Nordson Sapphire Adhesive Applicator User Manual

Nordson Sapphire Adhesive Applicator

Description

Figure 3 shows the front view of a typical Sapphire driver

1. Power LED
2. Status LEDs

Figure 4 shows the bottom view of a typical Sapphire driver.

1. Trigger ports
2. Output ports
3. Power input
4. Power switch

Information on the Sapphire Applicator

Refer to Figure 5 for the locations of the following information:

• Serial Numbers
• Part Numbers
• Power Information

1. Power information
2. Module part number/serial number
3. Applicator part number/serial number

Cordset

Refer to Figure 6. Manifold cordsets are available in T-style versions and are replaceable. Module cordsets include an M16-type connector and are not replaceable.

Temperature Control
All Sapphire applicators use 120‐ohm nickel resistance temperature detectors (RTDs) for precise temperature sensing and for applicator temperature control to within +0.5°C (1.0°F) of a setpoint temperature.

Intended Use
Sapphire applicators are specifically designed for industrial applications that require the deposition of a precisely controlled bead of hot melt material onto a moving substrate. The applicators are designed to be rigidly mounted. Sapphire applicators are designed for use with Nordson melters and hoses.

Auxiliary Devices and Spare Parts
Sapphire applicators should only be connected to approved auxiliary devices. Use only new Nordson replacement parts or approved factory-refurbished parts.

Installation

Applicators are installed using the following process:

• Unpack and inspect
• Mount
• Connect the hose
• Flush
• Install nozzles

Items Needed

To ensure a smooth installation, have the following items on hand:

• Personal protective equipment for working with hot adhesive
• Product manuals for associated equipment (melter, hose, etc.)
• Mounting equipment, such as a mounting rod, is appropriate for the parent machine
• Automatic applicator hose
• Flat‐blade and Phillips‐head screwdrivers
• Drain pans and waste containers suitable for waste adhesive
• 13 mm open‐end wrench
• 11/16″ open‐end wrench (x2)
• M3 hex wrench
• M4 hex wrench
• M5 hex wrench

Applicator Installation Guidelines

Use the following installation guidelines for optimum applicator performance.

Unpacking and Inspecting the Applicator

1. Carefully unpack the applicator.
2. Inspect the applicator. Applicators are shipped fully assembled except for the nozzle. The nozzle is sold separately. Refer to Using the Illustrated Parts Lists for the nozzle parts list.
3. Inventory the contents of the ship‐with kit. It includes the following components:

• 90° hose connector
• 45° hose connector

Mounting the Applicator

The configuration of your equipment and production line may require a variation in the mounting options described in this section. Regardless of the mounting method used, please follow these guidelines:

• Mount the applicator such that the nozzle will be as close as possible to the substrate, but at a distance that works best for your application. Typically, the minimum distance is two times the diameter of the nozzle orifice.
• Ensure that the mounting location provides sufficient clearance around the rear or sides of the applicator to allow for removal of the manifold covers.
• Mount the applicator on a rigid support that is isolated from external vibrations and that prevents the applicator from rotating.
• Insulate the applicator from the support using the insulator provided with the applicator.

1. Refer to Figure 7. Remove the clamp assembly from the applicator using an M5 hex wrench.
2. Attach the clamp assembly to the mounting bar. Tighten using an M3 hex wrench.
3. Connect the applicator to the clamp. Tighten using an M5 hex wrench.
4. Position the applicator by loosening the top screw with an M3 hex wrench, moving it into the desired position, and then re-tightening the screw.

Hydraulic Connections

• Use only one fitting to connect a hose‐to‐a‐hose connector on the applicator.
• Insulate hose‐to‐applicator joints. Insulating cuffs may be ordered separately.
• Refer to Using the Illustrated Parts Lists for more information.

Connecting the Hose

1. Refer to Figure 8. Connect the hydraulic hose to the applicator using two 11/16″ wrenches.
2. Connect the applicator cordset to the hose or extension cable.

Unpacking and Inspecting the Driver

1. Carefully unpack the driver.
2. Inspect the driver. Drivers are shipped fully assembled.
3. Inventory the contents of the ship‐with kit. It includes the following components:

• Power connection terminal block
• DIN rail clip and screws
• M16 field wireable trigger signal connector(s)

Mounting the Driver

There are two ways to mount the Sapphire driver:

• On a DIN rail strip
• Using a Through-Hole mount

Mounting the Driver on a DIN Rail Strip

1. Refer to Figure 10. Turn the driver upside down on a clean, flat surface.
2. Attach the DIN rail clip to the back of the driver with the screws using a M3 hex wrench.

1. Sapphire driver
2. M4 screws (x2)
3. DIN rail mount

Mounting the Driver using a Through-Hole Mount

1. Refer to Figure 12. Mount the driver using the mounting hole pattern shown below.
2. Open the lid on the driver box to access the through holes, and then install the screws

Connect the Field Wiring to the Sapphire Driver

The steps to wiring the Sapphire driver are as follow

• Connecting the power supply
• Connecting the trigger signal
• Connecting the applicator

Connecting the Power Supply

1. Refer to Figure 13. Wire the three‐pin terminal block connector using a 12-18 AWG wire and a small flat head screwdriver.
2. Connect the three-pin terminal box connector to the driver
3. Secure with two screws using the flat head screwdriver.

