ITW Dynatec OPERATIONS & SERVICE MANUAL #40-44

An Illinois Tool Works Company Revised 12/66

31 Volunteer Drive
Hendersonville, TN 37075 USA
Telephone 615.824.3634
FAX 615.264.5222

Adhesive Application Solutions · ISO 9001 Certified

OPERATIONS AND SERVICE MANUAL

BF MICRO ADHESIVE APPLICATOR

with MICRO OPTIMA MODULE
HOT MELT ADHESIVE APPLICATOR

IMPORTANT ! - 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
 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

SAFETY INSTRUCTIONS

GENERAL CONSIDERATIONS SERVICING EQUIPMENT

1. Read and follow these instructions. 1. Only trained personnel are to operate and
Failure to do this could result in severe service this equipment.
personal injury or death.
2. Never service or clean equipment while it
2. Additional safety instructions and/ or is in motion.
symbols are located throughout this
manual. They serve to warn maintenance Shut off the equipment and lock out all
personnel and operators about potentially input power at the source before
hazardous situations. attempting any maintenance.

3. Inspect the machine for unsafe conditions 3. Follow the maintenance and service
daily and replace all worn or defective instructions in the manual.
parts.
SIGNS
4. Keep work area uncluttered and well lit.
1. Read and obey all of the warning labels,
5. All covers and guards must be in place signs and caution statements on the
before operating this equipment. equipment.

2. Do not remove or deface any of the

For precautions and definitions of safety warning labels, signs and caution
symbols, refer to the Safety Chapter of the statements on the equipment.
service manual.
3. Replace any warning labels, signs and
caution statements which have been
removed or defaced. Replacements are
available from ITW Dynatec.

ADDITIONAL CONSIDERATIONS

1. To ensure proper operation of the

equipment, use specified electrical and/ or
air supply sources.

2. Do not attempt to alter the design of the

equipment unless written approval is
received from ITW Dynatec.

3. Keep all manuals readily accessible at all

times and refer to it often for the best
performance from your equipment.
ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002 Page iii
BF MICRO APPLICATOR Manual #40-44 Revised 6/03

TABLE OF CONTENTS

Chapter - Page #

Chapter 1 Safety Precautions

Chapter 2 Description & Specifications

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Chapter 3 Installation & Start Up

Handling and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4 Maintenence

Maintenence Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adhesive Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Replacement of the Built-in Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Module Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Chapter 5 Troubleshooting & Service

In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Replacement of the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Testing Resistance of Heater Cartridge or Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Replacement of the Heater Cartridge or RTD Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Re-Assembly Procedures and General Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Chapter 6 Component Illustrations & Bills of Material

Model Designation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Bill of Materials: Micro Module Service Body Assemblies (120v & 240v) . . . . . . . . . . . . . . . . . . 6-2
Component Illustration: Micro Module Service Body Assemblies (120v & 240v) . . . . . . . . . . . . . 6-3

Chapter 7 Ordering Guides

Optima Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Optima Module Dummy (Blank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Service Block Assembly Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Chapter 8 Engineering Drawings & Schematics

DynaControl/ Dynamini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Upgradei . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Appendix Air Control FIlter Coalescing Kit for Applicator Heads

Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pneumatic Drawing for Head Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Illustration & Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Page iv ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44
ITW Dynatec c. 1997 Page 1-1
ALL MODELS Revised 1/07

Chapter 1
SAFETY PRECAUTIONS

All operators and service personnel must read All maintenance and service on this equip-
and understand this manual before operating ment must be performed by trained techni-
or servicing equipment. cians.

Electrical

power is on. Disconnect, lockout and tag external

DANGER electrical power before removing protective panels.

A secure connection to a reliable earth ground is

HIGH VOLTAGE essential for safe operation.

A disconnect switch with lockout capability must be

Dangerous voltages exist at several points in this provided in the line ahead of the unit. Wiring used to
equipment. To avoid personal injury, do not touch supply electrical power should be installed by a
exposed connections and components while input qualified electrician.

High Temperatures

Severe burns can occur if unprotected skin comes in

WARNING contact with molten adhesive or hot application system
parts.
HOT
Safety glasses, gloves and long- sleeved clothing must
SURFACE be worn whenever working with or around adhesive
application systems.

