HFS 1000 Hopper/Feeder System

Transcription

1 HFS 1000 Hopper/Feeder System Manual Number: MZ012 Release Date: November 2006

2 2006 Valco Cincinnati, Inc. All Rights Reserved. This manual is furnished with the HFS 1000 hopper/feeder system and may be used or copied only in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by Valco Cincinnati, Inc. This manual was written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio Part Number: MZ012 Printed in the USA Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio TEL: (513) FAX: (513) Valco Cincinnati Limited Hortonwood 32 Telford, TF1 7YN, England TEL: (+44) FAX: (+44) Valco GmbH Storkower Str. 6 D Gallun,Germany TEL: (+49) FAX: (+49)

3 Table of Contents Section 1 Introduction About this Manual Section 2 Safety Information General Information Warnings Cautions What to do if Contact with Hot Adhesive Occurs What to do if Fire/Exposion Occurs What to do if Inhalation of Adhesive Fumes Occurs Section 3 General Wiring Guidelines Routing Low-Voltage Leads Connecting the Supply of Electrical Power Section 4 Basic Features Description of the HFS 1000 Hopper/Feeder System Section 5 Installation Installing the HFS Mechanical/Electrical Installation Section 6 Calibrating/Testing Calibrating the HFS Testing the HFS Final Test Section 7 Troubleshooting Section 8 Part-Number List How to Order Parts HFS 1000 Parts List Section 9 Warranty Warranty Information Cold-Glue Equipment and Electronic Controls Hot-Melt Units, Hoses, Valves, and Related Equipment Section 10 Service Service Needs

4 Section 1 Introduction Since hot-melt adhesive has been in use, the melt tank has often demanded considerable attention from the system's operator. If proper attention is not paid to the melt tank, the following situations can develop and possibly hamper productivity. If adhesive is not added to the melt tank when necessary, there is insufficient time to melt and condition the adhesive. While the operator waits for the adhesive to rise to the required application temperature, production line speed is reduced and product output suffers. If the melt tank or the adhesive case is left open or is being opened and closed during the filling procedure, external debris, box dust or pieces of corrugated material can contaminate the system. The result is decreased production and increased maintenance costs because of char formation causing plugged nozzles, clogged filters, and cut seals. As the adhesive level in the melt tank drops, adhesive residue remains on the walls of the tank. The combination of high temperature, adhesive residue, and oxygen causes char to form on the melt tank's interior walls. Eventually, the char breaks free and enters the system. Again, production goes down while maintenance costs increase. The HFS 1000 Hopper Feeder System automatically maintains a constant level of adhesive in the melt tank and provides a barrier to prevent the entry of debris into the system. About this Manual Valco Cincinnati has prepared this manual as an aid for installing, operating, and servicing the HFS 1000 hopper/ feeder system. It also contains a list of part numbers for replacement parts. If you need more information, please contact your Valco Cincinnati representative. Valco Cincinnati 1-1

5 Section 2 Safety Information General Information It is the purchaser s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed. The best safeguard is trained personnel. The purchaser is responsible for providing personnel who are adequately trained to install, operate, and maintain Valco components and systems. This section contains information that is essential to the safety of personnel. Safety information is included throughout the rest of the manual as well. The following safety conventions are used to indicate potential safety hazards: WARNING! This symbol indicates the presence of un-insulated dangerous voltage within the product s enclosure. This voltage may cause electrical shock or fire. FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH, PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. WARNING! This convention is used to alert the user to important installation, operation, and/or maintenance information. FAILURE TO OBSERVE WARN- ING MAY RESULT IN DEATH, PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. CAUTION! This convention is used to alert the user to important installation, operation, and/or maintenance information. FAILURE TO OBSERVE CAUTION MAY CAUSE EQUIPMENT DAMAGE. Warnings All personnel involved with the installation, operation, and maintenance of the equipment must read and thoroughly understand the following warnings: WARNING! Disconnect all power before opening the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Only qualified personnel should open and service the control. WARNING! Promptly repair or replace all worn or damaged electrical wiring and equipment wires. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. WARNING! Properly route all electrical wires. OTHERWISE, DEATH, PER- SONAL INJURY, OR DAMAGE TO THE MOVING PARTS OF THE MACHINE MAY OCCUR. Valco Cincinnati 2-1

