instructions for the component you are replacing.

Replacing the Manifold Heateror RTD Sensor

Repair 7-73


107 144DIssued 3/99

Manual 41-190

To Replace the Manifold Heater

1. Disconnect the heater wire leads from the ceramic terminal block atthe back of the cabinet and pull the leads out of the block.

2. Push the leads into the back of the heater housing so that the heaterprotrudes from the cartridge bore in the front of the housing. Graspthe heater and pull it out.

4904156

213

4

Fig. 7-41 Removing the Manifold Heater Cartridge

1. Heater cartridge protruding fromthe cartridge bore

2. Heater housing

3. Heater cartridge wires4. Ceramic terminal block

3. Install wire ferrules over the ends of the new heater’s wire leads.

4. Install the new heater by placing the wire leads into the cartridge boreon the front of the housing and pushing the heater into the bore.

5. Insert the wire leads into the ceramic terminal block.



Repair7-74


107 144DIssued 3/99

Manual 41-190

To Replace the Manifold RTD

1. Cut the strip of tape that secures the insulation to the bottom of themanifold.

2. Unscrew and remove the three hex head cap screws and flat washersthat secure the heater housing to the manifold.

3. Insert a flat screwdriver blade between the heater housing and themanifold. Pry the housing away from the manifold to break the seal.

4. Pull the RTD out of the back of the housing.


4904157

53

24

1

Fig. 7-42 Removing the Manifold RTD Sensor

1. Heater housing2. RTD wires3. Flat washers

4. Hex head cap screws5. XT-15 terminal block

Repair 7-75


107 144DIssued 3/99

Manual 41-190

6. Coat the new RTD with heat sink compound and slide it into the rearof the heater housing.

7. Apply a layer of heat sink compound to the smooth surface of theheater housing.

8. Mount the heater housing so that the heat sink compound contactsthe manifold and the cartridge bore is toward the inside of the unit.

9. Install and tighten the three flat washers and hex head cap screwsthat secure the housing to the manifold.


11. Replace the insulation against the bottom of the manifold and secureit with insulation tape.



4904158

12

Repair7-76


107 144DIssued 3/99

Manual 41-190

After servicing any component in the gas circuit, be sure to:

� Ensure there are no gas leaks.� Ensure there are no air leaks.� Check that pressure can be achieved.

Follow these procedures to prepare for gas/pneumatic repairs.

WARNING: Cylinders of compressed gas are under highpressure and can present significant safety hazards if handledimproperly. Follow all safety precautions that apply to the use,handling and storage of compressed gases.

1. Shut off the gas supply at the gas cylinder and turn the cylinder’s gasregulator to zero.

2. Disconnect the gas supply from the FM-190 processor.



Fig. 7-43 Disconnecting the GasSupply

1. Supply tube2. Quick disconnect fitting

5. Gas/Pneumatic Repairs

Preparing the System for GasRepairs

4904159

4

1

2

3

1. Gas pressure control assembly2. Bulkhead fittings3. Pan head screws4. Pump Outlet Pressure monitor

Repair 7-77


107 144DIssued 3/99

Manual 41-190

Follow the procedures below to replace the gas pressure regulator, gasgauge, or Reedex valve.

General Preparation

1. Perform procedures described earlier in Preparing the System forGas Repairs.

2. Remove the 4 pan head screws and lockwashers that secure the gaspressure control assembly to the cabinet. Then swing the controlassembly forward.

3. On the inside of the cabinet, disconnect the gas tubes from thebulkhead fittings by pressing the red connector towards the fitting torelease the tube.

4. Disconnect the two wires that attach to the Reedex valve on the backof the assembly panel.

NOTE: The wires are not polarized.

5. Pull the assembly out of the cabinet and place it on a work surface.


Fig. 7-44 Removing the GasPressure Control Panel

Replacing the Gas PressureRegulator, Gas Gauge, orReedex Valve

4904160

1

2

3

1. Gas pressure regulator2. Quick-disconnect fittings3. Panel assembly cover

4904161

1

3

4

2

Repair7-78


107 144DIssued 3/99

Manual 41-190

To Replace the Gas Pressure Regulator

1. With the panel assembly face down on a work surface, disconnect thetubing from the regulator at the quick-disconnect fittings.

2. Turn the assembly over and open the cover.

3. Loosen the set screw in the pressure regulator knob, then remove theknob.

Fig. 7-45 Gas Pressure RegulatorTubing

4. Remove the knurled trim nut and the locknut that secure theregulator, then remove the regulator from the rear of the panelassembly.

Fig. 7-46 Removing the RegulatorKnob

1. Set screw2. Knurled trim nut3. Locknut4. Knob

Repair 7-79


107 144DIssued 3/99

Manual 41-190

5. Position the new pressure regulator on the assembly and replace andtighten the locknut, then the knurled trim nut, to secure the regulator.

6. Replace the knob and tighten the set screw.

7. Reconnect the tubing at the quick-disconnect fittings.

8. Holding the panel assembly just outside its bay in the cabinet,reconnect the wires to the Reedex valve and the gas lines to thebulkhead fittings.

9. Position the panel assembly in the cabinet opening.

10. Replace and tighten the pan head screws that secure the panelassembly to the cabinet.

11. Reconnect gas lines and restore power. Be sure to check for leakson pressurized gas lines. Refer to Connecting the Gas Supply in theInstallation section for details.

Repair7-80


107 144DIssued 3/99

Manual 41-190

To Replace the Gas Pressure Gauge

1. With the panel assembly face down on a work surface, pull the tubingout of its fitting on the gas pressure gauge.

4904162

3

2

1

Fig. 7-47 Gas Pressure Gauge Tubing

1. Gas pressure gauge2. Fitting

3. Panel assembly cover

2. Turn the panel assembly over and open the cover.

3. On the front of the control panel, remove the pair of hex nuts andlockwashers that secure the gauge to the control panel assembly.Then remove the gauge from the back of the panel assembly.

4. Place the new gauge on the assembly and insert and tighten thescrews and lockwasher to secure the gauge in place.

5. Reconnect the tubing to the fittings on the back of the gauge.

6. Holding the panel assembly just outside its bay in the cabinet,reconnect the wire leads to the Reedex valve and the gas lines to thebulkhead fittings.

4904163

3

2

2

1

1. Reedex valve2. Fitting3. Panel assembly cover

Repair 7-81


107 144DIssued 3/99

Manual 41-190


8. Replace and tighten the pan head screws that secure the panelassembly to the cabinet.


To Replace the Reedex Valve

1. With the panel assembly face down on a work surface, pull tubingfrom fittings at both ends of the Reedex valve.

2. Turn the panel assembly over and open the cover.

3. On the front of the control panel, remove the two screws that securethe valve to the control panel assembly. Then remove the valve fromthe back.

4. Place the new valve on the assembly and insert and tighten thescrews to secure the valve in place.

5. Reconnect the tubing to the fittings at both ends of the valve.

6. Holding the panel assembly just outside its bay in the cabinet,reconnect the wires to the Reedex valve and the gas lines to thebulkhead fittings.

Fig. 7-48 Reedex Valve Tubing

NOTE: The wires are not polarized.


8. Replace the pan head screws to secure the panel assembly to thecabinet.


Repair7-82


107 144DIssued 3/99

Manual 41-190

The gas pressure check valve is located on the manifold above thepressure control valve. The valve ensures that no hotmelt flows into thegas line.

Replace the check valve if hotmelt clogs it and prevents gas flow.




2. Remove the hopper enclosure, unit cover, and corner enclosure.Refer to instructions for removing enclosures earlier in this section.

3. Disconnect the tubing from the valve, then unscrew the valve andremove it.

4904165

Fig. 7-49 Removing the Gas Pressure Check Valve

Replacing the Gas PressureCheck Valve

Repair 7-83


107 144DIssued 3/99

Manual 41-190

4. Installation is the reverse of disassembly.

NOTE: Be sure to install the new check valve so the arrow on thevalve body points down.

NOTE: Coat the check valve threads with PTFE paste beforeinstallation.

5. Replace all covers and enclosures and restore the unit to normaloperation. Refer to Routine Operating Procedures in the Operationsection.

The gas pressure switch is located inside the base frame cabinet and isaccessed through an opening with a removable panel in the back of theunit. The switch detects low pressure in the gas supply cylinder.

Replace the switch if you cannot raise the gas pressure or when the gaspressure gauge in the Gas Pressure Control Panel is at zero and theLOW GAS light is off.


2. Remove the access panel at the back of the unit.

3. Inside the cabinet, carefully cut the heat shrink material off the switchand remove the wire leads from the switch.

4904164

1

3

2

Fig. 7-50 Accessing and Removing the Gas Pressure Switch

1. Access opening2. Gas pressure switch

3. Wire leads

Replacing the Gas PressureSwitch

Repair7-84


107 144DIssued 3/99

Manual 41-190

4. Unscrew the switch from the special tee fitting.

5. Screw the new switch into the tee fitting and connect the wire leads tothe new switch.

NOTE: Coat the threads of the new pressure switch with PTFE pastebefore installation.

NOTE: Wrap the bare wire terminals with electrical tape.

6. Replace the access panel.


The I/P transducer is located inside the base frame cabinet and isaccessed through an opening with a removable panel in the back of theunit. The transducer converts electrical impulses into an air pressureequivalent and controls air flow to the pressure control valve. Thetransducer enables the system to adjust hydraulic pressure in responseto variable line speeds (in automatic mode) or to manual adjustment ofelectrical impulses.

The pressure gauge on the I/P transducer should change (up or down)when you manually adjust electrical impulses using the potentiometer.Replace the I/P transducer when the gauge is obviously inaccurate orbroken.

1. Turn off the air supply to the processor.

2. Remove the access panel on the back of the unit.

3. Disconnect tubing from the transducer at the quick-disconnect fittingsfor both the input and output air. (Push the connector towards thefitting to release the tube and pull the tube out of the fitting.)

4. Unplug the electrical wire leads for the I/P.

Replacing the Gas PressureSwitch (contd.)

Replacing the I/P Transducer

Repair 7-85


107 144DIssued 3/99

Manual 41-190

5. Remove the screws and lockwashers that secure the transducer tothe unit and remove the transducer assembly.

4904166

3

2

2

5

4

1

Fig. 7-51 Removing the I/P Transducer

1. I/P Transducer2. Tubing3. Access panel

4. Screws and lock washers5. Wire lead quick-disconnect

Installation is the reverse of disassembly.

Repair7-86


107 144DIssued 3/99

Manual 41-190

The pressure transducer is composed of two diaphrams separated by ametal conduit. One diaphram is located on the reservoir near thethermostat. The second valve is clamped to the back of the unit. Thetransducer assembly converts hydraulic pressure into electrical signalsthat display the pump outlet pressure on the pressure monitor display.

Replace the pressure transducer assembly when the digital display onthe Pump Outlet Pressure monitor is obviously inaccurate or broken.

NOTE: Solidified hot melt material on the valve surface or inside thereservoir block may make it difficult to install the valve. To easeinstallation and avoid damage to the o-rings, bring the applicator tooperating temperature at zero pressure before attempting to install thetransducer.






3. Remove the hopper enclosure, unit cover, and corner enclosure.(Refer to instructions for removing enclosures earlier in this section.)

Replacing the PressureTransducer Assembly

Repair 7-87


107 144DIssued 3/99

Manual 41-190

4. At the reservoir, turn the transducer’s hex nut nearest the reservoircounterclockwise to screw the transducer off the unit.

4904168

Fig. 7-52 Removing the Pressure Transducer at the Reservoir

5. Loosen the screw on the clamp that holds the transducer valve to theback of the unit and remove the valve.

6. Disconnect the electrical connector to the transducer.

7. Remove both ends of the transducer valve assembly and the metalconduit pick-up wire from the unit.

4904167

Fig. 7-53 Removing the Pressure Transducer Valve from the Rear of the Unit

Repair7-88


107 144DIssued 3/99

Manual 41-190

8. Lubricate the new valve’s threads with Never Seez and the o-ringswith o-ring lubricant.

9. Install the appropriate valve in the clamp at the back of the unit andfirmly tighten the clamp.

10. Reconnect the wire leads.

11. Place the pick-up conduit across the reservoir and screw the otherend of the transducer valve assembly into the reservoir.

