ITW Dynatec DynaFiber UFD Technical Documentation Manual
www.itwdynatec.com
Adhesive Applic at i on S olut i on s | ISO 9001 certified
DynaFiber UFD
Spray Applicator, 1-6 Port
Technical Documentation
ITW Dynatec
An Illinois Tool Works Company
ITW Dynatec
Information about this manual
Read all instructions before operating this equipment!
NOTICE:
Information about this manual
It is the customer’s responsibility to have all operators and service
personnel read and understand this information. Contact your ITW
Dynatec customer service representative for additional copies.
Please be sure to include the serial number of your application
system each time you order replacement parts and/or supplies. This
will enable us to send you the correct items that you need.
ITW Dynatec Service Parts Direct Dial: 1-800-538-9540
ITW Dynatec Technical Service Direct Dial: 1-800-654-6711
Page 2 UFD Applicator, Manual 40-43, Rev. 6.16
Index
ITW Dynatec
Index
Information about this ma nua l ................................................ 2
Index .......................................................................................... 3
Chapter 1 Declaration of Incorporation .................................. 7
Chapter 2 Safety Instructions ................................................. 9
General Considerations ............................................................................................................ 9
Warning Labels ......................................................................................................................... 9
Safety Symbols in this Manual ................................................................................................ 10
Safe Installation and Operation ............................................................................................... 10
Explosion/ Fire Hazard ............................................................................................................ 11
Use of PUR (Polyurethane) Adhesives ................................................................................... 11
Eye Protection & Protective Clothing ...................................................................................... 11
Electrical .................................................................................................................................. 12
Lockout/ Tagout ...................................................................................................................... 12
High Temperatures ................................................................................................................. 12
High Pressure ......................................................................................................................... 13
Protective Covers .................................................................................................................... 13
Servicing, maintenance ........................................................................................................... 14
Secure transport ...................................................................................................................... 14
Treatment for Burns from Hot Melt Adhesives ........................................................................ 15
Measures in case of fire .......................................................................................................... 15
Keep attention to environmental protection standards ........................................................... 16
Chapter 3 Description and Technical Specs ....................... 17
3.1 Applicable Safety Regulations ...................................................................... 17
Intended Use ........................................................................................................................... 17
Unintended Use, Examples..................................................................................................... 17
Residual Risks ........................................................................................................................ 17
Technical changes .................................................................................................................. 18
Using foreign components ...................................................................................................... 18
Setting-up operation ................................................................................................................ 18
3.2 Description of UFD Spray Applicator ............................................................ 19
Description .............................................................................................................................. 19
Technical Data ........................................................................................................................ 21
Model Designation Guide ........................................................................................................ 22
Dimensions.............................................................................................................................. 23
Chapter 4 Installation & Startup ............................................ 25
4.1 Conditions for set-up and mounting .............................................................. 25
4.2 Installation & Startup ..................................................................................... 26
Special Installation Notes on HiSpeed, Vertical Snuffback, Direct-Air Module ....................... 29
Operation of Optional Drain Valve .......................................................................................... 29
Purging Adhesive Through the App licat or .............................................................................. 30
4.3 Quality of compressed Air ............................................................................. 30
Chapter 5 Maintenance and Repair Notes ........................... 31
5.1 Security advices for maintenance and repair ................................................ 31
5.2 Re-Assembly Procedures and General Cautions ......................................... 32
UFD Applicator, Manual 40-43, Rev. 6.16 Page 3
ITW Dynatec
Index
5.3 Stroke Limit Adjustmen t ................................................................................ 32
5.4 Relieving Adhesive Pressure ........................................................................ 33
5.5 Replacement of the Built-in Filter .................................................................. 34
5.6 Replacement of the Module .......................................................................... 36
Modules Which Are Not Serviceable ...................................................................................... 36
Replacement of the Standard Module .................................................................................... 36
Module Assembly Instructions for the PN 104993 UFD Module ............................................. 37
Module Assembly Instructions for the PN 106224 UFD or 106226 HiTemp UFD Module ..... 38
Module Assembly Instructions for the PN 110840 Horizontal SB and PN 111074 Vertical SB
UFD Modules .......................................................................................................................... 39
5.7 Replacement of the UFD Nozzle .................................................................. 40
5.8 Cleaning of the UFD Nozzle ......................................................................... 41
5.9 Testing of Resistance ................................................................................... 43
Testing Resistance of Heater Cartridges ................................................................................ 43
Testing Resistance of the RTD Temperature Sensor ............................................................. 44
Testing the J-type Thermocouple Temperature Sensor ......................................................... 44
Resistance Tables, Temperature sensors .............................................................................. 45
5.10 Replacement of Heater Cartridge or Temperature Sensor ......................... 46
5.11 Maintenance plan ....................................................................................... 49
Chapter 6 Troubleshooting ................................................... 51
Troubleshooting In General..................................................................................................... 51
Troubleshooting Guide UFD Applicator .................................................................................. 51