High Pressure

IMPORTANT NOTE: Even when a system’s pressure

WARNING gauge reads “0” psig, residual pressure and trapped air
can remain within it causing hot adhesive and pressure
HIGH PRESSURE to escape without warning when a filter cap or a hose
or hydraulic connection is loosened or removed. For
PRESENT this reason, always wear eye protection and protective
clothing.
To avoid personal injury, do not operate the equipment Either of the two High Pressure symbols shown may be
without all covers, panels and safety guards properly used on equipment.
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.
Page 1-2 ITW Dynatec c. 1997
Revised 3/97 ALL MODELS

Protective Covers

Keep all guards in place!

WARNING To avoid personal injury, do not operate the application
DO NOT OPERATE system without all covers, panels and safety guards
properly installed.
WITHOUT GUARDS
IN PLACE

Eye Protection & Protective Clothing

Wear safety glasses with side shields which conform to

WARNING ANSI Z87.1 or EN166.

EYE PROTECTION Failure to wear safety glasses could result in severe eye
injury.
REQUIRED
It is important to protect yourself from potential burns
when working around hot melt adhesive equipment.
PROTECTIVE
CLOTHING Wear protective gloves and long-sleeved, protective
REQUIRED clothing to prevent burns that could result from contact
with hot material or hot components.

Always wear steel-reinforced safety shoes.

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 clogging and pump damage.
are routed to avoid kinking, tight radius turns (8” or
less) and abrasive contact. Hot-melt hoses should not When adhesive hand-held applicators or other movable
have prolonged contact with heat-absorbing surfaces applicators are used, never point them at yourself or at
such as cold floors or metal troughs. These any other person. Never leave a hand-held applicator’s
heat-absorbing surfaces can alter adhesive flow and trigger unlocked when not actually in use.
cause incorrect calibration. Hoses should never be
covered with materials that prevent heat dissipation, Do not operate the hopper or other system components
such as insulation or sheathing. without adhesive for more than 15 minutes if the
temperature is 150 degrees C (300 degrees F) or more.
Read this manual before applying electrical power to To do so will cause charring of the residual adhesive.
the equipment. Equipment may be damaged by
incorrect electrical connections. Never activate the heads, hand-held applicators and/ or
other application devices until the adhesive’s
Do not use adhesive that is dirty or that may be temperature is within the operating range. Severe
chemically contaminated. Doing so can cause system damage could result to internal parts and seals.

Treatment for Burns From Hot Melt Adhesives

Burns caused by hot melt adhesive must be treated solidify, they present a unique hazard.
at a burn center. Even when first solidified, they are still hot and can
cause severe burns. When working near a hot melt
Care should be used when working with hot melt application system, always wear safety gloves, safety
adhesives in the molten state. Because they rapidly glasses and long-sleeved, protective clothing.
ITW Dynatec c. 1997 Page 1-3
ALL MODELS Revised 1/07

Call a physician and/or an emergency medical

Always have first-aid information and supplies technician immediately.
available.

Service
Refer all servicing to qualified personnel only.

Explosion/ Fire Hazard

Never operate this unit in an explosive environment. of cleaning compounds vary according to their com-
position, so consult with your supplier to determine the
Use cleaning compounds recommended by ITW maximum heating temperatures and safety precautions.
Dynatec or your adhesive supplier only. Flash points

Lockout/ Tagout
Follow OSHA 1910.147 (Lockout/ Tagout Regulation) Even after the equipment has been locked out, there
for equipment’s lockout procedures and other impor- may be stored energy in the application system, partic-
tant lockout/ tagout guidelines. ularly in the capacitors within the panel box. To ensure
that all stored energy is relieved, wait at least one min-
Be familiar with all lockout sources on the equipment. ute before servicing electrical capacitors.

Use of PUR (Polyurethane) Adhesives

PUR adhesives emit fumes (MDI and TDI) that can be CAUTION: Because of the nature of PUR
dangerous to anyone exposed to them. These fumes adhesives to strongly bond in the presence
cannot be detected by the sense of smell. ITW Dynatec of moisture, care must be taken to prevent
strongly recommends that an exhaust hood or system them from curing inside Dynatec equipment. If PUR
be installed over any PUR system. adhesive solidifies in a unit, the unit must be replaced.
Always purge old PUR adhesive from the system per
Consult with your adhesive manufacturer for specifics your adhesive manufacturer’s instructions and time-
about required ventilation. table. ALLOWING PUR ADHESIVE TO CURE IN A
UNIT VOIDS ITW DYNATEC’S WARRANTY.

