CH410 & CH420 - Nordsonemanuals.nordson.com/adhesives/English_Manuals/321191.pdf · Fenwal Temperature Controller 23 ... Troubleshooting 25 ... 321 191B. CH410 & CH420 Cable Coating

CH410 & CH420Cable Coating Dies

Customer Product ManualPart 321 191B

NORDSON CORPORATION AMHERST, OHIO USA

2000 Nordson CorporationAll rights reserved

59-53Issued 1/00

Manual 321 191B

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999. No part ofthis document may be photocopied, reproduced, or translated to another language without the prior written consent

of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks

AquaGuard, Blue Box, Control Coat, Equi=Bead, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, Meltex,MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Package of Values, Porous Coat, Posi-Stop, ProLink,

PRX, RBX, Shur-Lock, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation.

BetterBook, CF, Controlled Fiberization, Eclipse, Saturn, Seal Sentry, Swirl Coat, and Vista are trademarks of Nordson Corporation.

Never Seez is a registered trademark of Bostik Corporation.

Parker is a registered trademark of Parker Hannifin Corporation.

Viton is a registered trademark of E.I. DuPont de Nemours & Co.

Table of Contents i


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Table of Contents

1. Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Safety Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended Use 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and Electrical Connections 4. . . . . . . . . . . . . . . . . . . . . . .

Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Danger of Burns 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance/Repair 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermoplastic Hot Melt Material 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment and Material Disposal 8. . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Description 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coating Dies 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH410 Cable Coating Die 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH420 Cable Coating Die 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature and Level Control 16. . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Space and Equipment Floorplan 16. . . . . . . . . . . . . . . . .

Control Panels 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH410 Cable Coating Die 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii


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Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AG-900 Pressure Regulator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panels 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH410 Control Panel 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH420 Control Panel 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Control Circuit 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cordset 30A 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How the Level Control works: 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fenwal Temperature Controller 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fenwal Temperature Control Contacts 24. . . . . . . . . . . . . . . . . . . . . .

4. Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Circuit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Regulator 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Repair 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Regulator Replacement 33. . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Parts 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Pressure Regulator 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AG-900 Pressure Regulator Module 44. . . . . . . . . . . . . . . . . . . . . . . .

AG-900 Recommended Spare Parts 46. . . . . . . . . . . . . . . . . . . . . . .

Cordset 30A 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Control Harness 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH410 Control Panel 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH420 Control Panel 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CH410 & CH420 Cable Coating Die System 1


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CH410 & CH420 Cable Coating Die System

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. Safety

Operate Safely

CH410 & CH420 Cable Coating Die System2


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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.

Safety Symbols



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“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

Qualified Personnel

Intended Use



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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.

Installation and ElectricalConnections

Operation



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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.

Less-Obvious Dangers

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

Action in the Event of Unit Malfunction

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.



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Danger of Burns

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.

Maintenance/Repair



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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 anymaterial.

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.

Cleaning



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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.

Thermoplastic Hot MeltMaterial

Equipment and MaterialDisposal



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Cable coating dies are used to apply melted mastic (water blocking)material to power cable manufacturing processes.

The coating dies used in the mastic system are:

CH410 (open-face, non-pressurized) CH420 (closed, pressurized)

CH410 Cable Coating Die

The CH410 cable coating die is used with or without strander stations ina power cable manufacturing process. When used with strander stations,the mastic material is applied between the strands to ensure 100% fillingof the power cable with the mastic material.

There is a shut-off valve controlled by the level control on the CH410cable coating die. The CH410 is used in systems where multiple cablecoating dies are supported by one or more feed systems.

The CH410 is installed in the position of the sizing die holder. If theCH410 cable coating die is used, the sizing die holder needs to beremoved and the sizing die will find a new location inside the CH410.

If the strands coming into the sizing are at an angle (cone shaped) androtating in this process, the mastic material is applied in between thestrands. As the sizing die compacts/compresses the power cable, themastic material is secured in place.

2. Description

Coating Dies



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CH410 Cable Coating Die (contd)

See Figure 1. The CH410 consists of the following parts.

5960029A

81

7

6

5

4

3

2

1

Fig. 1 CH410 Assembly

1. Delta bracket2. Die holder3. Hose fitting/Shut-off valve adapter4. Shut-off valve

5. Heater band6. Bracket7. Insulation ring8. Mastic ring (strander stations

only)

CH410 Bracket

The CH410 bracket is the adapter used to fit the complete CH410assembly into the cable machine. The CH410 bracket is 3 in. x 3 in.square.

5960031A

1

1

2

Fig. 2 CH410 Bracket

1. Keyway 2. Bracket



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The CH410 is designed with square brackets to fit most of the cablemachines on the market. If your cable machine does not have squarebrackets, round ones can be ordered.

The CH410 bracket is connected to the CH410 die holder. Between the CH410 bracket and the CH410 die holder is a PTFE Ring for heat insulation. This insulation ring is used to prevent extreme heat losses into the machine holder which holds the CH410 bracket.

CH410 Die Holder

The CH410 die holder takes the place of the sizing die holder previouslyused in the cable production. Cone shapes guide the strands along thewalls of the CH410 die holder. The strands are held at a constantdistance of 2–4 mm (0.078–0.157 in.) away from the walls.

The sizing die is located in the center of the die holder and recessedaway from the cone shape entry section. The moving direction of thecable and the force generated from the cable holds the sizing dies inplace. As a result, it is easy to change the sizing die when the cablespecification changes. The CH410 die holder is made to accept a67 mm (3 in.) sizing die, but it is possible to custom fit other sizing diedimensions as well. Together the CH410 bracket and CH410 die holderbuild the central pieces for the CH410 assembly.

CH410 Delta Bracket

Since the CH410 cable coating die is an open face coating die, it isessential to control the mastic material level during operation. Themastic material level is controlled by a fiber-optic based level control.