6 Section 2 Safety Information HFS 1000 Hopper/Feeder System WARNING! When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. WARNING! Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures. OTHERWISE, DEATH OR PER- SONAL INJURY COULD OCCUR. WARNING! Promptly repair or replace all worn or damaged parts. OTHER- WISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. Cautions WARNING! Always wear insulated gloves and proper eye protection when working around hot-melt equipment. A protective screen around the face is also recommended. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. WARNING! Purge the fluid pressure from the system before disconnecting any part of the system. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. WARNING! People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROB- LEMS MAY BE AGGRAVATED BY THE FUMES. Do not wear a face mask when working around molten adhesive. THE MASK MAY TRAP THE FUMES AND DEATH OR PERSONAL INJURY COULD OCCUR. WARNING! Keep hot-melt hoses away from walkways and the moving parts of hot-melt systems. OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. WARNING! The hot-melt unit should be installed so that it can be turned off at a location away from the hot-melt unit. OTHERWISE, DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE COULD OCCUR. All personnel involved with the installation, operation, and maintenance of the equipment must read and thoroughly understand the following cautions: CAUTION! Never hose or steam-clean the unit. If the surrounding area is cleaned in this manner, protect the unit by covering it with plastic or other waterproof material. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. CAUTION! Do not bend hot-melt hoses less than an 18-inch (460 mm) radius. OTHERWISE, EQUIPMENT DAMAGE COULD OCCUR. CAUTION! Place Material Safety Data Sheets for the adhesive near the unit. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. 2-2 Valco Cincinnati

7 HFS 1000 Hopper/Feeder System Section 2 Safety Information What to Do if Contact with Hot Adhesive Occurs WARNING! The heat that is contained in hot-melt material will continue to penetrate and deeply burn the skin unless rapidly cooled by external means such as water. Do not attempt to remove set hot-melt adhesive from the skin. OTHERWISE, PERSONAL INJURY COULD OCCUR. If hot adhesive comes in contact with the skin, do the following: 1. Immediately immerse the contacted area in clean, cold water. Note! It is recommended that a source of clean, cold water be provided near the hot-melt work area. 2. Cover the affected area with a clean, wet compress and see a physician immediately. What to Do if Adhesive-Related Fire or Explosion Occurs During the heating and melting process, the surface of the adhesive will be exposed to air. The mixture of polymer fumes and air can catch fire if the hot-melt is overheated. WARNING! Poor ventilation, smoking, and open flames can cause overheated hot-melt to ignite. Adequate ventilation must be provided. Smoking should be prohibited in the immediate vicinity of the molten adhesive. Open flames must be kept away from the area around molten adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. WARNING! Exposed arcing may ignite the fume/air mixture. Shield all electrical equipment from melt fumes to avoid exposed arcing. OTHERWISE, PER- SONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. WARNING! Do not use a water extinguisher to extinguish the fire! OTHER- WISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. If the hot-melt adhesive ignites, promptly perform the following steps: 1. Sound a fire alarm. 2. Evacuate the immediate area. 3. Turn off all local electrical equipment at the source. 4. Fight the fire in one of the following ways: Smother the fire with a fire blanket. Aim a CO 2 fire extinguisher at the base of the flames. Aim a dry-powder fire extinguisher at the base of the flames. Valco Cincinnati 2-3

8 Section 2 Safety Information HFS 1000 Hopper/Feeder System What to Do if Inhalation of Adhesive Fumes Occurs If Adhesive fumes are inhaled, immediately follow these steps: 1. Take the victim away from the immediate work area. 2. Provide victim with fresh air. 3. Call a qualified medical authority. 2-4 Valco Cincinnati

9 Section 3 General Wiring Guidelines Routing Low-Voltage Leads WARNING! Electrical installation should be made only by experienced service personnel! OTHERWISE, DEATH, PERSONAL INJURY, OR EQUIP- MENT DAMAGE COULD OCCUR. When routing low-voltage leads, follow these guidelines: Do not route low-voltage leads in the same conduit as wires carrying a high-current load. Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from high-current wires. Do not splice or solder leads. Trim leads to the required length. Leads should be only as long as necessary for installation. All wiring should be in conduits or wireways. Connecting the Supply of Electrical Power WARNING! Electrical connections should be made only by experienced service personnel! OTHERWISE, DEATH, PERSONAL INJURY, OR EQUIP- MENT DAMAGE COULD OCCUR. When connecting the supply of electrical power, follow these guidelines: Connect the control to a clean supply of electrical power. Use a dedicated circuit if possible. Note! If a dedicated circuit is not available, do not connect the control to a circuit that supplies highamperage equipment use another circuit such as a lighting circuit. Otherwise, equipment may not function properly. Valco Cincinnati 3-1