In This Manual
WARNINGS and CAUTIONS are found throughout instructions may cause injury to personnel.
this manual.
CAUTIONS mean that failure to observe the specific
WARNINGS mean that failure to observe the specific instructions may damage the equipment.
Page 1-4 ITW Dynatec c. 1997
Revised 3/97 ALL MODELS

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002 Page 2-1
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Chapter 2
DESCRIPTION AND SPECIFICATIONS
Description

ITW Dynatec’s BF Micro Applicator is an air-operated, single-nozzle hot melt adhesive applicator
assembly with an integrated filter cartridge which prevents particulate matter from obstructing flow
through the head. It is used with intermittent pressure and constant pressure hot melt adhesive sup-
ply units (ASUs).

Each applicator features one Micro Optima module mounted to a single service block. The module
is “optimized” (self-cleaning). It’s nozzle is integrated into the module, making it maintenance free.
The Micro Optima module is designed for high speed/ high pressure (above 400 psi) applications
where a sharp cutoff is necessary.

The module is opened and closed by air pressure. The rate of adhesive flow from the applicator is
determined by the adhesive pressure applied by the ASU’s pump, the size of the nozzle orifice and
the characteristics of the adhesive.

The applicator is heated by replaceable cartridge heating elements which are controlled by an inte-
grated RTD sensor and electronic control.

As seen in the illustration below, a module is mounted onto a service block. A piston inside the
module is pneumatically triggered by a solenoid air valve, which allows adhesive to flow through a
valve within the module.

The heated adhesive supply hose may be connected at the rear of the service block or at the top. A
variety of optional 45 and 90 degree
fittings allows positioning flexibility. Air Inlets
Adhesive flows from the hose into Electrical
and through the channels within the Connection
block to the module. Air pressure
opens the adhesive module, allowing
adhesive to flow through the nozzle
when the valve is open. Supply
Hose
Inlet
Operating air connections, from the
solenoid valve, and electrical connect- Micro
ions are made at the top of the service Optima Service
Module
block. Block

Piston
The applicator is configured for ITW
Filter
Dynatec’s DynaControl or Dynamini Cap
controller. Both 120 and 240 volt
configurations are available. The
applicator is water-tight for wash- Nozzle
Pressure Relief
down service. Pressure Plug Filter
Relief Port
 Page 2-2 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

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)

Physical:
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See dimensional layout on following page
Weight (with module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.58 kg (1.3 lb.)
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated clamp-mount for 1/2” (12 to 13 mm) rod
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anodized aluminum with stainless steel screws

Performance:
Temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38°C to 218°C (100°F to 425°F)
Warm-up time . . . . . . . . . . . . . . . . . . . . 15 minutes for cold start/ 1 minute for module change only
Cycle rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5000 cycles/ minute maximum
Adhesive pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 bar maximum (1000 psi maximum)

Air Requirements:
Air pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 9.5 bar (70 to 140 psi)

Electrical:
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC or 240 VAC/ 1ph/ 50-60 Hz
Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC: 125 watts
or 240 VAC: 125 watts

CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
ITW Dynatec c. 2002 Page 2-3
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Dimensions

B A

73.5mm
2.89”

84mm
3.31”
22mm
106.3mm .87”
4.16”
12.5mm
.49”
Page 2-4 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002 Page 3-1
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Chapter 3
INSTALLATION & START UP

Note: Re-read Chapter 1 “Safety Precautions” before performing any installation or start-up proce-
dures. All installation and start-up procedures must be performed by qualified, trained technicians.

Handling and Shipping

BF Micro applicator head assemblies are packaged within protective cushioning material in a fiber
packing carton. This package may be shipped inside another carton along with other individual
boxes containing components of the system.

Service Requirements

The applicator assembly consists of a service block assembly and a micro-module assembly.

Incoming electrical power and temperature control is supplied through the flexible cable exiting the
adhesive supply hose cuff. The applicator has a circular, plastic connector which mates with the
connector attached to this cable.

Incoming (operating) air is supplied through a solenoid valve (not supplied). It must be clean and
unlubricated. It is controlled by a four-way solenoid valve and should be separately regulated and
maintained at a pressure between 4.8 to 9.5 bar (70 to 140 psi). Air lines from the solenoid valve
should be 6.4mm (1/4 inch). Head air inlet ports are 1/8 NPT. The air outlet ports on the solenoid air
valve are marked “A” or “1” (open/ ON) and “B” or “2” (closed/ OFF).

