Tank and Manifold. Part B, Section 3. This section covers the following unit configurations. Model B3EN-03-[3-TANK]-1

Transcription

1 Part B, Section 3 This section covers the following unit configurations. Model Voltage All Pump All Manifold All Control All

2 B 3-0

3 B 3-1 Section B 3 WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section describes how to disassemble and reassemble the tank and manifold. It also includes procedures for replacing the pressure relief valve, drain valve, and, if applicable, the circulation control valve, pressure control valve, or air-piloted pressure control valve. Refer to the following sections for additional information on the tank and manifold: Technical Data provides tank specifications, including the tank capacity, the tank volume, and the dimensions of the tank lid opening. Operation includes the procedure for filling the tank with adhesive. Maintenance includes procedures for flushing the tank and manifold and for draining adhesive from the tank. Control System includes procedures for replacing the tank resistance temperature detector (RTD) or thermostat. Parts includes illustrated parts lists for the melter and all major assemblies. Refer to this section for the part number of any component that needs to be replaced. 2. Overview of the Tank The tank holds a supply of adhesive and melts it before it is pumped to the hoses and guns. An RTD and overtemperature thermostat sense the tank temperature and provide input to the control system. The tank is heated by cast-in heating elements.

4 B Replacement Because the tank and manifold have no moving parts, you should not need to replace them. However, if you need to remove them from the melter for any reason, follow these procedures. Refer to the Parts section for the part numbers of any components that need to be replaced. You can use the parts list illustrations as a guide as you perform the following disassembly and reassembly procedures. To replace both the tank and the manifold, you must complete all of the following procedures: Preparing to Replace the Tank or Manifold Disassembling the Reassembling the Restoring the Melter to Normal Operation These instructions can also be used to replace just one part of the tank assembly. Preparing to Replace the Tank or Manifold Complete this procedure before you perform any tank repairs. 1. Heat the melter to operating temperature to aid disassembly and to prepare for draining as much adhesive as possible from the tank. 2. Drain the tank. For information about different ways to drain the tank, refer to Flushing the System in the Maintenance section. 3. Piston pump and MPC melters: Turn the pump air pressure regulator to 0; then disconnect the air regulator from the melter. 4. Remove the pump from the melter. Refer to the Pump section for the pump removal procedure. 5. Turn off the melter; disconnect and lock out electrical power to the melter at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring.

5 B 3-3 Disassembling the Tank and Manifold Follow this procedure to remove the tank and manifold and to disassemble them. 1. If you have not already done so, complete Preparing to Replace the Tank or Manifold. 2. Remove the melter s front and back panels. To do so, you will need to remove the electrical enclosure lid loosen some of the tank lid screws disconnect any ground wires 3. See Figure B 3-1. Remove the tank lid assembly Fig. B 3-1 Removing the Tank Lid Assembly 4. Piston pump and MPC melters: See Figure B 3-2. Remove the screws (2) that hold the air-line adapter (3) to the hose-end panel (1) Fig. B 3-2 Removing the Air Line Adapter Screws 1. Hose-end panel 3. Air-line adapter 2. Screws

6 B 3-4 Disassembling the Tank and Manifold (contd.) 5. Remove the screws on the bottom of the hose-end panel. Swing the panel and wire harness away from the melter. 6. If the melter is attached to a support platform, remove any anchoring bolts. 7. See Figure B 3-3. Remove the RTD, thermostat, and ground wire (if present) from the tank. Î Î ÎÎ Î ÎÎÎÎ ÎÎ ÏÏÏÏ ÎÏÏÏ ÎÎ A Fig. B 3-3 Removing an RTD and Thermostat (typical) 1. RTD 2. Retainer plate 8. Tilt the melter back at an angle to gain access to the base and remove the screws and washers that attach the manifold to the base. Return the melter to the level position. NOTE: Ask an assistant to help you tilt the melter and support it while you remove the screws and washers. 9. Pull the tank and manifold away from the melter. The spacers between the manifold and the base may come loose at this time. If they do not, remove them by hand. 10. Disconnect the tank heater wires. 11. Carefully remove all insulation. 12. Separate the tank cover and gasket from the tank. 13. Remove the tank strainer from inside the tank.

7 B Remove the screws and washers that secure the manifold to the tank; then separate the manifold from the tank. 15. Remove the two O-rings from the grooves in the manifold and discard them. You should replace the O-rings any time the manifold is separated from the tank. Refer to the Parts section for the O-ring part number. Reassembling the Tank and Manifold Follow this procedure to reassemble the tank and manifold and to reinstall them on the melter. 1. Turn the tank upside down and place it on a flat surface. 2. See Figure B 3-4. Lubricate two new O-rings with O-ring lubricant and place the O-rings in their grooves on the manifold. Fig. B 3-4 Installing New O-rings A 3. Turn the manifold upside down and align it correctly on the tank. NOTE: If the O-rings are lubricated, they will stay in the grooves when you turn the manifold upside down.