Chapter 7 Component Illustrations & Bills of Materials ..... 53
1-Port UFD Vertical & Horizontal Apply Applicator Assemblies .......................... 54
Air Preheater Assembly for 1-Port UFD Vertical & Horizontal Apply ...................................... 56
Air Preheater Assembl y for 1- or 2-Port UFD Slim Design ..................................................... 58
2-Port UFD Vertical & Horizontal Apply, 1 or 2 Program, Applicator Assemblies 60
Air Preheater Assembly for 2-Port UFD Vertical & Horizontal Apply, 1 or 2 Program ............ 62
3-Port UFD Vertical & Horizontal Apply, 1, 2 or 3 Program, Applicator Assemblies
............................................................................................................................ 64
Air Preheater Assembly for 3-Port UFD Vertical & Horizontal Apply, 1 or 3 Program ............ 66
Air Preheater Assembly for 3-Port UFD Slim Design ............................................................. 68
4-Port UFD Vertical & Horizontal Apply, 1 or 4 Program, Applicator Assemblies 70
Air Preheater Assembly for 4-Port UFD Vertical & Horizontal Apply, 1 or 4 Program ............ 72
Air Preheater Assembly PN 112793 for 4-Port UFD Slim Design .......................................... 74
6-Port UFD Vertical & Horizontal Apply, 1 or 6 Program, Applicator Assemblies 76
Air Preheater Assembly for 6-Port UFD Vertical & Horizontal Apply, 1 or 6 Program ............ 78
Air Preheater Assembly PN 112794 for 6-Port UFD Slim Design .......................................... 80
UFD Modules ...................................................................................................... 82
UFD Spray Module Assembly, Horizontal, PN 104993 .......................................................... 82
UFD Spray Module Assembly, Vertical, Extended, PN 106224 ............................................. 84
UFD Spray Module Assembly, Horizontal, Snuffback, PN 110840 ........................................ 86
UFD Spray Module Assembly, High Speed, Vertical, PN 113778 .......................................... 86
UFD Spray Module Assembly, Snuffback, Vertical, PN 111074 ............................................. 87
UPD Spray Module Assembly, High Speed, Vertical, PN 113346 .......................................... 88
UFD Spray Module Assembly, High Speed, Horizontal, PN 113550...................................... 89
UFD Spray Module Assembly, High Speed, Horizontal, PN 115160...................................... 90
Blank Module, Horizontal & Vertica .................................................................... 91
Page 4 UFD Applicator, Manual 40-43, Rev. 6.16
Index
ITW Dynatec
Blank Module, Vertical Air Only, PN 111053 .......................................................................... 91
Blank Module, Horizontal Air Only, PN 111052 ...................................................................... 91
UFD Nozzle Seals .............................................................................................. 92
Festo Solenoid Assemblies, PN 115055 & 115056 ............................................ 93
Chapter 8 Options & Accessories ........................................ 95
Applicator Heater Cartridges ................................................................................................... 95
Applicator RTD Sensors .......................................................................................................... 95
Filters ....................................................................................................................................... 95
Filter Kits ................................................................................................................................. 96
Service Kits ............................................................................................................................. 96
High-Temp Splice Kit, PN1 0264 5 ........................................................................................... 96
UFD Nozzle Cleaning Oven .................................................................................................... 96
Pressure Transducer Tap ....................................................................................................... 97
Drain Valve PN 107820 ........................................................................................................... 97
Balanced Solenoid Manifold.................................................................................................... 97
Low-Profile (Slim line) Models (codes A, J, M, P) ................................................................... 97
Elastic Guide Bracket Assembly, PN 107622 ......................................................................... 98
Extension Cable Assemblies................................................................................................... 99
Strand Coating System (SCS) .............................................................................................. 100
Recommended Service Parts List ......................................................................................... 102
Chapter 9 Engineering Drawings & Schematics ............... 103
Pin Connectors & Electrical Schematics ............................................................................... 103
Chapter 10 Appendix............................................................ 105
Solenoid Valve Configurations, Schematics & Setup ........................................................... 105
Air Filter/ Regulator Installation Notes .................................................................................. 105
Section 1, 24 VDC MAC solenoid valve, 4 way, 02, 1/8 NPT, PN 100054 ........................... 106
Section 2, MAC solenoid valve, 4 way, 1/4 NPT................................................................... 107
Section 3, 24 VDC MAC solenoid valve, 5 way, 1/8 NPT, PN 106937 ................................. 108
Section 4, 24 VDC MAC solenoid valve, 4 way, 1/4 NPT, PN 112496 ................................. 109
Section 5, 24 VDC MAC solenoid valve, 4 way, 1/4 NPT, PN 112496 ................................. 110
Section 6, Air Control Kit PN 100055, Component Illustration.............................................. 111
Process (Preheater) Air Control Filter/ Regulator, PN 107404 ............................................. 112
UFD Applicator, Manual 40-43, Rev. 6.16 Page 5
ITW Dynatec
Index
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Page 6 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 1 Declaration of Incorporation
ITW Dynatec
Chapter 1
Declaration of Incorporation
UFD Applicator, Manual 40-43, Rev. 6.16 Page 7
ITW Dynatec
Chapter 1
Declaration of Incorporation
Page 8 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 2 Safety Instructions
ITW Dynatec
General Considerations
All operators and service personnel must read and understand this manual
before operating or servicing equipmen t.
All maintenance and service on this equipment must be performed by trained
technicians.
Read and adhere to the manual!
1. Read and follow these instructions.
Failure to do this could result in severe personal injury or death.
2. Keep the binding rules for accident prevention valid for your country and the place of
installation. Also keep the approved qualified technical rules for safety-conscious and
professional work.
3. Additional safety instructions and/ or symbols are located throughout this manual.
They serve to warn maintenance personnel and operators about potentially hazardous
situations.
4. Inspect the machine for unsafe conditions daily and replace all worn or defective parts.
5. Keep work area uncluttered and well lit. Remove all material or things not needed for
the production from the workspace of the equipment!
6. All covers and guards must be in place before operating this equipment.
7. Subject to technical modifications without notice!
8. To ensure proper operation of the equipment, use specified electrical and/ or air
supply sources.
9. Do not attempt to alter the design of the equipment unless written approval is received
from ITW Dynatec.
10. Keep all manuals readily accessible at all times and refer to it often for the best
performance from your equipment.
Warning Labels
Chapter 2
Safety Instructions
1. Read and obey all of the warning labels, signs and caution statements on the
equipment.
2. Do not remove or deface any of the warning labels, signs and caution statements on
the equipment.
3. Replace any warning labels, signs and caution statements which have been removed
or defaced. Replacements are available from ITW Dynatec.
