Nordson 3400 User manual

E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Part B, Section 2
Pump
This section covers the following unit configurations.
Model 3400
3500
3700
3860
3890
3960
Voltage 1, 2
Pump DC Gear (O, R, S, T, U, or W)
Manifold 4-Port (J or F)
6-Port (K, L, O, or P)
2-Port (R or U)
Control MultiScan (3)

Pump
B 2-0
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5

Pump B 2-1
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Section B 2
Pump
WARNING: Allow only qualified personnel to perform the
following tasks. Follow the safety instructions in this document
and all other related documentation.
This section includes troubleshooting procedures for adhesive application
problems and pump troubleshooting procedures and repair procedures.
Refer to the Parts section for the part number of any pump component
that needs to be replaced. If you try all the suggestions in this section
and still cannot solve the problem, call your Nordson representative for
assistance.
Refer to the Control System section for troubleshooting procedures and
repair procedures for the melter’s control system, including the
key-to-line (KTL) and motor and pressure control (MPC) features. For
hose or gun troubleshooting, refer to your hose or gun manual.
The following sections of this manual contain additional information on
the hydraulic system:
STechnical Data includes pump specifications.
SMaintenance includes a procedure for checking the pump motor
speed reducer.
STank and Manifold includes procedures for replacing the tank,
manifold, drain valve, pressure relief valve, circulation control
valve, and pressure control valve.
If your melter has any of the following options, refer to the Options
section at the end of this manual for additional troubleshooting, repair,
and parts information:
SInput/output (I/O) board
SLow-level switch
SElectric line filter
SPressure dump
1. Introduction

Pump
B 2-2
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
These troubleshooting tables describe the kinds of adhesive application
and pump-operation problems you may encounter and provide corrective
actions for handling those problems. When necessary, the tables refer to
more detailed diagnostic procedures. Refer to the appropriate
troubleshooting table for the type of problem you are experiencing:
SAdhesive Not Applying Properly
SPump or Motor Not Working
Problem Possible Cause Corrective Action
1. Little or no adhesive output Melter not at operating temperature Wait for the time delay to expire and
the SYSTEM READY light to turn on.
Adhesive level too low Keep the tank at least half full of
adhesive. Refer to Adhesive Filling in
the Operation section.
Adhesive too cold Check the tank, hose, or gun
operating temperature setpoints and
adjust them as necessary.
Motor speed and/or pressure control
dials not properly set Set the motor speed and/or pressure control dials to the normal operating
setting.
Clogged manifold filter Clean the manifold filter. Refer to
Cleaning a Manifold Filter in the
Maintenance section.
Blockage in manifold Check for blockage. Refer to
Manifold Blockage Check.
Circulation control valve or pressure
control valve not properly set or
clogged
Check the circulation control or
pressure control valve. Refer to
system flushing procedure for DC
gear pump systems in the Installation
section to set up the valve.
Cold hose-to-melter or hose-to-gun
joints Insulate the joints.
Guns not operating properly Refer to the gun manual to
troubleshoot gun problems.
Manifold heat exchanger blocked Check manifold heat exchanger for
blockage. Clean if necessary.
2. Troubleshooting Tables
Adhesive Not Applying
Properly

Pump B 2-3
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Problem Possible Cause Corrective Action
2. Wavy beads Adhesive too cold Check the tank, hose, or gun
temperature setpoints and adjust
them as necessary.
Ambient temperature below freezing
or guns subject to draft Protect the melter and guns from freezing temperature conditions and
drafts.
Nozzles too far from product Position the guns so the nozzles are
no more than 13 mm (0.5 in.) from
the product.
3. Excessive adhesive at
beginning of bead Nozzles too far from product Position the guns so the nozzles are no more than 13 mm (0.5 in.) from
the product.
Nozzles partially clogged Clean the nozzles. Refer to the
nozzle cleaning procedure in the gun
manual.
4. Adhesive stringing Nozzle too far from product Position the guns so the nozzles are
no more than 13 mm (0.5 in.) from
the product.
Adhesive too viscous Change to a compatible
lower-viscosity adhesive.
Adhesive too cold Check the tank, hose, or gun
operating temperature setpoints and
adjust them as necessary.
Adhesive old Do not exceed the recommended pot
life of the adhesive.
5. Concentric circles in bead Adhesive too hot Check the tank, hose, or gun
operating temperature setpoints and
adjust them as necessary.
Adhesive not viscous enough Change to a compatible
higher-viscosity adhesive.
6. Adhesive bouncing or
splashing from product Adhesive too hot Check the tank, hose, or gun operating temperature setpoints and
adjust them as necessary.
Adhesive not viscous enough Change to a compatible
higher-viscosity adhesive.
Nozzle orifice too large for
application Change to a nozzle with a smaller orifice.
Too much hydraulic pressure Decrease hydraulic pressure.
Continued on next page

