Hot Melt Application Head EP 48-V EP 48-VLemanuals.nordson.com/adhesives/English_Manuals/458361.pdf · adhesives commonly used in the book binding industry to glue the spines of books

Hot Melt Application HeadEP 48-V

EP 48-VLManual P/N 458361M

− English −

Issued 08/06

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

P/N 458361M � 2006 Nordson CorporationEP48V

NoteThis document is for products with the following P/N:

204055 8014754 8039972

204981 8014766 7100500

396020 8016858 7100501

396021 8021218 7141038

463815 8021806

464209 8039223

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2000.No part of this document may be photocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information contained in this publication is subject to

change without notice.

� 2006 All rights reserved.

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem,Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry,Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson,OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus,ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat,Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat,Sure-Max, Tela-Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat,Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect more. are registered trademarks − ® − of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series,CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure,DuraBraid, DuraCoat, DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, FilEasy, Fill Sentry, FluxPlus,Gluie, G-Net, G-Site, HDLV, Ink-Dot, iON, Iso-Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, Mikros, MiniBlue,MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc,Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue,Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue,Ultrasmart, Universal, ValveMate, Viper, Vista, VersaDrum, VersaPail, WebCure, 2 Rings (Design) are trademarks − � − of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners’ rights.

Table of Contents I

P/N 458361M� 2006 Nordson Corporation EP48V

Table of Contents

Safety Instructions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use - Examples - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Residual Risks 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note on Manual 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ID Plate 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Various Models 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components of the Application Head 6. . . . . . . . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhausting Adhesive Vapors 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching to Parent Machine 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parallelism 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laying Cable 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Control Air 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Heated Hose 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Second Open-jawed Wrench 12. . . . . . . . . . . . . . . . . . . . . . Connecting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Light Barrier Sensitivity 13. . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Application Width Display 13. . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important When Using Polyurethane Application Materials (PUR) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triggering Solenoid Valves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Temperature 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Operating Temperature 14. . . . . . . . . . . . . . . . . . . . . . . . Applying Hot Melt Adhesive 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Exhaust Throttle on the Retrosuction Module 15. . . . . . . Setting Application Width 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Application Thickness 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Shutdown 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings Record 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving Pressure 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Table 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Inspection for External Damage 20. . . . . . . . . . . . . . . . . . . . . . External Cleaning 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging with Cleaning Agent 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Plan 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Cartridge 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Filter Cartridge 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Filter Screen 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Filter Cartridge 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Record 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Table 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Notes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving Pressure 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Sealing Cord 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Control Module 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

New Application Module 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Processing Materials 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Melt Application Head EP 48-V / EP 48-VL 1


Safety InstructionsWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

Description

Intended UseHot melt application heads of the series EP 48-V − hereafter also referredto as application head − may be used only to apply PUR and other hot meltadhesives commonly used in the book binding industry to glue the spines ofbooks.

Any other use is considered to be unintended. Nordson will not be liable forpersonal injury or property damage resulting from unintended use.

Intended use includes the observance of Nordson safety instructions.Nordson recommends obtaining detailed information on the materials to beused.

Unintended Use - Examples -The application head may not be used under the following conditions:

� In defective condition

� When changes or modifications have been made by the customer

� In a potentially explosive atmosphere

� When hot melt adhesives not suitable for the unit are used

� When the values stated under Technical Data are not complied with.

The application head may not be used to process the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

WV

Nordson Engineering GmbHD 21337 Lüneburg − Germany

Made in Germany

2 Hot Melt Application Head EP 48-V / EP 48-VL


Residual RisksIn the design of the unit, every measure was taken to protect personnelfrom potential danger. However, some residual risks can not be avoided.Personnel should be aware of the following:

� Risk of burns on the hot application head: from hot adhesive and whenmaking adjustments

� Material fumes can be hazardous. Avoid inhalation.

Note on ManualThe position numbers in the illustrations do not correspond to the positionnumbers in the technical drawings and parts lists.