Installation Instructions

The ITW Dynatec applicator’s service block has been tested at the factory and is ready for installa-
tion and operation. BF Micro applicators require a 4-way solenoid valve for each applicator. The
modular applicator has an very high speed capability. To take advantage of this, the solenoid air
valve should be located as close to the applicator as possible to keep applicator air lines short.
(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 ap-
plicators (see the Air Control Filter Coalescing Kit Manual in the appendix of this manual).

Applicator control solenoid valves may be controlled by timers or limit switches which sense the
position of the package or object to which adhesive is being applied. Switches should be mounted
on moveable brackets to provide adjustment for proper location of adhesive application.

cont.
Page 3-2 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

Electrical Connection
Air Inlet Port

To Timer or Limit Switch

Muffler

Purge Button B A Solenoid

(not supplied)

Air-to-open
Air-to-close
air line
air line

Adhesive Supply Hose

Adhesive Inlet

Micro Optima Module

Nozzle Pressure relief bleed valve

Pressure Relief Port

Installation Diagram

See the diagram above for location of the components referred to in the following section.

1. The applicator should be supported from brackets that permit lateral and vertical adjustments.
Mount the applicator on a 12mm to 13mm (1/2 inch) rod or bracketry using the clamp provided.
Allow access to the filter. Be sure that the module’s “weep” holes are visible for periodic
inspection.

2. 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 male fitting on the service block. When
tightening the hose fitting, hold the hose cuff to prevent the hose core from rotating.

3. Make the electrical connection from the hose to the applicator by connecting the female
connector of the hose to the male connector of the applicator.

cont.
ITW Dynatec c. 2002 Page 3-3
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

4. When connecting the air lines to the applicator, the air line which has air pressure to the
module when the 4-way solenoid is OFF is the closing air line (marked “B” or “2” on the
solenoid air valve). This line connects to the ”close” air fitting on the applicator. The other air
line is connected to the “open” air port on the air valve. The “A” (or “1”) air line has pressure
when the solenoid is ON (open). This line can be checked by loosening the air line after the
system has been pressurized. The air line closest to the module is always the closed/ OFF line.

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 be installed
between the standard air regulator/ filter and the applicator.

5. It is advisable to check the temperature of the applicator. This can be done through 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 (1 minute for module change) before
reading temperature.

6. Purge the applicator of air and test fluid. Turn the applicator ON electrically and pneumatically.
Allow adhesive and applicator to warm up.

WARNING HIGH PRESSURE

During the purging procedure, hot adhesive and fluid can come out of the head
under high pressure. Wear safety glasses, gloves and protective clothing.

WARNING
Use a stable, deep container to collect hot-melt adhesive and/ or fluid.

Place a heat resistant container under the module to collect the material that drains from the
applicator. Manually open the solenoid air valve 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 fluid have drained and only adhesive flows from the module.

7. Orient the nozzle tip so it points toward the substrate.

Page 3-4 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002 Page 4-1
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Chapter 4
MAINTENENCE

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

The BF Micro Applicator requires no regular maintenance. Wipe the applicator clean of adhesive
with a clean cloth while still hot at the end of each shift. Inspect the applicator periodically as out-
lined in the following table.

Maintenence Schedule

ITEM CHECK FREQUENCY ACTION

Adhesive supply hose Inspect for leaks As required Tighten if loose

fitting connection

Air supply connections Inspect for leaks As required Tighten if loose

Module weep holes Inspect for adhesive As required Replace module

Nozzle performance Inspect all nozzles As required Replace module

for proper operation

Built-in filter Inspect for Monthly or Replace filter

cleanliness as required element
by use
Page 4-2 ITW Dynatec c. 2002
Revised 9/07 BF MICRO APPLICATOR Manual #40-44

Adhesive Pressure Relief

WARNING HIGH PRESSURE

During this procedure, hot adhesive can come out of the applicator under high
pressure. Wear safety glasses, gloves and protective clothing.

The applicator should be at operating temperature. Turn the ASU’s pump/ motor OFF.

1. Place a heat-resistant container under the module. Back View

2. With a 5mm hex key (allen wrench), slowly loosen the

screw recessed under the service body (do not try to
remove it). Stand clear since there may be residual adhesive
pressure in the applicator.

Replacement of the Built-in Filter

Observe the warning and conditions for “Adhesive Pressure

Relief”, see above.

The applicator should be at operating temperature. Turn the Pressure Relief Pressure Relief
ASU’s pump/ motor OFF. Port Plug Screw

1. Relieve adhesive pressure as described above.

2. Remove the filter cap with an open wrench and

remove (and discard) the old filter element. At the
base of a new filter element, install an o-ring
(PN N00179). Insert the new filter element into
the filter cap.