Pump
B 2-4
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Problem Possible Cause Corrective Action
7. Adhesive not penetrating
product Adhesive too cold Check the tank, hose, or gun operating temperature setpoints and
adjust them as necessary.
Special coating on product Increase operating temperature
setpoints slightly or change
adhesives.
Not enough adhesive being applied Change to a higher-flow nozzle,
increase operating temperature
setpoints slightly, or increase
hydraulic pressure.
Adhesive too viscous Change to a compatible
lower-viscosity adhesive.
8. Air or moisture in bead Adhesive level too low Keep the tank at least half full of
adhesive. Refer to Adhesive Filling in
the Operation section.
Adhesive too viscous Change to a compatible
lower-viscosity adhesive.
Product wet Preheat the product.
9. Adhesive gelling Changing to an adhesive
incompatible with the previous
adhesive without first cleaning the
system
Clean the system. Refer to Cleaning
the System in the Maintenance
section.
Flushing Type-R cleaning fluid
through a system that was using
polyamide, surlyn, polyester, or
some other high-performance
adhesive
Clean the system. Refer to Cleaning
the System in the Maintenance
section. If the gelled adhesive cannot
be pumped out, replace the
tank/manifold assembly, hoses,
and/or guns.
Adhesive heated for too long Clean the system. Refer to Cleaning
the System in the Maintenance
section. Do not exceed the
recommended adhesive pot life.
Adhesive overheated Clean the system. Refer to Cleaning
the System in the Maintenance
section. Decrease the operating
temperature setpoints.
Adhesive Not Applying
Properly (contd)

Pump B 2-5
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Problem Corrective ActionPossible Cause
10. Adhesive drooling from gun Guns not applying adhesive properly Refer to the gun manual to
troubleshoot gun problems.
11. Cartons popping open Adhesive not cooling fast enough Decrease hydraulic pressure to
decrease the bead size. Decrease
the operating temperature setpoints
slightly. Reduce the line speed
through the compression section.
Increase the distance between the
nozzles and the product. Increase
the distance between bead
application and bead compression.
Increase the length of the
compression section. Cool the
product. Use a lower-flow nozzle.
Use a stitched bead pattern.
Adhesive open time too long Change to an adhesive with a shorter
open time.
Adhesive cooling too fast Increase the hydraulic pressure to
increase the bead size. Increase the
operating temperature setpoints
slightly. Decrease the distance
between the nozzles and the product.
Decrease the distance between bead
application and bead compression.
Heat the adhesive. Use a higher-flow
nozzle. Avoid stitched bead patterns.
Protect the gun or bead from cold air.
Adhesive deposit shearing Check for twisting or other adverse
movement during the compression
section.
12. Adhesive fuming or
smoking Adhesive in tank too hot Check the tank operating temperature setpoint and adjust it as necessary.
Unstable adhesive Keep the lid closed when the melter
is operating. Change to a more
stable adhesive.
Continued on next page

Pump
B 2-6
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Problem Possible Cause Corrective Action
13. Adhesive charring in tank Adhesive in tank too hot Check the tank operating temperature
setpoint and adjust it as necessary.
Tank overheating Refer to the troubleshooting tables in
the Control System section.
Adhesive level too low Keep the tank at least half full of
adhesive. Refer to Adhesive Filling in
the Operation section.
Adhesive oxidizing in tank Keep the lid closed when the melter
is operating. Change to a more
stable adhesive. Switch to a melter
with a nitrogen blanket.
14. Bead size does not change
when line speed changes
(KTL and MPC only)
Air pressure to melter too low Increase the air pressure. The
recommended range is
5.5–6.9 bar (80–100 psi).
Adhesive output exceeding adhesive
melt rate Adjust the tank, hose, or gun temperature settings.
Adhesive level too low Keep the tank at least half full of
adhesive. Refer to Adhesive Filling in
the Operation section.
Nozzles clogged Clean the nozzles. Refer to the
nozzle cleaning procedure in your
gun manual.
Adhesive Not Applying
Properly (contd)