ID PlateType of application head

Nordson order number

Serial number

Operating voltage V = Volt

Power consumption W = Watt



Various ModelsTechnological advances have resulted in various models of the EP 48 V.Thus illustrations in this manual may deviate from the actual design. Moredetailed illustrations can be found in the included technical drawings.

NOTE: The following table indicates the order numbers (P/N) of thecomplete heads as well as of the subordinate assembly (head withoutbracket).

P/Ns Modifications

410284 Prototype

411647

411646� Bracket is now part of head

� Improved details

783810

783809� Control module for PUR

� Modified, additional seals

� Nozzle slit can be closed completely with application width adjuster

464209

463815

8021218

204055

� Improved constant pressure controller LA 330

� Improved details

204981

204980� No stroke adjuster on control modules

� Air relief valve on body no longer necessary due to improved design

396021

396020� Linear carriage: The head is clamped into place with four hexagonal screws instead of

clamping levers; an adjusting screw is used instead of an adjusting wheel.

� Improved control module with longer operational lifetime

� Improved constant pressure controller LA 330-II

7100500

7100501

Light version EP 48-VL:

� Without constant pressure controller

� Without light barrier

� Filter cartridge can be horizontal or vertical



FunctionThe application head EP48-V is designed especially for coating book spines(substrate) with PUR and other hot melt adhesives commonly used in thebook binding industry.

The adhesive flows from a hot melt feeding unit through a heated hose thena filter and into the application head. The outlet adhesive pressure iscontrolled pneumatically via the constant pressure controller (6). Theadhesive pressure or the quantity emitted can be adapted to the speed ofthe parent machine with an external control unit and a proportional valve.

The adhesive is applied to the spine from underneath. A pneumaticallycontrolled retrosuction module (control module, 5) sucks the adhesive out ofthe nozzle area (1) as soon as the control module closes. This ensuresexact adhesive edges. The adhesive output is monitored by a light barrier(4).

The application width can be set steplessly from 1 to 60 mm. A display (3)indicates the set application width.

The application head can be positioned perpendicular to the direction ofmovement of the spine with a linear unit (7). A swiveling guide plate (8)compensates for width deviation of the fed substrate up to 2 mm.

2

7 5

11 3

8

4

6



HeatingElectrical heater cartridges are used to heat the unit. The temperature iscontinuously measured by temperature sensors and regulated by electronictemperature controllers usually located in the electrical cabinet of the hotmelt adhesive feeding unit.

FilterThe heated filter between the material inlet and the constant pressurecontroller is equipped with a filter cartridge that can be easily replaced.



Components of the Application Head

1 4 6 7

9101214

32

151617 8

5

1113

Fig. 1 Shown without bracket

1 Setscrew2 Set collar3 Display Application width4 Hose connection5 Drip tray6 Application module

(control module)

7 Retrosuction module (controlmodule)

8 Electrical connection Application head

9 Solenoid valve Retrosuction module

10 Solenoid valve Applicationmodule

11 Air connection Control air (NW 6)

12 Air connection Constant pressure controller (NW 4)

13 Constant pressure controller * #

14 Filter block15 Electrical connection Filter16 Filter cartridge17 Clamping plate

Note:The actual model can deviate from the illustration.Note:There are separate manuals available for components marked with an asterisk (*).Note:The components marked with a # are not available on all models.



4 6 7 9 102

1920 18 16 15 14 12 1117

1 5

13

3

21

8

Fig. 2

1 Reflector (light barrier)2 Left guide plate3 Groove Sealing cord4 Width of application slit5 Right guide plate (mobile)6 Switching unit (light barrier) #

7 Pressure gage Adhesive pressure

8 Spindle guide9 Handwheel

Application width adjustment10 Connection light barrier #

11 Electrical connection Application head

12 Locking screw13 Setting wheel Axial position #

14 Setting screws Radial position

15 Linear unit16 Span piece Application width #

17 Clamp lever Axial position #

18 Air relief valve Body #

19 Heater cartridge20 Bracket21 Drip tray Body #

Note:The components marked with a # are not available on all models.



InstallationWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

UnpackingUnpack carefully. Then check for any damage caused during shipping.Reuse packaging materials or dispose of properly according to localregulations.

TransportThe application head is a high precision, valuable part. Handle verycarefully! Protect the nozzle from damage.

StorageDo not store outside! Protect from humidity and dust. Do not lay unit on thenozzle. Protect the nozzle from damage.

DisposalWhen your Nordson product has exhausted its purpose and/or is no longerneeded, dispose of it properly according to local regulations.

InstallationWhen installing the application head, the following points should beobserved in order to avoid unnecessary effort later.

� Protect from humidity, vibrations, dust and drafts

� Ensure access to parts relevant for maintenance and operation

� When installing the unit, ensure that cables, air hoses and heatedadhesive hoses can not be bent, pinched, torn off or otherwisedamaged.

Also refer to technical drawing in appendix.

1

2

1 2

3 4



Exhausting Adhesive VaporsEnsure that adhesive vapors do not exceed the prescribed limits. Exhaustadhesive vapors when necessary. Provide sufficient ventilation of thelocation where the unit is installed.

Attaching to Parent MachineScrew application head to the intended place on the parent machine or thetrolley. There are six threaded bores M8 in the bottom of the linear unit forthis purpose. Observe the following:

� The path of the linear unit is 50 mm

� The application slit must be at a right angle to the direction of movementof the substrate.

Adjusting

ParallelismTo achieve even application, the application head must be adjusted suchthat the application slit is parallel to the substrate.

1. Release the locking screw (1).

2. Release locknuts on setting screws Radial position (2).

3. Turn setting screws Radial position to align application head parallel tothe substrate.

4. Tighten locknuts.

5. Tighten locking screw.

PositionNOTE: Depending on the model of the linear carriage: The head isclamped into place with four hexagonal screws (3) or with clamping levers(1); an adjusting screw (4) or an adjusting wheel (2) is used.

1. Release clamp.

2. Position the head such that the edge of the left guide plate is aligned tothe left edge of the substrate:

� Turn clockwise: Head moves away from operator

� Turn counterclockwise: Head moves towards operator.

3. Tighten clamp.

NOTE: Depending on how the pages are displaced by the pressure appliedby the clamps on the parent machine, the position of the application slit mayneed to be adjusted perpendicular to the direction of movement of thesubstrate after the format is changed.



Electrical ConnectionWARNING: Observe voltage values found on the ID plate of the applicationhead and solenoid valves.

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

1. Connect the cables from the application head, filter and − when required− from the constant pressure controller to the electrical cabinet of theadhesive feeding unit or to an external electrical cabinet.

2. Use safety clips − when available − to secure the plug connection.

NOTE: Depending on the model of the hot melt application system, thesolenoid valves are triggered either via the valve control lead of the heatedhose or via a separate control lead that can also be part of a special cableharness.

3. Connect light barrier cable and − when required − control lead ofsolenoid valves to the control unit.

Laying CableWARNING: Ensure that cables do not touch rotating and/or hot unitcomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

2 13



Pneumatic ConnectionThe application head may only be connected to pressure controlled andconditioned compressed air.

Connecting Control AirUse dry, regulated, nonlubricated compressed air.

NOTE: Pneumatic lines can be part of a special cable harness.

1. Connect customer’s air conditioning unit to the air connection Control air(1).

2. Set air pressure to 6 bar / 0.6 MPa / 87 psi.

3. Connect customer’s air conditioning unit to the air connection Constantpressure controller (2) via the customer’s compressed air controller orproportional valve.

4. Adjust control air pressure for constant pressure controller as required(refer to Operation, Applying Hot Melt Adhesive).

NOTE: The constant pressure controller has a transmission ratio of 10:1.The resulting adhesive pressure is shown on the pressure gage (3).

1 2 3



Connecting Heated HoseWARNING: Hot! Risk of burns. Wear heat-protective gloves.

Using Second Open-jawed WrenchUse a second open-jawed wrench when connecting and disconnecting theheated hose. This prevents the unit’s hose connection from turning.