3. Re-install the filter cap slowly, taking care to

seat the cap o-ring without pinching it.
CAUTION: Apply a coat of anti-seize com-
pound onto the threads of the filter cap Filter
before re-installing it.
Filter Cap
Module Maintenance

Refer to the Optima Module’s User Manual for details on its care.

Observe the warning and conditions for “Adhesive Pressure Relief” (see above) before removing or
working on modules.
ITW Dynatec c. 2002 Page 5-1
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Chapter 5
TROUBLESHOOTING & SERVICE

Note: Re-read Chapter 1 Safety Precautions” before performing any troubleshooting or repair proce-
durs. All troubleshooting or repair procedures must be performed by qualified, trained technicians.

In General

If failure occurs, first check all the electrical and pneumatic connections. Verify that the main
power switch is ON at the ASU. Verify that the pump is ON and the application heads have sufficient
air pressure. Verify that the temperature controller is in operation and that the setpoints are correct for
the application. Check to see if all components are heating properly.

Troubleshooting Guide

Problem Possible Cause Solution

Module does not open 1. Temperature adjustment 1. Check temperature adjustment.

of head is too low.

2. Inoperative solenoid valve. 2. Push the solenoid’s manual button.

If it opens, the problem is electrical.

No adhesive flowing 1. Filter element is dirty. 1. Replace filter, see instructions in

out of module Ch. 4 Maintenence.

2. Module seals (o-rings) 2. Replace module.

are inoperative.

3. ASU’s hopper is empty. 3. Re-fill hopper.

4. Adhesive is too cold. 4. Adjust temperature, see ASU manual.

Hot melt is coming out 1. Module seals are dam- 1. Replace module, see instructions in this
of the module’s “weep” aged. chapter.
holes

cont.
Page 5-2 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

Problem Possible Cause Solution

Applicator does not 1. Hopper temperature set- 1. Change setpoint, see ASU manual.
reach operating point is too low.
temperature
2. Inoperative heater 2. Check/ replace heater cartridge, see
cartridge. instructions in this chapter.

3. Inoperative temperature 3. Check/ replace sensor, see instruc-

sensor. tions in this chapter.

Applicator is too hot 1. Applicator temperature 1. Change setpoint, see ASU manual.
setpoint is too high.

2. Inoperative temperature 2. Check/ replace sensor, see instruc-

sensor. tions in this chapter.

Air escapes from 1. Piston seal failure. 1. Replace module.

module
2. O-rings located between 2. Remove module from block (see
module and service block instructions in this chapter: “Re-
are out of position or placement of Module”) and replace
damaged. o-rings.

Application pattern is 1. Adhesive pressure is too 1. a. For units without speed control:
erratic low. increase adhesive pressure at ASU.

b. For units with speed control (tach

follower): adjust pump speed control.

2. Adjust pattern controller. 2. See pattern controller manual for

proper adjustment.
ITW Dynatec c. 2002 Page 5-3
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Replacement of the Module

Turn the ASU OFF. Turn all adhesive and air pressure OFF.

WARNING HIGH PRESSURE

During this procedure, hot adhesive can come out of the applicator under high
pressure. Wear safety glasses, gloves and protective clothing.

1. Place a heat-resistant container under the manifold.

2. With a 5mm hex key (allen wrench), slowly loosen loosen the screw recessed under the service
body (do not try to remove it). Allow the adhesive to flow out of applicator. Be sure to stand
clear since there may be residual adhesive pressure in the applicator.

3. Verify that there is no internal pressure.

4. Remove the module from the service block by removing the two 4mm socket head cap screws
on the front of the module with a 3mm hex key screwdriver (allen wrench). Make sure that the
three old o-rings located on the back of the module are also removed (the new module will
include three new o-rings).

5. Mount the new module using a 3mm hex key on the socket head cap screws.

Testing of Heater Cartridge or Temperature Sensor

1. Turn the ASU OFF and make sure all adhesive air pressure and the pump are turned OFF.

2. Unplug the electrical cable from the adhesive supply hose to expose the pins in the cable.

Note: Pin connectors and pinout numbers vary depending on the control scheme of the applicator.
See Chapter 8 for a pinout diagram.

