ITW Dynatec DYNAMINI Operation And Service Manual

ITW Dynatec
An Illinois Tool Works Company
31 V olunteer Drive
Hendersonville, TN 37075 USA
Telephone [phone]
FAX [phone]

Adhesive Application Solutions · ISO 9001 Certified

ITW Dynatec GmbH
Industiestrasse 28
D-40822 Mettmann, Germany
Telephone [phone]
FAX [phone]

ITW Dynatec K.K.
Daiwashinagawa Bldg., 7-15 Konan, 3-Chome
Minata-Ku, Tokoyo 108 Japan
Telephone [phone]
FAX [phone]

OPERATIONS & SERVICE MANUAL

Manual 20 -25

Revised 1/05

DYNAMINI

ä

ADHESIVE SUPPLY UNIT

OPERATIONS AND SERVICE MANUAL

with Software Version 2.00

For an online copy of this manual, go to www.itwdynatec.com/manuals.htm

IMPORT ANT! -READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT

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.

NOTICE! 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 ii
Revised 1/05

ITW Dynatec c. 2004

DYNAMINI ASU Manual #20 -25

The Dynamini ASU is manufactured under one or more of the following PA TENTS:

United States:

D388,800 5,613,451
5,632,918 5,645,743
5,683,578 5,719,378
5,806,720

Europe:

97309164.8-2206

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25

TABLE OF CONTENTS

Chapter 1 Safety Precautions Chapter -Page #
Chapter 2 Specifications & Dimensions

Model Description Matrix 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Dimensions 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 Installation & Start Up

Mounting the ASU/ Lifting the ASU 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W attageAvailabilityChart 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding to or Changing the Adhesive Formula 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Control Filter Unit/ Rear Cover: Head & Hose Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Start Up and Shut Down Procedures 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage and Disposal of the Application System 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 Dynamini Temperature Controller Set- Up

Page iii

Revised 1/05

Temperature Control Functions in General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defining Dynamini Temperature Control Terms 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Indication Messages 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Software Chip (EPROM) and Checksum 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Settings for a Typical Operation 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System V alues 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Default Settings of the Controller 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Helpful Tips for the User 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 Programming of the Dynamini Controller

Controller Keypad 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn On 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Setpoints 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning Zones On/ Off 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Indication Messages 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keypad Locking 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Functions 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram of the Service Functions Loop 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standby 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tolerance 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequential Startup 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Scale 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ready Delay 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Access Code 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 Preventive Maintenence

General Cleaning 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenanace 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Filter 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Fittings and Fasteners 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page iv
Revised 1/05

DYNAMINI ASU Manual #20 -25

Hopper Filter Inspection and Cleaning 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purging the Filter Manifold of Adhesive and Pressure 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the System 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 Troubleshooting

Handling Printed Circuit Boards 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printed Circuit Board & Layout Illustration 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overtemp Thermostat 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of PCB & Overtemp Thermostat Re-set 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistance Tables 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Guide 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Operation & Adjustable Pressure Relief 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pump Troubleshooting Guide 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Pump Troubleshooting Guide 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 Disassembly & Re- assembly Procedures

To Remove the Pump & Electronics Cover 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Hopper Cover 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove the Hopper Lid 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat Replacement 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RTD Sensor Replacement 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Access & Replace the Electrical Components 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Access & Replace the Pumps or Motors 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note on Cast-in Heaters 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Re-assembly Procedures & Cautions 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ITW Dynatec c. 2004

Chapter 9 Available Options & Accessories

Pressure Gauge Kit 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Option 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Options & Accessories 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Job Aide 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Service Parts List 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10 Component Illustrations & Bills of Material

Electrical Panel Assembly 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pump Assembly 10-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cabinet Assembly 10-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Section 10-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter & Melt Assembly 10-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assemblies 10-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1 1 System Schematics & Engineering Drawings

Hose Schematic: all models 11-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Head Schematic: all models 11-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W iringDiagrams 11-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

Page 1-1

Revised 9/98

Chapter 1

SAFETY PRECAUTIONS

All operators and service personnel must read
and understand this manual before operating
or servicing equipment.