ConnectingIf cold material can be found in the hose connection, these components(1, 2) must be heated until the material softens (approx. 80 �C, 176 �F).

1. First connect the hose (3) electrically to the unit. For more than onehose: Every hose connection is allocated to a corresponding receptacle.Do not mistakenly exchange!

2. Heat the system and hose to approx. 80 �C (176 �F).

3. Screw on heated hose.

NOTE: Close unused hose connections with Nordson port plugs.

DisconnectingWARNING: System and material pressurized. Relieve system pressurebefore disconnecting heated hoses. Failure to observe can result in seriousburns.

WARNING: Hot! Risk of burns. Wear safety goggles and heat-protectivegloves.

1. Turn off material supply.

2. Place a container under the nozzle(s) of the application head.

3. Activate the solenoid valves electrically or manually. Repeat thisprocedure until no more adhesive flows out.

4. Properly dispose of material according to local regulations.

1

1 2

6

3

5 4



Adjusting Light Barrier Sensitivity1. Turn the setting screw on the light barrier (1) to Min.

2. Position a book to be coated over the application slit between the lightbarrier and the reflector.

3. Turn setting screw towards Max until the red LED lights up.

4. Make a note of the value that is shown on the light barrier scale.

5. Remove book.

6. First set screw to Max then turn towards Min until the red LED goes off.

7. Optimum setting: average of the value displayed now and the valuerecorded previously.

The setting is correct when the green LED lights up.

Calibrating Application Width DisplayCAUTION: The thread slack of the width adjustment may lead to incorrectreadings in the display. To avoid incorrect readings, the display should beread and adjusted as the thread is turned clockwise (decreasing applicationwidth).

WARNING: Hot! Risk of burns. Wear heat-protective gloves.

1. Heat application head.

2. Release span piece Application width (16, Fig. 2) (if present).

3. Use the handwheel Application width (3) to close the application slit untilthe left and right guide plates (1 and 2) touch one another.

4. Tighten span piece again.

5. Release the setscrew (4).

6. Turn the set collar (5) until the value 000.00 appears in the displayApplication width (6).

7. Tighten setscrew again.



OperationWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

Important When Using Polyurethane ApplicationMaterials (PUR)

It is imperative that the following guidelines are followed when processingpolyurethane application materials (PUR):

� Wear respiratory protection when the maximum permissibleconcentration of hazardous substances is exceeded.

� Before prolonged standstill of the application system, purge with asuitable cleaning agent. Use only a cleaning agent recommended by thematerial manufacturer.

� Close open material connections airtight.

For a short break in operation, it is sufficient to close the application slit allthe way and coat it with lubricant.

CAUTION: Use only special high-temperature grease. Refer to ProcessingMaterials! Any other grease may cause the PUR material to cross-link.

Triggering Solenoid ValvesCAUTION: Trigger the solenoid valves only when the application head isheated to operating temperature! If the adhesive is too cold, seals on theapplication module and retrosuction module may be damaged.

Setting TemperatureThe procedure for setting the temperatures is described in the temperaturecontroller manual. Temperature controllers are not part of the applicationhead. They can be located e.g. in the electrical cabinet of a hot meltapplication unit or in a separate electrical cabinet.

Maximum Operating Temperature180 °C / 356 °F

NOTE: When setting the temperature, the temperature prescribed by thehot melt adhesive manufacturer is decisive. The maximum operatingtemperature for the product described here and the heated systemcomponents may not be exceeded.

Nordson will grant no warranty and assume no liability for damage resultingfrom incorrect temperature settings.

LongerShorter



Applying Hot Melt AdhesiveSince there are many different applications, depending on the product, nostandard instructions can be given for applying the hot melt adhesive.

Preliminary experiments must be conducted to determine the setting forretrosuction module, adhesive pressure and distance between nozzle andsubstrate.

Decisive factors are e.g.:

� Viscosity of the adhesive (The heat effect and the duration thereofinfluence the viscosity)

� Set application width (Medium application widths have proven to requirea lower adhesive pressure than small or large application widths)

� Substrate condition

� Work cycle.

