The D-90 Hot Melt Unit is a high-volume system designed for melting and pumping thermoplastic adhesives. It features precision electronic temperature control, a digital multi-zone temperature display, a variable-speed electric motor-driven gear pump, and adjustable pressure control.
Function Description:
The D-90 Hot Melt Unit serves as a central system for industrial adhesive applications. It melts thermoplastic adhesives and delivers them under pressure to applicators. The unit's design emphasizes precise temperature management across multiple heating zones (collector, grid, manifold, filter block, hoses, and guns) to minimize adhesive degradation and charring. The variable frequency drive (VFD) controls the AC gear motor, which in turn drives the positive displacement gear pump, allowing for adjustable adhesive flow and pressure. The system can accept encoder or tachometer inputs for variable speed applications, enabling integration with production lines for precise adhesive dispensing based on line speed.
Important Technical Specifications:
- Dimensions: 53 inches (1,346 mm) in height, 30 inches (762 mm) in width, and 41 inches (1,041 mm) in depth.
- Weight: Approximately 1050 lbs (maximum weight with all options installed and crate).
- Tank Capacity: 90 kg (200 lbs).
- Drop-In Grid: Standard.
- Melt Rate: 100 kg/hr (220 lb/hr).
- Gear Pump Rates:
- 0.7 lb/hr (0.3 kg/hr) - 41 lb/hr (19 kg/hr)
- 1.4 lb/hr (0.6 kg/hr) - 85 lb/hr (39 kg/hr)
- 3 lb/hr (1.3 kg/hr) - 170 lb/hr (77 kg/hr)
- 6 lb/hr (2.5 kg/hr) - 334 lb/hr (152 kg/hr)
(Pump rate based on a motor speed of 100 rpm and material with a specific gravity of 1.0.)
- Gear Pump Control: A.C. with line-tracking feature for variable speeds.
- Number of Pumps: 1-2.
- Number of Hoses/Guns: 1-6.
- Hose Fittings: #6 (3/8"), #8 (1/2"), #12 (3/4"), and #16 (1") options.
- Pressure Safety Relief: Manual relief with internal safety relief; optional pneumatic relief with manual relief (Uniflow 12V or 24V).
- Temperature Control: UTC-20 Microprocessor PID 16-Zone capable.
- Voltage: 380, 400, 440, 480, 575, 595 VAC, 3PH, 50/60 Hz.
- Level Sensors: Optional Low and High Level Sensors.
- Pressure Monitor: Optional.
- Applications: Profile Wrapping, Laminating, Book Binding.
Usage Features:
The D-90 unit is designed for user-friendly operation with a comprehensive control panel.
- Control Panel: Features a display screen for menus and events, dedicated keys for pump on/off, standby, clock on/off, and temperature menu access. Plus/minus and arrow keys allow for navigation and value adjustment. LEDs indicate system status (ready, warning, low adhesive level, heating zones).
- Power On/Off and Standby Mode: A main power disconnect switch controls system power. The standby button activates/deactivates heater circuits, with an orange LED indicating standby mode and a green LED for active operation. The internal clock continues to function in standby mode for scheduled operations.
- Display Adjustment: Contrast can be adjusted via front panel keys for fine-tuning or a pot on the CPU board for coarse adjustment. Screen position can also be adjusted.
- User Interface Navigation: Navigation symbols on the display indicate available menus, accessed via dedicated buttons. Editable information is highlighted, allowing for single-digit or thumbwheel editing.
- Password Levels: Multiple security levels (Operator, Advanced Operator, Supervisor, Protected) prevent unauthorized access to programming.
- Language and Temperature Units: Users can select the desired language and temperature units (°F or °C).
- Temperature Programming: Individual temperatures can be set for various heating zones (grid, collector, manifold, hoses, valves, tank inlet filter block).
- System/Pump Ready Temperature Offset: This feature ensures the pump motor is enabled only after all zones reach their setpoint temperature minus a defined offset (default 5°F/3°C), allowing adhesive to soften properly.
- Ready Delay Time: A programmable delay (1 to 120 minutes, default 30 minutes) after reaching ready temperature before the pump motor is enabled, prolonging pump seal life.
- Over/Under Temperature Alarms: Settings define temperature deviations that trigger alarms, with automatic heater shutdown for over-temperature conditions.
- Maximum Temperature: Sets the maximum allowable setpoint for any zone (default 390°F/199°C).
- Beacon/Alarm Setup: An optional two-light beacon (blue and red) indicates various conditions like pump on, system ready, zone faults, low level, or setback on.
- Automatic Pump Mode: When enabled, the pump automatically starts when the system reaches ready temperature, considering any ready delay time.
- Level Sensor Setup: Configures internal and external level sensors for automatic tank filling and programmable outputs.
- Filter Change Timer: A countdown timer (up to 2000 hours) for filter replacement, triggering an alarm when due.
- Clock and 7-Day Timer: Allows setting current day/time and programming up to three shifts with on, off, and setback times/temperatures for automatic operation.
- Diagnostics: Provides current software version, temperature, and status of each zone.
- Setback: Reduces zone temperatures by a differential (default 90°F/50°C) during inactivity to keep hot melt soft but not molten.
- Automatic Setback Timeout: Automatically initiates setback if no external input is received within a set period (1 to 120 minutes, default OFF).
- Startup Setup (Sequential Start): Allows hoses and valves to begin heating after the tank reaches a specified temperature offset, reducing adhesive degradation.
- History: Logs all faults and parameter changes.
- User Inputs and Outputs: Four configurable inputs and outputs for remote control of devices or system functions.
- Configuration: Sets the number of hose outlets, auxiliary I/O enablement, number of pumps, gramage enable, and RTD type.
- Pump Setup Menu: Configures speed gain (0-200%), creep speed, minimum speed, and maximum pump speed.
- Encoder Setup Menu: Sets pulses per revolution and circumference for encoder-based speed input.
- PID Setup Menu: Allows adjustment of PID settings for temperature control, with an AutoTune feature to optimize settings for each zone.
- Initialize Screen: Resets all control parameters to factory settings, initiating a setup wizard for reconfiguring the unit.
- Adjusting Pressure Control Valve: Manual adjustment of the adjustable pressure relief valve (factory set to 750 psi). The fixed pressure relief valve (1000 psi) should not be adjusted.
- Gramage Feature: For coating applications, automatically calculates pump speed to achieve desired coat weight, requiring input of pump displacement, adhesive density, speed reference, coating width, and desired coating weight.
Maintenance Features:
- General Maintenance: Regular cleaning of the exterior, immediate removal of adhesive spills, and inspection for damage.
- Cleaning the Exterior: Clean with a damp cloth and mild soap-and-water solution after turning off main power. Avoid hosing or steam-cleaning.
- Filter Replacement: Periodically clean or replace the tank inlet filter and manifold filter to prevent flow restriction. Requires turning off the pump, loosening the filter cap, removing the screen, cleaning/replacing, checking O-rings, and tightening the cap.
- Changing Adhesive: If adhesives are compatible, pump new adhesive through to clear old material. If incompatible, flush the system.
- Flushing the System: Use a purge material (compatible with system components) to flush the system when changing incompatible adhesives or after prolonged inactivity. Requires setting heating zones to purge material temperature and manually activating applicators to relieve pressure.
- Parts Replacement: Instructions for replacing components like the pump, motor, pressure relief valve, and beacon light bulb. Requires disconnecting power, relieving pressure, and using appropriate tools and safety gear.
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