10 Section 4 Basic Features Description of the HFS 1000 Hopper/Feeder System The HFS 1000 Hopper/Feeder System utilizes an air-driven, vacuum-transducer to deliver hot melt from the bulkadhesive container to the hot-melt unit. The transducer and a vibrator are attached to the bottom of the bulkadhesive container. The HFS 1000 system can deliver hot-melt chips up to 20 feet away and transfer chips up to 5/ 8" square. The level probe contains a sensor that signals the system to either fill or shut off, depending on the level of adhesive in the unit. If adhesive is below the level probe, the sensor signals the system to activate. When the system is activated, the green LED on the control box illuminates and the hot melt is transported from the container to the hotmelt unit. If the system does not fill in a specific time period, an alarm sounds and the red LED on the control box illuminates. This alerts the operator of low adhesive level or a system fault. HFS 1000 Hopper/Feeder System Components Valco Cincinnati 4-1

11 Section 4 Basic Features HFS 1000 Hopper/Feeder System The HFS 1000 System s electronics allow you to easily make melt-tank adjustments, even while the production line is running. Note! The adhesive is kept at room temperature until after it is loaded into the melt tank. The HFS 1000 is not transporting hot adhesive through heated hoses and/or pipe. The level-control s sensor probe, which extends down into the melt tank, is mounted to the melt tank lid. The probe initiates a Fill cycle when it senses the adhesive level in the melt tank has dropped to the refill level. This activates the vacuum transducer and vibrator. The vibrator fluffs the adhesive to make it easier for the vacuum transducer to pull the adhesive into the system. The room-temperature adhesive is then transported through the hose that connects the container to the melt tank lid, where it drops directly into the melt tank. During this cycle, a green light located on the top of the level-control box remains on until the cycle is completed. If the melt tank s fill cycle is not completed within a specified period of time, the level-control box s red light is activated. Both the alarm light and an audio alarm will remain on until the operator pushes the reset button. The alarm s timer adjustment is located inside the control. The fill cycle s green light, vacuum transducer, and vibrator shut off when the level of adhesive in the tank rises on the level-control s sensor probe to a user-specified position. The sensor probe is not affected by temperature changes. Air requirements are approximately 20 standard cubic feet per minute for 5 to 10 seconds. Required incoming air pressure depends on the particular adhesive s flow properties. 60 psi is a good starting point. Set the vibrator s air pressure to 35 psi initially. Normally, pressure to the vibrator should not exceed 50 psi. HFS 1000 Hopper/Feeder System Control 4-2 Valco Cincinnati

12 Section 5 Installation Installing the HFS 1000 Mechanical/Electrical Installation Note! Do not add adhesive to the dispensing container until directed to do so. To install the HFS 1000 Hopper/Feeder System, follow these steps: 1. Replace the previous Valco lid with a new lid assembly or bore holes into the existing lid using the template provided. 2. Place the casting onto the lid. 3. Wire the level probe to the control: 3a. Remove the casting cover 3b. Slide the three exposed wires from the control through the cord grip on the side of the casting. 3c. Each wire has a number (either 4, 5, or 6). Attach each numbered wire to its appropriate connection inside the casting. 3d. Replace the casting cover. 4. Place the hopper section onto the lid assembly. 5. Attach one end of the braided 1-1/4" hose to the adhesive inlet pipe on the hopper section. Note! Heating the end of the hose with a hot air gun or lightly lubricating the inlet pipe will help the hose slide over the pipe. 6. Inside the control box, attach the 3/8" poly tube air line to the push-lock fitting on the air valve. 7. Inside the control box, attach the 1/4" poly tube to the air regulator push-lock fitting. 8. Attach the air filter to the outside of the control box. 9. Connect plant air to the inlet on the control box air filter. (A minimum 1/2" air line is required.) 10. Set the air transducer-regulator to 60 psi initially. Note! Different forms of hot melt require different pressures. 11. Set the air vibrator regulator to 20 psi initially. Note! Do not exceed 40 psi on the air vibrator regulator. 12. Insert the other end of the 1 1/4" braided hose into the mating pipe on the side of the bulk adhesive tote. 13. Push both the 1/4" and 3/8" tubing into the appropriate push lock fitting on the side of the bulk adhesive tote. 14. Plug the supplied power cord into an acceptable 120V outlet. 15. Use plastic ties to secure poly air lines to the hose, as well as the electrical cable from the lid assembly. Valco Cincinnati 5-1