Setting Exhaust Throttle on the Retrosuction ModuleNOTE: Some older modules (control modules) are equipped with a nozzlestem stroke adjustment instead. Experience has shown that the nozzle stemstroke should be kept as low as possible.

Adjust the exhaust throttle on the retrosuction module to the applicationlength. Note:

� When the application head closes, the retrosuction module opens,meaning that the nozzle stem rises. The resulting suction preventsdripping.

� The next time the application head opens, the nozzle stem on theretrosuction module forces out the material that was previously suckedin.

� The nozzle stem motion can be slowed by throttling the exhaust air. Thisdistributes the additional material quantity along a greater applicationlength.

1 2 3

1 2



Setting Application WidthCAUTION: The application width may be adjusted only when theapplication module is closed and the application head is heated to operatingtemperature.

CAUTION: Thread slack may lead to incorrect readings in the displayApplication width. To avoid incorrect readings, the display should be readand adjusted as the thread is turned clockwise (decreasing applicationwidth).

NOTE: The right guide plate (2) can be swiveled to a small degree. Thisallows objects (book spines) that are up to 2 mm wider than the setapplication width to pass through the guide channel.

1. Release span piece Application width (16, Fig. 2) (if present).

2. Use the handwheel (3) to adjust the application width. Do this by guidinga book in and setting − with 0.1 mm slack − with a sensor gage.

3. Tighten span piece again.

4. Re-adjust application width during operation if required.

NOTE: Depending on how the pages are displaced by the pressure appliedby the clamps on the parent machine, the position of the application slit mayneed to be adjusted perpendicular to the direction of movement of thesubstrate after the format is changed. Refer to Installation, Installation,Adjusting.

Setting Application ThicknessGuide book in, then use the sensor gage to set a distance of 0.3 mmbetween the book spine and the application slit. This adjustment is usuallymade by modifying the height of the trolley to which the head is attached.

Daily ShutdownTo prevent the PUR material to be processed from hardening, opensurfaces must be coated with grease.

CAUTION: Use only special high-temperature grease. Refer to ProcessingMaterials! Any other grease may cause the PUR material to cross-link.

1. If necessary, remove adhesive from nozzle with wooden or plasticspatula, or wipe off with a cloth.

2. Release span piece Application width (16, Fig. 2) (if present) and setmax. application width.

3. Generously apply grease to the chamfers and under the guide plate.

4. Close the nozzle all the way until the right, mobile guide plate (2) visiblyturns away. Cover slit area with grease again.



Settings Record

Production information

Adhesive Manufacturer

Max. processingtemperature

Viscosity

Cleaning agent Manufacturer

Flash point

Temperatures

Application head Setpoint

Undertemperature

Overtemperature

Filter block Setpoint

Undertemperature

Overtemperature

Notes

Form filled out by:

Name Date



MaintenanceWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the service life of the unit. It should not beneglected under any circumstances.

Relieving PressureWARNING: System and adhesive pressurized. Before removing heatedhoses and the hot melt application heads, relieve system pressure. Failureto observe can result in serious burns.


1. Set motor speed of adhesive feeding unit to 0 rpm; switch off motor(s).

2. Set control air pressure for constant pressure controller to 0 bar.

3. Open air relief valve Filter by turning with a screwdriver.

4. Close air relief valve Filter again.



Maintenance TableThe maintenance intervals are general guidelines based on experience.Depending on operating environment, production conditions and hours ofoperation, other maintenance intervals may prove necessary.