The CH410 delta bracket holds the fiber-optic cables mounted on the leftand right side of the CH410 coating die. The delta brackets are mountedso the light beam from one side of the coating die passes underneath thepower cable to the other side of the coating die.

The CH410 delta brackets are extremely durable. Their unique shapeprevents slacking strands from hitting the fiber-optic cables or gettingbehind the brackets and pulling them loose.



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CH410 Heater Band

Mastic material at room temperature is almost solid. When heated, themastic material becomes a very viscous, but moveable material. Thetemperature needs to be stable throughout the application process.From the feed system, through the heated hose to the CH410 coatingdie, the temperature should be constant and controllable. The CH410coating die uses a high wattage heater band to heat the die to thedesired temperature and maintain the setpoint temperature duringoperation. Because the heater band uses a state-of-the-art temperaturecontroller, the application temperature is held at 1 C.

CH410 Hose Fitting/Shut-off Valve Adapter

The shut-off valve is connected to an adapter. The adapter is screwedinto the CH410 hose adapter allowing the shut-off valve to be connectedto the CH410. The heated hose is then connected to a hose fitting,supplied by the shut-off valve.

CH410 Mastic Ring

The stranding stations in a cable production machine have differentangles for the strands. The different angles result from the differentnumber of strands applied to the power cable. When only a few strandsare added at the stranding station, the angle of the strands leading intothe CH410 is very shallow resulting in a large angle between the diewalls and the wire(s). The CH410 mastic ring narrows the angle from thecone inside the CH410 die holder and allows the strands to take off moreof the mastic material.

5960026A

3.700max 1.000 TBD

1 2 3

Fig. 3 Mastic Ring

1. Maximum size cone opening2. Opening as shipped

3. Cone size to be determined bycustomer



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The CH410 mastic ring is delivered to the customer in a blank version.The cone is machined into the mastic ring during customer installation.

CH410 mastic rings can also be purchased later to fit new or differentcone sizes to the cable coating system.


The CH420 cable coating die is a closed pressure die. The CH420coating die is used in single cable coating processes. It applies themastic material to the outside of the cable.

After the CH420 cable coating die applies the mastic material, anotherlayer of strands can be applied to the cable. No mastic material isallowed to squeeze through the last layer of cable. If mastic material ismigrating through the last layer of the cable, the amount deposited mustbe reduced to produce acceptable cables.

The differences from the CH410 cable coatings are:

Closed die, and pressurized Two sizing dies instead of 1 Mastic material volume and pressure is controlled by the AG-900

pressure regulator



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CH420 Cable Coating Die (contd)

The coating thickness the CH420 applies to the cable is determined bythe opening of the exit sizing die. The cable opening from the entrysizing die may be as small as the outside dimension of the power cable.The cable opening from the exit die needs to equal the power cable size,plus the necessary coating thickness. If your application requires it, theentry and exit openings can be the same.

5960025A

5

2 43

6

1

Fig. 4 CH420 Die Operation

1. Cable2. Entry die3. Mastic material

4. Exit die5. Exit die opening6. Entry die opening

The CH420 cable coating die consists of the following parts:

5960032A

2

3

32

1

5

4

16

Fig. 5 CH420 Die

1. Heater bands2. Endcaps3. O-rings

4. Body5. Bracket6. AG-900 regulator



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CH420 Body

The CH420 body is one piece. All other parts for the CH420 cablecoating die are added to the CH420 body. The massive walls of theCH420 body ensure that the temperature is kept constant even if largeamounts of mastic material are moved through the die. Because of thelarge contact area to the power cable (entry sizing die and exit sizingdie), the CH420 needs to hold heat in its own structure.

CH420 Endcaps

The CH420 endcaps hold the sizing dies in place and are designed to beeasily removed for changing sizing dies and/or cleaning the CH420 cablecoating die.

CH420 O-rings

Two O-rings are supplied with the CH420. The CH420 O-rings preventmastic material from migrating to the outside of the sizing die and fromthere to the CH420 endcaps.

The O-rings need to be checked for damage each time the sizing die ischanged or the CH420 cable coating die is cleaned. If any damage isvisible, the CH420 O-rings need to be changed.

CH420 Heater Band

Since mastic material is almost solid at room temperature, it needs to beheated to be useable. When heated the mastic material becomes a veryviscous, but moveable material. The temperature needs to be stablethroughout the application process. From the feed system, through theheated hose to the CH420 coating die, the temperature should beconstant and controllable. The CH420 coating die uses high wattageheater bands to heat the entry and exit dies to the desired temperatureand maintain the setpoint temperature during the operation. Because theheater bands use a state-of-the-art temperature controller, the applicationtemperature is held at +/– 1 C.

The large size of the CH420 cable coating die requires two heater bands.These bands are marked #1 and #2. Each heater band has a differentcut-out to fit on the CH420 cable coating die.

AG-900 Pressure Regulator

This is a spring-loaded regulator which precisely controls pressurefluctuations to maintain a consistent rate of material output to the CH420die. It is manually adjustable.



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CH420 Bracket

The CH420 bracket enables the cable coating die to be mounted ontoany flat surface. The CH420 bracket is connected to the CH420 bodywith screws and has thermal insulation between the bracket and the bodyto help retard heat loss to the bracket and base.

It is very important that the CH420 cable coating die is accuratelyadjusted to the power cable. The CH420 cable coating die must becentered and level to the center of the power cable.

Temperature and Level Control

The heating of the cable coating dies is controlled by a fuzzy logictemperature control unit that ensures a stable temperature. Each CH410and CH420 cable coating die has its own temperature control panel. Thecontrol panels include the temperature controller, main switch fuses andcircuit breakers. The control panel for the level control is mounted to theside of the CH410 control panel.

The temperature control panel is connected to the cable coating die by acordset. In the case of the CH410 cable coating die, another cordset isused to operate the level control. All cordsets have quick disconnectsand can be easily removed for service or relocation of equipment.