12. Replace all covers and enclosures, reconnect power, and restore theunit to normal operation (refer to Routine Operating Procedures in theOperation section).

Replacing the PressureTransducer Assembly (contd.)


107 144DIssued 3/99

Manual 41-190

Section 8

Parts

Parts8-0


107 144DIssued 3/99

Manual 41-190

Parts 8-1


107 144DIssued 3/99

Manual 41-190

Section 8Parts

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (−) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

− 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

1. Introduction

Using the Illustrated Parts List

Parts8-2


107 144DIssued 3/99

Manual 41-190


1 225 621 Base, pedestal 1

2 981 145 Screw, pan-head, slotted, 10-24 x 0.50 in. 2

3 186 077 Terminal block, XT-15 1 A

4 983 192 Washer, flat, regular, M10 3

5 982 616 Screw, hex-head, machine, M10 x 25 3

6 983 010 Washer, flat, 0.188 x 0.375 x 0.040 in. 2

7 983 110 Lockwasher, external, #8 2


9 147 465 Bracket, hose connector 1

10 984 111 Nut, hex, #8-32 2

11 229 949 Plate assembly, air control 1

12 982 712 Screw, truss head, slotted, 1/4-20 x 0.750 in. 4

13 229 956 Frame assembly w/insulation 1

14 983 515 Washer, flat, 0.406 x 1.00 x 0.063 in. 3

15 983 160 Lockwasher, split, 3/8 3

16 984 163 Nut, hex, 3/8-16 3

17 225 337 Terminal block, 380 V 1

18 981 028 Screw, fillister head, 6-32 x 0.750 in. 1

NOTE A: Refer to Terminal Blocks Parts List.

2. Base and FrameAssembly Parts List

Parts 8-3


107 144DIssued 3/99

Manual 41-190

4904101

1

2

3

45

67

8

10

9

12

13

14

15

16

11

17, 18

Fig. 8-1 Base and Frame Assembly

Parts8-4


107 144DIssued 3/99

Manual 41-190


1 981 233 Screw, socket, 1/4-20 x 1.00 in. 3


3 148 142 Heatsink, manifold, Left 1 A

4 365 026 Spacer, 10-32, male-female 4 B

5 236 146 Hydraulic/heating assembly 1 C

6 270 672 Key, 3/16 in. square x 0.81 in. long 1

7 310 362 Transducer assembly w/plug, pressure 1

— 310 361 � Transducer assembly, pressure 1

— 933 312 � Connector, cap, 3-pin 1

— 939 110 � Strap, cable, 0.875 in. 2

8 310 452 Clamp, loop, 0.875 in. ID 1

9 983 011 Lockwasher, internal, #8 1


11 983 255 Washer, flat, 0.406 x 1.250 x 0.10 in. 6

12 984 163 Nut, hex, 3/8-16 6

13 310 229 Assembly, valve, pressure control 1 D

14 983 123 Washer, Flat, 0.219 x 0.500 x 0.048 in. 4

15 110 980 Transducer, assembly, I/P 1

NS 101 695 � Transducer, current-to-pressure 1

NS 939 110 � Strap, cable, 0.06−0.75, natural 3

NS 939 877 � Wire, vinyl, 22 AWG, blue 1

NOTE A: Apply heat sink compound, part 900 298.

B: Apply cylindrical retaining adhesive, part 900 463.

C: Refer to Hopper Assembly Parts List.

D: Refer to Pressure Control Valve Assembly Parts List.

NS: Not Shown

3. Melting System Parts List

Parts 8-5


107 144DIssued 3/99

Manual 41-190

4904102

5

12 3

4

6

7

8

7 9

10

11

12

13

14

15

Fig. 8-2 Melting System

Parts8-6


107 144DIssued 3/99

Manual 41-190


1 273 434 Bushing, sprocket 1

— - - - - - - � Screw, 10-24 3

2 983 120 Lockwasher, E, split, #10, steel, nickel-plated 3

3 273 432 Sprocket, timing belt, FM-B 1

4 310 850 Belt, timing, 30 x 800 mm, high-temperature 1

5 273 435 Sprocket w/key, seat, motor 1

6 981 736 Screw, set, w/Nylok, 1/4-20 x 0.375 in., zinc-plated 1 A

7 983 515 Washer, flat, E, 0.406 x 1.000 x 0.063 in., zinc-plated 4

8 981 732 Screw, hex-head, 3/8-16 x 0.875 in., zinc-plated,grade 5

4

9 983 160 Lockwasher, E, split, 3/8, steel, nickel-plated 4

10 310 393 motor assembly 1

— 310 460 � Motor, DC, 2 HP, 1200 rpm 1

— 933 163 � Connector, pin, 22-18 AWG, tin 2

— 933 191 � Connector, pin, 20-14 AWG, tin 2


11 981 402 Screw, hex-head, cap, 3/8-16 x 1.00 in., zinc-plated 4



14 310 449 Strap, wire 2

15 981 074 Screw, round, slotted, 8-32 x 0.50 in., zinc-plated 4

16 983 011 Lockwasher, E, internal, #8, steel, zinc-plated 4

17 229 947 Sensor assembly, magnetic 1

— 225 623 � Sensor, magnetic pickup 1


— 933 437 � Pin, 24-18 gauge, gold 3

— 931 000 � Sleeving, insulation, 0.129 in. ID 1 B

18 221 635 Bracket, speed sensor mounting 1

19 273 864 Clamp, ring, belt base 1

20 981 233 Screw, socket, 1/4-20 x 1.00 in., zinc-plated 1

21 147 466 Plate, belt, painted 1


23 981 906 Screw, socket, 1/4-20 x .750 in., zinc-plated 4

NOTE A: Use key provided with item 10.

B: Order this part by the foot. Trim to suit your needs. Need 5.5 in. maximum.

4. Motor AssemblyParts List

Parts 8-7


107 144DIssued 3/99

Manual 41-190

4904103

1

2

3

4

5

6

7

8

9

15

1418

23

22

21

19

15

16

10

11

12

13

20

17

16

1

Fig. 8-3 Motor Assembly

Parts8-8


107 144DIssued 3/99

Manual 41-190


1 939 110 Strap, cable, 0.875 in. 6

2 229 962 Grommet, extruded, cont, 0.125 in. 1

3 310 452 Clamp, loop, 0.875 in. ID 1

4 981 597 Screw, pan-head, 6-32 x 0.50 in. , slotted, zinc-plated 5 A

5 939 004 Strap, cable, 0.06-1.75 in., natural 3

6 984 101 Nut, hex-head, machine, # 6-32, steel 24

7 983 102 Lockwasher, E, split, # 6, Steel 24

8 274 650 Gasket, connector, cordset, unit 6

9 221 645 Panel, connector, 6-hose port 1

10 274 653 Cover, connector, socket, 12-Pin 6

11 983 010 Washer, flat, E, 0.188 x 0.375 x 0.040 in. 4

12 983 110 Lockwasher, E, external, # 8 4


14 981 511 Screw, pan-head, slotted, 6-32 x 0.50, black 24

15 310 717 Tubing, PFA, 0.25 in. OD x 0.12 in. ID 1

16 229 959 Clamp, nylon, 0.187 in. 3 A

17 970 979 Clamp, cable, 0.375 in. 2


19 970 973 Clamp, nylon, 0.625 in. 1

20

21

22

310 384

981 028

225 337

Tubing, PFA, 1/16 in. ID x 1/8 in. OD

Screw, fillister, 6-32 x 0.750 mm

Terminal block, 380 V

1

1

1

NOTE A: One not shown.

5. Routing HardwareParts List

Parts 8-9


107 144DIssued 3/99

Manual 41-190

4904104

1

2

3 4

5

6 7

8 9

10

1112

13

14

2

4, 17

20 19, 18

17, 4 116, 4

15

21, 22

Fig. 8-4 Routing Hardware

Parts8-10


107 144DIssued 3/99

Manual 41-190


1 - - - - - - Electrical cabinet 1

2 229 950 Insulation, enclosure, assembly 1 A

3 229 951 Insulation, enclosure, corner 1 A

4 275 936 Screw, captive, 10-32 x 0.750 in., steel 4

5 983 120 Lockwasher, E, split, #10, steel, nickel-plated 4

6 310 397 Lid assembly

— 111 663 � Screw, shoulder, slotted, 6-32 x 0.50 in. 3

— 111 664 � Spacer, al, 0.125 in. ID x 0.25 in. OD x 0.37 in. 6

— 240 475 � Hinge, loading lid 1

— 275 366 � Brace, ball stud, retainer 3

— 310 403 � Lid, inner 1

— 310 404 � Lid, outer 1

— 310 435 � Handle, Lid 1

— 900 419 � Adhesive, retaining cylindrical

— 902 522 � Retainer, stud, 0.028 in. 3

— 902 523 � Stud, serrated 3

— 981 105 � Screw, pan-head, slotted, 10-24 x 0.375 in.zinc-plated

2

— 983 101 � Lockwasher, E, internal, #4, steel, zinc-plated 6

— 983 121 � Lockwasher, E, external, #10, steel, zinc-plated 2

— 984 104 � Nut, hex-head, machine, #4-40, steel, zinc-plated 6

— 985 101 � Rivet, blind, 3/32 x 0.125 in., aluminum 6

7 310 405 Pan, condensate 1

8 229 952 Enclosure assembly, hopper 1

9 229 945 Cover assembly, unit 1

10 981 105 Screw, pan-head, slotted, 10-24 x 0.375 in., zinc-plated

3

11 983 121 Lockwasher, E, external, #10, steel, zinc-plated 3

12 227 702 Cover, belt 1

13 982 712 Screw, truss, slotted, 1/4-20 x 0.750, black 17

14 226 170 Enclosure, corner 1

15 981 860 Receptacle, No.12, clip-on 1

16 981 239 Screw, hex-head, cap,1/4-20 x 0.50 in., zinc-plated 2


18 310 490 Cover, manifold 1

19 981 861 Screw, quick-opening 1

20 981 862 Retainer, stud 1

21 101 844 Grommet, extruded, 0.06 x 0.44 in. 3.5 ft B

NOTE A: Apply rubber and gasket adhesive, part 900 409.

B: Order by the foot and trim as required.

6. Enclosures Parts List

Parts 8-11


107 144DIssued 3/99

Manual 41-190

4904105

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÏÏÏÏ

ÏÏÏÏ

1

2

3

4

5

6

7

8

9

10

11

1213

1416

1718

19, 20

13

15

13

13

21

21

Fig. 8-5 Enclosures

Parts8-12


107 144DIssued 3/99

Manual 41-190


1 365 352 Seal, extrusion, hopper, 4 ft 1

2 310 477 Hopper, PTFE coated, heated 1

3 981 571 Screw, pan-head, slotted, 1/4-20 x 0.625 in., zinc-plated

2 A

4 189 605 Heater, strip, 1.50 x 19.50 in. 2 B

5 984 210 Nut, hex-head, jam, 1/4-20, steel, zinc-plated 2


7 190 294 Clamp, heater, FM-180 6

8 805 002 Cover, ceramic terminal 4

9 981 586 Screw, hex head, 5/16-18 x 5.50, zinc-plated, grade 8 6

10 310 431 Washer, belleville, 5/16 in. ID 32


12 981 000 Screw, fillister, slotted, 5-40 x 0.250 in., zinc-plated 2

13 234 006 Thermostat assembly, hopper 1 B

— 939 740 � Thermostat, open-on-rise, 500 F 1

— 273 730 � Insulator, thermostat, electric 1

— 972 815 � Ferrule, wire, 18 AWG, insulated, red 2

— 939 009 � Markers,wire, 1-99, A−Z

14 234 013 RTD assembly, hopper 1 B

— 939 739 � Sensor, temp RTD, w/48-in. leads 1

— 972 849 � Ferrule, wire, 22 AWG, insulated, white 2

— 931 000 � Sleeving, insulation, 0.129 in. ID 2 ft

— 939 110 � Strap, cable, 0.06-0.75 in., natural 1

— 939 009 � Markers, wire, 1-99, A−Z

15 981 729 Screw, pan head, slotted, 10-32 x 0.375 in., zinc-plated

1

16 981 509 Screw, hex-head, 5/16-18 x 60.50, zinc-lated, grade 8 2

17 234 003 Jumper, heater, FM-190 2

NOTE A: Apply threadlocking adhesive, part 900 470.