Unit part Activity Interval Refer to

Complete applicationsystem

Purge with cleaningagent

When changing adhesive, if theadhesives used can not be mixed

Before prolonged productioninterruptions, if PUR adhesive isprocessed

Page 20

Observe adhesivemanufacturer’s

instructions

Entire application head Visual inspection Daily Page 20

External cleaning Daily Page 20

Application module andretrosuction module

Check performance When bleeding −

Replace When malfunction occurs Page 30

Movable parts, seals Lubricate Weekly, upon reassembly ifnecessary

Page 21

Light barrier lens Clean with softcloth

Daily −

Sealing cord Replace When adjustable mouthpieceleaks, preventive if necessary

Page 29

Filter cartridge Clean or replacefilter screen ifnecessary

Approx. every 100 hours ofoperation

Page 23

Constant pressurecontroller

Refer to separate manual



Visual Inspection for External DamageWARNING: When damaged parts pose a risk to the operational safety ofthe unit and/or safety of personnel, switch off the unit and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

External CleaningExternal cleaning prevents impurities created during production fromcausing the unit to malfunction.

CAUTION: Use only a cleaning agent recommended by the adhesivemanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

CAUTION: Do not damage or remove warning labels. Damaged orremoved warning labels must be replaced by new ones.

WARNING: Hot! Risk of burns. Wear heat-protective gloves.

Remove adhesive residue only with a cleaning agent recommended by theadhesive supplier. Heat with an air heater if necessary. Remove dust, flakesetc. with a vacuum cleaner or a soft cloth.

1. Remove adhesive residue from the nozzle promptly with a soft cloth,before it chars.

2. Remove severe and hardened residue with a wooden or plastic spatulaif necessary.

Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the adhesivemanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.


1. Empty the adhesive feeding unit and fill with cleaning agent.

2. Continue as described under Bleeding. Feed cleaning agent untilcleaning agent comes out free of adhesive residue.

NOTE: Properly dispose of cleaning agent according to local regulations.

NOTE: Before starting production again, flush out cleaning agent residueusing the new adhesive.



Lubricating Plan

7 8

2 3 5 64

1

Fig. 3

1 Drip tray2 Left guide plate3 Seal

4 Disk and spring washer5 Right guide plate6 Seal

7 Clamp bar8 Mouthpiece

CAUTION: Use only special high-temperature grease! Any other greasemay cause the PUR material to cross-link. Refer to Processing Materials.

Pos. Place to lubricate Interval

1 Contact surface between drip tray and body When reassembling

2, 5 Sliding surface between guide plate and body Weekly

3, 6 Complete seal Weekly

4 Disk and spring washer, complete When reassembling

NS Spindle and spindle bearing of application width adjuster Weekly

7, 8 Contact surface between mouthpiece and clamp bar When reassembling

7 Mouthpiece end face When reassembling

NS Screw threads When reassembling

NS: Not Shown

NOTE: The linear unit (15, Fig. 2) requires no maintenance.

1 2



BleedingIf air penetrates the system, e.g. when purging, the application head mustbe relieved of air. The sections Filter, Body and Application slit must berelieved of air one after the other:


1. Heat up heated system components.

2. Close application slit completely with handwheel Application width.

3. Switch on feeding unit motor(s).

4. Bleeding filter section

a. Open air relief valve Filter by turning with a screwdriver until materialflows out free of bubbles.

b. Close air relief valve Filter again.

5. Bleeding body section

NOTE: Omitted for models without air relief valve Body.

a. Open air relief valve Body by turning with a screwdriver.

b. Close air relief valve Body again.

6. Bleeding application slit section

a. Put bleeding reservoir (1) into place:

� Insert clamping plate (2) to prevent right guide plate from swiveling

� Set application width such that the bleeding reservoir can bepositioned above the application slit

� Position bleeding reservoir and clamp in place lightly by adjustingapplication width.

b. Electrically or manually trigger solenoid valve Application module.

c. Apply control air to constant pressure controller until adhesive flowsout free of bubbles.

d. Remove bleeding reservoir and clamping plate.

7. If necessary, remove adhesive from nozzle with wooden or plasticspatula, or wipe off with a cloth.

8. Properly dispose of adhesive according to local regulations.



Filter CartridgeWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

WARNING: System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

Removing Filter CartridgeNOTE: Remove the filter cartridge only when the application head is hot.

CAUTION: As soon as the thread is visible, cease turning. Otherwise partof the filter cartridge may remain in the borehole.