This section explains how to properly install a cable coating system.Several steps need to be taken before the Nordson technician arrives atyour facility. Some of the parameters can be changed depending on theequipment you received. Check the specification sheet for your cablecoating system.

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

The space needs to be prepared for the feed system and the controlpanel outside of the cable machine. The feed system needs to havesufficient space around it to be easily accessible for drum loading andmaintenance work. Refer to the floor plan for detail space information.

The control panel needs to be accessible for temperature changes, toswitch units off and on, and for maintenance work. The control panelshould be installed at a comfortable height for the operator and within thereach of the control panel via the control cables.

3. Installation

Equipment Space andEquipment Floorplan



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The control panels control the temperature of the CH410 and CH420cable coating dies and the level controller for the CH410 units.

The power supply to the control panel is separate from the feed systemand needs to be fused differently. The support cable to the cable coatingdies and the level control will need to be connected as well.

Electrical

The electrical connections need to comply with the local electrical codeand need to be grounded.

WARNING: Always ground the equipment before working on it.Failure to ground the equipment could result in personal injuryor damage to the equipment.

The electrical parameters for the control panels are:

240 VAC Single phase 50–60 Hz 20 A for the CH410 Control Panel 30 A for the CH420 Control Panel

Mechanical

The control panels can be installed onto a support bracket (supplied bythe customer) or directly to the wall. The control panels are deliveredwith installation feet, but they can be installed without them.

When installing the control panels, note that the CH410 cable coating dieshould be within the reach of the control panel via the control cables.The control panels should be accessible to change the temperature andfor maintenance.

The mechanical parameters for the control panels are:

Height = 500 mm (19.7 in.) Width = 400 mm (15.7 in.) Depth = 210 mm (8.3 in.) Weight = 25 kg (55 lbs.)

Control Panels



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The CH410 cable coating die is used with or without strander stations ina power cable manufacturing process. When used with strander stations,the mastic material is applied between the strands to ensure 100% fillingof the power cable with the mastic material.

Electrical

The CH410 has two electrical connections to the control panel. One ofthe connections is for the cordset 30A (temperature control connections),the second connection is for the level control (fiber-optic leads).

The cordset 30A is connected to the control panel with a quickdisconnect and is easily removed for maintenance and relocation of thecable coating die. The level control and the shut-off valve cordsets arealso connected with quick disconnects. The level control cordsetprovides the solenoid plug for the shut-off valve.

The fiber-optic leads need to be installed on the delta brackets of theCH410 cable coating die. They need to be inserted into the holes andfixed into place using the setscrews. After installing the level controlfiber-optic leads, the level control needs to be checked for function andcorrect alignment. Make sure that the delta bracket screws are tight andthe delta bracket is in the correct position.

Mechanical

The CH410 cable coating die is installed in the position of the sizing die.In most cases the sizing die holder has to be removed and the CH410 dieholder is installed in its place. The CH410 cable coating die is deliveredwith a square bracket. The CH410 needs to be installed so the levelcontrol fiber-optic leads are horizontal. The shut-off valve will be 45 offcenter.

H410 Cable Coating Die



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The CH420 is used to apply the mastic material to the outside of thepower cable. The closed design and the use of two sizing dies ensures aprecise coating.

The coating thickness the CH420 applies to the cable is determined bythe opening of the exit sizing die. The cable opening from the entrysizing die may be as small as the outside dimension of the power cable.The cable opening from the exit die needs to equal the power cable size,plus the necessary coating thickness. If your application requires it, theentry and exit openings can be the same.

5960025A

5

2 43

6

1

Fig. 6 CH420 Die Operation

1. Cable2. Entry die3. Mastic material

4. Exit die5. Exit die opening6. Entry die opening

Electrical

The CH420 cable coating die has a single electrical connection. Thisconnection is to the temperature control panel and has the same quickdisconnect as the CH410 cable coating die. This connection ensuresthat the base is properly grounded to the power cable machine andprovides a continuous ground throughout the system.

H420 Cable Coating Die



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Mechanical

The CH420 cable coating die needs to be installed onto an adjustablebase. The base needs to be adjustable for height, level to the powercable, and side-ways. It is very important that the CH420 cable coatingdie is precisely adjusted to the center of the cable. Failure to make thisadjustment results in an uneven coating on the power cable.

It is important to consider that the CH420 cable coating die is heavierthan the CH410 cable coating dies. The base needs to be able to handlethe additional weight and also needs to withstand the force of the passingpower cable.

AG-900 Pressure Regulator

The pressure regulator has a spring tension control that is adjusted usinga hex key. This controls the pressure of the material entering the diewhere another passage directs the material to the exit area of the die.

There are two types of control panel for the cable coating system. One isfor the CH410 cable coating die and includes the level control. The othercontrol panel is for the CH420.

Both control panels have identical temperature control circuits for heatingthe heater band. The difference is in the amount of heating power thecontrol panel can handle. The CH410 control panel can handle amaximum of 20 Ampere, that when supplied with 240 Volts equals4800 Watts. The CH420 control panel has a maximum of 30 Ampere,that when supplied with 240 Volts equals 7200 Watts.

NOTE: A CH420 control panel can run a CH410 cable coating die, but aCH410 control panel can not run a CH420 cable coating die.

CH410 Control Panel

The CH410 control panel includes the temperature control circuit and thelevel control circuit for the CH410 cable coating die. Both circuits areindependent and have separate connection cables to the CH410 cablecoating die. The CH410 control panel can handle a maximum of20 Ampere/4800 Watts.

The control panel should be secured in one place and be accessible tothe front and to the side where the level control main control box islocated. Enough space needs to be provided to remove and secure thecordset 30A and the level control harness. In addition, the control panelshould be protected from rain, direct water contact, extreme dust andmechanical vibration.