13 Section 6 Calibrating/Testing Calibrating the HFS 1000 After installation is complete, the level probe sensor must be calibrated (See Figure, page 4-2 for the location of the sensitivity potentiometer, timing adjustment, and selector switches.) Note! Air pressure should not be applied to the system until after the level probe sensor has been calibrated. To calibrate the level probe sensor, follow these steps: 1. Manually fill the tank s adhesive level to within 1 of the bottom of the probe (when tank lid is closed). 2. Close the tank lid. 3. Set the B and the C sequence switches in the up position. 4. Set the A and the D sequence switches in the down position. 5. Open the control box. If the red LED inside is on, turn the sensitivitympotentiometer counter-clockwise in 1/2 turn increments until the red LED light goes out and the green LED comes on. Note! The red LED indicates that the adhesive level in the tank is touching the probe; the green LED indicates that the adhesive level in the tank is not touching the probe. 6. Manually fill the tank of the HSF 1000 until adhesive comes in contact with the level probe. (The red LED will come on and the green LED will shut off). Note! If this does not occur, turn the sensitivity potentiometer clockwise in 1/4 turn increments until the red LED comes on. Testing the HFS 1000 To conduct an initial test of the HFS 1000 System, follow these steps: 1. Fill the bulk adhesive container with the correct adhesive. 2. Set air pressure to 60 psi and allow the system to fill with adhesive. (The red LED will illuminate.) 3. If the red LED does not illuminate, turn the sensitivity potentiometer clockwise in 1/2 turn increments until it does illuminate. Note! The potentiometer setting can be checked by raising and lowering the tank lid. The green LED light should illuminate when the lid is raised 1/2", and go off when the lid is lowered. 4. Adjust the sensitivity potentiometer until the unit activates and deactivates when the lid is moved. The unit is now ready to operate. Valco Cincinnati 6-1

14 Section 6 Calibrating/Testing HFS 1000 Hopper/Feeder System Final Test Once the system is operational, follow these steps: 1. Observe the adhesive level in the tank after the fill cycle is complete. Note! The system electrical or system air should be turned off when observing the level. Otherwise, the filling cycle will be activated. 2. Readjust the level if adhesive is above the lower tip of the probe. Failure to obtain this low level can cause a clog in the breather or fill opening. 6-2 Valco Cincinnati

15 Section 7 Troubleshooting Problem Possible Cause Possible Solution 1. Red LED cannot be adjusted to turn illuminate. 2. Red LED remains on at all times. 3. Unit triggers when material touches probe, but will not reset when material recedes from probe or unit and gives false alarm. 4. Unit does not detect material. 5. Unit stays in calibration. 6. Relay operated properly, but no signal at terminal's circuit board. 7. Unit triggers and fill light comes on but does not fill or material "spirals" inside braided hose, but does not move. 1a. Probe lead not connected 1b. No power to unit 1c. On-board fuse blown 1d. Bad sensing card 2a. Probe shorted to case or ground. 2b. Bad sensing card 3a. Improper probe mounting 3b. Improper calibration procedure 3c. Excessive material buildup on probe 4a. Improper calibration 4b. Probe lead not plugged into probe 4c. Unit was calibrated with material touching 4d. Too much delay 5a. Poor grounding of unit to vessel 6a. Burned or broken electrical path on power-supply printed circuit 6b. Bad relay contacts 7a. Vent blocked 7b. Transducer in container blocked 7c. Transducer plugged at bottom venturi 7d. Air fitting plugged 1a. Plug probe lead into probe. 1b. Check for correct voltage to unit (120V). 1c. Replace fuse. 1d. Replace sensing card. 2a. Unplug probe lead and position it so the bare end is not touching anything. Turn calibration pot 20 turns counter clockwise. LED should go out. If it doesn t, repair, replace or clean antenna probe. 2b. Repair or replace card. 3a. Contact factory. 3b. See calibration/setup section. 3c. Clean probe and recalibrate. 4a. See calibration/set-up section. 4b. Plug probe lead into probe. 4c. Recalibrate with material not touching the probe. 4d. Check dip switches and recalibrate. 5a. Provide secure ground connection. 6a. Turn off power, remove module from housing, and inspect. 6b. Replace board. 7a. Clean out vent. 7b. Clean out inlet and transducer inlet. 7c. Remove transducer from container, and disassemble and clean inside transducer. 7d. Remove and clean fittings. Valco Cincinnati 7-1

16 Section 8 Part-Number List How to Order Parts To order parts, please contact one of the following offices: Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio TEL: (513) FAX: (513) Valco Cincinnati Limited Hortonwood 32 Telford, TF1 4 EU, England TEL: (+44) FAX: (+44) Valco GmbH Storkower Str. 6 D Gallun,Germany TEL: (+49) FAX: (+49) Note! You may also contact a Valco sales representative in your country. Valco Cincinnati 8-1