UFD Applicator, Manual 40-43, Rev. 6.16 Page 9
ITW Dynatec
Chapter 2
Safety Instructions
Safety Symbols in this Manual
1. WARNINGS and CAUTIONS are found throughout this manual.
WARNINGS mean that failure to observe the specific instructions may cause injury to
personnel.
2. CAUTIONS mean that failure to observe the specific instructions may damage the
equipment.
Safe Installation and O per at ion
Read and adhere to the manual!
1. Read this manual before applying electrical power to the equipment. Equipment may
be damaged by incorrect electrical connections.
2. To avoid possible failure of hoses, make sure all hoses are routed to avoid kinking,
tight radius turns (8” or less) and abrasive contact. Hot‐melt hoses should not have
prolonged contact with heat‐absorbing surfaces such as cold floors or metal troughs.
These heat‐absorbing surfaces can alter adhesive flow and cause incorrect
calibration. Hoses should never be covered with materials that prevent heat
dissipation, such as insulation or sheathing. Hoses should be spaced apart from each
other, not making direct contact.
3. Do not use adhesive that is dirty or that may be chemically contaminated. Doing so
can cause system clogging and pump damage.
4. When adhesive hand‐ held applicators or other movable applicators are used, never
point them at yourself or at any other person. Never leave a hand‐held applicator's
trigger unlocked when not actually in use.
5. Do not operate the hopper or other system components without adhesive for more
than 15 minutes if the temperature is 150 degrees C (300 degrees F) or more. To do
so will cause charring of the residual adhesive.
6. Never activate the heads, hand‐held applicators and/ or other application devices until
the adhesive's temperature is within the operating range. Severe damage could result
to internal parts and seals.
7. Never attempt to lift or move the unit when there is molten adhesive in the system.
8. In case of an emergency or exceptional incident, press the emergency stop button in
order to stop the unit quickly.
9. Use the unit only as it is intended to.
10. Never let the unit run unattended.
11. Operate the unit only in a faultless and fully functional condition. Check and make
sure that all safety devices work in proper form!
Page 10 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 2
Safety Instructions
ITW Dynatec
DYNATEC'S WARRANTY.
Explosion/ Fire Hazard
1. Never operate this unit in an explosive environment.
2. Use cleaning compounds recommended by ITW Dynatec or your adhesive supplier
only.
3. Flash points of cleaning compounds vary according to their composition, so consult
with your supplier to determine the maximum heating temperatures and safety
precautions.
Use of PUR (Polyurethane) Adhesives
1. PUR adhesives emit fumes (MDI and TDI) that can be dangerous to anyone exposed
to them. These fumes cannot be detected by the sense of smell. ITW Dynatec strongly
recommends that a power‐vented exhaust hood or system be installed over any PUR
system.
2. Consult with your adhesive manufacturer for specifics about required ventilation.
CAUTION
Because of the nature of PUR adhesives to strongly bond in the presence of moisture,
care must be taken to prevent them from curing inside ITW Dynatec equipment.
If PUR adhesive solidifies in a unit, the unit must be replaced. Always purge old PUR
adhesive from the system per your adhesive manufacturer's instructions and time table.
ALLOWING PUR ADHESIVE TO CURE IN A UNIT OR ITS COMPONENTS VOIDS ITW
Eye Protection & Protective Clothing
WARNING
EYE PROTECTION & PROTECTIVE CLOTHING REQUIRED
1. It is very important that you PROTECT YOUR EYES when working around
hot melt adhesive equipment!
2. Wear a face shield conforming to ANSI Z87.1 or safety glasses with side
shields which conform to ANSI Z87.1 or EN166.
3. Failure to wear a face shield or safety glasses could result in severe eye injury.
4. It is important to protect yourself from potential burns when working around hot melt
adhesive equipment.
5. Wear heat-resistant protective gloves and long‐sleeved, protective clothing to prevent
burns that could result from contact with hot material or hot components.
6. Always wear steel‐reinforced safety shoes.
UFD Applicator, Manual 40-43, Rev. 6.16 Page 11
ITW Dynatec
Chapter 2
Safety Instructions
WARNING HOT SURFACE
Electrical
DANGER HIGH VOLTAGE
1. Dangerous voltages exist at several points in this equipment. To avoid personal injury,
do not touch exposed connections and components while input power is on.
2. Disconnect, lockout and tag external electrical power before removing protective
panels.
3. A secure connection to a reliable earth ground is essential for safe operation.
4. An electrical disconnect switch with lockout capability must be provided in the line
ahead of the unit. Wiring used to supply electrical power should be installed by a
qualified electrician.
5. Notify the maintenance personnel immediately, if cables are damaged. Provide for
exchanging the defective components immediately.
Lockout/ Tagout
Switch the unit voltage-free before working!
Main switch OFF!
1. Follow OSHA 1910.147 (Lockout/ Tagout Regulation) for equipment's lockout
procedures and other important lockout/tagout guidelines.
2. Be familiar with all lockout sources on the equipment.
3. Even after the equipment has been locked out, there may be stored energy in the
application system, particularly in the capacitors within the panel box. To ensure that
all stored energy is relieved, wait at least one minute after removing power before
servicing electrical capacitors.
High Temperatures
1. Severe burns can occur if unprotected skin comes in contact with molten adhesive or
hot application system parts.
2. Face shields (preferred) or safety glasses (for minimum protection), heat-resistant
protective gloves and long-sleeved clothing m us t be worn whene ver wor k ing with or
around adhesive application systems.
Page 12 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 2
Safety Instructions
ITW Dynatec
WARNING HIGH PRESSURE PRESENT
WARNING
High Pressure
1. To avoid personal injury, do not operate the equipment without all covers, panels and
safety guards properly installed.