Control Panels



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CH420 Control Panel

The CH420 control panel includes a temperature control circuit, similar tothe CH410 temperature control circuit. The CH420 control panel canhandle up to 30 Ampere/7200 Watts.

The control panel should be secured in one place and must beaccessible to the front. Enough space needs to be provided to removeand to secure the cordset 30A. In addition, the control panel should beprotected from rain, direct water contact, extreme dust and mechanicalvibration.

Temperature Control Circuit

The key component of the temperature control circuit is the temperaturecontroller. The Fenwal 922 temperature controller is a sophisticatedcontroller with self teaching (fuzzy logic) capabilities. The temperaturecontroller is able to control the temperature of the cable coating die to arange of 1 C. The fuzzy logic option allows the temperaturecontroller to learn the exact heating curve of the cable coating dies andadjust itself to prevent overheating or extensive heat loss periods.

Once adjusted, the temperature controller is easy to handle and monitor.There are two (2) displays, one for the setpoint temperature and one forthe current temperature, plus an indicator LED for the heating poweroutput. The operator has all application important parameters in hisimmediate view. The alarm function can be set so the operator isimmediately alerted to any changes in the heating process. A passwordfunction prevents unauthorized changes of the temperature settings.

The temperature controller is connected to a solid state relay to handlethe high power value for the heating band. The solid state relay ismaintenance free. An LED on the solid state relay indicates if the relay isworking.

The temperature control circuit consists of the ON/OFF switch, a lightindicator and circuit breakers.

Refer to the troubleshooting section and the vendor manuals for furtherinformation on these components.

NOTE: Except for troubleshooting or maintenance, the control panelcabinet door should be closed at all the times. The control panel door isequipped with a key lock, and should only be opened by qualifiedpersonnel.



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The cordset 30A connects the control panel to the CH410 or CH420cable coating die. The cordset 30A is designed to work on both types ofcontrol panels.

Equipped with a quick disconnect on the side of the control panel and aconnection box on the side of the cable coating dies, it is easy and quickto change the cordset. The cordset includes all wires (heating wires,ground wires and the temperature sensor wires). The cordset is coveredwith an armored, liquid-tight conduit to withstand most industrial use.

The level control controls the amount of adhesive at the face of theCH410 cable coating die. It ensures that the appropriate amount ofmastic material to coat the power cable is present. The level control unitis a fiber-optic through-beam level control system. The level controlincludes the main control box (mounted outside of the control panel), apower supply and the fiber-optic harness to the CH410 cable coating die.

How the Level Control works:

The fiber-optic leads attached to the fiber-optic harness are installed intothe delta brackets of the CH410 cable coating die. These fiber-opticleads are the source. The detector (a light beam) looks across theCH410 open surface and signals the main control box that the light beamis uninterrupted. The main control box gives a 24 VDC signal to thesolenoid which opens the shut-off valve.

Mastic material now enters the CH410 cable coating die filling the innerpart of the die. As the mastic material fills the CH410 cable coating dieinlet area, it breaks the light beam from the level control. This indicatesto the main control box that enough material is present at the die face.The 24 VDC signal to the shut-off valve solenoid is switched off and theflow of material into the CH410 cable coating die stops. When the masticmaterial level drops again and the light beam is restored the main controlbox restores the 24 VDC to the shut-off valve solenoid and the CH410cable coating die inlet is filled again.

If the power cable is rotating in front of the fiber-optic level control and theseparate wires are interrupting the light beam, a delay board is added tothe main control box. The delay board is adjusted to 18 ms and delaysthe switching of the 24 VDC to the shut-off valve solenoid.

To set the delay time on the main control board and to adjust thedetector/source response mode, refer to your level controldocumentation.

Cordset 30A

Level Control



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Once adjusted, the temperature controller is easy to handle and tomonitor. The controller has two (2) displays, one for the setpointtemperature and one for the current temperature as well as the indicatorLED for the heating power output. These displays put all applicationimportant parameters in the operators immediate view. The Alarmfunction can be set so the operator is immediately alerted if any changesoccur to the heating process. A supervisor password function canprevent unauthorized changes on the temperature settings.

Tables 1, 2, and 3 show the default factory settings of the temperaturecontroller. If any settings are changed, use these parameters to restorethe default settings. Also if any problems occur with the temperaturecontrol unit, check if the parameters listed below are still in thetemperature control units memory.

Table 1 Fenwal Default Parameter Settings

Component Default Setting Possible Settings

DIP Switch 1 ON On/Off

Key lock Unlock Lock/Unlock

DIP Switch 2 ON ON/OFF

Parameter Operating Parameter Operating Parameter/

Setup Parameter


Control Mode PID Control PID Control/

ON/OFF Control


Control Action Reverse Reverse/Direct

Table 2 Fenwal Default Switch Settings

Switch Setting Description

Rotary Switch A B Pt100

Rotary Switch B 1 15 VDC SSR Output

Table 3 Fenwal Default Setup Parameters

Setup Parameters Value

Display Units Centigrade

Fenwal Temperature Controller



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Table 4 lists the contacts available from the Fenwal temperaturecontroller and indicates the contacts used in the cable coating system.This list can serve as a quick reference during setup and troubleshooting.Some of the available contacts are not used with the cable coatingsystem. These contacts are available for interfacing with the power cablemachine.

Refer to the Fenwal manual for further information on how to use theavailable contacts.

Table 4 Fenwal Contacts

Fenwal Contact#

Value Description

1 +VDC SSR Output

2 –VDC SSR Output

3 SP/Key Not Used

4 SP/Key Not Used

5 VDC Input Not Used

6 A Pt100 REd

7 B Pt100 White

8 Common Pt100 White

9 NC Not Used

10 No Not Used

11 Common Not Used

12 AL2 Not Used

13 AL1 Not Used

14 Common Not Used

15 L1 240 VAC

16 L2 240 VAC

17 Ground

Fenwal Temperature ControlContacts



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This section contains troubleshooting procedures. The troubleshootingsection gives you a guideline of where to look and logical steps to take inlocating the problem. These procedures cover only the most commonproblems that you may encounter.