8 B 3-6 Reassembling the Tank and Manifold (contd.) 4. Insert the manifold washers and screws in the bottom of the manifold and tighten them finger tight only. Then tighten the screws in the sequence shown in Figure B 3-5. Tighten the screws to N m (4 5 ft-lb) A Fig. B 3-5 Correct Sequence for Tightening Manifold Screws 5. Turn the tank and manifold over so that the tank s open side is up and wrap the insulation around the tank and manifold. Use high-temperature duct tape to secure the insulation. 6. Reconnect the heater wires to the tank heater connections. 7. Hold the spacers in place and attach the tank and manifold to the base of the melter with the screws and washers removed earlier. It may be necessary to tilt the melter to gain access to the bottom of the base. Tighten the screws to N m (8 10 ft-lb). NOTE: Be sure you do not pinch the heater wires when you are securing the tank and manifold to the base. NOTE: To ease assembly, you can cut the heads off of four M8 screws that are longer than the spacers (do not use the screws supplied with the service kit). Loosely thread the cut screws into the tapped holes in the bottom of the manifold. Slip the spacers over the screws. This will keep the spacers in line until you are ready to install the supplied screws. When you are ready to install the supplied screws, remove the cut screws. Ask an assistant to help you tilt the melter and support it while you replace the screws and washers.

9 B Apply thermal compound to the RTD and thermostat and install them on the side of the tank. Make sure the RTD retainer plate is installed as shown in Figure B Reconnect the ground wire (if present) to the tank. 10. If the melter was attached to a support platform, anchor it to the platform now. 11. Lay the tank strainer in the bottom of the tank. 12. Install a new tank gasket and secure the tank cover to the tank. NOTE: You should replace the tank gasket any time the tank cover is separated from the tank. 13. Swing the wire harness and hose-end panel into position and secure the hose-end panel with the screws you removed earlier. 14. Make sure the air-line adapter is securely inserted in the recessed area on the inside of the hose-end panel. Secure the adapter with the screws you removed earlier. 15. Install the pump air pressure regulator and connect the incoming air line to the regulator. 16. Install the tank lid assembly using the screws you removed earlier. 17. Install the melter s front and back panels. Restoring the Melter to Normal Operation Follow this procedure to reinstall the pump and restore the melter to normal operation. 1. Install the pump. Refer to the Pump section for pump installation procedures. 2. Install and secure the pump cover and, if applicable, the drive cover. 3. Piston pump and MPC melters: Return the pump air pressure to the normal operating setting. 4. Remove the lock-out and restore power to the melter.

10 B Valve Replacement Procedures Use these procedures to replace the pressure relief valve, drain valve, or other manifold valves as applicable. Replacing the Pressure Relief Valve Follow this procedure to replace the pressure relief valve. The pressure relief valve is installed in the bottom of the tank. 1. Drain as much adhesive from the tank as possible. Refer to Cleaning the System in the Maintenance section for different ways to drain the tank. 2. See Figure B 3-6. Use a socket wrench to loosen the pressure relief valve; then carefully unscrew the valve and remove it. 3. Screw the new valve into the tank until it is finger-tight. 4. Use a socket wrench to tighten the valve. Tighten to N m (10 12 ft-lb). 5. Refill the tank with adhesive and resume normal operation. 1 2 Fig. B 3-6 Replacing the Pressure Control Valve (typical) 1. Pressure control valve 2. Tank

11 B 3-9 Replacing the Drain Valve Follow this procedure to replace the drain valve. Your melter may have one or two drain valves. A standard manifold filter has one drain valve, and a reverse-flush manifold filter has two drain valves. Refer to the manifold parts list illustration in the Parts section as necessary as you perform this procedure. 1. Make sure the melter is at operating temperature. 2. Relieve hydraulic pressure. Refer to Relieving Hydraulic Pressure in the Maintenance section. 3. See Figure B 3-7. Remove the drain valve alignment screw (1) and washer (2); then remove the valve (3) from the melter. Some adhesive will flow from the valve. 4. Screw the new drain valve into the manifold until it is secure; then adjust it as necessary to install and tighten the alignment screw and washer. 5. Resume normal operation Fig. B 3-7 Drain Valve Components 1. Alignment screw 2. Washer 3. Drain valve

12 B 3-10 Replacing Other Manifold Valves Depending on the configuration of your melter, the manifold may include a circulation control valve, pressure control valve, or air-piloted pressure control valve. Follow this procedure to replace any of these valves. Refer to the manifold parts list illustration in the Parts section as necessary as you perform this procedure. 1. Make sure the melter is at operating temperature. 2. Turn off the melter; disconnect and lock out electrical power to the melter at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 3. Relieve hydraulic pressure. Refer to Relieving Hydraulic Pressure in the Maintenance section. 4. If applicable, shut off and lock out the air supply to the melter. 5. Air-piloted pressure control valve: Disconnect the air line from the air-piloted pressure control valve. 6. See Figure B 3-8. Unscrew the valve (1, 2, or 3) from the manifold. Some adhesive will flow from the manifold when the valve is removed. 7. Install the new valve and a new O-ring. The O-ring must be replaced any time the valve is removed. 8. Restore air and power to the melter and resume normal operation A Fig. B 3-8 Replacing Other Manifold Valves 1. Circulation control valve 3. Air-piloted pressure control 2. Pressure control valve valve