Electrical

DANGER

HIGH VOLTAGE

Dangerous voltages exist at several points in this
equipment. Toavoid personal injury, do not touch
exposed connections and components while input

High Temperatures

WARNING

HOT

SURFACE

All maintenance and service on this equip­ment must be performed by trained techni­cians.

power is on. Disconnect, lockout and tag external
electrical power before removing protective panels.

A secure connection to a reliable earth ground is
essential for safe operation.

A disconnect switch with lockout capability must be
provided in the line ahead of the unit. Wiringused to
supply electrical power should be installed by a
qualified electrician.

Severe burns can occur if unprotected skin comes in
contact with molten adhesive or hot application system
parts.

Safety glasses, gloves and long- sleeved clothing must
be worn whenever working with or around adhesive
application systems.

High Pressure

WARNING

HIGH PRESSURE

PRESENT

To avoid personal injury, do not operate the equipment

Protective Covers

WARNING

DO NOT OPERATE

WITHOUT GUARDS

IN PLACE

without all covers, panels and safety guards properly
installed.

To prevent serious injury from molten adhesive under
pressure when servicing the equipment, disengage the
pumps and relieve the adhesive system’s hydraulic
pressure (e.g., trigger the heads, hand-held applicators,
and/or other application devices into a waste container)
before opening any hydraulic fittings or connections.

Keep all guards in place!
To avoid personal injury, do not operate the application

system without all covers, panels and safety guards
properly installed.

Page 1-2
Revised 3/97

Eye Protection & Protective Clothing

WARNING

ITW Dynatec c. 2004

DYNAMINI ASU Manual 20-25

Wear safety glasses with side shields which conform to
ANSI Z87.1 or EN166.

EYE PROTECTION

REQUIRED

PROTECTIVE

CLOTHING
REQUIRED

It is very important that you PROTECT YOUR EYES
when working around hot melt adhesive equipment!

Safe Installation and Operation

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 p revent heat dissipation,
such as insulation or sheathing.

Read this manual before applying electrical power to
the equipment. Equipment may be damaged by
incorrect electrical connections.

Do not use adhesive that is dirty or that may be
chemically contaminated. Doing so can cause system

Failure to wear safety glasses could result in severe eye
injury.

It is important to protect yourself from potential burns
when working around hot melt adhesive equipment.

Wear protective gloves and long-sleeved, protective
clothing to prevent burns that could result from contact
with hot material or hot components.

Always wear steel-reinforced safety shoes.

clogging and pump damage.
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.

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.

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.

Treatment for Burns From Hot Melt Adhesives

Burns caused by hot melt adhesive must be treated at a
burn center.

Care should be used when working 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. When working near a hot melt

application system, always wear safety gloves, safety
glasses and long-sleeved, protective clothing.

Always have first-aid information and supplies
available.

Call a physician and/or an emergency medical
technician immediately.

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

Service

Refer all servicing to qualified personnel only.

Explosion/ Fire Hazard

Page 1-3

Revised 9/98

Never operate this unit in an explosive environment.
Use cleaning compounds recommended by ITW

Dynatec or your adhesive supplier only.Flash points

Lockout/ Tagout

Follow OSHA 1910.147 (Lockout/ Tagout Regulation)
for equipment’slockout procedures and other impor­tant lockout/ tagout guidelines.

Be familiar with all lockout sources on the equipment.

In This Manual

WARNINGS and CAUTIONS are found throughout
this manual.

WARNINGS mean that failure to observe the specific

of cleaning compounds vary according to their com­position, so consult with your supplier to determine the
maximum heating temperatures and safety precautions.

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. Toensure
that all stored energy is relieved, wait at least one min­ute before servicing electrical capacitors.

instructions may cause injury to personnel.
CAUTIONS mean that failure to observe the specific

instructions may damage the equipment.