2. To prevent serious injury from molten adhesive under pressure when servicing the
equipment, disengage the pumps and relieve the adhesive system's hydraulic
pressure (i.e. trigger the heads, hand‐held applicators, and/or other application
devices into a waste container) before opening any hydraulic fittings or connections.
3. IMPORTANT NOTE: Even when a system's pressure gauge reads “0” psi, residual
pressure and trapped air can remain within it causing hot adhesive and pressure to
escape without warning when a filter cap or a hose or hydraulic connection is
loosened or removed. For this reason, always wear eye protection and protective
clothing.
4. Either of the two High Pressure symbols shown may be used on ITW Dynatec
equipment.
5. Keep the given operating pressure.
6. Notify the maintenance personnel immediately, if hoses or components are damaged.
Provide for exchanging the defective components immediately.
Protective Covers
DO NOT OPERATE WITHOUT GUARDS IN PL ACE
1. Keep all guards in place!
2. To avoid personal injury, do not operate the application system without all covers,
panels and safety guards properly installed.
3. Never get your extremities and/or objects into the danger area of the unit. Keep your
hands away from running parts of the unit (pumps, motors, rolls or others).
UFD Applicator, Manual 40-43, Rev. 6.16 Page 13
ITW Dynatec
Chapter 2
Safety Instructions
Servicing, maintenance
1. Only trained an d qualified personnel are to operate and service this equipment.
2. Before any service work disconnect the external power supply and the pressure air
supply!
3. Never service or clean equipment while it is in motion. Shut off the equipment and lock
out all input power at the source before attempting any maintenance.
4. Follow the maintenance and service instructions in the manual.
5. Keep the maintenance rates given in this documentation!
6. Any defects in the equipment that impact safe operation have to be repaired
immediately.
7. Check screws that have been loosened during the repair or maintenance, if they are
tight again.
8. Replace the air hoses in preventive maintenance regularly, even if they have got no
viewable damages! Adhere to the manufacturers` instructions!
9. Never clean control cabinets or other houses of electrical equipment with a jet of
water!
10. Adhere to the current safety data sheet of the manufacturer when using hazardous
materials (cleaning agents, etc.)!
Secure transport
1. Examine the entire unit immediately after receipt, if it has been delivered in perf ec t
condition.
2. Let damages in transit certify by the carrier and announce them immediately to ITW
Dynatec.
3. Use only lifting devices that are suitable for the weight and the dimensions of the
equipment (see drawing of the equipment).
4. The unit has to be transported upright and horizontally!
5. The unit has to cool down to room temperature before packaged and transported.
Page 14 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 2
Safety Instructions
ITW Dynatec
EXTINGUISH FIRE
For safety reasons not appropriate extinguishing agents: None.
Treatment for Burns from Hot Melt Adhesives
Measures after being burned:
1. Burns caused by hot melt adhesive must be treated at a burn center. Provide the burn
center's staff a copy of the adhesive's M.S.D.S. to expedite treatment.
2. Cool burnt parts immediately!
3. Do not remove adhesive forcibly from the skin!
4. Care should be used when work ing with hot melt adhesives in the molten state.
Because they rapidly solidify, they present a unique hazard. Even when first solidified,
they are still hot and can cause severe burns.
5. When working near a hot melt application system, always wear safety shoes, heatresistant protective gloves, safety goggles and protective clothes that cover all
vulnerable parts of the body.
6. Always have first-aid information and supplies available.
7. Call a physician and/or an emergency medical technician immediately. Let the burns
medicate by a medic immediately.
Measures in case of fire
UFD Applicator, Manual 40-43, Rev. 6.16 Page 15
1. Please heed that not covered hot parts of the engine and molten hot melt may cause
heavy burns. Risk of burns!
2. Work very carefully with molten hot melt. Keep in mind, that already jelled hot melt can
be very hot, too.
3. When working near a hot melt application system, always wear safety shoes, heatresistant protective gloves, safety goggles and protective clothes that cover all
vulnerable parts of the body!
Measures in case of fire:
Wear safety shoes, heat-resistant protective gloves, safety goggles and protective
clothes that cover all vulnerable parts of the body.
Firefighting - burning hot melt:
Please keep attention to the safety data sheet given by the adhesive manufacturer.
Appropriate extinguishing agents:
Foam extinguisher, Dry powder, Spray, Carbon dioxide (CO2), Dry sand.
Firefighting - burning electrical equipment:
Appropriate extinguishing agents:
Carbon dioxide (CO2), Dry powder.
ITW Dynatec
Chapter 2
Safety Instructions
1. When working on or with the unit, the legal obligations for waste avoidance and the
Keep attention to environmental protection standards
duly recycling / disposals have to be fulfilled.
2. Keep attention, that during installations, repairs or maintenance matters hazardous
to water, like adhesive / adhesive scrap, lubricating grease or oil, hydraulic oil,
coolant and cleaner containing solvent not pollute the ground or get into the
canalization!
3. These matters have to be caught, kept, transported and disposed in appropriate
reservoirs!
4. Dispose these matters according to the international, national and regional
regulations.
Page 16 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 3 Description and Technical Specs
ITW Dynatec
If the unit is not used in accordance with this regulation, a safe operation cannot be
resulting from unintended use!
Intended use includes, that you
• do all maintenance within the given maintenance rates.
• Risk of burns from hot material.
• The safety valves may malfunction due to hardened or charred material.
Chapter 3
Description and Technical Specs
3.1 Applicable Safety Regulations
Intended Use
The UFD Applicator may be used only to apply suitable materials, e.g. adhesives. When
in doubt, seek permission from ITW Dynatec.
guaranteed.
The operator - and not ITW D ynatec - is liable for all personal injury or property damages
• read this documentation,
• heed all given warnings and safety instructions, and
Any other use is considered to be unintended.
Unintended Use, Examples
The UFD Applicator may not be used under the following conditions:
• In defective condition.
• In a potentially explosive atmosphere.