B: Apply heat sink compound, part 900 298.

7. Hopper Assembly PartsList

Parts 8-13


107 144DIssued 3/99

Manual 41-190

4904108

1

2

34

5

6

7

8

9

10

11

1213

14

15

7

10

11

8

4

5

6

3

16

17

Fig. 8-6 Hopper Assembly

Parts8-14


107 144DIssued 3/99

Manual 41-190


1 234 015 RTD Assembly, grid 1 A

— 939 739 � Sensor, temperature, RTD, w/48-in. leads 1



— 939 110 � Strap, cable, 0.06−0.75 in., natural 1

— 939 009 � Markers, wire, 1−99, A−Z, PSNC

2 234 004 Thermostat assembly, grid 1 A

— 939 740 � Thermostat, open-on-rise, 500 �F 1



3 981 000 Screw, fillister head, slotted, 5-40 x 0.250 in. 2


5 310 449 Strap, wire 1

6 310 480 Grid, sealed 1

7 310 325 Insulator, hopper/grid 1 B

8 310 324 Insulator, Reservoir/Grid 1 B

9 981 748 Screw, hex-head, cap, 1/4-28 x 1.750 in. 6

10 310 432 Washer, belleville, 1/4 in. ID 6

11 983 504 Washer, flat, 0.281 x 0.734 x 0.063 in. 2


13 147 427 Spacer, thermal 4

14 236 142 Drive assembly 1

15 272 859 Spacer, drive 1

16 144 469 Support, drive 1 B


18 236 145 Assembly, coupling, drive, standard 1 C

18 236 144 Assembly, coupling, drive, high-output 1 C

NOTE A: Apply heat sink compound, part 900 298.

B: Apply RTV reducing sealant, part 900 413.

C: Refer to Drive Coupling Assembly Parts List. Apply RTV reducing sealant, part 900 413.

8. Grid Assembly Parts List

Parts 8-15


107 144DIssued 3/99

Manual 41-190

4904109

1

2

3

4

8

119

16

17

12

5

610

7

13

14

12

9

18

15

Fig. 8-7 Grid Assembly

Parts8-16


107 144DIssued 3/99

Manual 41-190


1 981 452 Screw, hex-head, 5/16-18 x 5.000, zinc-plated,grade 8

2 A


3 234 011 RTD assembly, reservoir 1 B





— 939 009 � Markers, wire, 1−99, A−Z

4 310 479 Reservoir, sealed 1 C

5 973 543 Plug, o-ring, straight thread, 7/16-20 1 A


7 981 451 Screw, socket set, cup, 3/8-16 x 2.50, zinc-plated 3 D

8 984 140 Nut, hex-head, regular, 5/16-18, steel, zinc-plated 10


10 234 008 Thermostat assembly, reservoir 1 B

— 939 740 � Thermostat, open-on-rise, 500 F 1



— 939 009 � Markers, wire, 1−99, A−Z

11 981 000 Screw, fillister, slotted, 5-40 x 0.250, zinc-plated 2

12 945 026 O-ring, Viton, 1/4 tube 1

13 972 006 Connector, 37�, hydraulic, 7/16-20, straight thread 1 A

14 310 362 Transducer assembly w/plug, pressure 1

15 236 151 Jumper, reservoir 1

NOTE A: Apply Never Seez lubricant, part 900 344.

B: Apply heat sink compound, part 900 298.

C: Apply RTV reducing sealant, part 900 413.

D: Apply retaining cylindrical adhesive, part 900 419.

9. Reservoir AssemblyParts List

Parts 8-17


107 144DIssued 3/99

Manual 41-190

4904110

1

2

3

4

5

12

11

10

2

9

8

7

6

13

14

15

Fig. 8-8 Reservoir Assembly

Parts8-18


107 144DIssued 3/99

Manual 41-190


1 984 204 Nut, hex-head, high, 1/4-28 2 A

2 983 140 Lockwasher, split, 1/4, steel, nickel-plated 2

3 983 503 Flat washer, 0.281 x 0.625 x 0.125 in. 2

4 310 171 Pump assembly, gear, FoamMelt, standard 1

— 139 351 Pump assembly, gear, FoamMelt, high-output 1

5 941 521 O-ring, Viton, 3.250 x 3.438 x 0.094 in. 1

6 940 111 O-ring, Viton, 0.301 in. ID x 0.070 in. W 1

7 236 139 Manifold, w/plugs, standard 1

— 138 730 Manifold, w/plugs, high-output 1

8 310 137 Valve, pressure relief, 1500 psi 1 B

— 940 121 � O-ring, Viton, 0.364 in. ID x 0.070 in. wide, brown 1

— 945 032 � O-ring, Viton, 3/8 tube 1

— 987 021 � Spring, compression, 0.900 x 0.265 in. OD x 0.051in.

1

9 983 050 Washer, flat, E, 0.344 x 0.625 x 0.063 in.,zinc-plated 15


11 190 500 Heater cartridge assembly 1

— 938 236 � Heater, cartridge, 0.375 in. diameter, 9.50 in. long,600 W, 240 V

1

— 972 815 � Ferrule, wire, 18 AWG, insulated, reducing 2Continued on next page

10. Manifold Assembly PartsList

Parts 8-19


107 144DIssued 3/99

Manual 41-190

Item NoteQuantityDescriptionPart

12 234 009 RTD assembly, manifold 1





— 939 009 � Markers, wire, 1−99, A−Z

13 190 296 Housing, heater cartridge 1

14 310 385 Screw, hex-head, cap, special, 5/16 3


16 981 451 Screw, socket set, 3/8-16 x 2.50 in., cup, zinc-plated 3 C

17 984 140 Nut, hex-head, regular, 5/16-18, steel, zinc-plated 7


19 940 161 O-ring, Viton, 0.614 in. ID x 0.070 in. wide, brown 3

20 310 229 Assembly, valve, run-up 1 D

21 236 152 Wire, ground, density control 1

22 - - - - - - Valve assembly, density control/filter 1 B, E

23 275 481 Valve assembly, drain 1 F

24 981 316 Screw, hex-head, cap, 5/16-18 x 1.50 in., zinc-plated 3

25 973 000 Nipple, steel, schedule 40, 1/8, 0.75 in. 1 G

26 901 131 Valve, check, 1/8 ports, 7 psi 1

27 971 157 Connector, male, hydraulic, compression, 1/8t x 1/8 NPT

1 G

NOTE A: Apply Never Seez lubricant, part 900 344.

B: Apply Parker o-ring lubricant, part 900 223.

C: Apply retaining cylindrical adhesive, part 900 419.

D: Refer to Pressure Control Valve Assembly Parts List.

E: Refer to Density Control/Filter Assembly Parts List.

F: Refer to Drain Valve Assembly Parts List.

G: Apply paste sealant, part 900 236.

Parts8-20


107 144DIssued 3/99

Manual 41-190

4904107

27

26

25

249

23

22

918

17

9

14

12

10

13

9

11

4

5

7

15

8

10

16

1

2

3

6

19

209

21

Fig. 8-9 Manifold Assembly

Parts 8-21


107 144DIssued 3/99

Manual 41-190


— 275 481 Valve assembly, drain 1

1 986 601 � Retaining ring, internal, 68, basic 1

2 954 028 � Back-up ring, single, 5/16 x 7/16 1

3 940 111 � O-ring, Viton, 0.301 ID x 0.070 wide 1

4 275 471 � Stem, assembly, drain valve 1

5 275 480 � Body, drain valve 1


7 275 472 � Spacer, drain valve 1

4904111

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

ÉÉÇÇÉÉÇÇ

3 4 5

7

1 2

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

6

Fig. 8-10 Drain Valve Assembly

11. Drain Valve AssemblyParts List

Parts8-22


107 144DIssued 3/99

Manual 41-190


— 310 229 Assembly, valve run-up 1

1 310 162 � Seat, valve, lapped 1


3 310 169 � Carrier, ball 1

4 987 051 � Spring, comp, 1.280 x 0.530 OD x 0.090 in. 1

5 310 161 � Body, valve 1

6 942 111 � O-ring, Viton, 0.812 x 1.062 x 0.125 in. 1

7 310 165 � Ring, stop 1

8 - - - - - - � Actuator assembly, valve, run-up 1

4904106

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

ÌÌÌÌ

ÌÌÌÌ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÑÑÑÑÑÑÑÑÑÑÑÑ

ÓÓÓÓÓÓ

ÌÌÌÌ

ÑÑ

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

ÌÌÌÌÌÌÓÓÓÓÓÓÇÇÇ

ÇÇÇ

ÌÌÌÌÌÌ

2 3 4 51 6 7 8

Fig. 8-11 Pressure Control Valve Assembly

12. Pressure Control ValveAssembly Parts List

Parts 8-23


107 144DIssued 3/99

Manual 41-190


— - - - - - - Valve, density controller/filter, standard 1

1 981 022 � Screw, fillister, slotted, 6-32 x 0.375 in., zinc-plated 1

2 983 253 � Washer, flat, E, 0.156 x 0.438 x 0.040 in.,zinc-plated

1

3 310 129 � Knob, adjustment 1

4 981 020 � Screw, pan-head, slotted, 6-32 x 0.250 in.,zinc-plated

2

5 941 240 � O-ring, Viton, 1.250 x 1.438 x 0.063 in. 1 A

6 310 123 � Core, density controller/filter 1 B

7 310 133 � Stop screw assembly 1

8 240 459 � Support, filter 1

9 310 124 � Slug, 2-hole 1

10 987 013 � Spring, compression, 2.535 x 0.488 in. OD x0.051 in.

1

11 310 131 � Tip w/ball assembly 1 B

12 161 106 � Screen, reinforced, 0.006 in. 1

13 310 125 � Rod, adjustment 1

14 310 246 � Bung with index plate, controller, density 1

15 986 305 � Clip, wire retaining 1

16 310 247 � Insulator, shaft, with o-rings 1 A

17 310 127 � Plate, insulator 2

18 310 130 � Tube, insulator 4

19 310 128 � Contactor, rod 1

20 983 111 � Lockwasher, E, split, #8, steel, zinc-plated 4

21 981 705 � Screw, socket, 8-32 x 1.000, zinc-plated 4

22 983 102 � Lockwasher, E, split, #6, steel, zinc-plated 1

23 981 045 � Screw, socket set, 6-32 x 0.50, cup, black 2 C

NS - - - - - - � Vial, tube and cap assembly 1

NOTE A: Apply Parker o-ring lubricant, part 900 223.

B: Apply retaining cylindrical adhesive, part 900 419.

C: Apply threadlocking compound,part 900 424.

NS: Not Shown

13. Density Control/FilterAssembly Parts List

Parts8-24


107 144DIssued 3/99

Manual 41-190

ÌÌÌÌÌÌÌÌÌÌÌÌ

4904119

ÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔ

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

ÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔ

ÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌ

ÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔ

ÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉÉ

ST

D1 3 5 7 9 1113 15

1 2 3 4 5 6 7 8

22 21

20

17

19

18 16 15 14 13 12

11

10

17

9

23

Fig. 8-12 Density Control/Filter Assembly

Parts 8-25


107 144DIssued 3/99

Manual 41-190


— 236 144 Assembly, coupling, drive, FM-190, high-output 1

— 236 145 Assembly, coupling, drive, FM-190, standard 1

1 163 071 � Coupling, shaft, drive, FM-190 high-output 1

— 153 904 � Coupling, shaft, drive, FM-190, standard 1

2 985 417 � Pin, dowel, 0.188 x 1.000 in., hose & gun 1

3 987 030 � Sping, compression, 2.000 x 0.472 in.OD x0.038 in.