Testing Resistance of the Heater Cartridge

a. The resistance value (Ohms) of the applicator’s 125 watt heater cartridge is 122.9-106.2 Ohms
(120v) or 492.1-425.0 Ohms (240v).

b. For DynaControl or Dynamini: With an ohmmeter, contact pins 7 and 8 and measure heater
resistance.

c. A heater cartridge that tests outside of the above noted range must be replaced. Replacement
instructions follow in this chapter.
Page 5-4 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

Testing Resistance of the RTD Temperature Sensor

a. The resistance value (Ohms) of your temperature sensor depends on the temperature of the
sensor at the time it is being tested. At 25°C (77°F), the resistance of a PT 100 (Platinum)
sensor should be 110 Ohms.

b. For DynaControl/Dynamini: With an ohmmeter, contact pins 5 and 6 and measure sensor
resistance.

c. A tolerance range of ± 10% is allowed. A sensor that tests outside of this range must be
replaced. Replacement instructions follow in this chapter.

Replacement of Heater Cartridge or Sensor

RTD Sensor

Heater Cartridge
Ground Wire

Pin Connector*

Set
Screw
RTD Sensor

Ground Wire Ground Wire

& Screw & Screw
Heater
Cartridge
(in a verticle port)

2 Set Screws
RTD Sensor
Heater/ RTD Sensor Replacement Diagram (directly behind heater in this view)
ITW Dynatec c. 2002 Page 5-5
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

1. Disconnect power to the ASU and make sure all adhesive air pressure and pumps are turned OFF.

2. Loosen the two screws in the cable anchor and withdraw anchor from the service block body.

3. Disconnect the ground wire screw.

4. Remove the two set screws in the bottom of the back of the service body. Note: It may be
necessary to apply heat in order to break the thread sealant.

5. Pull the cable assembly out of the service block.

6. Loosen the set screw in the cable anchor and remove the cable assembly from the anchor.

Re-assembly
1. Re-assemble the cable assembly to the cable anchor. Re-attach the ground wire to the
service block body. Insert the heater and sensor into their respective holes in the service block
body and carefully insert the anchor and cable assembly into the body.

2. Tighten the two cable anchor screws.

3. Re-assemble and tighten the two set screws in the back of the service body. If a water-tight seal is
desired, re-apply thread sealant (Loctite 242 or equal) to the set screws.

Re-Assembly Procedures and General Cautions

Unless noted, head re-assembly is simply the reverse sequence of the disassembly procedures. How-
ever, the following “cautions” should be followed (whenever they apply) for proper re-assembly:
CAUTION: In general, all O-RINGS AND SEALS must be replaced whenever
hot-melt equipment is re-assembled. All new o-rings must be lubricated with
o-ring lube (PN N07588).

CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the
pump air supply and on the outlet filter manifold. Apply thread sealant (PN
N02892) whenever tapered pipe threaded parts are re-assembled.

CAUTION: SOME FITTINGS used for adhesive on hot melt equipment have
straight threads and o-ring seals. Use of thread sealant is not necessary with
these parts, but the o-ring seals should be clean and lubricated. Tighten
straight-threaded parts and fittings until their shoulders are firmly seated.
Excessive torque may damage straight-threaded parts and the use of power
wrenches is not recommended.

CAUTION: HOT-MELT RESIDUE must be cleaned from parts before they are
re-assembled, particularly from threaded parts. As a precaution against adhesive
residue preventing proper re-assembly, threaded parts must always be
re-tightened at operating temperature.
Page 5-6 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44
ITW Dynatec c. 2002 Page 6-1
BF MICRO APPLICATOR Manual #40-44 Revised 8/02

Chapter 6
COMPONENT ILLUSTRATIONS & BILLS OF MATERIAL

WARNING
All parts must be periodically inspected and replaced if worn or broken. Failure
to do this can affect equipment’s operation and can result in personal injury.

The following pages provide exploded-view reference drawings to assist users of the applicator to
identify parts and aid in servicing the equipment.

BF Micro Applicator Model Designation Guide

BFXXXX X XXXX
0 2 21 M 1D1S
BF Micro Applicator Z 2N 2
Options:
3 S = Standard (water-resistant)
Service Block Length/ # of Modules: 4 Applicator Voltage:
0221 = 22mm/ 1 module
1 = 120 AC
5 2 = 240 AC
6
Module Type Control Scheme:
M = Micro Optima 7 D = DynaControl
Z = No Module P = Dynapro or Dynaplus
8 M = MTC or CompuVision
E = ETCRO
9 N = Upgrade
0

Module Size/ ref. #:

1 = 7020/ #1
2 = 7021/ #2
3 = 7022/ #3
4 = 7023/ #4
5 = 7024/ #5
6 = 7025/ #6
7 = 7026/ #7
8 = 7027/ #8
9 = 7028/ #9
0 = 7029/ #10
Page 6-2 ITW Dynatec c. 2002
Revised 4/05 BF MICRO APPLICATOR Manual #40-44

BF Micro Applicator Service Block Assemblies: 109740 (120V) &109741 (240v)

110066 (240v Ni120)

Item No. Part Number Description Qty.