For in-depth technical information on components or how to setparameters, refer to the equipment documentation for the item you aretroubleshooting.

WARNING: For some troubleshooting procedures, it isnecessary to have the equipment energized to correctly locatethe problem. Only take voltage measurements with theequipment energized. Perform all other troubleshootingprocedures with the power to the equipment off. Failure toobserve can cause serious injuries or death.

If you cannot locate the problem or your personnel is not trained on thistype of equipment, contact your local Nordson office for the help of aservice technician or to request additional training for your technicalpersonnel.

The simple layout of the heater circuit makes troubleshooting very easy.In the heater circuits you have five (5) single components that could failor have problems.

The temperature control unit The solid state relay The cordset 30A The temperature sensor PT100 The heater band in the CH410 or CH420

4. Troubleshooting

Heater Circuit



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Problem Possible Cause Corrective Action

1. Control unit displayshows setpoint but unitnot heating

Cordset 30A not properly connected Connect the cordset 30A correctly.

Cordset 30A wires broken Check the cordset 30A wires fordamage or breakage. Replace cordsetif any wires are broken.

Solid state relay not functioning Check the LED on the solid state relay.If LED is not on, check the voltage onthe Fenwal contacts 1 & 2. Voltageshould be 15 VDC, if not check outputvoltage of solid state relay. Voltage ofrelay should be 240 VAC. If not, replacesolid state relay.

Bad heater band Set setpoint to 100C/212F overcurrent temperature – if the display doesnot increase by the amount you entered,and you have checked the solid staterelay, open the junction box on the 30Acordset and check the voltage oncontacts 1 & 2. If there is voltage there,check the resistance for the heaterband. Resistance should be 18–25 Ω, ifnot replace heater band.

Fenwal controller not functioningproperly

If none of the above procedures correctthe problem and you have properreadings for the solid state relay and theheater band, check the internal settingsof the Fenwal controller. If the settingsare correct but the unit is still notfunctioning, replace the unit.



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Problem Corrective ActionPossible Cause

2. Temperature controlunit does not have anydisplay

No 240 VAC Check that both lines of the incomingpower to the control panel are present.

Power not turned on Turn main control switch on.

Heater toggle switch (S1) is not on Turn the heater toggle switch (S1) onthe front of the panel to ON.

NOTE: Only on CH410 control panels

Fuse F1 and/or F2 is tripped Check fuses F1 and F2, reset or replaceas needed.

Fuse F3 and/or F4 is tripped Check fuses F3 and F4, reset or replaceas needed.

NOTE: If fuses keep tripping, replaceFenwal unit.

Poor connections at contacts 15 & 16 ofthe temperature control unit

Check contacts 15 & 16 connections tothe wires on the temperature controlunit. Correct as necessary.

Insufficient power Check that voltage is 240 VAC at thefollowing points:

Main switch in/out

Toggle switch (S1) in/out.

Temperature control unit contacts15 & 16.

Temperature control unit malfunctioning Replace temperature control unit.



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3. Temperature controlunit shows setpointdisplay and currenttemperature display,but heater band notheating

LED “Out” not flashing Check the internal setting of thetemperature control unit. Refer totemperature controller documentation.

Voltage on contact 1 & 2 of thetemperature control unit not at 15 VDC

Check internal settings of thetemperature control unit.

A1+ & A2– contact of solid state relaynot at 15 VDC

Replace solid state relay.

Red LED on solid state relay is not onwhen 15 VDC is present at A1+ & A2–

Replace solid state relay.

240 VAC not present at contact 1 & 2 ofthe solid state relay.

Check triac inside the solid state relay.

Circuit breaker (CB1) is tripped Check circuit breaker, reset or replaceas necessary.

Heat1 connector pins 1 & 2 do not have240 VAC

Replace heater.

Open connector box on cordset 30A Close connector box.

Terminal blocks 1 & 2 do not have240 VAC

Check the cordset 30A wires fordamage or breakage. Replace cordsetif any wires are broken.

Resistance on heater band is not16–25 Ω

Replace heater band.

Broken PT100 sensor Refer to temperature controller manual.

Error codes Refer to temperature controller manual.



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The level control is used with the CH410 cable coating die. The levelcontrol components are mostly inside the main control box (Blue box onthe outside of the control panel). The level control has the followingcomponents.

Main control board Time delay board Output device 24 VDC power supply (contained in main control box) Level control harness Fiber-optic leads

An important factor that the level control is working is that the shields arerouted from the main control board to the detector/source heads. If theshields are interrupted or have contact to each other, the level control willnot work or it will give an incorrect signal.

Do not bend the fiber-optic leads to less than a radius of 50 mm (2 in.).This may cause the leads to break making it necessary to replace them.

If the lenses of the fiber-optic leads need cleaning, use only a clean, drycloth to avoid scratching the fiber-optic lenses.

The troubleshooting section will guide you to the most common situationswith the level control. If more information is needed, refer to the levelcontrol documentation.

Level Control



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1. Level control does notwork at all

Main power switch is not on Turn power switch on.

Fuse F3 is tripped Check fuse. Replace if necessary.

Toggle switch (S2) not switched on Turn toggle switch (S2) on.

Voltage on contacts 2 & 3 inside themain control box is not at 240 VAC

Check wiring to contacts 2 & 3.Repair/replace as needed.

Voltage on 24 VDC power supply oncontacts L & N is not at 240 VAC(CH410 only)

Check wiring to contacts L & N.Repair/replace as needed.

Voltage on 24 VDC power supply oncontact V– & V+ is not 24 VDC(CH410 only)

Refer to power supply manual. Ifproblem cannot be located, replacepower supply.