Pump B 2-7
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
WARNING: Risk of electrical shock. Failure to observe
electrical safety procedures may result in equipment damage,
personal injury, or death. Allow only qualified personnel to
perform electrical troubleshooting. Observe all high voltage
indicators.
Problem Possible Cause Corrective Action
1. Pump not turning but motor
running Misaligned, damaged, or loose chain or damaged or worn sprockets Check the motor chain and sprockets. Refer to Motor Chain and Sprocket
Check.
2. Motor fails to start Melter not at operating temperature Wait for the time delay to expire and
the SYSTEM READY light to turn on.
Motor speed control dial set at 0 Change the setting.
Blown fuse Remove the electrical enclosure lid
and check the input power neon on
the motor control interface board. If
the neon is off, replace the fuses.
Failed motor control interface board Measure the input voltage to the
motor control board at J2-6 and J2-8
on the motor control interface board.
If you do not measure line voltage,
replace the motor control interface
board.
Failed motor drive board Measure the voltage at the motor
drive board A+ (red wire no. 31) and
A- (black wire no. 31) wires. If the
voltage is less than 10 VDC, replace
the motor drive board.
Continued on next page
Pump or Motor Not Working

Pump
B 2-8
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Problem Possible Cause Corrective Action
2. Motor fails to start (contd.) Loose wire nut connections Disconnect and lock out electrical
power to the melter. Remove the
cover on the bottom of the motor and
inspect the wire nuts connections.
Tighten any loose connections.
Failed ribbon cable on motor control
board Disconnect ribbon cable no. 31 (red and black) from the motor control
board and check the continuity. If
there is no continuity, replace the
ribbon cable. If there is continuity,
replace the motor. Refer to Checking
a Ribbon Cable in the Control System
section.
Melters with I/O board: Failed
I/O board Check the status of the motor stop input. If the status is not okay,
change the I/O board input.
Failed ribbon cable between motor
control board and motor control
interface boards
Check the continuity of the ribbon
cables between the motor control
interface boards and the motor
control board. If there is no
continuity, replace the ribbon cable.
Failed motor control board or motor
control interface boards Disconnect the ribbon cable from a motor control interface board and
measure the voltage on the ribbon
cable between positions 16 and 10. If
the voltage is 1.0–2.0 VDC, replace
the motor control interface board. If
the voltage is outside 1.0–2.0 VDC,
replace the motor control board.
Pump or Motor Not Working
(contd)

Pump B 2-9
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Use these procedures as directed by the troubleshooting tables to further
troubleshoot pump-operation problems.
Motor Chain and Sprocket Check
1. Remove the drive cover.
2. Check the chain and sprocket:
SChain misaligned or sprocket worn: realign the chain or replace
the sprocket.
SChain and sprocket okay: continue to the next step.
3. Disassemble the chain by taking out the removable chain link. Jog
the pump motor and see if the speed reducer output shaft rotates.
SShaft does not rotate: Replace the speed reducer.
SShaft rotates: continue to the next step.
4. Manually rotate the sprocket above the gear pump by pulling on the
chain.
SDrive shaft does not rotate: drain the tank so the adhesive level is
lower than the pump mount. Remove the pump. Manually rotate
the sprocket. If the sprocket rotates, replace the pump. If the
sprocket does not rotate, replace the bearings and pack with
grease.
SDrive shaft rotates: drain the tank so the adhesive level is lower
than the pump mount. Remove the pump. Check the drive shaft
coupling. If the coupling is worn or damaged, replace it. If the
coupling is okay, replace the pump.
Troubleshooting Procedures

Pump
B 2-10
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Manifold Blockage Check
1. Stop the pump.
2. Standard manifold filter: Open the manifold drain valve.
Reverse-flush manifold filter: With the manifold filter in the RUN
position, open the right-side drain valve.
3. Start the pump.
SAdhesive flows: filter is clear and manifold is not blocked. Return
to the troubleshooting table.
SAdhesive does not flow: manifold may be blocked. Turn the
pump off and remove the manifold filter. Check for blockage in
the manifold and remove any blockage. Clean the manifold filter if
necessary. Refer to Cleaning a Manifold Filter in the Maintenance
section.
Use these procedures to replace the pump, to replace any pump
component, or to clean pump components. Refer to the parts lists at the
end of this section for the part numbers of any components that need to
be replaced. You can also use the parts list illustration as a guide as you
perform the following procedures.
Follow this procedure to safely prepare for pump repairs.
1. Make sure the melter is at operating temperature.
2. Make sure the adhesive level in the hopper is lower than the pump
cavity.
3. Relieve hydraulic pressure. Refer to Relieving Hydraulic Pressure in
the Maintenance section.
4. Place the melter circuit breaker in the OFF position, 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. Pump Procedures
Preparing for Repairs