• With unsuitable operating/processing materials.
• When the values stated under Specifications are not complied with.
The UFD Applicator may not be used to process the following materials:
• Toxic, explosive and easily flammable materials.
• Erosive and corrosive materials.
• Food products.
Residual Risks
In the design of the UFD Applicator, every measure was taken to protect personnel from
potential danger. However, some residual risks cannot be avoided.
Personnel should be aware of the following:
• Risk of burns from hot Applicator components.
• Risk of burns when conducting maintenance and repair work for which the system
must be heated up.
• Risk of burns when attaching and removing heated hoses.
• Material fumes can be hazardous. Avoid inhalation. If necessary, exhaust material
vapors and/or provide sufficient ventilation of the location of the system.
• Risk of pinching parts of the body at running parts of the unit (pumps, motors, rolls or
others).
UFD Applicator, Manual 40-43, Rev. 6.16 Page 17
ITW Dynatec
Chapter 3
Description and Technical Specs
Technical changes
Any kind of technical changes having impact to the security or the operational liability of
the system should only be done by written agreement of ITW Dynatec. Suchlike changes
made without given a corresponding written agreement will lead to immediate exclusion
of liability granted by ITW Dynatec for all direct and indirect subsequent damages.
Using foreign components
ITW Dynatec takes no responsibility for consequential damages caused by using foreign
components or controllers that have not been provided or installed by ITW Dynatec.
ITW Dynatec does not guarantee that foreign components or controllers used by the
operating company are compatible to the ITW Dynatec-system.
Setting-up operation
We recommend asking for an ITW Dynatec-service technician for the setting-up
operation, to ensure a functioning system. Let yourself and the people working with or
working on the system be introduced to the system on this occasion.
ITW Dynatec takes no responsibility for damages or faults caused by any untrained
personal.
Page 18 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 3
Description and Technical Specs
ITW Dynatec
UFD Omega:
UFD Random:
3.2 Description of UFD Spray Applicator
Description
ITW Dynatec’s UFD Spray Applicators are air-operated, single or multi-module hot melt
adhesive applicator assemblies with integrated basket filters, which prevent particulate
matter from obstructing flow through the heads.
The Applicator is heated by replaceable cartridge heating elements which are controlled
by an integrated sensor and electronic control. Each model can be configured for ITW
Dynatec’s DynaControl, MCV or Upgrade control schemes or for Allen-Bradley PLC
controls. Pressure transducer ports are standard features for all Applicators. A choice of
adhesive inlets and an angled filter nut allows either vertical or horizontal spray.
Four standard UFD models supporting up to six modules, are available, ranging in width
from 50mm to 150mm (2” to 6”). Their design is metric.
Theory of Operation
Each Applicator features one or more modules (adhesive valve) mounted to a single
service block. Each module is opened and closed by air pressure (solenoid valve).
Springs are used to keep the stem closed when no air pressure is supplied to the head.
The rate of adhesive flow from the applicator is determined by the adhesive pressure
applied by the Adhesive Supply Unit’s (ASU’s) pump, the nozzle type and the stem stroke
adjustment.
As shown in the illustration below, the heated adhesive supply hose may be connected at
the rear of the applicator or at the top. Adhesive flows from the hose into the service
block, through the filter and then to the module. Air pressure (Control Air) opens the
module, allowing adhesive to flow through the module’s nozzle.
Adapters are available to allow indus try-standard pressure transducers (1/2-20 thread) to
be connected to monitor adhesive pressure within the service block.
On the UFD spray models, an air preheater is located below the service block. The
preheater supplies heated air (Process Air), used to fiberize the adhesive streams, to the
UFD modules. The air preheater is thermally isolated from the service block and its
temperature is controlled independently.
The adhesive pressure in the system is influenced by the following parameters:
• Temperature and viscosity of the adhesive
• Size and speed of the Adhesive Application Unit’s (ASU’s) pump
• Cross-section and length of the adhesive hoses
• Adjusted adhesive pressure at Applicator (if adjustable pressure relief valve)
• Nozzle type
See illustration typical parts of UFD Applicator on next page.
Nozzles compatible with UFD Applicator:
Two different UFD nozzles (Omega and Random) are available to fiberize the
adhesive streams:
UFD Applicator, Manual 40-43, Rev. 6.16 Page 19
ITW Dynatec
Chapter 3
Description and Technical Specs
Alternate Hose
Inlet
Process Air Inlet
Air Preheater
Piston
Accessory Port
UFD Module
Control Air Inlet
Electrical
Inlet
Mounting screw
Nozzle
Filter
O-ring
Filter Nut
Lock
Nut
Optional Drain
(Purge) Valve
Stroke Adjustment Screw
Connection
Alternate Glue
Fiberizing Nozzle
Filter Cap
Glue Inlet
Page 20 UFD Applicator, Manual 40-43, Rev. 6.16
Illustration: Standard UFD Spray Applicator
Basket
Chapter 3
Description and Technical Specs
ITW Dynatec
Technical Data
Model UFD 0501 0502 0753 1004 1506
Number of Modules
Spacing between nozzle centers
Wattage Adhesive Manifold
Wattage Standard Air Perheater
Wattage Slim Line Preheater
Supply voltage
Dimensions
Weight (including module and
solenoid valve)
Mounting
Temperature range
Warm-up time
1 2 3 4 6
- 25.2 mm 25.2 mm 25.2 mm 25.2 mm
450 450 525 600 900
600 600 900 1200 1200
400 400 600 800 1200
200-240 VAC/ 1p/ 50-60 Hz
See dimensional layout on follo wing pag e.
Model UFD0501: 3.52 kg (7.75 lb.)