Voltage on terminals 6 & 8 inside themain control box is not 24 VDC(CH410 only)

Check wiring to terminals 6 & 8.Repair/replace as needed.

Detector cable and/or source cable oflevel control harness not connectedcorrectly (CH410 only)

Check the appropriate contact pins to besure contact is made. Also check thatthe color coding of each wire matches.Make sure shields are connected.

LC1 connector not secure Check if the LC1 connector (underneaththe control panel) is securely connected,if not, secure it.

Fiber-optic leads not connected Check cable shield to be sure it is inproper location.

Take the fiber-optic lead connected tothe source and the fiber-optic leadconnected to the detector and hold themtogether face to face (both ends facingeach other). The red LED on the maincontrol board inside the main control boxshould light up, indicating the sourceand the detector have contact. If not,replace source or detector.



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1. Level control does notwork at all (contd.)

Voltage at terminal points 5 & 7 notcorrect

Check that voltage at terminal points5 &7 inside the main control box is at24 VDC when red LED is on. Considerthat there is a time delay between whenthe red LED is on and when the outputrelay is energized (18 ms).

Solenoid plug on end of the level controlharness not functioning

Check pins on solenoid to make surethey are making contact. If not, replacesolenoid.

Check that voltage at the solenoid plugon the end of the level control harness is24 VDC. If voltage is present inside thesolenoid plug, check if compressed air isapplied to the solenoid and if thesolenoid would trigger manually (pushthe hand activator on the solenoid). Ifthe solenoid works in hand mode,replace the complete solenoid.



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The AG-900 pressure regulator is used with the CH420 die.


1. Material evident atregulator adjustment nuthole

Piston or back-up O-ring worn ordamaged

Disassemble regulator to remove pistonand check piston, back-up O-ring andregulator walls for wear or damage.Replace as needed.

2. Material evident atregulator lower flange

Piston shaft retainer nut too loose Adjust piston shaft retainer nut to15–18 psi

Lower flange O-ring worn ordamaged

Replace O-ring.

Flange sealing faces worn ordamaged

Replace flange.

Flange retainer seal worn ordamaged

Replace seal.

O-ring on piston shaft retainer wornor damaged

Replace O-ring.

Sealing surface of componentdamaged

Replace damaged part.

3. Material evident at hoseregulator connection

Sealing bore on regulator bodydamaged

Replace shaft seal and regulator body.

4. Pressure/flowfluctuations occur

Piston seal leaking Refer to troubleshooting procedureMaterial evident at regulator adjustmentnut hole.

Material built up at seals Refer to troubleshooting proceduresMaterial evident at regulator adjustmentnut hole and Material evident atregulator lower flange.

Insufficient air pressure Adjust air pressure as needed.

Pressure Regulator



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The following procedures describe how to disassemble and re-assemblethe AG-900 regulator.

Disassembly

To disassemble the regulator, perform the following procedure:

1. Disconnect and lock out input electrical power from the die.

2. See Figure 7. Relieve pressure to the regulator. Disconnect thematerial supply hose from the hose connector, then remove the fourM5 socket head screws (1). Remove the regulator assembly from theCH420 die.

5960040A

1

Fig. 7 Removing Pressure Regulator from CH420 Die

1. Screws

5. Repair

Pressure RegulatorReplacement



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Disassembly (contd)

CAUTION: Peform this step to prevent damage to thenozzle/needle service kit during regulator assembly.

3. See Figure 8. Unscrew and remove the regulator adjusting screw (1)from the regulator body. Remove the spring seat (2), thrust bearing(17), and spring (5) from the regulator piston bore.

2

4

5

6

1214

15

16

1

3

7

8

9

10

11

13

17

5960035A

Fig. 8 Regulator Assembly

1. Regulator adjusting screw2. Spring seat3. Screw4. Lockwasher5. Spring6. Piston back-up ring7. Piston O-ring8. Poppet O-ring9. Piston shaft

10. O-ring11. Poppet O-ring12. Poppet back-up ring13. Poppet housing14. Poppet housing O-ring15. Seat16. Piston17. Thrust bearing



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4. Using an 11/16-inch wrench, remove the poppet housing (13) from thebottom of the regulator body.

5. Using either a 15/64-inch open-end wrench or a pair of pliers, hold thebottom of the poppet with piston shaft (9). Insert a 5 mm hex wrenchinto the regulator piston bore and remove the screw (3) andlockwasher (4).

6. Pull the poppet with piston shaft from the bottom of the regulator bodyusing a pair of pliers.

7. Insert a 5/32-inch dowel through the bottom of the regulator to pushthe piston (16) out through the regulator piston bore.

CAUTION: Be careful to push on the bottom of the piston anddo not insert the dowel into the piston shaft bore to preventdamage to the bore.

8. Remove the seat (15) from the regulator body by pushing with adowel inserted through the piston bore.

9. Thoroughly wipe clean the internal cavities of the regulator, thepiston, and the poppet housing.



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Assembly

To assemble the AG-900 regulator, perform the following procedure:

1. See Figure 8. Place a new O-ring (10) on a new seat. Lubricate theO-ring with Parker O-ring lubricant and replace the seat in theregulator. Make sure that the chamfered face of the seat is facingdown.

2. Place a new O-ring (7) and backup ring (6) on the piston. Lubricatewith Parker O-ring lubricant and reinstall the piston into the regulatorbody.

3. Place new O-rings (8, 11) and backup ring (12) on a new poppet withpiston shaft (9). Lubricate O-rings with Parker O-ring lubricant andinsert the poppet with piston shaft into the regulator body from thebottom.

4. Hold the bottom of the poppet with piston shaft with either pliers ora 15/64-inch wrench. Apply adhesive to the screw (3). Insert screwand lockwasher through the top of the regulator body and tighten intothe poppet with piston shaft with a 5 mm hex wrench.

5. Install a new O-ring (14) on the poppet housing (13). Lubricate theO-ring with Parker O-ring lubricant and install poppet housing in thebottom of the regulator with a 11/16-inch wrench.