Page 1-4
Revised 3/97

ITW Dynatec c. 2004

DYNAMINI ASU Manual 20-25

ITW Dynatec
An Illinois Tool Works Company

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25

SPECIFICATIONS AND DIMENSIONS

DYNAMINI

5 = 5 kg/ 10 lb.

1 = 10 kg/ 20 lb.
HOSE: 2- hose capable
PUMP TYPE:

P12 = Piston Pump 12:1

GAS = Gear Pump 1.5cc

GBS = Gear Pump 3.2cc

GCS = Gear Pump 4.5cc

GDS = Gear Pump 0.55cc

GES = Gear Pump 10cc

Page 2 -1

Revised 1/05

Chapter 2

N X 2 X X X X - X X X X

VOL TAGE:

1 = 100 - 120VAC, 1 phase

2 = 200 - 240VAC, 1 phase
OPTIONS:

ACCESSORIES:

F = 100 mesh/ 149 micron outlet filter (40 mesh/ 420 micron is standard)
G = Analog pressure gauge
V = Swirl kit, 1 hose
W = Swirl kit, 2 hose

CONFIGURED SYSTEM OPTIONS:

C24 = 2.4m/ 8 ft. Abrasion resistant hose
C36 = 3.6m/ 12 ft. Abrasion resistant hose

CHB = Hand Bead Applicator
CHS = Hand Swirl Applicator

STACKTITE SYSTEM OPTIONS:

SB = Bead applicator
SS = Swirl applicator

EXAMPLE:

N52GAS2- F = Dynamini 10 lb. hopper w/ 1.5cc gear pump, 240 VAC/ 1 phase and 100 mesh outlet
filter .

DYNAMINI Model Designation Matrix

Page 2 -2
Revised 1/05

DYNAMINI ASU Manual #20 -25

ITW Dynatec c. 2004

Specifications

Environmental:

Storage/ shipping temperature -40° C to 70°C (-40° F to 158°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient service temperature -7° C to 50°C (20° F to 122°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise emission TBD < db(A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical:

Dimensions see dimensional layouts on following pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of heads/ hoses 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of hopper temperature zones 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of pumps 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston pump ratio 12:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear pump see options on page 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure styled, durable metal and high temp plastic, dust and splatter resistant. . . . . . . . . . . . . . . . .

Hose connections Electrical: universal 15-pin Amphenol connectors at asu,. . . . . . . . . . . . . . . . . . . . .

Mechanical: wrench-secured fluid fittings (#6 JIC)

Hopper (tank) capacity Model 05: 5 kg/ 11 lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 10: 10 kg/ 20 lb

Hopper construction cast-in heaters, TFE Teflon impregnated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filtration hopper bottom screen, manifold basket filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight, empty tbd kg/ tbd lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive form standard grades (non-water based only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical:

Power Supply Required 100-120 VAC/ 1p/ 50-60 Hz/ 15 Ampere. . . . . . . . . . . . . . . . . . . . . . . . . . .

or 200-240 VAC/ 1p/ 50-60 Hz/ 30 Ampere

Hopper heater type cast-in tubular. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power consumption, system maximum 100-120 VAC system: 1800 watts. . . . . . . . . . . . . . . . . . . . . .

200-240 VAC system: 6800 watts (w. piston pump)

200-240 VAC system: 7200 watts (w. gear pump)

Hopper Power 100-120 VAC system: 600 watts at 120 VAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200-240 VAC system: 1200 watts at 240 VAC

Temperature control microcontroller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensors 100 Ohm Platinum RTD standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear pump Motor 1/4 hp, constant speed, AC, direct drive, horizontal orientation. . . . . . . . . . . . . . . .

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20 -25

Pressurized Air:

Air pressure supply 1.4 to 6.8 bar (20 to 100 psig). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air consumption at 60 pump cycles per minute 90 normal liters/ minute. . . . . . . . . . . . . . . . . . . . . . .