M6 x 1 screws with insulators or 1/2” rod mount,
insulated clamps, 12 to 13 mm rod
38°C to 218°C (100°F to 425°F)
15 minutes for cold start/
5 minutes for module change only
Adhesive viscosity
Adhesive pressure range
Noise emission
Air pressure range
Air pressure range for high
speed snuffback modules (only)
Storage/ shipping temperature
Ambient service temperature
CE approval granted
100 to 30.000 mPa. sec. (100 to 30.000 centipoise)
68 bar maximum (1000 psi maximum)
70 dB(A)
4.1 to 6.9 bar (60 to 100 psi)
4.8 to 6.2 bar (70 to 90 psi)
-40°C to 70°C (-40°F to 158°F)
-7°C to 50°C (20°F to 122°F)
Yes
UFD Applicator, Manual 40-43, Rev. 6.16 Page 21
ITW Dynatec
Chapter 3
Description and Technical Specs
Service Block Length:
150 6 = 150mm (6 port/ 1 solenoid)
Module Type:
No. of Modules installed:
Z (no modules)
Voltage:
Control:
Filter Options:
Number of Solenoids:
(not available for J, M)
Applicator Options:
A = Adds Purge Valve
Model Designation Guide
UFD XXX X X X X X X X X
Example: UFD 100 4 V 4 A 1 D 2 S
050 1 = (1 port/1 solenoid)
050 2 = 50mm (2 port/1 solenoid)
075 3 = 75mm (3 port/1 solenoid)
100 4 = 100mm (4 port/ 1 solenoid)
S = Standard (No Options)
2 = 240VAC
A = Vertic al Hi-Speed SB (manifold air)
H = Horizontal UFD* (continuous)
V = Vertical UFD* (continuous)
K = Horizontal UFD SB (intermittent)
F = Vertical UFD SB (intermittent)
J = Verti cal, Hi-Speed SB, (intermittent)
Festo
M = Horizontal, Hi-Speed SB, (intermittent)
Festo
P = Horizontal Hi-Speed SB (manifold air)
D = DynaControl / PLC
M = MCV
N = Upgrade, Nor (Nickel RTD)
L = Upgrade, Mel (J -type t herm ocouple)
P = Upgrade, Mel (Platinum RTD)
1, 2, 3, 4, 5 or 6
0 = Only for options J, M
E = Adds Balanced Solenoid Manifold
1, 2, 3, 4, 5, 6 or
A = 100 mesh, basket
B = 150 mesh, basket
C = 150 mesh, spin-on
D = 200 mesh, spin-on
Notes: When specifying an Applicator with no modules, (see “Z” above), the Module Type (H, V, etc.)
must still be specified for the application.
Page 22 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 3
Description and Technical Specs
ITW Dynatec
Dynafiber UFD Applicator,
side view:
Dynafiber UFD Applicator,
front view:
Dynafiber UFD
Width
Centers
Model No.
A
B
50mm
2“
50mm
2“
25.2mm
1“
75mm
3“
50.4mm
2“
100mm
4“
75.6mm
3“
150mm
6“
126mm
5“
Dimensions
UFD0501
UFD0502
UFD0753
UFD1004
UFD1506
SlimLine Applicator
-
UFD Applicator, Manual 40-43, Rev. 6.16 Page 23
ITW Dynatec
Chapter 3
Description and Technical Specs
This page intentionally left blank.
Page 24 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 4 Installation & Startup
ITW Dynatec
CAUTION
• Heed all safety instructions mentioned in Chapter 2.
• In any case the air has to be clean and dry! See advice in Chapter 4.3 “Quality of
applicator, 3/8” O.D. airline is recommended.
Advices:
occurs.
Chapter 4
Installation & Startup
• Before setting up, please read this documentation carefully.
• Pay attention to all the installation and connecting advices.
4.1 Conditions for set-up and mounting
Place requirement
Install the Applicator in the machine so that the operator is able to work on it from all
sides, for e.g. for adjusting, preparing, maintaining, repairing, cleaning, etc. See drawing
of the unit for admeasurements.
Mounting and alignment
• The complete unit has to be set up on solid, stable and flat ground.
• The alignment in height of the complete system has to be considered.
• The alignment of the machine has to be considered.
Electrical connection
• Necessary electrical connection has to be provided. See electrical schematics.
• Never connect or disconnect plug-and-socket connections under load!
• The service block’s incoming electrical power and temperature control is supplied
through the flexible cable exiting the adhesive supply hose cuff or through an
extension cable from the ASU. The Applicator has a circular, plastic connector which
mates with the connector attached to this cable.
• Incoming power and temperature control for the air preheater, if applicable, is supplied
by a cable extension from the ASU.
Pneumatic connection
compressed air”.
• Please heed that units with high air demand may not be used at the same time with
the same air supply.
• Incoming module-activation air is supplied through a solenoid valve. It must be clean
and unlubricated.
For conventional modules (module option H, V, HQ or VQ in the model number (see
previous pages), the module activation air is controlled by a four-way solenoid valve
and should be separately regulated and maintained at a pressure between 4.1 to 6.9
bar (60 to 100 psi). Air lines from the solenoid valve should be 6.4mm (1/4 inch).
Head air inlet ports are G 1/8 threads (1/8 NPT).
For snuffback modules (all other module options), the module activation air is
UFD Applicator, Manual 40-43, Rev. 6.16 Page 25
controlled by a either a four-way or a five-way solenoid valve. See Appendix A and B
for details on the solenoid setup.
• Incoming process (preheater) air must be supplied through a pressure regulator. The
air must be clean and unlubricated. Operating pressure depends on the choice of
nozzle. The Applicator’s air supply line must be at least 1/4” O.D. For the UFD 150
• Check all screw connections at the unit and retighten if necessary.
• Lay the cables and heated hoses so that no risk or least possible risk of stumbling
ITW Dynatec
Chapter 4
Installation & Startup
CAUTION
valid regulations.
WARNING
• Risk of burns and risk of injury!