1

4 981 014 � Screw, pan-head, slotted, 4-40 x 0.250 in.,zinc-plated

1

5 144 693 � Sleeve, coupling, 1.25 in. OD x 1.00 in. 1

14. Drive Assembly PartsList

Parts8-26


107 144DIssued 3/99

Manual 41-190

4904120

ÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔÔ

ÌÌÌÌÌÌÌÌÌÌÌÌÌ

1

45 3 2

Fig. 8-13 Drive Shaft Assembly

Parts 8-27


107 144DIssued 3/99

Manual 41-190


1 221 690 Enclosure assembly 1

2 179 324 Gasket, membrane panel, N/D 1

3 - - - - - - Controller, standard 1 A

4 982 604 Screw, pan-head, thread-forming, M4 x 12 mm, black 10

5 229 066 Display assembly, RPM, complete 1 B

5 - - - - - - Motor controller assembly, Fenner 1 C

6 - - - - - - Gas controller 1 D

7 - - - - - - Pressure display 1 E

8 178 934 Bell, Sonalert 75 db 1

9 178 933 Alarm, Sonalert 90 db 1

10 - - - - - - Pressure and gas control panel assembly 1 F

11 186 087 Handle assembly with 5 ft cable, disconnect 1

NOTE A: Refer to System Controller Assembly Parts List.

B: Refer to Motor Controller or RPM Display for Standard Units Parts List.

C: Refer to Motor Controller for Gear-to-Line Units Parts List.

D: Refer to Gas Controller Parts List.

E: Refer to Pressure Display Parts List.

F: Refer to Pressure and Gas Control Panel Parts List.

15. Electrical Cabinet FrontPanel Exterior Parts List

Parts8-28


107 144DIssued 3/99

Manual 41-190

4904121

23

4

1

9

8

11

5

6

7

10

Fig. 8-14 Electrical Cabinet Front Panel Exterior

Parts 8-29


107 144DIssued 3/99

Manual 41-190


— - - - - - Motor controller assembly, fenner 1

1 138 707 � Fuse, 100 mA, fast-acting, 250 Vac 1

2 221 672 � Terminal block, XT-12 1 A

3 178 940 � Push-button, flush-head, illuminated 1

4 178 935 � Lamp holder w/1 normally-open contact 1

N/S 229 090 � Wire group, center, motor controller 1

5 148 354 � Motor control, M-drive, Nordson, I/O 1


NS: Not Shown

4904189A

XT12

2

14

3

5

Fig. 8-15 Motor Controller for Gear-to-Line Units

16. Motor Controller forGear-to-Line Parts List

Parts8-30


107 144DIssued 3/99

Manual 41-190


1 211 204 Cover, support bar 2

2 229 062 Gasket RPM panel 1

3 229 061 Panel, RPM indicator 1

4 229 066 Display, digital, RPM assembly, complete 1 A

5 983 416 Lockwasher, M, internal, M4, steel, zinc-plated 4

6 984 715 Nut, hex-head, M4, steel, zinc-plated 4

NS 939 113 Fuse, 20 A, non-time delay, 250 V 1

NOTE A: Mounting rails shown with item 4 are not part of this assembly

NS: Not Shown

4904179A

1

1

2

3

5

6

4

4

Fig. 8-16 RPM Display for Standard Units

17. RPM Display forStandard Units Parts List

Parts 8-31


107 144DIssued 3/99

Manual 41-190


1 221 684 Enclosure, gas assembly 1

2 223 894 Gasket, gas control 1

3 310 444 Tubing, 0.12 in. OD, nylon 3

4 982 675 Screw, pan-head, thread-forming, M5 x 12, black 4

5 971 292 Elbow, male, 1/8 tube x 1/8 NPT 3

6 310 284 Gauge, panel 1

7 982 261 Screw, pan-head, recessed, M3.5 x 10, zinc-plated 2

8 226 831 Washer, flat, M, 3.5 mm, steel, zinc-plated 2

9 983 424 Lockwasher, M, split, 3.5 mm, zinc-plated 2

10 984 714 Nut, hex-head, M 3.5, steel, zinc-plated 2

11 221 664 Panel, gas control 1

12 983 137 Washer, flat, M, regular, 4, black 4

13 983 116 Lockwasher, M, split, M4, black 4

14 226 898 Screw, machine, M, black-phos, M4 x 15,cross-recessed

4

15 223 892 Gasket, pressure assembly 1

16 223 895 Spacer, M4 x 6 mm x 6 mm 4

17 983 403 Lockwasher, M, split, M4, steel, zinc-plated 4

18 211 211 Cover assembly, pressure display 1

19 982 699 Screw, flat-head, recessed, M4 x 20, zinc-plated 8

20 221 657 Valve, Reedex 1

21 984 700 Nut, hex-head, M3, steel, zinc-plated 2

22 983 411 Washer, flat, M, narrow, M3, steel, zinc-plated 2


24 982 343 Screw, pan-head, recessed, M3 x 10, black 2

25 310 440 Regulator, air pressure 1

26 971 293 Union, bulkhead, 1/8 tube x 1/2-20 2

27 221 687 Cover, gas assembly 1

28 982 604 Screw, pan-head, thread-form, M4 x 12, black 6

18. Gas Controller Parts List

Parts8-32


107 144DIssued 3/99

Manual 41-190

4904124

11

18

1

28

275 25

20, 22, 23,.24 19

6, 7, 8, 9, 10

2

4

5

1213

14

15

3

1716

26

Fig. 8-17 Gas Controller Assembly

Parts 8-33


107 144DIssued 3/99

Manual 41-190


1 223 893 Gasket, pressure, readout 1

2 982 699 Screw, flat-head, recessed, M4 x 20, zinc-plated 4

3 221 688 Plate, adapter, pressure assembly 1

4 223 892 Gasket, pressure assembly 1

5 211 211 Cover assembly, pressure display 1

6 223 895 Spacer, M4 x 6 mm x 6 mm 4


8 365 341 Readout assembly, pressure 1

9 984 720 Nut, hex-head, M4, steel, zinc-plated, Nylok 4

19. Pressure Display PartsList

Parts8-34


107 144DIssued 3/99

Manual 41-190

4904122

9

8

1

2

3

4

7

6

5

Fig. 8-18 Pressure Display Assembly

Parts 8-35


107 144DIssued 3/99

Manual 41-190


1 178 935 Lamp, holder w/1 normally-open contact 3 A

2 221 659 Potentiometer, 10-turn, 2k ohm, water-wash, panelmount

1

3 221 649 Gasket, push button panel 1

4 221 647 Panel, push button control 1

5 178 940 Push button, flush-head, illuminated 3 A

6 223 907 Knob, vernier dial, 11-turn 1

7 179 332 Lamp, standard amber round pilot 1

8 221 658 Lamp, standard white round pilot 1

9 982 604 Screw, pan-head, thread-forming, M4 x 12, black 6

10 178 939 Lamp, holder block w/bulb, 22 mm 2

NS 184 529 Bulb 5

NOTE A: Standard (non-gear-to-line) units have only two holders and push buttons.

NS: Not Shown

4904127

1 23

4

5

6

8

9

10

7

Fig. 8-19 Pressure and Gas Control Panel

20. Pressure and GasControl Panel Parts List

Parts8-36


107 144DIssued 3/99

Manual 41-190


1 186 038 Tower assembly, light, 5000EX 1 A

2 211 218 Fitting, conduit, 90�, elbow 1

3 211 203 Gasket, heatsink 1

4 178 337 Heatsink, sold state relay mounting 1

5 272 122 Seal, conduit fitting, 1.00 in. 1

6 223 906 Cover, EMT, 0.062 in., foam rubber 1

7 223 909 Fitting, 1 in. conduit, straight EMT 1

8 223 908 Fitting, 1.25 in. conduit, straight EMT 1

9 274 385 Seal, conduit fitting, 1.25 in. 1

NS 982 680 Screw, hex, washerhead, threadfForming, M5 x 12 16

NOTE A: Refer to Light Tower Assembly Parts List.

NS: Not Shown

21. Heatsink Panel andAdjacent Main PanelExterior Parts List

Parts 8-37


107 144DIssued 3/99

Manual 41-190

4904116

1

2

3

4

5

7, 6

9

6, 8

Fig. 8-20 Heatsink Panel and Main Panel Exteriors

Parts8-38


107 144DIssued 3/99

Manual 41-190


— 186 038 Warning light tower assembly 1

1 - - - - - � Cover, light tower 1 A

2 336 089 � Lens, red (w/gasket) 1

3 336 090 � Lens, yellow (w/gasket) 1

4 220 986 � Bulb, 24 V 3

5 130 230 � Lens, green (w/gasket) 1

6 336 095 � Flange, mounting 1

7 336 098 � Gasket 1

8 189 805 � Harness, wiring 1

9 982 675 � Screw, pan-head, thread-forming, M5 x 12, black 4

10 336 091 � Tube 1

11 336 096 � Base, light tower 1

NOTE A: This part is included with item 11, the light tower base.

22. Light Tower AssemblyParts List

Parts 8-39


107 144DIssued 3/99

Manual 41-190

4710243

7

6

8

9

10

11

1

2

3

5

4

Fig. 8-21 Light Tower Assembly

Parts8-40


107 144DIssued 3/99

Manual 41-190


— 174 289 System controller assembly, standard, English 1

— 220 299 System controller assembly, standard, symbols 1

— 220 298 System controller assembly, standard, German 1

1 170 149 � Board, LED 1

2 174 285 � Panel, membrane, standard, English 1

— 220 306 � Panel, membrane, standard, symbols 1

— 185 877 � Panel, membrane, standard, German 1

NS 229 057 � Label, top FM-190 panel 1

NS 229 058 � Label, bottom FM-190, hose/gun panel 1

3 224 385 � Board, main controller 1

4 177 765 � Lens, lamp, red 1

5 177 764 � Socket, lamp, panel-mount 3

6 177 768 � Bulb, 24 VDC, T-2 pilot 3

7 177 766 � Lens, lamp, yellow 1

8 177 767 � Lens, lamp, green 1

9 983 003 � Washer, flat 9

10 983 102 � Lockwasher, split, No. 6 9

11 981 039 � Screw, pan-head, 6-32 x 0.312 in. 9

12 177 771 � Battery, 3.6 V, lithium 1

13 170 155 � Board, CPU 1

NS 184 878 � Standoff, hex-head, 6 x 32 9

NS 174 312 � Wire harness, lamp 1

NS 174 313 � Wire harness, keyswitch 1

NS 225 037 � Wire, braid, flat 3

NS 933 384 � Terminal, ringtong, Insulated, 12-10 2

NS 984 111 � Nut, hex, #8-32 1


23. System ControllerAssembly Parts List

Parts 8-41


107 144DIssued 3/99

Manual 41-190


14 183 690 Cable, ribbon, 34-pin 1 A




18 179 324 Gasket, controller 1

19 982 604 Screw, pan-head, thread-forming, M4 x 12 mm 10

NOTE A: Use part 186 025 to order a ribbon cable kit with all four cables used on the controller.

NS: Not Shown

4904169

2

1

12

14

15

17

3

19

16

4, 5, 6

7, 5, 6

8, 5, 6

9

10

11

13

18

Fig. 8-22 System Controller Assembly

Parts8-42


107 144DIssued 3/99

Manual 41-190


1 187 594 Bar, bus, ground 1

2 221 660 Lug, ground 4


4 221 653 Bracket, disconnect support 1

6 186 020 PCA, 21 channel interface, 5600 1

NS 120 995 Fuse, 5.0 A, slo-blo, 250 V, 5 x 20 mm 1 B

NS 177 676 Fuse, .063 A, slo-blo, 250 V, 5 x 20 mm 1 B

7 982 308 Screw, pan-head, M4 x 10 7

8 983 137 Washer, flat, reg, M4 7

9 983 116 Lockwasher, split, M4 7

10 186 089 Spacer, hex-head, threaded, steel, M4 7

11 186 078 Bracket, power, support supply 1

12 178 480 Power supply, AC-DC, 5 Vdc, 12 V 1


14 178 013 Fuse block, 1-pole, midget, pressure, Pl/QC 3

15 225 102 Fuse, slo-blo, 10 A, 500 V, 0.41 x 1.5 1


17 178 472 Rectifier, bridge 35 A, 100 V, full wave 1

18 982 602 Screw, pan-head, thread-forming, M4 x 16 7

19 178 015 Transformer, control, 240/18V 1

20 982 680 Screw, hex-head, thread-forming, M5 x 12 mm 4

21 221 666 Block, power terminal, 1.75 A, XT6 1 A

22 984 721 Nut, hex, M5, Nylok 2

23 221 674 Grommet, plastic, 2.0 in. diameter 2

24 - - - - - - Terminal block, XT-11, w/fuse block and relay 1 A

25 113 806 Clamp, cable, nylon, 0.25 in. diameter 1

26 - - - - - - Terminal block XT−10 w/24 Vdc and 5 Vdc powersupplies

1 A

27 229 053 Overload relay 1


B: Replacement fuse for item 6.