(3.2 SCFM at 100 psig)

Performance:

Adhesive temperature control range 40°C to 218°C (100°F to 425°F). . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive temperature control accuracy ± 1°C (± 1°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Over-temperature cutoff for hopper 232°C (450°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive viscosity 500 to 50,000 centipoise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm-up time, full hopper approximately .5 hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive delivery rate, open line .91 kg/min (2 lb/min)(12:1 piston pump). . . . . . . . . . . . . . . . . . . . .

Adhesive melt rate (depends on adhesive used) 8 kg/hr (17.3 lb/hr). . . . . . . . . . . . . . . . . . . . . . . . . . .

Adhesive pressure up to 68 bar (1000 psi) maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum pump speed, piston pump 60 pump cycles per minute. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum pump speed, gear pump 87 revolutions per minute, 60 Hz, constant speed. . . . . . . . . . . . . .

73 revolutions per minute, 50 Hz, constant speed

Page 2 -3

Revised 1/05

Dynamini Temperature Control:

Controller board 1 printed circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display type long-life, light-emitting diode (LED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature control zones 5 triac-output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other:

Operator interface digital display with simplified, all-icon keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature offset no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor open error message yes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 2 -4
Revised 1/05

ITW Dynatec c. 2004

DYNAMINI ASU Manual #20 -25

A

F

A

DIMENSION A B C D E F G H

MODEL 05 (mm)
MODEL 05 (inches)

MODEL 10 (mm)
MODEL 10 (inches)

D

B

C
H

G

mounting holes*

289 527 540 238 451 635 249 381

11.38 20.75 21.25 9.37 17.75 25.0 9.8 15.0

289 527 540 238 654 838 249 381

11.38 20.75 21.25 9.37 25.75 33.0 9.8 15.0

E

* All Mounting holes are 10mm diameter .

DYNAMINI Installation Dimensions

ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25

Page 3-1

Revised 1/05

Chapter 3

INSTALLATION & START-UP

Mounting the DYNAMINI ASU

The DYNAMINI ASU can be mounted on most flat surfaces, on either an open or a solid frame (as
shown below). The main electrical power and the serial communication connections come in from
below the unit and connect under the keypad. Access to the underside of the ASU is not a necessary
consideration in mounting the unit.

The Dynamini’s hinged hopper lid may be rotated 90 degrees in any direction.
For installation dimensions, see illustration on page 2-4.

Lifting the ASU

Hopper Cover

WARNING

The unit must be lifted by two persons, using proper lifting technique, one
person at either end. Securely hold it under its base plate. No belts or hooks
should be used. Never allow anyone to stand on the ASU.

Hopper Lid

Access Cover

Pump & Electronics Cover

Pump ON/OFF

Switch

Main ON/OFF
Power Switch

Controller

Keypad

Captive Cover Screws

Base

Plate

Page 3-2
Revised 1/05

DYNAMINI ASU Manual #20-25

ITW Dynatec c. 2004

Installation

NOTE: Re-read Chapter 1 “Safety Precautions” before performing any installation procedures. All
installation procedures must be performed by qualified, trained technicians.

After the DYNAMINI ASU has been properly mounted, the following general sequence should be
followed for installation:

1. Make sure that incoming line power to the ASU is turned OFF at a customer-providedcircuit
breaker. Incoming line power must be overcurrent-protected.

DANGER HIGH VOLTAGE

Disconnect and lockout input power to the application system before start­ing any installation procedures. Make sure there is no electrical power on the
leads you will be connecting. THE UNIT’S MAIN SWITCH DOES NOT SHUT OFF
ALL POWER WITHIN UNIT!! Make sure incoming line power is turned off at the
customer-provided circuit breaker before opening unit.

2. For 200-240 VAC units, power supply wires should be rated for 30 Amperes service and
should include an earth ground conductor.

CAUTION: Grounding conductors never carry electrical current. The use of a
neutral conducting wire as earth ground is incorrect and may cause damage to
the equipment.

3. 100-120 VAC units are supplied with a line cord and a plug suitable for use in North America
on 15 AMP power supplies. For other types of 100-120 VAC power wiring, supply wires should
be rated for 1.5 Amp service and include an earth ground conductor.