Air Inlet
Fitting
Muffler
To Timer or
Limit Switch
Purge Button
Solenoid
Mounting of
assemblies
Stroke Limit Adjustment
Alternate Hose Inlet
(one on each side)
Weep Hole
Nozzle
Accessory Port (for a drain
(one on each side)
Hose/ Head Electrical
Connection
Alternative
Control Air
Inlet Port
Rod Mount Bracket
Filter Nut
Adhesive Inlet
or
90° Hose Fitting
45° Hose Fitting
Rod Mount Bracket & Plug
position.
Process Air Inlet for Air Preheater
Electrical Connection
For Air Preheater
4.2 Installation & Startup
• All work on or with this unit is only permitted for sk illed personnel!
• Pay attention to the electrical schematics!
• Clean and dry air and air pressure of 6 bar to the applicator solenoids is required.
• All heating elements have to be mounted and operated secured and according to the
• While installing the Applicator, use an appropriate protection device to avoid
unintended contact with heated parts and with spilling out Hotmelt. The protection
device has to prevent also the operator against not reaching into the adhesive
application and against injuring.
Typical installation for an ULTRA Applicator:
1. Install the Applicator on the machine at the foreseen place.
The Applicator should be supported from brackets that permit lateral and vertical
adjustments. Mount the Applicator on a 12mm to 13mm rod or bracketry using the 6
mm screws and insulators provided. Allow access to the filter. Be sure that the stroke
limit adjustment screws are accessible and that the “weep” holes are visible for
periodic inspection. Leave s uff ic ient clearance to install a pressure transducer, if
applicable, and allow access to a drain valve, if installed.
Installation Diagram: See the diagram for location of the components referred to in the following
section.
optional
solenoid
valve and/ or transducer tap)
Page 26 UFD Applicator, Manual 40-43, Rev. 6.16
Adhesive Supply Hose
used in alternate glue inlet
Chapter 4
Installation & Startup
ITW Dynatec
6 bar air pressure are required. Reason:
be installed between the standard air regulator/ filter and the UFD Applicator.
Heed the following for the installation of the heated hoses:
they cannot be repaired the hose would have to be changed completely.
2. Connect the compressed-air supply to Applicator. Connect all solenoids with air hoses
as required.
• Lower air pressure causes uneven adhesive application.
• The modules do not switch or switch with delay, resp. open and close again, if the air
supply is uneven.
• Only permanent pressure and sufficient volume flow leads to reproducible application
accuracy regarding position and amount.
CAUTION: Do not use lubricating oil with the air supply as Applicators are
lubricated at the factory and do not require lubrication when used in production.
Where oil is present in the air supply, a coalescing filter (Dynatec PN 100055) must
UFD Applicators require at least one solenoid valve for each applicator. If your head was
ordered without a solenoid valve, a 4-way valve (or a 5-way valve for snuffback modules)
should be mounted so that the air lines to each Applicator are as close to the same length
as practical.
Note: Air lines and fittings must be capable of withstanding temperatures up to 218°C
(425°F). ITW Dynatec supplies Air Control Filter Coalescing Kits (PN 100055) to be used
with air-operated Applicators (see the Air Control Filter Coalescing Kit Manual in
Appendix A of this manual).
For process (preheater) air control, the filter/ regulator kit PN 107404 is recommended. It
contains a 0-50 psi air filter/ regulator combination and a liquid-filled gauge for accurate
process air control.
See the Process (Preheater) Air Control Filter/ Regulator information in Appendix B.
When connecting the air lines to the applicator, the air line which has air pressure to the
module when the solenoid is OFF is the closing air line. See Appendix A and B for details
and diagrams of solenoid setup.
3. If a pre- or post- filter pressure transducer is to be utilized: install the supplied adapter
into the desired accessory port. Thread the transducer into the adapter (transducer
adapter has 1/2-20 thread). Follow the transducer manufacturer’s recommendations
for torque specifications. Note: the alternate hose inlets on either side of the Applicator
can also be used for the transducer adapter.
4. Before making the adhesive connection to the Applicator, align the adhesive supply
hose with its electrical connector oriented in relation to the electrical connector on the
top of the Applicator.
Connect the swivel fitting of the hot melt hose to the adapter on the service block,
using either the inlet port located below the filter nut or the port located on the top of
the Applicator (beside the electrical connection in the diagram). When tightening the
hose fitting, hold the hose cuff to prevent the hose core from rotating.
• Heated hoses may be damaged by overheating, if they are laid faulty.
• The heated hoses may not be stacked one on the other!
• The heated hoses may not be pressed together and / or bound.
• Put the hoses separated next to each other!
• The connections for supply resp. return hoses may not be mixed up.
• It is essential that the hoses will be laid without twisting!
• Heated hoses may not be fastened with binders or similar.
• Heated hoses may not be laid on a sharp edge.
• When using a balancer, a hose support with a radius of 400mm has to be mounted.
Reason: The sensor cables and heating cables within the hoses can be damaged. As
UFD Applicator, Manual 40-43, Rev. 6.16 Page 27
ITW Dynatec
Chapter 4
Installation & Startup
WARNING! HIGH PRESSURE! HOT ADHESIVE!
Use a stable, deep container to collect hot-melt adhesive and/ or oil.
Purge the Applicator before every start of production respectively of a shift by allowing
Bring the Applicator in work position and continue production.
5. Make the electrical connection from the hose to the applicator by connecting the
6. Connect the spray air line to the preheater using the adapter provided. Do not
7. Make the electrical connection from the extension cable to the preheater by
8. It is advisable to check the temperature of the applicator. This can be done through
9. Purge the Applicator of air and oil. Turn the Applicator O N electric a l ly and
10. Replace the nozzle, orienting the nozzle tip so it points toward the substrate.
11. Interconnect the components with the foreseen Profibus (or EtherNet, etc.) interface
Daily operation
female connector of the hose to the male connector of the applicator.
overtighten the compression fitting, or the air line could collapse, reducing air flow.
connecting the female connector of the cable to the male connector of the preheater
the temperature readout of the adhesive supply unit. Surface temperature may be
checked with a separate pyrometer and surface probe or with a dial thermometer.