1 109954 Service Body Assembly, With Pressure Relief Plug 1
2 109700 Insulator, Mount 1
3 N00175 O-ring,-008, Viton 4
4 109701 Base, Mount, Micro Head 1
5 109745 M4 x 0.7 x 20mm, SHC Screw, SST 4
6 N00093 Fitting, Straight Male Adapter, 1/8 NPT x .25T, Brass 2
7 109702 Clamp, Mount, Micro Head 1
8 106853 M6 x 1 x 25mm SHC Screw, SST 2
9 109707 Anchor, Cable, Micro Head 1
10 N00182 O-ring, -015, 75 Duro Viton 1
11 109742 Cable Assembly,120vac (Service Block Assembly 109740) 1
109708 Cable Assembly, 240vac (Service Block Assembly 109741) 1
110065 Cable Assembly, 240vac (Service Block Assembly 110066) 1
12 106857 M3 x 0.5 x 5mm Flat Point Set Screw, SST 1
13 103405 Screw, SHC, M3 x 0.5 x 6mm, Black Oxide 1
14 108362 Lock Washer, External Tooth, M3 1
15 109747 M3 x 0.5 x 14mm, SHC Screw, SST 2
16 109746 M4 x 0.7 x 4mm, Flatpoint Set Screw, SST 2
17 106374 Adhesive/ sealant, Loctite 242
18 109710 Fitting, Male Adapter, #6 SAE 37° x #4 ST Thd ORS 1
19 N01702 O-ring, -904, 75 Duro Viton 1
20 111987 Filter Assembly, Applicator, 200 mesh 1
21 109840 Filter Cap, Micro Head 1
22 110182 Label, Info, Micro Head 1
23 109883 Label, Warning, Micro Head 1
24 109748 M2.5 x 0.45 x 6mm SST Socket Flat Head Screw 2
108700 Lube, TFE (Not Shown)
Anti-Seize Compound (Not Shown)
25 L13533 Tube, Aluminum, .25 OD x .035 wall x 8.0, Lg. 2
26 N02028 CAPLUG, Red Poly, T-1-X 2
27 N02212 CAPLUG, Red Poly, T-6 1
100978 Tag, QAC (Not Shown) 1
103053 Tag Oil Free (Not Shown) 1
28 Optima Micro Module (See Ordering Guide) 1
29 N00175 O-ring, -008 (shown for ref. only) 3
30 109706 O-ring,-15mm x 1,8mm 1

Bill of Materials
ITW Dynatec c. 2002 Page 6-3
BF MICRO APPLICATOR Manual #40-44 Revised 3/05

26

23

25

8 22
24

Assembled Front View

7

4
13

15 14

11

2 9
3

28 10 12
29
15

27

17 16 19
18
20
30

21
1

BF Micro Applicator Service Block Assemblies: 109740 (120V) & 109741 (240v)
Page 6-4 ITW Dynatec c. 2002
Revised 6/03 BF MICRO APPLICATOR Manual #40-44

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

ITW Dynatec c. 2002 Page 7-1
BF MICRO APPLICATOR Manual #40-44 Revised 12/06

Chapter 7
ORDERING GUIDES

Micro Optima Modules

Modules are listed in order of increasing adhesive flow. The diameter of the module orifice is not
shown because this is not the only flow control variable incorporated into module design. For assis-
tance in module selsection, contact your ITW Dynatec representation or visit our website at

Module Part Number Reference #

7020 No. 1
7021 No. 2
7022 No. 3
7023 No. 4
7024 No. 5
7025 No. 6
7026 No. 7
7027 No. 8
7028 No. 9
7029 No. 10

Filters

The standard filter for the Micro Optima is the 200 mesh filter.