4. Acceptable power supplies are either 100-120 VAC 1-Ph 50/60 Hz with a neutral wire, or
200-240 VAC 1-Ph 50/60 Hz with or without a neutral wire. The information plate on the ASU
(adhesive supply unit) will indicate the required power supply.

5. Power supply wires are to be connected to the removable plug at header X1 on the printed
circuit board,, as shown below.

Printed
Circuit
Board

X1

GROUND

L2/ N

L1

POWER IN

Supply Power Installation Diagram

ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25

6. Choose ASU Voltage:
Using the selection switch on the printed circuit board, set the controller for the appropriate
supply voltage.

Voltage Selection Switch:

“230” for 200-240VAC

or

“115” for 100-120VAC

Printed Circuit Board

7. Reassemble the pump and electronics cover to the ASU.

8. Gear Pump models: omit this step.
Piston Pump models: Install t he Air Control/ Filter Unit (containing the air regulator,the
coalescing filter and pre-filter). See illustration on page 3-5. The air control/ filter unit is
mounted directly to the ASU via a threaded hole on the rear cover. WrapTeflon tape around
the nipple fitting before installing in the ASU. The unit requires clean, dry air. NEVER use
lubricated oil.

Page 3-3

Revised 1/05

For operator convenience, the air pressure gauge can be mounted to either side of the air
control regulator.

Withthe air pressure regulator, a clockwise turn increases pressure. A counter-clockwise
turn decreases pressure. The recommended pressure is 1.4 to 6.8 bar (20 to 100 psi).

9. Refer to the WattageAvailability Chart on the next page to determine the hose and head

power available for the various configurations of the Dynamini ASU.

10. The adhesive hoses are connected at the rear cover (see illustration on page 3-5). Make
your electrical hose connections at the two numbered connects on the left side of the cover.
Route hoses so that there is at least an eight-inch radius at any bend. Do not hang hoses
without proper support. Do not crimp, clamp, squeeze or tie hoses.

The hose adhesive ports are located at the bottom of the filter block, to the right of the
electrical connections. There are three ports for the use of up to two hoses and for the
(optional) adhesive pressure gauge.When making hose connections, use the numbered
guides shown on the illustration to coordinate; ie. when using one hose make your hookup
to electrical connection #1 and adhesive port #1. When using two heads/ hoses, hookup
hose/ head #1 to electrical connection #1 and adhesive port #1, then hookup hose/ head #2
to electrical connection #2 and adhesive port #2.

Refer to the hose and applicator manuals for further details on these items.

11.Install the hose manifold outlet cover by sliding it into place and attaching with the two M4
screws provided.

Page 3-4
Revised 1/05

DYNAMINI ASU Manual #20-25

ITW Dynatec c. 2004

Wattage Availability Chart

Wattage Available for
All Hoses and Heads

ASU Voltage Max. System Hopper Gear Pump Piston Pump Gear Pump

Wattage Wattage Motor Wattage

100-120 VAC 1800 @ 120VAC 600 @ 120VAC 370 @120VAC 1200 @ 120VAC 830 @ 120VAC
200-240 VAC 7200 @ 240VAC 1200 @ 240VAC 370 @ 240VAC 6000 @ 240VAC 5630 @ 240VAC

Notes:

1. Assume 33 Watts per foot of hose, #6 hose at 120VAC or 240VAC.

2. Assume 100 Watts per inch of head width, at 120VAC or 240VAC.

3. The power available for any one hose or head is 720 Watts at 120VAC or 1440 Watts at 240VAC.

4. At reduced voltage, less wattage is available. For example: 120 volt equipment operated on 100
volts or 240 volt equipment on 200 volts, will develop wattage 31% lower than the wattage available
at 120 or 240 volts.

Adding Adhesive

WARNING HOT ADHESIVE

Do not overfill the hopper (melt tank) since adhesive generally expands as it
melts and a full hopper will overflow.

CAUTION: Using adhesive with viscosity over 50,000 centipoise could cause
motor stall and/ or pump failure.