Pump B 2-11
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Follow this procedure to remove the pump assembly from the melter.
1. See Figure B 2-1. Remove the hopper and drive covers (1).
2. Remove the drive chain (3) as follows:
a. Loosen the speed reducer screws (5).
b. Remove the chain-tensioning screw (6).
c. Push the motor and speed reducer assembly in far enough to lift
the chain off the speed reducer sprocket (4).
d. Remove the screws and washers from the upper bearing
mount (2) and remove the mount.
e. Remove the drive chain.
f. Reattach the upper bearing mount to the pump assembly.
3. Remove the screws, washers, and lock washers that secure the
pump mount to the hopper mount. Lift the pump assembly out of the
melter.
4130902A
1
6
4
2
5
3
1
87
Fig. B 2-1 Removing the Pump from the Melter
1. Hopper and drive covers
2. Upper bearing mount
3. Drive chain
4. Speed reducer sprocket
5. Speed reducer screw
6. Chain-tensioning screw
Removing the Pump

Pump
B 2-12
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Follow this procedure to disassemble the pump .
1. See Figure B 2-2. Remove the bolts that secure the pump to the
pump mount (1). Be careful not to lose the drive shaft coupling (4)
and key (3).
2. Remove the return tube (7) and the crossover tube (5).
3. Check the crossover tube O-ring (6) for damage. Replace the O-ring
if necessary.
NOTE: Nordson Corporation recommends replacing the crossover
tube O-ring any time the pump is removed.
4130903A
3
4
6
7
1
5
2
Fig. B 2-2 Return Tube and Crossover Tube Components
1. Pump mount
2. Key
3. Pump mount insulator
4. Coupling
5. Crossover tube
6. Crossover tube O-ring
7. Return tube
Disassembling the Pump

Pump B 2-13
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
WARNING: Risk of burns. Solidified adhesive may make the
pump plates difficult to separate. If you need to heat the pump
plates, use an electric oven with forced-air circulation or a
flameless electric heat gun. Do not use a torch or other open
flame.
4. Disassemble the pump as shown in Figure B 2-3. Be careful not to
lose the steel balls (2).
4130904A
1
23
4
6
7
8
5
9
Fig. B 2-3 Pump Components
1. Drive shaft
2. Steel ball (one of two)
3. Bottom plate
4. Center plate
5. Spur gears
6. Idler shaft
7. Top plate
8. Socket-head screw (one of four)
9. Dowel pins

Pump
B 2-14
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
If necessary, follow this procedure to clean the pump components. If the
components are damaged, replace the entire pump.
WARNING: Risk of fire or explosion. Do not heat Nordson
Type-R cleaning fluid above 246 °C (475 °F). Do not heat
cleaning fluid with an open flame or in an unregulated heating
device.
1. Use one of the following methods to heat the components:
SPlace the components, except for O-rings, in a container of
Type-R cleaning fluid and heat the fluid above the melting point of
the adhesive.
SUse a flameless heat gun to heat the components, except for
O-rings.
2. Scrub the components with a fine-bristled brush and wipe them with a
clean, dry cloth.
Follow this procedure to reassemble the gear pump assembly.
1. Reassemble the pump components. See Figure B 2-3 for the proper
placement of the shafts, gears, balls, pump plates, and dowel pins.
NOTE: The plates are marked T for top, C for center, and B for
bottom. Use these markings to properly align the plates.
2. Screw the socket-head screws into the top of the pump. Tighten to
19.78–20.91 NSm (175–185 in.-lb).
NOTE: The drive shaft must rotate a full revolution without binding or
dragging before you tighten the screws. To ensure proper alignment,
you may need to strike the side of the pump with a soft-face hammer
while tightening the screws. After tightening the screws, a maximum
of 0.56 NSm (80 in.-oz) of torque is required to turn the drive shaft on
a clean pump.
3. Reattach the crossover tube and the return tube to the pump.
4. Attach the pump to the pump mount. The drive shaft must be free to
rotate after the pump is locked down. Tighten the hex-head screws
and washers to 6.78–9.04 NSm (60–80 in.-lb).
NOTE: Your pump may include a pump mount insulator. If so, place
the insulator between the pump and the pump mount.
Cleaning the Pump
Components
Reassembling the Pump