M10

SW 24

Replacing Filter ScreenRefer to technical drawing and parts list of the filter cartridge.

Installing Filter CartridgeNOTE: Install the filter cartridge only when the application head is hot.

1. Apply high temperature grease to all threads and O-rings. Refer toProcessing Materials.

2. Slide in the filter cartridge and tighten somewhat (approx. 1 Nm / 8.85 lbin).

3. Feed material by allowing the pump to run until the material comes outof the application head free of bubbles.

4. Properly dispose of material according to local regulations.



Maintenance Record

Unit part Activity Date Name Date Name

Completeapplication head

Lubricate weekly

Filter cartridge Clean or replace filterscreen if necessary

Constant pressurecontroller

Refer to separatemanual



TroubleshootingWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

WARNING: Troubleshooting activities may sometimes have to be carriedout when the unit is energized. Observe all safety instructions andregulations concerning energized unit components (active parts). Failure toobserve may result in an electric shock.

Troubleshooting TableWhen troubleshooting, other components of the application system mayneed to be considered.

The troubleshooting table serves as an aid to qualified personnel. It can nothowever replace targeted troubleshooting using e.g the wiring diagram andmeasuring instruments. They also do not include all possible problems, onlythose which most typically occur.

Problem Possible Cause Corrective Action Refer to

Application heador parts thereof donot get hot

Temperature on correspondingtemperature controller setincorrectly or not at all

Adjust temperature Page 14

Plug has no contact Secure plug −

Fuses in hot melt feeding unit /electrical cabinet defective

Disconnect unit from line voltage,check fuses and replace ifnecessary

Manual forfeeding

unit, wiringdiagram

Heater cartridge(s) defective Have heater cartridge(s) checkedby qualified personnel; replace ifnecessary

−

Adhesive comesout continuouslyin automatic mode

Light barrier lens polluted Clean with soft cloth −

Continued on next page



Problem Refer toCorrective ActionPossible Cause

No hot meltadhesive comesout of applicationslit

Application head has not yetreached operating temperature

Wait until temperature has beenreached, check temperaturesetting if necessary

Page 14

Not enough adhesive in feedingunit

Fill Manual forfeeding

unit

Control air not connected Connect Page 11

Pump of the hot melt adhesivefeeding unit not working

Check; replace if necessary Manual forfeeding

unit

Light barrier sensitivity setincorrectly

Check; adjust if necessary Page 13

Application slit blocked External cleaning Page 20

Nozzle stem of applicationmodule stuck

If the nozzle stem does not movewhen triggered, the applicationmodule must be checked byqualified personnel and replacedif necessary

−

Format piston in constantpressure controller is blocked

Service constant pressurecontroller

Manual forconstantpressurecontroller

Continued on next page



Problem Refer toCorrective ActionPossible Cause

Adhesiveapplication is notexact

Application slit partially blockedor damaged

External cleaning Page 20

Distance between applicationhead and substrate not even

Adjust application head Page 9

Application quantity andsubstrate processing speed notattuned to one another

Attune process variables to oneanother by trial and error

−

Control air pressure fluctuates onconstant pressure controller

Check compressed air controllerand proportional valve

−

Hot melt adhesive unsuitable Consult adhesive manufacturer −

Air within system Bleed Page 22

Format piston in constantpressure controller is blocked

Service constant pressurecontroller

Manual forconstantpressurecontroller

Adjustablemouthpiece leaks

Cross-linked adhesive ordamaged sealing cord aroundsliding surface betweenmouthpiece and body

Clean section, replace sealingcord

Page 29

Lubricate sliding surfaces andseals

Page 21



RepairWARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

General Notes1. Before beginning any repair work, ensure that the application head has

been relieved of pressure.

2. Observe lubricating plan (Refer to Maintenance).

Relieving PressureWARNING: System and adhesive pressurized. Before removing heatedhoses and the hot melt application heads, relieve system pressure. Failureto observe can result in serious burns.