6. Grease the thrust bearing (17). Replace the spring, spring seat, andthrust bearing into the regulator body.

7. Lubricate the adjusting screw (1) with Never Seez lubricant and insertit into the regulator body.

8. See Figure 7. Position the regulator assembly against the CH420 dieand secure it in place with the four M5 socket head screws (1). ApplyNever Seez lubricant to the screws before installing them.

9. Reconnect the input electrical power to the die. Plug in the regulatorheater and hose cordsets and resume normal operation.



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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 Notes

— 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.

6. Parts

Using the Illustrated PartsList



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Use the following parts list to order replacement parts for the CH410cable coating die.


— 332 295 Cable Coating Die, CH410

1 332 305 RTD, platinum, 100 ohm, 30 lead 1

2 332 306 Bracket, square 1

3 332 307 Holder, sizing die 1

4 332 308 Gasket, ring 1

5 332 309 Heater, band 1

6 332 310 Bracket, delta 2

7 332 311 Adapter, shut-off valve 1

8 332 312 Ring, mastic, blank 1

9 981 606 Screw, socket head, 1/2-13 x 1.250 in. 4

10 325 111 Gun, automatic, H20, 3/8 HP, 240V 1

11 901 138 Valve, solenoid, 24 VDC, 1/8 NPT 1

12 973 001 Nipple, schedule 40, 1/8 x 2.500 in. 1



15 900 344 Lubricant, Never Seez, 8 oz. can —




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5960020A

8

613

1 4

29

511

12

10

7

3

6

14

Fig. 9 CH410 Cable Coating Die Assembly



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Use the following parts list to order replacement parts for the CH420cable coating die.


— 332 297 Cable Coating Die, CH420

1 332 305 RTD, platinum, 100 ohm, 30 lead 1

2 332 313 Body 1

3 332 314 Cap, end 2

4 332 315 Insulator, heat 2

5 233 749 O-ring, Viton, 2.500 x 2.870 x 0.187 in. 2

6 332 316 Bracket, mounting 1

7 332 317 Heater, band, CH420, left 1

8 332 318 Heater, band, CH420, right 1

9 816 163 Connector, straight. thread, 90 elbow 1

10 302 305 Module, regulator, AG-900 pressure 1 A

11 940 141 O-ring, Viton, 0.489 ID x 0.070W in., brass 1

12 983 140 Washer, lock, split, 1/4 in. 4

13 983 180 Washer, lock, split, 1/2 in. 4

14 981 564 Screw, hex head, 1/4-20 x 0.875 in. 4

15 981 601 Screw, hex head, 1/2-13 x 1.500 in. 4

16 983 123 Washer, flat, 0.219 x 0.500 x 0.490 in. 1

17 981 146 Screw, hex head, 10-24 x 0.500 in. 1


19 900 223 Lubricant, O-ring, Parker, 4 oz. —

NOTE A: Refer to Pressure Regulator for individual parts.




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5960023A

3

5

910

14

17

53

7

11

6

13

4

2

8

1 16

12

15

Fig. 10 CH420 Cable Coating Die Assembly



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— 302 305 Module, regulator, AG-900 pressure 1

1 324 759 Seal, shaft, 0.56 ID x 0.80 OD x 0.10 in. 1

2 900 349 Lubricant, 0.75 oz. tube —

3 135 008 Adapter, 10 SAE, gun 1

4 231 328 Module, regulator, without adapter 1 A

5 940 133 O-ring, Viton, 0.426 ID x 0.70W in. 1

6 982 372 Screw, socket head, M5 x 12 6


8 302 315 Plate, mounting, regulator 1

NOTE A: Refer to separate parts list.

Pressure Regulator



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5960039A

1

8

6

5

7

4

3

2

7

6

Fig. 11 Pressure Regulator



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See Figure 12. Use the following parts list to order replacement parts forthe pressure regulator on the CH420 cable coating die.


— 231 328 Module, regulator, without adapter, AG-900 1

1 155 815 Body, regulator, hi temperature, AG-900 1

2 155 822 Seat, spring, with bearing, AG-900 1

3 981 766 Screw, socket head, M6 x 10 mm 1

4 983 409 Lockwasher, split, M6 1

5 134 303 Spring, AG-900 1

6 954 049 Ring, backup, single turn, 13/16 in. 1

7 942 111 O-ring, Viton, 0.812 x 1.062 x 0.125 in. 1

8 900 223 Lubricant, O-ring, Parker, 4 oz —


10 941 151 O-ring, Viton, 0.688 x 0.875 x 0.094 in. 1


12 954 036 Ring, back up, single turn, 1/4 x 3/8 in. 1

13 155 818 Housing, poppet regulator, AG-900 1


15 155 816 Seat, 0.420 floating, AG-900 1

16 155 817 Poppet, with piston shaft, AG-900 1


18 155 821 Piston, lip seal, AG-900, hi temperature regulator 1

19 324 762 Bearing, thrust, 0.075 x 1.250 x 0.078 in. 1

20 982 224 Screw, set, adjusting, regulator, AG-900 1

21 900 301 Grease, lubricant, silicone, 150 grams —

22 900 464 Adhesive, threadlocking —

— 900 344 Lubricant, Never Seez, 8 oz. can NS

NS: Not Shown

AG-900 Pressure RegulatorModule



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Manual 59-53

5960038A

1

6

3

2

4

13

14

15

16

18

21

20

7

12

11

10

5

22

8

9 8

178

19

Fig. 12 AG-900 Regulator Module



321 191BIssued 1/00

Manual 59-53

See Figure 12.