24. Main Panel Interior PartsList

Parts 8-43


107 144DIssued 3/99

Manual 41-190


28 229 052 Overload relay mounting kit 1

29 221 665 Terminal block, XT−7 1 A

30 220 998 Contactor, 3P, 40A cont, 24 Vdc coil 1

31 706 426 Fuse, KLK fast-acting,13/32 x 1.50, 12 A 2 C

31 706 426 Fuse, KLK fast-acting,13/32 x 1.50, 12 A 1 D

32 225 103 Fuse, slo-blo, 12, 600 V, 0.41 x 1.5 2 C

32 225 103 Fuse, slo-blo, 12, 600 V, 0.41 x 1.5 1 D

NS 706 424 Fuse, 6.00, fast-acting, 600 V A 2

NS 120 995 Fuse, 5 A, slo-blo, 250 V, 5 x 20 mm 11

NS 138 707 Fuse, 100 mA, fast-acting, 250 V, 5 x 2 2

NS 939 767 Fuse, 1A, fast-acting,350 V 2

33 178 012 Fuse block, 1 pole, CC, pressure, Pl/Qc 2

34 221 663 Block, distribution, 175A, 1 pole (XT−4, XT−5) 2

35 186 084 Duct, wire, 30 in. long, vertical 1

36 221 682 Cover, wire duct, 30 in. long, vertical 1


38 180 138 Contactor, 3-pole, 63 A, cont, 24 Vdc coil 2


40 221 661 Fuse holder 4

41 178 471 Transformer, current, 200:1, ground fault 3

42 184 540 Mount, cable tie 3

43 939 004 Strap, cable, 0.06−1.75, natural 3

44 223 915 Switch, disconnect, remote, 100 A 1

45 229 064 Label, line disconnect 1

46 229 065 Label, ground, terminals 1

47 186 092 Block, distribution, 3 pole (XT−3) 1

48 178 011 Fuse, 50A, fast 4 C

48

49

178 011

223 896

Fuse, 50A, fast

Terminal block, power, 1 pole

2

1

D

D


C: 240 V units

D: 400 V units

NS: Not Shown

Parts8-44


107 144DIssued 3/99

Manual 41-190

4904125A

6, 7, 8, 9, 10

11, 12, 13

14, 15, 16

17, 18

19, 20

21, 13

23

24, 13

25, 16

26, 13

18, 27, 28

29, 13

30, 18

46

45

44

47, 13

13, 41, 42, 43

3, 40, 48

39, 49

39, 38

35, 36, 37 16, 33, 32 31, 14, 16

1, 2, 3 4

XT3

XT5

TA1

QS1

XT2

TA2

TA3

FU1 FU2

XT4

FU3 FU4

KM1

KM2

GS1

AP4

FU11 VC1

TC1

XT6

XT11

GS2 GS3

XT10

KL1

XT7

FU6 FU9KM3

FU5 FU10

39, 34

13, 41, 42, 43

Fig. 8-23 Main Panel Interior

Parts 8-45


107 144DIssued 3/99

Manual 41-190


— 221 666 Terminal block, XT6

1 221 695 � Fuse holder end cap 3

2 221 693 � Fuse holder 3

3 288 911 � Terminal block accessory, terminal marker, 1−10 1

4 235 463 � DIN−mounted terminal blocks, row, 2-terminal 3


6 229 069 � Terminal block accessory,, DIN, rail, 9 in. long 1

7 235 457 � Terminal block accessory, bam 3, DIN, end stop, w/block 2

8 235 454 � Terminal block accessory, DIN, end cap 3

9 235 447 � DIN−mounted terminal blocks, row, 2-terminal 5


11

12

13

232 561

120 995

939 767

� Terminal block accessory, terminal marker, FFuse, 5A, slo-blo, 250 V, 5 x 20 mm

Fuse, 1.00, fast-acting, 250 V

1

1

2


1 229 073 � Terminal block accessory, DIN, rail, 6.5 in. long 1

2 235 457 � Terminal block accessory, DIN, end stop, w/block 2

3 235 449 � DIN-mounted terminal blocks, M10/10,1 row, 2-terminal 9


5 232 562 � Terminal block accessory, DIN, jumper, 3-pole 3

6 235 455 � Terminal block accessory, DIN, end cover 2



25. Terminal Blocks PartsList

Parts8-46


107 144DIssued 3/99

Manual 41-190



1 229 074 � Terminal block accessory, DIN, rail, 12 in. long 1


3 235 475 � Terminal block, w/partition 1

4 235 449 � DIN−mounted terminal blocks, M10/10,1 row, 2-terminal 23



7 232 566 � Terminal block accessory terminal marker, 21−30 1

8 235 454 � Terminal block accessory, DIN, end cap, 2.5 mm T 1

9 235 455 � Terminal block accessory, DIN, end cover 5

10 232 562 � Terminal block accessory, jumper, 3-pole 2

11 232 569 � Terminal block accessory, jumper, 4-pole 1

12 232 571 � Terminal block accessory, jumper, 6-pole 2 A

NOTE A: Install terminal jumpers at positions 1−6, 7−12, 13−16, and 20−22. Do not jumper 23 and 24.

Parts 8-47


107 144DIssued 3/99

Manual 41-190

4904185A

XT6

XT7

1

1

1

XT8

2, 12 4 4

9 9 9 8

6

7

2 3 5 7 8 9 10 11

2 3 5 7 8 9 10 11F24

F25

F26

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

2 3

67

1

1

4

2

2

3

3

4

4

5

5

6

6

7 8 9 10 11 12

7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23

13 14 15 16 17 18 19 20 21 22 23

24

24

2 7 8

10

3 5

5

3 4 5 6

91112

2, 13

10, 11

Fig. 8-24 Terminal Blocks XT6, XT7 and XT8

Parts8-48


107 144DIssued 3/99

Manual 41-190



1 235 457 � Terminal block accessory, DIN, end Stop, w/block 2

2 221 693 � Fuse holder 10

3 221 695 � Fuse holdereEnd cap 1

4 229 073 � Terminal block accessory, DIN, rail, 6.5 in. long 1



7

8

232 561

120 995

� Terminal block accessory, terminal marker letter, F

� Fuse, 5A, slo-blo, 250 V, 5 x 20 mm

1

10


1 229 075 � Terminal block accessory, DIN, rail, 9 in. long

2 185 940 � Label, XT10


4 229 051 Power supply, 230 Vac/24 Vdc, 1A 1

5 221 011 Power supply, 230 Vac/5 Vdc, 1A 1

— 226 671 Terminal block, XT11 1


2 221 695 � Fuse holder end cap 1

3 229 059 � Diode assembly 1

4 229 060 � Resistor assembly 1


6 229 069 � Terminal block accessory, DIN, rail, 9 in. long 1


8 235 458 � DIN-mounted terminal blocks, M4/6, SB, 1 row,2-terminal, 300V

2


10 232 561 � Terminal block accessory, terminal marker letter, F 1

11 221 693 � Fuse holder, 5x20, 250 V, 10A 1

12

13

221 652

138 707

Socket, relay, DIN

Fuse, 0.100A, fast-acting, 250 V, 5 x 20 mm

6

1

NS 221 696 Relay, SPDT, 24 Vdc, w/LED indicator 6

NS: Not Shown

Parts 8-49


107 144DIssued 3/99

Manual 41-190

4904186A

XT10

XT11

XT9

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

1 2, 8 3 4

5, 6, 7

1 3 4

1 3 4 5

6

11, 1312

8

F22 2

1

2

1

5

2

9, 10

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

2

7

Fig. 8-25 Terminal Blocks XT9, XT10 and XT11

Parts8-50


107 144DIssued 3/99

Manual 41-190


— 221 672 Terminal block, XT12 1

1 229 068 � Terminal block accessory, DIN rail, 4 in. long 1

2 221 693 � Fuse holder 1


4 235 447 � DIN-mounted terminal blocks, M4/6,1 row 3

5 235 463 � DIN-mounted terminal blocks, M4/6. P, 1 row, 2-term 1


7 235 454 � Terminal block accessory, DIN, end cap, 2.5 mm T 1



10

11

232 561

138 707

� Terminal block accessory, terminal marker letter F

� Fuse, 0.100A, fast-acting, 250 V, 5 x 20 mm

1

1

— 186 077 DIN-mounted terminal blocks, 500 V, XT15 1

1 236 154 � Terminal block accessory, rail, DIN, 32 mm x 7.5 mm, G 1

2 233 998 � Terminal block accessory, terminal cover, end 1

3 233 997 � DIN-mounted terminal blocks, terminal block, ceramic,XT15

15

4 233 999 � Terminal block accessory, terminal clamp, end 2



7 234 002 � Terminal block accessory, insert holder, XT15 1

8 229 966 � Terminal block accessory, terminal insert, XT15 1

Parts 8-51


107 144DIssued 3/99

Manual 41-190

4904187A

XT12

2

F24

3 4 5

2 3 4 5

1 2, 11 3 4 5

6710, 91 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

XT-

15

1 2

7, 8 6 5 4 3

8

Fig. 8-26 Terminal Blocks XT12 and XT15

Parts8-52


107 144DIssued 3/99

Manual 41-190


1 223 896 Terminal block, power, 1 pole (XT−1) 1

2 982 320 Screw, pan-head, recessed, M5 x 16 mm 2

3 984 721 Nut, hex, M5, steel, 2N Nylok 2

4 983 163 Washer, flat, oversized, M4 2

5 187 576 Plug, switch hole 1

6 939 774 Relay, solid state, 25 A, 480 V 10


8 173 183 Motor control, 2HP, 180 Vdc, heatsink 1 A

9 982 952 Screw, pan-head, recessed, M4 x 35 mm 4 A

10 229 063 Cover, Danfoss drive 1 A

11 220 990 Relay, dold state, 480 V, 40 A 4 B

12 221 668 Terminal block, XT−9 1

13 236 426 Capacitor, filter assembly (AP 9) 1

14 221 667 Terminal block, XT−8 1 B


16 240 674 Tag, ground 2

NOTE A: Present only when the unit is configured with a standard non-gear-to-line motor controller.

B: Refer to Terminal Blocks Parts List.

26. Back Panel Interior PartsList

Parts 8-53


107 144DIssued 3/99

Manual 41-190

4904126

NK7 NK8NK6

NK2 NK3NK1

NK4 NK5

NK9 NK10

NK11 NK12 NK13 NK14

XT1

XT9

AP8

5

8

4, 3, 2, 1

11, 7 6, 7

7, 4

16

13

12

14, 15

Fig. 8-27 Heatsink Panel Interior

Parts8-54


107 144DIssued 3/99

Manual 41-190


1

1

185 947

224 379

Label, input power, 240 V

Label, input power, 400 V

1

1

A

B

2 183 684 Label, diagnostic indicator 1

3 185 945 Label, configuration switch 1

4 185 946 Label, component map 1

NOTE A: 240 V units

B: 400 V units

27. Cabinet Door InteriorParts List

Parts 8-55


107 144DIssued 3/99

Manual 41-190

4904128

1

2

4

3

Fig. 8-28 Cabinet Door Interior

Parts8-56


107 144DIssued 3/99

Manual 41-190

To order consumable and wear items, refer to the following tables for partnumbers and recommended quantities. Both electrical and mechanicalspare parts are available.

