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Quattro Service and Operating Manual

Quattro Service and Operating Manual

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Quattro Service and Operating Manual

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Safety Instructions

Operators and service personnel must read and understand the manual before using the equipment to prevent severe injury or death.
Daily inspection of the machine for unsafe conditions is required, and worn or defective parts must be replaced.
Ensure all covers and guards are in place before operation, and only trained personnel should operate and service the equipment.
Power sources must be shut off and locked out before maintenance.
All warning labels must be read, obeyed, and replaced if removed or defaced.

Servicing Equipment

Only trained technicians should perform service, and equipment should never be serviced or cleaned while in motion.
Maintenance instructions in the manual must be followed, using specified electrical and air supply sources.

Installation & Start-Up

Installation procedures must be followed carefully for proper setup and operation.
Use clean, uncontaminated adhesive to prevent system clogging and damage.

Temperature Controller Set-Up

Understanding temperature control terms and error messages is crucial for effective operation.
Correct settings are necessary for typical operation to maintain system efficiency.

Preventive Maintenance

Regular cleaning and inspection of filters and fittings are essential to maintain system performance.
System pressure must be relieved before servicing to prevent injury from hot adhesive.

Troubleshooting

Follow the troubleshooting guide for common issues such as temperature zones not heating or overcurrent problems.
Handle printed circuit boards with care to avoid damage.

Disassembly & Re-assembly Procedures

Detailed procedures for removing and accessing components safely must be followed.
Proper re-assembly is crucial to avoid operational issues.

Recommended Spare Parts & Available Kits

Maintain a list of recommended spare parts for quick replacement and minimal downtime.

System Schematics & Engineering Drawings

Refer to schematics and drawings for a detailed understanding of system components and wiring.

Safety Precautions
Consult with your supplier to determine maximum heating temperatures and safety precautions. Follow OSHA 1910.147 for lockout/tagout procedures. Be aware of stored energy in capacitors and wait at least one minute before servicing. Use exhaust systems for PUR adhesives due to dangerous fumes. Prevent PUR adhesives from curing inside equipment to avoid warranty voidance.

Warnings and Cautions
Warnings indicate potential injury risks, while cautions highlight possible equipment damage.

Description and Specifications
The ITW Challenger Quattro ASU is a computer-controlled hot-melt adhesive supply unit with a user-friendly control panel. It features microprocessor temperature control for up to nine zones, ensuring precise temperature management and energy efficiency. The system includes a dependable piston pump and can accommodate various adhesive forms and applicators.

Specifications

Environmental: Storage temperature -40°C to 70°C; service temperature 0°C to 50°C; noise emission < 70 db(A).
Physical: Supports up to 4 hoses/heads; tank capacity 8.5 kg; weight 39 kg.
Electrical: Power supply options include 230 VAC configurations; maximum power consumption 7200 watts.
Performance: Adhesive temperature range 40°C to 218°C; warm-up time approximately 0.5 hour; adhesive pressure up to 97 bar.

Installation and Start-Up
The Quattro ASU can be mounted on flat surfaces. Ensure power is off before installation. Connect power supply and ground, and configure the power plug according to system requirements. Connect compressed air supply and adhesive hoses as per guidelines. Maintain adhesive level and flush the system when changing adhesive formulations.

Installation Dimensions
Detailed dimensions and mounting hole specifications are provided for proper installation.

Warning and Caution:
- Do not overfill the melt tank as adhesive expands when melted, risking overflow.
- Adhesive viscosity over 50,000 centipoise may stall the pump.
- Compressed air must be clean and dry; avoid lubricated oil. An air line filter may be necessary.

Start-Up Procedures:
1. Fill the ASU tank with clean hot-melt adhesive and close the lid immediately.
2. Turn on the Main Power Switch; the controller will calibrate and display "CAL".
3. Program adhesive setpoints or use factory settings (Tank, Hose, Applicator: 177°C/350°F).
4. Once temperature is reached, the ASU will pump adhesive automatically.
5. Regulate pump speed and adhesive output using the air pressure regulator.

Shut Down Procedures:
1. Turn off the Main Power Switch.

Storage and Disposal:
Temporary Storage:
1. Flush the system with flushing fluid.
2. Clean or replace filters.
3. Shut off all pressure and power sources.
4. Release residual air pressure and remove adhesive.
5. Pack the unit to prevent corrosion and store safely.
Disposal:
1. Shut off all pressure and power sources.
2. Release residual air pressure and remove adhesive.
3. Dismantle components for recycling.