Turn the system power switch ON. Permit the applicator to warm up at least 15
minutes (5 minutes for module change) before reading temper ature.
pneumatically.
During the purging procedure, hot adhe sive and oil can come out of
the Applicator under high pressure. Wear safety glasses, gloves and
protective clothing.
Remove the nozzle from the module. Place a heat resistant container under the
module to collect the material that drains from the Applicator. Manually open the
solenoid by pushing (with a small screwdriver or other tool) the purge button located
on the solenoid coil. Continue to hold in the purge button until all air and oil have
drained and only adhesive flows from the module.
cables (if applicable).
the adhesive flows out until it is satisfactory.
Then switch off the adhesive and clean the nozzle from adhesive.
Page 28 UFD Applicator, Manual 40-43, Rev. 6.16
Chapter 4
Installation & Startup
ITW Dynatec
WARNING! HOT SURFACE & ADHESIVE!
Special Installation Notes on HiSpeed, Vertical Snuffback, Direct-Air Module
Special Installation Notes on Optional PN 112690, 112440 & 112934 HiSpeed, Vertical
Snuffback, Direct-Air Module (Option Code C,D, G see Chapter Model Designation Guide)
The PN 112690, 112440 & 112934 modules are designed for the solenoid valve to be
connected directly to the module air cylinder. Fittings and tubing are included with the
module assembly.
If alternative fittings or tubing are desired, the recommended tubing is aluminum or
stainless steel, 1/4” OD x 3/16” ID. For best performance, the tubing length should be as
short as practical (recommended length is 2.5” min. to 6” max.). The port threads in the
module are 1/8-27 NPT.
If necessary for clearance, the air cylinder can be rotated to re-position the tube fittings.
Remove the four cap screws securing the air cylinder, and without removing the air
cylinder, rotate to the desired position. Replace the cap screws and torque crosswise,
first to 5 in-lb., then to 20 in-lbs.
Recommended operating air pressure is 70-90 psi.
Operation of Optional Drain Valve
(Option Code A, see Chapter Model Designation Guide)
UFD Applicators with the “A” option are equipped with a drain valve located on the right
side of the Applicator. This drain valve allows residual adhesive pressure to be relieved
prior to maintenance or repair of the Ap pl icator . Dur ing Applicator installation, the drain
valve can be relocated to the left side of the Applicator for access, if necessary.
The drain valve consists of a valve body with a rotatable outlet collar that directs the flow
of adhesive. A plug is located inside the body, retained by a snap ring to prevent the plug
from being fully removed.
Operation
1. Ensure that all pumps in the ASU (Adhesive Supply Unit) are turned off. Power down
the ASU or disable the Applicator and preheater zones at the control panel.
Disconnect all electrical cables from the Applicator.
The equipmet will still be hot when this procedure is being done.
Use insulated gloves and protective c lothing.
2. Place a suitable container under the Applicator to catch adhesive. Using pliers, rotate
the knurled outlet collar of the drain valve so that the exit hole points toward the
container, and away from any personnel. Stand away from the valve while the
adhesive pressure is being relieved.
3. Using a 19mm (3/4”) wrench on the valve body to prevent rotation, insert a 5mm hex
wrench into the plug. Rotate the plug counter-clockwise to allow adhesive to flow
through the valve.
4. If no adhesive flows from the drain valve, do not assume that there is no adhesive
pressure in the system. Always verify that adhesive pressure has been completely
relieved before proceeding with maintenance or repairs. Never remove the snap ring
in the end of the valve, as this would allow the plug to be removed, possibly resulting
in personal injury.
5. After maintenance or repairs are complete, tighten the plug securely. Wipe any
adhesive from the outer surface of the drain valve.
UFD Applicator, Manual 40-43, Rev. 6.16 Page 29
ITW Dynatec
Chapter 4
Installation & Startup
WARNING! HOT SURFACE & ADHESIVE!
max. oil
(mg/m3)
1
0,1
0,1
-70
0,01 2 1 1 -40
0,1
3
5 5 -20
1 4 15
8
+3
5
5
40
10
+7
25 6 +10
7 not defined
Purging Adhesive Through the Applicator
This procedure may be used anytime the operator wishes to purge old adhesive from the
Applicator and replace it with fresh adhesive. For example, this procedure could be used
in instances where the adhesive system has been held at temperature for an extended
time without running, such as during a produc tio n line s tar t-up.
The equipment will still be hot when this procedure is being do ne.
Use insulated gloves and protective c lothing.
Procedure
1. Remove all nozzles. Place a suitable container under the Applicator to catch adhesive.
2. Activate the modules and manually run the adhesive pump to purge the hoses and
Applicators of old adhesive. Purge until the adhesive exiting the modules is fresh.
3. Check system pressure to see if filters are clogged and need to be changed.
4. Replace the nozzles and check the adhesive flow through them. Compare to target
flow.
5. Check the nozzle spray pattern.
6. Clean any nozzles that do not spray properly and check the spray pattern again.
4.3 Quality of compressed Air
Compressed air quality class according to ISO 8573-1
• We recommend to use a maintenance-unit for compressed-air conditioning with a filter
40µm.
• Keep the quality class 5.4.2 according to ISO 8573-1.
Classification of Quality Classes According to ISO 8573-1:
Class 1. Particulate Material 2. Water Content 3. Oil Content
max. particle size
(μm)
max. particle density
Page 30 UFD Applicator, Manual 40-43, Rev. 6.16
(mg/m3)
max. pressure dew point
(°C)
concentration
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