Module Part Number Filter Filter Part Number Filter 10-pack

7020 200 mesh 111987 CF6001

7021 200 mesh 111987 CF6001
7022 200 mesh 111987 CF6001
7023 200 mesh 111987 CF6001
7024 100 mesh 109711 CF6002
7025 100 mesh 109711 CF6002
7026 100 mesh 109711 CF6002
7027 100 mesh 109711 CF6002
7028 100 mesh 109711 CF6002
7029 50 mesh n.a. CF6004

Filter Assembly PN Filter

109711 100 mesh

111987 200 mesh
Page 7-2 ITW Dynatec c. 2002
Revised 5/07 BF MICRO APPLICATOR Manual #40-44

Repair Kits
TBD

Optional Solenoids
PN 113314 kit for Festo, 24v solenoid is offered with standard fittings, tubing and cable for one- or
two-port Micro applicators. The Festo solenoid is more compact than conventional MAC solenoids.

PN 113682 kit for Festo, 24v solenoid is offered with standard fittings, tubing and cable for DY
2002-8 and DPC2 timers. The Festo solenoid is more compact than conventional MAC solenoids.

PN 113350 Festo, 24v, four-way solenoid only. This valve is contained in both of the above kits.

Service Block Assembly Recommended Service Parts List

Part Number Description Qty. per Service Block

N00175 O-ring, -008 14

N00182 O-ring, -019 1
N01702 O-ring, -904 1
108700 TFE Lube, 0.25 oz. 1
see list on pg. 7-1 Filter 2
Heaters and RTD Sensors are located in the Cable Assemblies, choose one of the following:
109742 or Cable Assembly, 120v 1
109708 or Cable Assembly, 240v (Pt100) 1
110065 Cable Assembly, 240v (Ni120) 1
ITW Dynatec c. 2002 Page 8-1
BF MICRO OPTIMA APPLICATOR Manual #40-44 Revised 6/03

Chapter 8
ENGINEERING DRAWINGS & SCHEMATICS

Pin Connectors & Electrical Schematics

Note: Pin connectors are viewed from the exposed end. Pins not shown on schematics are not used.

DynaControl/Dynamini Uses PN N07958 RTD Sensor, Pt100

5 7
6 4 Heater 8
7 3
5
8 2 RTD Sensor 6
1
Ground 9

Upgrade Uses PN N07864 RTD Sensor, Ni120

Heater
1 3
RTD Sensor
2 4 5
Ground
Page 8-2 ITW Dynatec c. 2002
Revised 8/02 BF MICRO APPLICATOR Manual #40-44

ITW Dynatec
An Illinois Tool Works Company

Adhesive Application Solutions

 Dynatec PN 100055
Page 1 of 2 pages

Appendix PN 100055 Air Control Filter Coalescing Kit

for Applicator Heads

ITW Dynatec applicator heads require compressed air for needle actuation. Air Control Filter Coas-
lescing Kits (PN 100055) are available to provide filter regulators, tubing and fittings for one or
more applicator heads.

In addition to the kit, a solenoid valve with voltage that matches the output voltage of the electrical
control device must be selected for the application. Use the following chart to select an appropriate
solenoid valve:

Part No. Voltage Application

100054 24 VDC Single-port head

100383 24 VDC Multi-port head
100421 120 VAC Single or multi-port head
100422 240 VAC Single or multi-port head

Air Control Filter Coalescing Kit Installation Notes

1) Compressed air for applicator head operation should be clean, dry and oil free.

2) Operation of more than two applicator heads by one kit may require additional lines, tee-
fittings and solenoid valves not supplied in one kit.

3) To provide identical operation of more than one head, air line circuits from solenoid valves
to heads should be the same length and contain similar fittings.

4) To minimize applicator response time, minimize length of the air line circuits from the
solenoid valve(s).

Pneumatic Drawing for Head Air Control

OFF
ON
3 2

5 1 4

} Electrical Signal for

Head Control

c. ITW Dynatec 1994 Issued 1/96

All Rights Reserved Supersedes 8/95
Dynatec PN 100055
Page 2 of 2 pages

Component Illustration: PN 100055 Air Control Filter Coalescing Kit

2
Air Lines to Head are to be
cut 3.5 - 4.0 inches long

1
8 7

1
6

to additional solenoid
valve assemblies

Item No. Part Number Description Qty.

1 N06438 Nylon Tubing, .250 Dia. 10 ’

2 N00318 Cable Tie, .09 x 3.62 Lg 10
3 100380 Filter Assembly 1
4 Solenoid Valve Assembly 1
5 N04264 Cable Tie Anchor 3
6 N06504 Push-in Union Tee Fitting 1
7 N06430 Male Connect Fitting 3
8 N04531 1/4 Treet T, Brass 1

Issued 2/00 c. ITW Dynatec 1994

Supersedes 3/97 All Rights Reserved