Part Description Quantity

— System controller assembly 1 (A)

186 010 � CPU board assembly 1

224 385 � Main control board assembly 1

170 149 � LED board assembly 1

177 771 Battery, 3.6 V 1

229 057 Label, top, FM-190 panel 1

229 058 Label, bottom, FM-190, hose/gun panel 1

236 424 Level, overlay 1

186 020 Interface board assembly 1

229 066 Display, digital RPM assembly 1

365 341 Readout assembly, pressure 1

NOTE A: The part number for the controller assembly depends on your unit’s configuration and is one of thefollowing:

174 289 System Controller Assembly, Standard, English220 299 System Controller Assembly, Standard Symbols220 298 System Controller Assembly, Standard, German


900 298 Compound, heatsink, (for sold state relay service) 1

220 998 Contactor, 3P 40 A cont, 24 Vdc 1

180 138 Contactor, 3P, 63 A cont, 24 Vdc 2

229 053 Overload relay 1

229 052 Overload relay mounting kit 1

220 990 Relay, solid state, 480 V, 40 A 2

221 696 Relay, 24 Vdc, w/LED indicator 2

939 774 Relay, solid state, 25 A, 480 V 4

28. Recommended SpareParts

Control Board

Relays

Parts 8-57


107 144DIssued 3/99

Manual 41-190


120 995 Fuse, 5 A, slo-blo, 250 V, 5 x 20 mm 12

138 707 Fuse, 100 mA, fast-acting, 250 V, 5 x 2 2

178 011 Fuse, 50 A, fast-acting 4

706 426 Fuse, 12.00 fast-acting, 600 V 2

225 102 Fuse, slo-blo, 10 A 500 V, 0.41 x 1.5 1

225 103 Fuse, slo-blo, 12 A, 600 V, 0.41 x 1.5 2

706 424 Fuse, 6.00, fast-acting, 600 V 2

939 767 Fuse, 1 A, fast-acting, 350 V 2


120 995 Fuse, 5.0 A, slo-blo, 250 V, 5 x 20 mm 1




804 261 Fuse, 1.0 A, fast-acting, 250 V (gear-to-line units only) 1

939 113 Fuse, 15 A, non-time delay, 250 V (gear-to-line units only) 2

939 114 Fuse, 20 A, non-time delay, 250 V (standard units only) 1


177 768 Bulb, controller assembly 1

220 986 Bulb, light tower 1

184 521 Bulb, gas control panel 1

Unit Fuses

Interface Board Fuses

Motor Controller or Drive Fuses

Lamps

Parts8-58


107 144DIssued 3/99

Manual 41-190


221 663 Block, distribution, 7.75 A (XT-4, XT-5) 1

186 092 Block, distribution, 3-Pole (XT-3) 1

226 671 Block, terminal, XT-11 1

365 335 Board assembly, pressure readout 1

179 321 Cover, fuse block 1

187 579 Cover, lexan, terminal block 1

221 662 Cover, lexan, control fuses 1

187 583 Cover, lexan, line fuse 1

229 059 Diode, assembly 1

221 668 Terminal block, XT9 1

310 284 Gauge, panel 1

186 025 Kit, ribbon cable 1

221 659 Pot, 10-turn, 2K Ohm, water-wash, panel mount 1

178 480 Power supply, AC-DC SW 5 Vdc, 12 V 1

221 011 Power supply, 230 Vac/5 Vdc-1A 1

229 051 Power supply, 230 Vac/24 Vdc-1A 1

178 472 Rectifier, bridge 35 A, 100 V, FW 1

310 440 Regulator, air pressure 1

229 060 Resistor assembly 1

221 652 Socket, relay 2

223 915 Switch, disconnect, remote, 100 A 1

178 015 Transformer, control, 240/18 V 1

178 471 Transformer, current, 200:1, ground, fault 1

221 671 Terminal block, XT-1 1








223 896 Terminal block, power, 1.75 A, XT1 1

Electrical

Parts 8-59


107 144DIssued 3/99

Manual 41-190

Part Description Quantity Note

310 159 Valve assembly, pressure control 1

310 137 Valve, relief, pressure, 1,500 psi 1

142 522 Controller, density w/filter assembly 1 A

161 106 Screen, 0.006 in. mesh 1 A

310 458 Filter base 1

310 850 Belt, timing, 30 x 800 mm, high-temperature 1

139 351 Pump assembly, gear, high-output 1

NOTE A: Needed during regular maintenance.


310 440 Regulator, air pressure (Gas) 1

901 131 Valve, check, 1/8 ports, 7 psi 1

221 657 Valve, Reedex 1

110 780 Service kit, transducer assembly 1

110 980 I/P transducer 1

Mechanical

Pneumatic and Gas

Parts8-60


107 144DIssued 3/99

Manual 41-190

Part Description Quantity Note

941 521 O-ring, Viton, 3.25 in. ID (pump OD) 1

940 161 O-ring, Viton, 0.63 in. ID (pump outlet) 1

940 111 O-ring, Viton, 0.31 in. ID (pump gas inlet) 1

940 161 O-ring, Viton, 0.63 in. ID (pressure readout ports) 2

945 026 O-ring, Viton, 1/4 tube (pressure readout fitting) 1

945 034 O-ring, Viton, 5/16 tube (manifold fitting Cross drill ports) 4

945 025 O-ring, Viton, 7/8 tube (manifold hose ports)

942 111 O-ring, Viton, 0.81 in. ID (pressure control valve) 1 A

940 141 O-ring, Viton, 0.50 in. ID (pressure control valve) 1 A

941 240 O-ring, Viton, 1.25 in. ID (density control/filter) 1

940 121 O-ring, Viton, 0.38 in. ID (pressure relief valve) 1

945 032 O-ring, Viton, 3/8 tube (pressure relieve valve) 1

940 151 O-ring, Viton, 0.56 in. ID (drain valve to manifold; for 4-mounting holedrain valves)

1

940 181 O-ring, Viton, 0.75 in. ID (drain valve to manifold; for 3-mounting holedrain valves)

1

941 261 O-ring, Viton, 0.563 in. ID (drive assembly to drive support) 1

NOTE A: Needed during regular maintenance.


900 223 Lubricant o-ring, 4 oz (for o-ring service) 1

900 236 Paste, 4 oz (for NPT fitting service) 1

229 966 Compound, electrical, insulating, DOW corning 4

901 513 Filter, air regulator (optional) 1

O-Rings

Miscellaneous

Parts 8-61


107 144DIssued 3/99

Manual 41-190

Service kits provide parts that are replaced with less frequency thanconsumable and wear items. To order a service kit, refer to the listsbelow.


153 197 Kit, service, drive bearing —

118 823 � Bearing with high-temp grease 1

147 869 � Bearing with high-temp grease, double row 1

986 311 � Ring, retaining, internal, 2.047 in. basic 1


153 203 Kit, service, drive coupling —

153 904 � Coupling, drive assembly 1

— � Coupling, drive 1

— � Pin, dowel, 0.188 x 1.00 in. 1

987 030 � Spring, compression, 2.00 x 0.48 x 0.04 in. 1

144 693 � Sleeve, coupling, 1.25 in. OD x 1.00 in. long 1

981 014 � Screw, pan-head, 4-40 x 0.25 in. 1


310 218 Kit, replacement, gear pump 1

— � Pump 1

941 521 � O-ring, Viton, 3.25 x 3.438 x 0.094 in. ID (pump OD) 1

940 161 � O-ring, Viton, 0.625 x 0.75 x 0.063 in. ID (pump outlet) 1

940 111 � O-ring, Viton, 0.313 x 0.438 x 0.063 in. ID (gas inlet) 1

273 749 � Tag, instruction 1

29. Available Service Kits

Bearings

Drive Coupling

Gear Pump

Parts8-62


107 144DIssued 3/99

Manual 41-190


110 775 Kit, service, grid —

— � Grid, sealed 1

— � Tag, warranty 1

900 413 � Sealant, rubber, RTV, red, 2.8 oz tube —

273 837 � Insulator, drive support 1


310 223 Kit, replacement, manifold 1

− � Manifold w/studs and plugs 1

983 503 � Washer, flat, 0.281 x 0.625 x 0.125 in. 2

983 140 � Lockwasher, 0.25 in. 2

984 204 � Nut, hex-head, high, 1/4-28 2

941 521 � O-ring, Viton, 3.25 in. ID (pump OD) 1

940 161 � O-ring, Viton, 0.63 in. ID (pump outlet) 3

940 111 � O-ring Viton, 0.31 in. ID (pump gas inlet) 1

940 151 � O-ring, Viton, 0.56 in. ID (drain valve to manifold; for 4-mounting holedrain valves)

1

940 181 � O-ring, Viton, 0.75 in. ID (drain valve to manifold; for 3-mounting holedrain valves)

1

945 026 � O-ring, Viton, 1/4 tube (pressure readout fitting) 1

940 121 � O-ring, Viton, 0.38 in. ID (pressure relief valve) 1

945 032 � O-ring, Viton, 3/8 tube (pressure relieve valve) 1

940 141 � O-ring, Viton, 0.50 in. ID (pressure control valve) 1

941 240 � O-ring, Viton, 1.25 in. ID (density control/filter) 1

273 749 � Tag, instruction 1

Grid

Manifold

Parts 8-63


107 144DIssued 3/99

Manual 41-190


110 776 Kit, service, reservoir —

— � Reservoir, sealed 1

— � Tag, warranty 1

900 413 � Sealant, rubber, RTV, Red, 2.8 oz tube —

941 521 � O-ring, Viton, 3.25 x 3.438 x 0.094 in. ID (pump OD) 1

940 161 � O-ring, Viton, 0.63 in. ID (pump outlet) 3

940 111 � O-ring Viton, 0.31 in. ID (pump gas inlet) 1

945 026 � O-ring, Viton, 1/4 tube (pressure readout fitting) 1

972 006 � Connector, 37, hydraulic, 7/16-20 straight threads 1

973 543 � Plug, o-ring, 7/16-20 straight threads 1

984 204 � Nut, hex, high, 1/4-28 2

983 140 � Lockwasher, split 2

983 503 � Washer, flat, 0.218. x 0.625 x 0.125 in. 2

984 158 � Nut, hex, jam, 3/8-16 2

981 451 � Screw, socket set, 3/8-16 x 2.50 in. 2

900 419 � Adhesive, Loctite No. 620 —

900 344 � Never Seez, 8 oz can —

Reservoir

Parts8-64


107 144DIssued 3/99

Manual 41-190


153 199 Kit, service, drive seal —

— � Pin, dowel, 0.188 x 1.00 in. 1

273 699 � Washer, flat, 0.63 x 1.00 x 0.055 in. 1

941 261 � O-ring, Viton, 1.375 x 1.583 x 0.103 in. 1

986 106 � Ring, retaining, external, 0.625 in., basic 1

273 698 � Seal, face, 0.825 in. diameter shaft 1


110 780 Kit, service, transducer assembly —

110 980 � Transducer assembly w/connectors 1

971 266 � Elbow, male, 1/4 tube x 1/4 NPT 1

900 236 � Paste, PTFE —

971 265 � Connector, male, 1/4 tube x 1/4 NPT 1


153 188 Kit, service, thermostat 1

221 632 Kit, service, brush, motor, Ohio Electric 1

271 765 Tool, pump removal 1

142 522 Service kit, density controller/filter, standard 1

142 523 Service kit, density controller/filter, low 1

142 517 Service kit, density controller/filter, high 1

Seal Assembly

Transducer Assembly

Miscellaneous

Parts 8-65


107 144DIssued 3/99

Manual 41-190


107 144 Manual, FM-190 2

272 749 Plug, connector 1

273 919 Tool, trimmer adjustment 1

274 466 Hood, plug 1

296 095 Connector, male 3 Pole 2

310 281 Fitting, size 6-10, w/o-ring 4

603 058 Box, small gun 1

900 300 Fluid, leak detector 1

900 348 Lubricant, Never-Seez, tube, 1 oz 1

901 492 Filter, air, 1/4 NPT 1

939 521 Pin, 20-16 GA, silver 5

973 037 Nipple, hex-head, 1/4 x 1/4 x 1.45�, steel, zinc-plated 1

150 067 Tool, pump alignment 1

226 150 Tag, warning, CE approval 1

224 308 Label, zone ID, 5600/5000 1

186 038 Tower assembly, light 1

30. Ship-With Kit Parts List

Parts8-66


107 144DIssued 3/99

Manual 41-190

These kits connect hoses to non-circulating guns.