17 Section 8 Part-Number List HFS 1000 Hopper/Feeder System HFS 1000 Parts List Item Number Description Part Number Quantity 01 HFS; 120V, Bent Probe 769xx Feed Tee Assembly; HFS 769xx Label, logo 794xx Label, logo 794xx Cut-out Detail; Lid 998IS Manual; HFS MZ Valco Cincinnati

18 HFS 1000 Hopper/Feeder System Section 11 Part-Number List Item Number Description Part Number Quantity 01 Feed Tee; Weldment 769xx Coupling; Tee-air Vent 769xx Louver; Aluminum, 4 769xx Label, logo 794xx917 1 Valco Cincinnati 8-3

19 Section 8 Part-Number List HFS 1000 Hopper/Feeder System Checklist HFS, 120V, Bent Probe Item Description Part Number 01 Dispense-Container Assembly; HFS 769xx Control Assembly, HFS, 120V-60Hz 098xx Casting Assembly, HFS w/o probe 775xx Transmitter, HFS 775xx Probe for HFS, 4 bent 080xx Hose, clear, reinforced, 1.25 ID 755xx Tubing (180 in) 755xx Tubing (180 in) 755xx Hose clamp 794xx Cable (15ft), 2 Cond shielded 24 AWG 030xx Filter Assembly, air inlet for HFS 594xx Valco Cincinnati

20 HFS 1000 Hopper/Feeder System Section 11 Part-Number List Item Description Part Number 01 Control board assembly, receiver, HFS 098xx Fuse, 250MA, 5x20mm, 250V 085xx Audio alarm, HFS Control 010xx Air regulator, HFS Control 594xx Gauge, air pressure, HFS Control 786xx Timer module for HFS Control 076xx Indicator light, green, HFS Control 155xx Indicator light, red, HFS Control 105xx Flasher for HFS Control 098xx Valve, sol., HIFLO for HFS 411xx Switch, reset for HFS Control 480xx Fuse, 5 AMP 085xx Switch, power for HFS Control 480xx191 Valco Cincinnati 8-5

21 Section 9 Warranty Warranty Information Valco Cincinnati, Inc. warrants its equipment worldwide against defects in material and workmanship as outlined in this section. Cold-Glue Equipment and Electronic Controls One (1) year from the date of shipment by Valco Cincinnati. Hot-Melt Units, Hoses, Valves, and Related Equipment All components except cast-in heating elements are warranted for a period of six (6) months from the date of shipment by Valco Cincinnati. Cast-in heaters carry an additional, pro-rated warranty not to exceed three (3) years from the date of shipment by Valco Cincinnati. Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, misuse, abuse, neglect, tampering or deterioration by corrosion. This warranty does not cover those items determined by Valco Cincinnati, Inc. to be normal wear items such as seals, O- rings, diaphragms, springs, etc. Reconditioned equipment, unless specified otherwise at the time of purchase, will be warranted as described above for a period of ninety (90) days from the date of shipment by Valco Cincinnati. Components purchased by Valco Cincinnati, Inc. from others for inclusion in its products are warranted only to the extent of the original manufacturer s warranty. In no event shall Valco Cincinnati, Inc. be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati, Inc. for examination and verification. If claimed defect is verified, repairs or replacements will be made F.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection of the equipment does not disclose any defect of workmanship or material, any necessary repairs will be made at a reasonable charge and return transportation will be charged. This is the only authorized Valco Cincinnati, Inc. warranty and is in lieu of all other expressed or implied warranties, representations or any other obligations on the part of Valco Cincinnati, Inc. Valco Cincinnati 9-1

22 Section 10 Service Service Needs If you have problems with your system, please contact your Valco Cincinnati representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) , or Valco Europe in the United Kingdom at (+44) If the problem cannot be resolved on the telephone, Valco will promptly arrange to have a technical representative visit your facility. Any charges for a service call will be quoted at that time.any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati by the customer for disposition. Note! Upon request, Valco Cincinnati personnel are available to repair or replace such parts at the customer s facility. Charges for this service include travel time and expenses. If an equipment problem is the result of customer abuse, improper installation or operation, all travel time, labor, parts, and expenses will be charged to the customer. If the responsibility for a problem cannot be absolutely determined, the customer will be charged for travel time and expenses only. No charge will be made for parts and labor. Valco Cincinnati 10-1