The adhesive level should be maintained at 13mm to 100mm (1/2” to 4”) from the top of the hop­per. Where applications demand a high output volume of adhesive, add small amounts of adhesive
frequently. Adding large amounts of adhesive to an almost empty hopper will lower the temperature
of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint.

Changing the Adhesive Formula

If a different adhesive formulation from the one being currently used is needed, the system will
have to be flushed if the two formulations are incompatible. See page 6-3 of this manual for the
proper flushing procedure. When in doubt about adhesive compatibility, flush your system.

ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25

Pressurized Air In

1/4 NPT female

Air pressure gauge

Page 3-5

Revised 1/05

Air Pressure Regulator (clockwise increases)

Air Flow

Coalescing filter

Air Control/ Filter Unit

Maintain adhesive level 13mm-100mm (1/2”­4”) from top of hopper.

Pre-filter

Adjustable Pressure
Relief Valve

Air Control/ Filter Unit

Hose/ Head

Electrical Connections

120v 240v

Electrical #1

Electrical #2

Electrical #1

Electrical #2

Rear Cover: Hose and Head Electrical and Adhesive Connections

Output Filter Manifold

Adhesive Supply

Hose

Pressure Gauge (optional)

Hose/ Head Adhesive Ports

Adhesive Port Connections

#1

Gauge

#2

Page 3-6
Revised 1/05

DYNAMINI ASU Manual #20-25

ITW Dynatec c. 2004

Typical Start-Up and Shut Down of the DYNAMINI Application System

Start Up Procedures

1. Fill the ASU’shopper with clean hot-melt adhesive as described on page 3-4. Close the
hopper lid immediately to prevent contaminants from falling in. (Cover your bulk supply of
adhesive to prevent contaminants also.)

2. At the control panel, turn ON the Main Power Switch. The controller will perform its initial
calibration cycle. The display will read “CAL”. Each of the five temperature zone’s LEDs will
flash as a lamp test.

3. Program your adhesive setpoints (see instructions on page 5-2) or use the factory settings listed
below. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the
temperatures of the temperature zones to stabilize.
Note: When the ASU leaves the ITW Dynatec factory, it is programmed with the following
factory settings (unless special factory settings were requested):

Hopper: 150°C (300°F)
Hose: 177°C (350°F)
Applicator: 177°C (350°F)
Sequential Startup: ON

4. Once the ASU has reached temperature, turn ON the Pump ON/ OFF Switch. The ASU will
begin to pump adhesive.

5. a. On piston pump units: use the air pressure regulator, located at the rear of the ASU, to
regulate adhesive output.
b. On gear pump units: use the pressure relief valve, located on the filter outlet manifold, to
regulate adhesive output.

Shut Down Procedures

1. Turn OFF the Pump Switch.

2. Turn OFF the Main Power Switch.

ITW Dynatec c. 2004
DYNAMINI ASU Manual 20-25

Revised 1/05

Storage and Disposal of the DYNAMINI Application System

Temporary Storage of the Unit

1. Flush the adhesive application system with flushing fluid (PN L15653), following the
instructions detailed in chapter 6 of this manual.

2. Clean or replace both the output filter and the primary filter, following instructions detailed
in chapter 6.

3. Shut OFF all pressure and power sources.

4. Release residual air pressure.

5. Remove all residual adhesive and wipe components clean.

6. Remove all air lines and all power supply cables.

Page 3-7

7. Pack the unit in a corrosion-proof manner.

8. Store the unit in such a way that it is protected from damage.

Disposal of the Unit

1. Shut OFF all pressure and power sources.

2. Release residual air pressure.

3. Remove all residual adhesive.

4. Remove all air and adhesive supply hoses and all power supply cables.

5. Dismantle all components and sort into mechanical and electrical components.

6. Arrange for all components to be recycled.

Page 3-8
Revised 1/05

ITW Dynatec c. 2004

DYNAMINI ASU Manual #20-25

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

Page 4-1

Revised 11/04

Chapter 4

DYNAMINI TEMPERATURE CONTROLLER SET-UP

Temperature Control Functions in General

The Dynamini temperature controller provides accurate temperature control for the hopper, hoses
and applicators. Setpoints are programmed at the user-friendly,all-icon keypad. The controller will
display an error message any time an open or shorted sensor condition occurs.