An installation kit is required for each H20 or multimodule H200 gunlisted. Kits can be ordered under the following part numbers:

Part Description

310 197 H20 gun kit

310 198 H200 gun kit

NOTE: These kits are not designed for use with waterwash hoses.

These kits connect hoses to the manifold.

Part Auto Biaxial Hose Part Standard Hose

310 787 90� 310 790 90�

310 788 45� 310 791 45�

310 789 Straight 310 792 Straight

These items are required to install on a deadend handgun. If two areused, order one additional hose connector and o-ring.


111 094 6 ft automatic hose 1

310 226 Handgun hose connector 1

945 025 O-ring for 310 226 1

719 023 5/8 in. hose-to-manifold fitting 1

31. Optional Parts andEquipment

Gun Installation Kit

Hose Installation Kit

Handgun Installation Kit

Parts 8-67


107 144DIssued 3/99

Manual 41-190

For some installations, electrical extension cords will be required. Thefollowing extension cords are available for connecting jumper hoses tothe unit.

Part Description

115 577 6 ft extension cord



Special fittings are required to connect 5/8 in. automatic hoses to unitsand guns.


719 042 5/8 in. automatic hose installation kit 1

719 023 5/8 in. hose-to-manifold fitting 1

719 024 5/8 in. hose-to-gun fitting (straight) 1

719 047 5/8 in. hose-to-gun fitting (45� version) 1

Extension Cords

Hose Fittings for 5/8 in. Hoses

Parts8-68


107 144DIssued 3/99

Manual 41-190

Part Description

Encoders with Cables

296 162 Encoder kit, 200-pulse

296 163 Encoder kit, 500-pulse

296 144 Friction wheel, 0.50 meter circumference (use with either encoder kit)

Gas Installation Kits (fits only non-European size gas containers)

271 382 Carbon dioxide gas cylinder installation kit

273 170 Nitrogen gas cylinder installation kit

Density Control/Filter Assemblies

310 120 Standard two-hole slug

142 523 One-hole slug for low viscosity materials

142 522 Two-hole slug for medium viscosity materials (shipped with unit)

142 517 Four-hole slug for high viscosity materials

Hydraulic Filter Screens (optional applicator filter screens)

161 104 0.004 in. (0.10 mm) mesh

161 106 0.006 in. (0.15 mm) mesh

161 109 0.009 in. (0.23 mm) mesh

161 112 0.012 in. (0.30 mm) mesh

161 115 0.015 in. (0.38 mm) mesh

161 120 0.020 in. (0.51 mm) mesh

Non-Heated In-Line Filter

274 290 Filter, straight, 0.011 in. (0.28 mm) 50 mesh



805 877 Filter, 45 degrees, 0.011 in. (0.28 mm) 50 mesh






805 138 Filter element, 0.028 in. (0.71 mm) 24 mesh




Miscellaneous

274 428 Hydraulic pressure gauge kit

719 025 Valve, pressure control, 1,200 psi (for use with 5/8 in. hoses)

809 652 Filter, heater in-line

901 515 Filter, air, 150 psi

973 032 Nipple, pipe, 1/4 NPT (use for run-up control air supply)

FM 190 Accessories

Parts 8-69


107 144DIssued 3/99

Manual 41-190

NordsonComponent

NordsonComponentwith Kalrez

BrandO-Ring

NordsonO-Ring Part

NordsonPart forKalrezBrand

Description Required

310 281 297 517 945 025 719 080 Processor-to-hose fittings (7/8 in.) 4

310 229 297 511 940 141

942 111

719 073

719 076

Pressure control valve 2

1

310 316 297 512 940 090

941 161

719 123

719 074

Pressure control valve actuator 1

2

310 137 297 509 940 121

945 032

709 774

719 079

Pressure relief valve 1

1

973 592 297 513 945 034 719 038 Manifold plug (1/2 in.) 4

973 543 297 515 945 026 719 077 Manifold plug (7/16 in.) 1

310 120

310 247*

297 506

297 505

941 240

940 121

940 181

719 075

709 774

719 072

DC to manifold

DC (isolator-external)

DC (isolator-internal)

1

1

1

973 384 297 514 945 025 719 080 Manifold plug (7/8 in.) 4

275 481** 297 508 940 111 710 742 Drain valve (3-hole) 1

236 142 297 510 941 261 941 262 Drive assembly 1

—

—

—

—

—

—

—

—

941 521

940 111

940 161

945 026

719 081

710 742

709 776

719 077

Pump OD

Gas inlet to pump

Manifold pressure gauge port

Pressure gauge fitting

1

1

3

1

— 719 099 — — Kit, pump replacement 1

— 719 095 — — Kit, manifold replacement 1

* It is suggested that this assembly be ordered instead of the separate o-rings for this part.

** Assemblies are interchangeable.

Kalrez Brand Assemblies andO-Rings

Parts8-70


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Use the following table to identify the type and rating of the fuses for thecontrol system.

Table 8-1 Fuse Replacement Table

ReferenceDesignator

ReplacementPart

AMPERERating Class/Type Littel Fuse

Series

FU1 178 011 50 Class J JLS




FU5 225 103 12 Class CC CCMR

FU6 225 103 12 Class CC CCMR

FU9 706 426 12 Class CC KLK

FU10 706 426 12 Class CC KLK

FU11 225 102 10 Class RK5 FLQ

FU12 120 995 5 Type T 218

FU13 120 995 5 Type T 218

FU14 120 995 5 Type T 218

FU15 120 995 5 Type T 218

FU16 120 995 5 Type T 218

FU17 120 995 5 Type T 218

FU18 120 995 5 Type T 218

FU19 120 995 5 Type T 218

FU20 120 995 5 Type T 218

FU21 120 995 5 Type T 218

FU22 138 707 0.1 Type T 218

FU23 138 707 0.1 Type T 218

FU24 120 995 5 Type T 218

FU25 939 767 1 Type F 235

FU26 939 767 1 Type F 235

AP4-F1 177 676 0.063 Type T 218

AP4-F2 120 995 5 Type T 218

AP4-F9 177 675 0.4 Type T 218

AP5-int 939 113 15 A Type F 314

AP5-ext 804 261 1 A Type F 312

AP8-F1 939 114 20 A Type F 314

32. Fuse Replacement Table


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Section 9

Nordson Glossary

Glossary9-0


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Glossary 9-1


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Section 9Nordson Glossary

Any material that can be used to adhere or “stick” one surface to another.

Fine threads of adhesive caused by incomplete transfer of the adhesivemass from applicator to substrate, followed by elongation of theconnecting bridges. May be caused by improper nozzle shutoff with ahigh viscosity adhesive.

That part of the hot melt system that is used to heat adhesive to itsrequired application temperature and pump it to the hose(s) and gun(s).It consists of a tank or reservoir, pump, filter, distribution manifold andtemperature controlled heating system.

An automatically actuated valve which is opened by fluid flow in onedirection and closed by flow in the opposite direction.

The width of an adhesive bead which has been deposited on a substrate.The measurement is taken before the bead has been flattened byadhering it to another surface.

See Heater Cartridge.

A non-replaceable heating element specifically shaped to provide auniform thermal profile in the heated object.

The degradation of a fluid that occurs as a result of time and exposure toatmospheric air and/or heat.

An electronic device that acts to shut down a powered AC circuit whencurrent draw (amps) exceeds some preselected value or when certainfault conditions exist.

A temperature control device that closes, completing an electronic circuitupon reaching a specific temperature.

The tube that connects the outlet port of a pump to the distributionmanifold of a hot melt applicator.

Adhesive

Angel Hair

Applicator

Ball Check Valve

Bead Thickness

Cartridge Heater

Cast-in Resistive HeatingElement

Char

Circuit Breaker

Close-on-rise Thermostat

Crossover Tube

Glossary9-2


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The time between when the gun is signaled to stop and when theadhesive flow actually does stop.

A pump that delivers material on both the upstroke and the downstroke.

A manufacturer’s statement of the maximum level of some externalcondition, such as water or dust level, that the enclosure is capable ofwithstanding.

A speed-sensing device which outputs a frequency of pulses proportionalto the measured line speed.

A spring-loaded triggering device for dispensing or depositing material.There are two basic types of guns, the manual gun which is actuated byhand and the automatic gun which is actuated by process controls.

That part of a filter assembly external to the unit to which the filteringelement is attached, or contained within the unit. It is also used foraccess or cleaning.

The amount of material flowing through the system per unit of time. Theamount may be expressed in gravimetric (weight) or volumetric terms.Examples: grams/minute, ml/min, lb/hour, gallons/hour.

A valve typically used to pressurize one side of a double acting cylinderwhile opening a exhaust path for the opposite side.

See Key-to-line.

A cross-linked, insoluble material which can form in a hot melt applicatorunder extended thermal stress.

A wire that connects device to earth ground.

The device that dispenses a material (adhesive) onto a substrate orproduct.

A replaceable resistive heating element, tubular in shape, designed to fitin a machined hole in the object to be heated.

A container allowing non-melted adhesive to be supplied on a continuousbasis to a melt zone.

Drop-out Time

Dual-acting Piston Pump

Enclosure Rating

Encoder

Extrusion Gun

Filter Bung

Flow Rate

Four-way Air Valve

Gear-to-line

Gel

Ground Wire

Gun

Heater Cartridge

Hopper

Glossary 9-3


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The adhesive or thermoplastic material dispensed by the hot meltsystem.

The applicator, hose(s), gun(s) and pattern control mechanism.

A system that regulates pressure in proportion to the substrate (line)speed.

A device that shows the level of material in a tank, reservoir or hopper.

A device that converts applied current to light. LEDs appear as coloredlights that indicate operating conditions.

See Level Indicator.

A device that distributes fluid and/or air.

The highest cycle rate of the gun that produces a repeatable pattern.

The maximum adhesive flow rate achievable without exceeding anyoperating limits. The maximum pumping rate is measured at themanifold outlet. The rate is based on an adhesive with a given viscosity.

The rate at which a material can be melted continuously on a long-termbasis while maintaining the output fluid temperature within a desiredtemperature band. Commonly expressed in units of grams/minute,grams/hour, lb/min or lb/hr.

The extrusion tip, the point at which the adhesive exits the gun. Thenozzle controls the adhesive stream’s volume, shape and direction.Nozzles may have single or multiple orifices.

The time after adhesive is applied during which a serviceable bond canbe made. Many factors affect open time, including temperature,substrate, the adhesive used and the amount of adhesive applied.

The pressure at which the pump and/or guns are operated. Refer toproduct specifications.

The range of temperatures in which the specific material or adhesive inuse functions satisfactorily in a particular application.

A product feature that shuts down the unit or produces an alarm whentemperatures are outside a specified band.

Hot Melt Material

Hot Melt System

Key-to-line

Level Indicator

Light Emitting Diode (LED)

Low Level Indicator

Manifold

Maximum Operating GunSpeed

Maximum Pumping Rate

Melt Rate

Nozzle

Open Time

Operating Air Pressure

Operating Temperature Range

Overtemperature Protection

Glossary9-4


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A product feature that prevents the parent machine from operating beforethe hot melt system is ready.

A device that controls the dispensing of material.

An adhesive that remains tacky after curing or setting.

The time between when the gun is signaled to start and when theadhesive flow actually begins.

Output signal frequency, often from an encoder pulse, tach, or similardevice.

The amount of material a pump can deliver per unit of time.

A Nordson program which offers factory rebuilt equipment at a reducedcost in exchange for the customer’s old equipment.

An adjustable device for maintaining pressure at the preset valve.

A safety device designed to release pressure if it exceeds a preset level.

The state of the processor after all heating zones have reached operatingsetpoint temperatures.

A user-specified time interval between when the heating zones reachoperating setpoint temperature and the READY light comes on.

A temperature-sensing device that changes resistance in response tochanges in temperature.

A special case of Key-to-line or Gear-to-line, often applied to air controlfor piston pumps.

Part of an automatic extrusion gun, the service block supplies the neededair, adhesive and heat to make the gun operate.

The time required for a material to reach a set state after being applied ina fluid state.

A mechanical or electrical device used to switch a 4-way air valve.