4131128A
1
2
3
4
5
6
7
8
11
910
Pump B 2-15
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
Follow this procedure to check the bearings and the seal and to replace
them if necessary. The pump assembly has two bearings, one in the
upper bearing mount and one in the pump mount. The seal is housed in
the pump mount.
1. See Figure B 2-4. Remove the upper bearing mount (1).
2. Remove the drive shaft (5) from the pump mount (11).
3. Remove both bearings (2,8), the retaining ring (9), and the seal (10).
4. Inspect the bearings and the seal for damage and replace any
components as needed.
5. If you are installing a new seal, lightly lubricate the seal to protect it
during reassembly.
6. Press the seal into the pump mount. The seal’s open face should be
towards the pump. Secure it with the retaining ring.
7. Pack both bearings with high-temperature grease and install them in
the upper bearing mount and pump mount.
NOTE: The bearings in the replacement kit are already pre-packed
with high-temperature grease.
8. Position the drive shaft coupling (7) and key (6) on the drive shaft.
9. Install the drive shaft. Take care not to mar, scratch, or cut the seal
during installation.
10. Reattach the upper bearing mount to the pump mount with the
hex-head screws and washers you removed earlier.
Fig. B 2-4 Pump Bearing and Seal
Components
1. Upper bearing mount
2. Upper bearing
3. Key
4. Sprocket
5. Drive shaft
6. Key
7. Coupling
8. Lower bearing
9. Retaining ring
10. Seal
11. Pump mount
Note: Some items shown for reference
only.
Checking the Bearing and the
Seal

Pump
B 2-16
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Follow this procedure to reinstall the pump assembly and to reinstall and
adjust the drive chain.
1. Check the pump gaskets for damage and replace if necessary. Then
position the pump insulator, gaskets, and pan on the hopper mount.
2. Install the pump assembly on the hopper mount. Tighten the
hex-head screws, washers, and lock washers to
12.20–13.56 NSm(9–10 ft-lb).
3. Remove the upper bearing mount.
4. Install the drive chain. Tighten the chain-tensioning screw just
enough to keep the chain on both sprockets.
5. Reinstall the upper bearing mount. Tighten the screws to
6.78–8.14 NSm (5–6 ft-lb).
NOTE: If the pump is properly installed, you should be able to rotate
the drive shaft clockwise by exerting a maximum torque of
0.56 NSm (80 in.-oz) or a maximum force of 62.5 oz. To measure
force, use a strain gauge to move the drive chain.
6. Adjust the drive chain slack as follows:
a. Adjust the height of the speed reducer sprocket so it is level with
the drive shaft sprocket.
b. With the chain attached to both sprockets and the speed reducer
screws snug but not tightened, adjust the chain-tensioning screw
to obtain the chain-deflection dimensions shown in Figure B 2-5.
Begin tightening the speed reducer screws that are closest to the
chain-tensioning screw and check the chain tension. If the chain
becomes too tight, loosen the same screws and turn the
chain-tensioning screw counterclockwise. Move the speed
reducer to decrease the chain tension.
Reinstalling the Pump

Pump B 2-17
E2000 Nordson Corporation
All rights reserved 41-3000
Issued 11/00 B2EN-02-[3-PUMP]-5
c. Tighten the screws again and recheck the chain tension.
Continue this process until tension/deflection matches the
dimensions shown in Figure B 2-5 when all four speed reducer
screws are tight. Tighten the screws to 6.78–8.14 NSm (5–6 ft-lb).
Lock the chain-tensioning screw nut.
d. Recheck the speed reducer sprocket. Make sure the sprocket is
level with the drive shaft sprocket.
4130914A
1
2
4.1–5.8 mm
(0.16–1.23 in.)
2.0–2.9 mm
(0.08–0.12 in.) 2.0–2.9 mm
(0.08–0.12 in.)
Fig. B 2-5 Chain Tension/Deflection
1. Chain-tensioning screw 2. Tight chain
7. Reinstall the hopper and drive covers.
8. Restore the system to normal operation.

Pump
B 2-18
E2000 Nordson Corporation
All rights reserved
41-3000
Issued 11/00
B2EN-02-[3-PUMP]-5
Use these procedures to replace the motor, check the speed reducer oil,
or replace the speed reducer. Refer to the Parts section for the part
numbers of any components that need to be replaced. You can also use
the parts list illustrations as a guide while performing the following
procedures.
Follow this procedure to replace the motor.
1. Place the melter circuit breaker in the OFF position, 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.
2. See Figure B 2-6. Remove the drive cover.
3. Remove the motor conduit box cover and disconnect the electrical
wires; then remove the conduit nut and separate the conduit and
wires from the motor.
4. Disconnect the motor (1) from the speed reducer.
5. Remove the speed reducer coupling (2). Apply anti-seize lubricant to
both the reducer and motor shafts. Reinstall the speed reducer
coupling.
4130906A
2
1
Fig. B 2-6 Replacing the Motor
1. Motor 2. Speed reducer coupling
6. Attach the new motor to the speed reducer. Tighten the screws,
washers, and lock washers to 6.78–8.14 NSm (5–6 ft-lb).
4. Motor and Speed
Reducer Procedures
Replacing the Motor