Temperature Controller Set-Up:
- Provides accurate control for tank, hoses, and applicators.
- Alarm signals for critical situations are available.
- Features include mechanical high-temperature protection and RTD sensors.
- Ready signal indicates system readiness for production.

Error Indication Messages:
- "EO1" indicates an open sensor; "EO2" indicates a shorted sensor.
- Verify connections and replace sensors if necessary.

Programming Instructions:
- Use the Quattro keypad to program temperature setpoints and control functions.
- Keypad locking restricts unauthorized programming.
- Service functions include setting tolerance, sequential startup, and temperature scale.

Helpful Tips:
- System retains settings from last use.
- All heaters activate unless set below 40°C (100°F).

Ready Delay Programming: To set a Ready Delay, enter programming mode by pressing the Tank icon. Adjust the delay from 0 (no delay) to 99 minutes. The controller will revert to the actual temperature after a few seconds.

Access Code Programming: Enter Access Code programming mode by pressing the Service icon six times. Change the code by scrolling to the desired value (1-999). No code deactivates keypad locking.

Error Indication Messages: "EO1" indicates an open or high resistance temperature sensor, while "EO2" indicates a shorted or low resistance sensor. A flashing LED indicates the ASU is not ready for production.

Copy and Paste Setpoints: The controller can copy the tank setpoint to other zones that are turned on. This is done by holding the Tank icon and pressing the Hose and Head icons sequentially.

Preventive Maintenance: Maintenance should be performed by qualified technicians. General cleaning should follow manufacturer directions. Relieve system pressure before changing filters or removing hoses. Replace or clean the manifold filter screen weekly initially, then as needed.

Flushing the System: Use 6 liters of flushing fluid to clean the system when changing adhesive formulations or when residue accumulates. Follow specific steps to ensure complete flushing and system readiness.

Troubleshooting: Only qualified technicians should perform troubleshooting. Handle PCBs with care to avoid electrostatic damage. Common issues include power supply problems, sensor errors, and circuit breaker trips. Follow specific procedures to diagnose and resolve these issues.

Resistance Tables: Provides resistance values for temperature sensors and heaters, useful for diagnosing electrical issues.

Overview: This document is a technical manual for the ITW Challenger QUATTRO ASU, revised in December 2003. It provides troubleshooting guides, disassembly and re-assembly procedures, and safety precautions for maintaining and repairing the ASU system.

Troubleshooting Guide:

Tank Heating Issues: If the tank does not heat and the LED is off, check the PCB connections, replace the sensor if resistance is incorrect, and inspect for short circuits.
Hose and Head Heating Issues: For inoperative hoses or heads, check plug connections, replace fuses, and verify PCB functionality. If the temperature is higher than the setpoint, check the triac and temperature sensor.
Display Errors: EO1 and EO2 errors indicate disconnections or sensor issues. Verify connections and replace sensors if necessary.
Pump Issues: For pumps not stroking, ensure adequate air pressure and check solenoid valves. Quick-stroking issues may require checking adhesive levels and valve blockages.

Disassembly & Re-Assembly Procedures:

Access Panels: Instructions for removing the pump cover, front panel, rear side panel, and control enclosure are provided. Ensure ground wires are handled carefully.
Component Replacement: Detailed steps for replacing thermostats, RTD sensors, and PCB fuses are included. Use correct replacement parts from ITW Dynatec.
Pump Removal: The pump should be removed at operating temperature. Follow safety warnings regarding hot surfaces, high voltage, and high pressure.
Re-Assembly Cautions: Replace all O-rings and seals during re-assembly, and apply appropriate lubricants and sealants.

Safety Precautions: Emphasizes the importance of wearing protective gear when working near hot adhesive and following proper procedures to avoid injury.

Chapter 9: Recommended Spare Parts & Options

Spare Parts List: Includes electrical components like control printed circuit board assembly, fuses, sensor assembly, and over-temperature thermostat. Filters and miscellaneous items such as O-rings, solenoid valve, pressure relief valve, and mini regulator are also listed.
Optional Accessories: Stand Assembly with pre-drilled mounting plates for auxiliary controls.

Chapter 10: Component Illustrations & Bills of Material

Inspection Warning: Regular inspection and replacement of worn or broken parts are crucial to prevent operational issues and personal injury.
Bills of Materials: Detailed lists for various assemblies including Cabinet Enclosure, Tank and Base Assembly, Piston Pump Assembly, Pump Air Manifold Assembly, Manifold Output Assembly, Filter Assembly, and Valve Hose End Panel Assembly. Each list includes item numbers, part numbers, descriptions, and quantities.

Chapter 11: System Schematics & Engineering Drawings