A common shape of adhesive.

A nozzle that applies a film of adhesive instead of a bead.

Control valve actuated by an electromagnetic coil.

Parent Machine Interlock (PMI)

Pattern Control

Pressure-Sensitive Adhesive

Pull-in Time

Pulses Per Minute

Pumping Rate

Rebuild and Exchange (RBX)

Pressure Regulator

Pressure Relief Valve

Ready

Ready Time Delay

Resistance TemperatureDetector (RTD)

Run-up

Service Block

Setting Time

Shifter Assembly

Slats

Slot Nozzle

Solenoid Valve

Glossary 9-5


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A device whose electrical functions are performed by semiconductors orotherwise completely static components such as resistors and capacitors.

In the Nordson context, a material used to dissolve hot melt adhesive tofacilitate system cleaning.

A defect in adhesive application characterized by hair-like fibers ofadhesive emanating from the trailing edge of the bead. Stringing mayproduce continuous fibers attached to the nozzle. It is most often causedby the gun temperature being too cold.

The material or product on which the adhesive is applied.

The amount of material that the tank can hold with the fluid level 25 mm(1 inch) from the top of the hopper or tank.

A product feature that helps keep large pieces of foreign material out ofthe pump.

The volume that the tank can hold when it is filled. The displacement ofthe pump is taken into account in this measurement.

That part of a temperature control system that detects the temperatureand provides this information to the control device.

See Standby.

A product feature by which the system temperature may be automaticallyreduced to a preset temperature.

A synthetic material which is solid at room temperature, becomes softwhen heated, and returns to solid form upon cooling.

See Pattern Control.

Air free of oil.

A physical measurement of resistance to flow.

Solid State Device

Solvent

Stringing

Substrate

Tank Capacity

Tank Strainer

Tank Volume

Temperature Sensor

Setback

Standby

Thermoplastic Material

Timing Device

Unlubricated Air

Viscosity

Glossary9-6


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Section 10

Index

Index10-0


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Index 10-1


107 144DIssued 3/99

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Section 10Index

AAccessory Equipment, Installation, 3-13

AdjustingCurrent Limits, 7-46IR Compensation, 7-49

Air SupplyDescription of, 2-6Installation, 3-4

Ammeter and Keypad Lockout Jumper, Removing, 4-18

Auto Shutdown, Description, 2-23

Auto Shutdown Timer, Changing, 3-25

Auto Standby, Description, 2-23

Auto Standby Timer, Changing, 3-24

Auto-startDescription, 2-23Function, 4-3

Automatic Pressure Control ModeDescription of, 2-30Placing System in, 4-39

BBattery, Replacing the, 7-35

CChanging Motor Speed, 4-38

Changing System Configuration Settings, 3-21Auto Shutdown Timer, 3-25Auto Standby Timer, 3-24Low Temperature Fault, 3-25Maximum Temperature, 3-26System-ready Time Delay, 3-23Temperature Band Warning, 3-24Temperature Display Units, 3-26

Checking and Cleaning Filter Assembly, 5-8

Checking Drive Belt, 5-17

Circuit boardsReplacing, 7-37Replacing AP2, 7-40Replacing AP5, AP6, AP7, or AP8, 7-42Resetting factory defaults on AP1, 7-39

Cleaning, Safety instructions, 1-7

Component Map Legend, 6-46

Configuringa replacement AP7 circuit board, 7-53a replacement controller, 7-50a replacement motor overload relay, 7-61the RPM Display, 7-53

Control system, Fuse replacement table, 8-70

Controller Battery, Replacing the, 7-35

CoverBelt, Removing the, 7-4Belt, Replacing the, 7-6Unit, Removing the, 7-4Unit, Replacing the, 7-6

Current Limits, Adjusting, 7-46

D

Density Controller, Rebuilding the, 7-29

Density Reduction, 4-30

DescriptionAutomatic Pressure Control Mode, 2-30Electrical and Pneumatic Components, 2-8FoamMelt Process, 2-2Mechanical Components, 2-11Motor Controller, 2-30Pressure and Gas Control Panel, 2-28PUMP OUTLET PRESSURE Monitor, 2-34System Controller, 2-13

Index10-2


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D (contd)

Diagnostics, Description of, 2-6

Drain ValveReinstalling, 7-34Removing the Valve Stem Assembly, 7-33Servicing, 7-31, 7-32

Drive AssemblyAccessing, 7-16Reinstalling, 7-21Replacing Face Seals, 7-19Servicing, 7-15

Drive BeltChecking, 5-17Removing, 5-19Replacing, 5-21

EElectrical Cabinet Door, Opening the, 3-14

electrical current requirements, 2-38

Electrical Installation240 VAC, Three-phase Service, 3-16400 VAC, 4-wire Service, 3-17Light Tower, 3-15

EnclosureCorner, Removing the, 7-8Corner, Replacing the, 7-9Hopper, Removing the, 7-4Hopper, Replacing the, 7-6

FFaults

Controller, 6-12Emergency Thermostat, 6-3, 6-12Ground, 6-3, 6-12Heater Open, 6-13Heater Overtemperature, 6-14Low Temperature, 3-22, 4-48Motor Overload, 6-14Resistance Temperature Detector (RTD), 6-15Responding to, 4-45Solid-State Relay, 6-13Specifications, 6-4

Watchdog Timer, 6-3

Filter AssemblyChecking and Cleaning, 5-8Flushing, 5-7

FlushingFilter Assembly, 5-7System, 5-15

Foam Sample, 4-27

FoamMelt Process, 2-2

FoamMelt Process, Functional Description of, 2-2

Form, Maintenance Record, 5-23

Fuse replacement table, 8-70

Fuses, Replacing, 7-58

GGas Controls, 2-29

Gas Modulation, Description of, 2-5

Gas Pressure Check Valve, Replacing the, 7-82

Gas Pressure GaugeReplacing the, 7-77To Replace the, 7-80

Gas Pressure RegulatorReplacing the, 7-77To Replace the, 7-78

Gas Pressure Switch, Replacing the, 7-83

Gas Supply, Installation, 3-9

Gear-to-Line Motor ControllerAdjusting current limits for, 7-47and 82-CP value, 7-52Calibrating, 7-45Configuring a replacement controller, 7-50

HHeater

Hopper, Replacing the, 7-62Manifold, Replacing the, 7-72

Hoses, Installation, 3-4

Hot Melt Sample, 4-26

Hydraulic Pressure Control, Description of, 2-5

Index 10-3


107 144DIssued 3/99

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II/P Transducer, Replacing the, 7-84Incoming Service Line, Installation, 3-16Indicators

Interface board, 6-24Main board, 6-22

Initial setup, 4-2Initial Setup Procedures, Setting Up PUMP OUTLET

PRESSURE Monitor, 3-18Installation

Equipment Location, 3-2Inspection, 3-1Unpacking, 3-1

Interface boardConnectors and test points, 6-24, 6-25, 6-26Indicators, 6-22

IR Compensation, Adjusting, 7-49

KKeypad Lockout Jumper, Removing, 4-13KL1 Relay, Configuring a Replacement , 7-61

LLED locations, Main board, 6-22Light Bulbs

Light Tower, Replacing, 7-59Replacing Unit, 7-57

Light Tower, Installation, 3-15Light Tower Assembly, Replacing the, 7-60Low Temperature Fault, Changing, 3-25

MMain board

Connectors, 6-23Indicators, 6-22

Maintenance ProceduresFlushing Filter Assembly, 5-7Record Form, 5-23

Maximum Temperature, Changing, 3-26Mechanical Installation

Processor, 3-3Accessory Equipment, 3-13Air Supply, 3-4

Gas Supply, 3-9Hoses, 3-4

MotorAccessing, 7-11Servicing, 7-10

Motor Controller, Description, 2-30

Motor Overload Relay, Configuring a Replacement ,7-61

Motor SpeedCalibrating, 7-44Changing, 4-38

O

O-ringsDrain Valve, Replacing, 7-32Hose Connector, Replacing, 7-30Pipe Plug, Replacing, 7-30Pump, Replacing, 7-22

Opening Electrical Cabinet Door, 3-14

Operating ProceduresChanging Motor Speed, 4-38Placing System in Auto Pressure Control Mode, 4-39Placing System in Manual Pressure Control Mode,

4-39Shutting Down System, 4-37

Operator Control Panel, description of, 2-4

overload relay switch, 2-27

P

Potentiometer, Settings for AP8, 7-42

Power Disconnection, 7-2

Pressure, Relieving System Hydraulic, 5-2

Pressure Control ModePlacing system in auto, 4-39Placing system in manual, 4-39

Index10-4


107 144DIssued 3/99

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P (contd)

Pressure Control ValveRebuilding, 7-26Replacing, 7-24

Pressure Controls, 2-28

Pressure Transducer Assembly, Replacing the, 7-86

Pressure-band Fault. See PUMP OUTLET PRESSUREMonitor

Program mode, Entering, 4-4

Programming System ControllerAuto Start Time, 4-9Day Setting, 4-11Securing Settings, 4-12Time Setting, 4-11

PumpO-rings, Replacing the, 7-22Replacing the, 7-22

Pump Charts, 2-40

PUMP OUTLET PRESSURE MonitorDescription, 2-34Pressure-band Fault, 3-18Setting Up, 3-18

PURGE buttonDescription of, 2-29Hot Melt Sample, 4-27Starting and stopping purge, 4-22, 4-25

RReedex Valve

Replacing the, 7-77To Replace the, 7-81

Relieving System Hydraulic Pressure, 5-2

Resuming Normal Operation, After Maintenance, 5-4

RPM Display, Configuring the, 7-53

RTD SensorGrid, Replacing the, 7-67Hopper, Replacing the, 7-62Reservoir, Replacing the, 7-69

RTD vs. temperature charts, 6-28Manifold, Replacing the, 7-72

SSafety

Cleaning, 1-7Installation and electrical connections, 1-4Maintenance/Repair, 1-6Operation, 1-4Symbols, 1-2Thermoplastic, 1-8

Sequential Start-upDescription of, 2-7Disabling, 3-23

Shutting Down System, 4-37

Solid State Relays, Replacing, 7-54

Specifications, 2-36

Standard I/O, description of, 2-5

Standard motor controllerAdjusting current limits for, 7-46Calibrating, 7-44

SwitchesResetting AP1 board to factory defaults, 7-39Settings for AP2, 7-40Settings for AP6 and AP7 , 7-42

SystemFlushing, 5-15Placing in Auto Pressure Control Mode, 4-39Placing in Manual Pressure Control Mode, 4-39Shutting Down, 4-37

System ControllerDescription, 2-13Motor, 2-26Programming the, 4-3System Status, 2-14Temperature Set, 2-20Temperature Status, 2-17

System-ready Time DelayChanging, 3-23description of, 2-7

Index 10-5


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TTechnical Data

Pump Charts, 2-40Specifications, 2-36

Temperature Band Warning, Changing, 3-24

Temperature Control, Description of, 2-6

Temperature Display Units, Changing, 3-26

Temperature SetupsCreating, 4-5Storing, 4-7

TemperaturesFactory settings for, 4-3Programmable, 4-3Setpoints for, 4-3Valid ranges for, 4-3

Test measurement procedures, 6-18

Test pointsInterface board, 6-24Main board, 6-23

ThermostatGrid, Replacing the, 7-67Hopper, Replacing the, 7-62Reservoir, Replacing the, 7-69

Troubleshooting, Test measurement procedures, 6-18

UUnpacking, 3-1

WWarm Start, 2-7

Index10-6


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DECLARATION of CONFORMITY(For CE Certified Systems)

PRODUCT:

Model FM190 Series FoamMelt Application Systems

APPLICABLE DIRECTIVES:98/37/EC (Machinery)73/23/EEC (Low Voltage Directive)89/336/EEC (Electromagnetic Compatibility Directive)

EN292 EN55011EN563 EN60204-1EN50082-2

This product has been manufactured according to good engineering practice.

The product specified conforms to the directive and standards described above.

STANDARDS USED TO VERIFY COMPLIANCE:

Nordson Corporation � Westlake, Ohio

DOC002

PRINCIPLES:

Date: 6 November 98John Jackson, Senior Vice President

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