Connecting the Trigger Signal

1. Refer to Figure 14. Wire the M16 signal trigger connector by disassembling the back shell from the connector and wiring it as shown below.
   1. Trigger signal
   2. Not used
   3. Trigger signal return
2. Remove the back shell.
3. Loosen the clamp.
4. Insert the cable connector wire.
5. Reassemble the connector.

Connecting to the Applicator

1. Connect the female end of the interconnection cable to the M16 circular DIN connector on the Sapphire driver.
2. Route the cable to the driver.
3. Connect the interconnection cable to the module cordset on the applicator

Flushing the Applicator

The applicator must be flushed of foreign material before it is placed into operation

1. Start the melter and heat the system to the operating temperature and pressure required for the adhesive being used. Refer to the melter product manual and the instructions provided with the adhesive as needed.
2. Place a drain pan under the applicator.
3. Remove the nozzle(s) from the applicator. Refer to the nozzle removal procedures under Cleaning Nozzles later in this manual as needed.
4. Purge the applicator by manually triggering the Purge feature on the pattern controller.
5. Stop dispensing when the adhesive flow is clear and free of foreign material.
6. Check for leaks between the applicator, hose, and melter.
7. Install the applicator nozzle by threading it onto the module by hand and then using a torque wrench to tighten the nozzle to no more than 4.5Nm (40 in.‐lb). Do not over-tighten.

Operational Theory

The Sapphire applicator dispenses adhesive when the module receives a signal from the Sapphire driver. This signal is initiated by a 5‐30 VDC input trigger signal to the driver. When the driver receives a 5‐30 VDC input trigger signal, it generates a specific waveform output that is sent to the applicator. The applicator then converts the signal into
electromechanical movement to lift the needle and begin dispensing. When the trigger signal is removed from the driver, the driver ramps the output signal down according to a specific waveform, resulting in closure of the module and the end of the dispense cycle. The output signal of the driver can range from 0.6 ms to infinitely open. Refer to Figure 15 for a graphical representation.

Operational Envelope

The Sapphire applicator is capable of cycle speeds up to approximately 1600 Hz (0.4ms open/0.2ms close). This capability and the maximum average number of dots per second are influenced by setpoint and environmental temperatures. Refer to the chart below.

Sapphire Controller LEDs Operation

The Sapphire applicator driver has seven LEDs that indicate product status. The LED in the upper-left corner indicates the power status. The six LEDs in the lower-left corner are channel pairs: the three left LEDs are for applicator 1 and the three right LEDs are for applicator 2.

1. Power LED
2. Trigger LEDs
3. Applicator LEDs
4. Fault LEDs

LED Sequence Test
The LEDs automatically perform a sequence test when the Sapphire driver is turned on to indicate whether each LED is functioning properly. All the LEDs go off, and then each LED comes back on one at a time. After the test, the LEDs resume normal operation.

Power LED
The LED in the top-left corner of the Sapphire driver is the power LED. It is on whenever the software is running properly.

Trigger LEDs
The top two LEDs in the lower-left corner are the trigger LEDs. They indicate when a trigger input has been detected. These LEDs come on when a trigger is active and go off when the trigger is inactive. The trigger is considered inactive at 0‐2 volts and active at 5‐30 volts.

Applicator LEDs
The middle two LEDs are the applicator LEDs. They indicate when a driver signal has been sent to the Sapphire driver board and a signal is sent to the applicator. These LEDs come on when an applicator is active and go off then the applicator is inactive.

Fault LEDs
The fault LED are the bottom two LEDS in the bottom‐left corner of the Sapphire driver. Whenever there is a problem, they send out a specific number of flashes followed by a period of no flashes to indicate a specific error code. Refer to Troubleshooting Table for Sapphire Drivers for more information.

Maintenance

Table 3 provides the recommended schedule for applicator maintenance. Detailed procedures for weekly and semi‐annual maintenance tasks are provided in the remainder of this section.

Cleaning Nozzles

Applicator nozzles may become clogged when char, a by‐product of overheating the hot melt, becomes lodged in the nozzle.

To clean the nozzle, follow these steps:

1. Heat the applicator to operating temperature.
2. Disable the applicator. Refer to Safety.
3. Remove the nozzle. Refer to Table 4.
4. Soak the nozzle in Nordson Type R cleaning fluid that has been heated above the melting point of the adhesive, to a maximum of 177 C (350F).
5. Remove the nozzle from the cleaning fluid.

Replacing the Filter

To replace the filter, follow these steps:

1. Relieve system pressure. Refer to Safety.
2. Trigger the applicator momentarily.
3. Disconnect and lock out power.
4. Refer to Figure 19. Unscrew the Saturn integrated applicator filter with a M4 hex wrench, and then remove the filter.
5. Insert a new Saturn integrated applicator filter, and then tighten it using a M4 hex wrench.
6. Restore the system to normal operation.

Troubleshooting

Troubleshooting Table for Sapphire Applicators

The following table lists the applicator problems that are most likely to occur, the possible causes of each problem, and steps for corrective action. Where applicable, cross‐references are made to expanded diagnostic procedures(DPs) provided later in this section or to other sections of this manual.

Troubleshooting Table for Sapphire Drivers

Specifications

FOR MORE MANUALS BY NORDSON, VISIT MANUALSLIBRARYY

Nordson Sapphire Adhesive Applicator-FAQs