1. Set motor speed of adhesive feeding unit to 0 rpm; switch off motor(s).

2. Set control air pressure for constant pressure controller to 0 bar.

3. Open air relief valve Filter by turning with a screwdriver.

4. Close air relief valve Filter again.

1 2 3

4 5 4 6



Replacing Sealing CordWARNING: Hot! Risk of burns. Wear heat-protective clothing, safetygoggles, and heat-protective gloves.

1. Electrically heat cold application head until adhesive is liquid.

2. Release span piece Application width (16, Fig. 2) (if present) and setmaximum application width.

3. Remove left and right guide plates (1 and 2).

4. Remove span piece: unscrew fastening screw.

5. Unscrew both screws of the spindle guide (3).

6. Unscrew the screws with spring washer package from the clamp bar (4),then remove clamp bar.

7. Pry mouthpiece (5) away from body somewhat and extract out the frontalong with the spindle and the handwheel.

8. Remove old sealing cord from the groove.

9. Clean groove and sliding surfaces on the body and mouthpiece:

CAUTION: Use only a cleaning agent recommended by the adhesivemanufacturer. Observe the Material Safety Data Sheet for thecleaning agent.

� Remove adhesive residue with cleaning agent. Heat with a hot airfan if necessary

� Remove severe and hardened residue with a wooden or plasticspatula if necessary.

10. Cut open O-ring (P/N 253625) and insert into groove as sealing cord.

11. Re-assemble parts. Observe particularly:

� Lubricating plan (Refer to Maintenance)

� Fastening screws on clamp bar: correct arrangement of springwashers (6); screw in screws with spring washer package all theway.



Replacing Control ModuleWARNING: Hot! Risk of burns. Wear heat-protective gloves.

CAUTION: To prevent damage to seals and nozzle stem, replace controlmodules only when the application head is heated.

1. Heat application head until adhesive is soft.

2. Relieve pressure.

3. Disconnect compressed air hoses.

4. Release fastening screws and replace control module.

5. Screw new control module into place.

6. Reconnect compressed air.

New Application ModuleModels built in approx. July 2006 and later use a control module as anapplication module (1) that is fastened to the body with an adapter plate.

1



MountingIf an older application module is replaced with the new module, the followingparts are required:

Item Part Description Quantity Note1 206080 control module EP48−V fold bellow 12 206083 adapter plate EP48−V fold bellow VX 13 206445 allan head cap screw M4x10 DIN6912−A2−70 44 256806 o−ring 23x1,5 Viton 15 206446 center bolt f.control modul EP48V 1

NOTE: Apply high temperature grease to all threads and O-rings. Refer toProcessing Materials.

1.

5

2.

3

2

4

3. 4.

1



Technical Data

Operating Data

Maximum operating temperature 180 °C 356 °F

Maximum operating air pressure 6 bar 0,6 MPa 87 psi

Maximum operating pressure(adhesive)

40 bar 4 MPa 580 psi

Maximum adhesive viscosity that canbe processed

30000 mPas 30 Ms/m2 30000 cP

Application width 1 to 60 mm

Max. deviation of applicationquantities

< � 5 %, depending on adhesive

Heatup time � 30 min

Application width 1 to 60 mm

Electrical Data

Operating voltage (heater) 230 VAC

Power consumption (heater) Body: 960 W

Filter: 600 W

Operating voltage (solenoid valves) 24VDC

Power consumption (solenoid valves) 8.5 W + 5.9 W

Temperature sensor Fe-CuNi, NI120 or Pt100 (Refer to separate parts list)

General Data

Weight Approx. 45 kg

Noise emission < 70 dB(A)

Degree of protection IP 50

Dimensions length x width x height[mm]

Approx. 343 x 441 x 200

Processing MaterialsHigh temperature grease

Tube 250 g

Cartridge 400 g

P/N 783959

P/N 402238

Caution: Do not mix thislubricant with otherlubricants! If necessary, firstclean grease off of parts.

Documents

Hot Melt Application Head EP 48-V EP 48-VLemanuals.nordson.com/adhesives/English_Manuals/458361.pdf · adhesives commonly used in the book binding industry to glue the spines of books