Defining Dynamini Temperature Control Terms

Adhesive Temperature Control Range

The temperature limits within which the ASU, hoses and applicators may be programmed and main­tained.

Printed Circuit Board (PCB)

The Dynamini contains one pcb. It contains the central processing unit (CPU) of the microprocessor
temperature control as well as providing control signals to, and monitoring signals from, the hopper,
hoses and applicators. It features lighted LEDs to indicate that heater power is ON. The ASU’s fuses
are located on this board.

Dynamini Temperature Controller

The built-in control system that controls, monitors and displays all system temperature values of the
Dynamini adhesive application system.

Mechanical High-Temperature Protection

A mechanical, redundant thermostat located on the hopper that will turn off t he system above 232°C
(450°F).

RTD Sensors

The Dynamini system uses 100-ohm platinum resistance temperature detector sensors for all temper­ature controls.

Sequential Startup

This feature allows the temperature zones to come on in sequence (hopper,followed by hose, fol­lowed by head). When activated, and the ASU is turned ON from a cold start, the hopper heats first.
When the hopper is within the programmable tolerance of setpoint, the Head(s) and hose(s) begin to
heat. No other features of the ASU are affected by sequential startup.

Note: sequential startup is rarelyused. In most cases, it should be de-activated to ensure rapid warm
up.

Page 4-2
Revised 1/05

Setpoint

DYNAMINI ASU Manual #20-25

ITW Dynatec c. 2004

A programmable temperature that has been selected for hopper, hoses and applicators.

Setpoint Limitation

This is a universal maximum temperature for all zones (218°C [425°F]). The programmer cannot
program a temperature setpoint higher than the setpoint limitation.

Stepped Function

(Future feature, not on V2.0)
Used on systems with electric applicators only. After programming the temperature (to the softening
point of your adhesive, see your adhesive manufacturer), the controller holds all electric heads at
the operator-selected temperature for ten minutes before releasing them to operating setpoint. This
feature allows for the stabilization of the electric valves.

Error Indication Messages

A controller display of “EO1” indiates that the selected zone (ie, a hose, applicator or the hopper)
has an open sensor. A display of “EO2” indicates a shorted sensor.

If either alarm occurs, first verify that the following three connections are made correctly:

1. The ASU-to-hose connection(s) located at the back of the ASU,

2. The hose-to-applicator connection(s),

3. The RTD Input connections (X4) located on the Control Printed Circuit Board.

If the problem is not with a connection, check the sensor and replace if necessary.

Software Chip (EPROM) and Checksum

The software EPROM is on the Control Printed Circuit Board (see Ch. 7). Inscribed on the control­ler’s software chip is information that is required if your controller needs service, including the con­troller’schecksum.

Software chip example:

Part Number of
Control PCB

The date this Software EPROM was manufactured

102434 OEF8
Date: 12-7-04

Software chip (EPROM)

Checksum example

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

Settings for a Typical Operation

Note: The values given here are approximate settings for a typical packaging operation. The values
you choose will be based on the type of equipment and adhesive you are using and the nature of
your particular operation.

If Application Temperature is 163°C (325°F):

·

Hose and head temperature: 177°C (350°F).

·

Hopper setpoint temperature: 150°C (300°F).

·

ASU operating range: 135°C to 177°C (275°F to 350°F).

·

Mechanical thermostat (for the hopper) over-temperature: 232°C (450°F)

Page 4-3

Revised 11/04

System Values That Are Permanently Programmed

·

Minimum setpoint value: 40°C (100°F).

·

Maximum setpoint value: 218°C (425°F).

System Values as Programmed by the Factory

ITW Dynatec can set the controller’s system values to customer’s specs, if provided.
If customer’s specs are not provided, the following values will be entered into the Dynamini tem-

perture controller at the factory. They may be changed by reprogramming through the keypad.
(These are not the “default” settings, see following section).