6 954 049 Ring, backup, single turn, 13/16 in. 1

7 942 111 O-ring, Viton, 0.812 x 1.062 x 0.125 in. 1


10 941 151 O-ring, Viton, 0.688 x 0.875 x 0.094 in. 1


12 954 036 Ring, backup, single turn, 1/4 x 3/8 in. 1


15 155 816 Seat, 0.420 floating, AG-900 1

16 155 817 Poppet, with piston shaft, AG-900 1


AG-900 Recommended SpareParts



321 191BIssued 1/00

Manual 59-53

Use the following information to order replacement parts for yourcordset 30A.

Item Part Number Manufacturer Description Quantity

1 10–1700, 10–0829 Contact Plug, male 1

2 39722 Anaconda Conduit 32 ft.

3 S55100 283 IES Box, terminal 1

4 3234/34 Kleinhuis Strain relief 1

5 USLKG10 Phoenix Terminal, ground 2

6 UK6N Phoenix Terminal 5

5960024A

6= SENSOR–WHITE (T1–6) 18 AWG5= SENSOR–RED (T1–7) 18 AWG4= SENSOR–RED (T1–8) 18 AWG3= NOT USED2= HEATER 10 AWG1= HEATER 10 AWG

12

34

56

1 2455

6 3

2

2

1

4

6

Fig. 13 Cordset 30A Assembly

Cordset 30A



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Manual 59-53

Use the following information to order replacement parts for your levelcontrol harness.


1 E51KF833-A1 Eaton Cable, fiber-optic, 3 ft. 2

2 6221A-7501 Eaton Adapter 2

3 6503A-030 Eaton Cable, source 30 ft.

4 6507A-030 Eaton Cable, detector 30 ft.

5 211678-1 AMP Plug, male, level control 1

6 206070-1 AMP Plug, male, level control 1

7 660-99-4 AMP Plug, male, level control 1

Level Control Harness



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Manual 59-53

5960033A

10 ft. 30 ft.

SOURCE

DETECTOR

3 1

6 4

79

1 = Source – Black2 = Source – Red3 = Source – Shield4 = Detector – Green/Red5 = Detector – White/Black6 = Detector – Shield7 = Not Used8 = L+/ 24 Vdc9 = M/ 24 Vdc

5

2

4

3

1

1

2

76

2

5

8

Fig. 14 Level Control Harness



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Manual 59-53

Use the following information to order replacement parts for the controlpanel of your CH410 .


DISC ED2–3D3FM EEC Switch, main 1

CB1, CB2 W92–X112–20 Siemens Circuit breaker 2

PL1 35R–2213T Leecraft Lamp, main power 1

TC1 92–211110–100 Fenwal Temperature controller 1

F1, F2, F3 215–1 Littlefuse Fuse, 1A 3

S1, S2 E10T215AS Eaton Switch, temperature control 2

HEAT1 10.1710, 10.0739 Contact Connector, cordset 1

SSR1 7710–2–03–3–27 ECS Relay, solid state 1

PS1 SIZTOP POWER 2 Siemans Power supply 1

PL2 35R–2212T Leecraft Lamp, level control 1

LC1 8170A–6502 Eaton Level control 1

LC1 8212B–6501 Eaton Level control 1

LC1 8526A–6501 Eaton Level control 1

LC1–C 211769–1 AMP Connector, level control 1

LC1–C 66101–8 AMP Connector, level control 1

CH410 Control Panel



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Manual 59-53

5960035A

L1

L2

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG

12AWG12AWG12AWG

12AWG

12AWG

16AWG

16AWG

16AWG

16AWG

16AWG

16AWG

16AWG

16AWG

16AWG 16AWG

16AWG16AWG16AWG16AWG

16AWG

16AWG

16AWG

16AWG

16AWG

16AWG16AWG

16AWG

16AWG

16AWG

16AWG

CB1\20A

CB1\20A

1

5

16AWG16AWG Tempreature Control Lamp

PL1

S1

TemperatureOn/Off Switch

3

711151

2 17 16

F1\1A

F2\1A

White

Red

Red

5

4

4

6

6

7 8

A2

A1

1

2

1 2

TC1 Temperature Control

SSR 1 / Solid State Relay HEAT1/Sensor

CB2\20A

CB2\20A

HEAT1/Heater

3–32Vdc\40A–240AC

PS1 \ Power Supply

V+ L

V– N

93–264Vac\24Vdc–2ALC1 \ Lrvel ControlMainboard

5

1

2

4

3

6

6

Level ControlOn/Off Switch

Level ControlControl Lamp

PL2

16AWG

L+ L+ M M

6 5 8 7 2 9

3

65432197 8

V– V+

S2

F3\1A

Detector Source

Black Red Shld White Green Shld

LC1–Conn

DISC

DISC

Fig. 15 CH410 Schematic



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Manual 59-53

Use the following information to order electrical replacement parts for thecontrol panel of your CH420 .


DISC ED2–3D3FM EEC Switch, main 1

CB1, CB2 W92–X112–30 Siemens Circuit breaker 2

PL1 35R–2213T Leecraft Lamp, main power 1

TC1 92–211110–100 Fenwal Temperature controller 1

F1, F2 215–1 Littlefuse Fuse, 1A 2

HEAT1 10.1710, 10.0739 Contact Connector, cordset 1

SSR1 7710–2–03–3–27 ECS Relay, solid state 1

5960037A

L1

L2

15

16

A2

A1

DISC

TC1 Temperature Control

CB1\30A

PL1CB1\30A

CB2\30A

CB2\30A

Temperature Control Lamp

F1\1A

F2\2A

51

2

6 7 8

White

RedRed

3

4

1

2

2

1

3

456

Heat 1 / Connector

Heat 1 / Connector

1 2

2

1

SSR 1 / Solid State Relay

DISC

Fig. 16 CH420 Schematic

CH420 Control Panel

Documents

CH410 & CH420 - Nordsonemanuals.nordson.com/adhesives/English_Manuals/321191.pdf · Fenwal Temperature Controller 23 ... Troubleshooting 25 ... 321 191B. CH410 & CH420 Cable Coating