·

Temperature scale: displayed in degrees Farenheit.

·

Applicator (head) and hose setpoints: 177°C (350°F).

·

Hopper setpoint: 150°C (300°F).

·

All zones are switched off, except for the hopper.

Page 4-4
Revised 1/05

Default Settings of the Controller

Default settings are the manufacturer’s preset values to which the system will return if the Dyna­mini tempearture control is subjected to an internal memory reset. While you can change your pro­grammed values to anything within the system’s limits, the default settings cannot be changed.

To cause an internal memory reset (ie, to restore the defaults) of a temperature zone, turn that tem­perature zone ON and then OFF.

Defaults

·

Temperature setpoint for each zone: 93°C (200°F).

·

Sequential Startup: SSO (OFF)

Helpful Tips for the User

DYNAMINI ASU Manual #20-25

ITW Dynatec c. 2004

·

When the ASU is turned on, all temperature setpoints and other operating parameters will

be exactly where they were when the ASU was turned off.

·

When the ASU is turned on, all system heaters go on unless they have previously been set
below 40°C (100°F).

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

PROGRAMMING INSTRUCTIONS FOR DYNAMINI CONTROLLER

Dynamini Keypad

Page 5-1

Revised 1/05

Chapter 5

Scroll Keys:

Pump Switch

O

Main Power Switch

O



Temperature

Display

Service Key

Hopper

Temperature

Zone

Temperature

Scale

1

1

22

to increase value to reduce value

I

I

Dynamini

Temperature Zones: Hose #1 Hose #2 Application Head #2 Application Head #1

Programming

Turn controller ON

O

I

Turn ON the main power switch.
System will go through its self-diagnostics (CAL).

Temperature zone LEDs will flash.

Controller will display “SS 1” (On) or “SS 0” (Off) to
indicate status of the Sequential Statup feature
(see info on “Sequential Startup” later in this chap­ter).

Controller will display it’s software version, ie.
V.2.XX

or

Page 5-2
Revised 1/05

Programming temperature setpoints

ITW Dynatec c. 2004

DYNAMINI ASU Manual #20-25

or

Choose a temperature zone.

or

Scroll to “increase value” or ”reduce value”,

or

in order to adjust the setpoint temperature.

After two seconds the display will read the
actual temperature. The setpoint is stored.

Turning temperature zones ON/OFF

or

Choose a temperature zone.

or

Scroll to “reduce value” until temperature
setpoint is 0. The temperature zone is now
turned OFF.

To turn ON the temperature zone, increase
the setpoint.

Error indication messages

The temperature sensor is open or has high resistance.

The temperature sensor is shorted or has low resistance.

ITW Dynatec c. 2004
DYNAMINI ASU Manual #20-25

Keypad Locking

Page 5-3

Revised 1/05

Itis possible to lockorunlock the controller inorderto restrict programming changes.Tochange the
code which is necessary to over-ride or unlock the keypad lock, see Service Functions.

Note: the ASU is shipped with de-activated keypad lock. If the keypad lock must be used, an access
code must be programmedprior to locking the keypad.

Locking or Unlocking the Keypad

Important Note: the controller must be in the Temperature Display mode in order to allow
locking or unlocking of the keypad.

Locking the Keypad

&

Unlocking the Keypad

&

or

Press the Down Scroll key, then hold and press the
Serviceiconkey.

You will see “Loc” to indicate that the Keypad Lock is
active.

Press the Down Scroll key, then hold and press the
Serviceiconkey.

You will see “Cod” to indicate that the access code is
required.

Enter your access code by scrolling up or down. Default
co de = “ -- -- -- ”.

Confirm your code input by pressing Tank key.

Notes:

1. Once the keypad lock is active, unauthorized programming is not possible, even after turning the
ASU OFF, then back ON again.

2.Once the keypad lockisunlocked,programming is possibleuntiltheASUis turnedOFF,then back
ON or the keypad is locked again.

3.Ifthekeypadmust be unlocked permanently,theaccesscodemust must be de-activatedin the Ser­vice Functions.