Dyna Tec

OPERATIONS & SERVICE MANUAL
Manual #20-38
Revised 8/1/13
DYNAMELT M SERIES ADHESIVE SUPPLY UNIT

OPERATIONS AND SERVICE MANUAL
Model DM M210 DCL

Software V5.11M and up with Expanded DynaControl
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
Page ii c. 2001
Revised 12/04 DYNAMELT M210 DCL ASU Manual 20-38
ITW Dynatec
An Illinois Tool Works Company
Adhesive Application Solutions

c. 2001 Table of Contents Page iii
DYNAMELT M ASU Manual #20-38 Revised 6/08
TABLE OF CONTENTS
Chapter 1 Safety Precautions Chapter - Page #
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Eye Protection & Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safe Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Treatment for Burns From Hot Melt Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Explosion/ Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lockout/ Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Chapter 2 Description & Specifications

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Total System Wattage Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Main Circuit Breaker Detrmination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Definition of ASU Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Chapter 3 Installation & Start Up

Placing the DYNAMELT ASU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
To Open/ Close Panel Box Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
User Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Printed Circuit Board Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hose/ Head Electrical & Adhesive Connections (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Electrical Connections & Filter Manifold Arrangement, Maximum Hose/ Head Configuration (illus.) . 3-6
Adding Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Changing the Adhesive Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Field Installation of Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Adjusting the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Pump Enable (Ready) Thermostat Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Calibration of the Optional Voltage Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installation of the Optional Tach Generator or DC Tracking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Calibration of the Optional Tach Generator or DC Tracking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Typical Start Up and Shut Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Storage and Disposal of the Application System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Chapter 4 DynaControl Controller Set-Up

Temperature Control Functions in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Defining DynaControl Temperature Control Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Error Indication and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Optional System Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Settings for a Typical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
System Values that are Factory Programmed (not customer accessible) . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Customer Programmable Values Preset at the Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Default Settings of the DynaControl Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Page iv Table of Contents c. 2001
Revised 9/10 DYNAMELT M ASU Manual 20-38
Helpful Tips for the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

EtherNet/IP Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chapter 5 Programming of DynaControl Controller
Controller Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Display & Keypad Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Basic Programming Sequence: Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Controller Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Turning the Controller On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Temperature Scale Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Actual Temperatures Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Use of the Actual Temperatures Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Programming Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Setpoints Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Use of the Setpoints Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Motor Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Use of the Motor Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Optional Clutch Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Use of the Optional Clutch Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Optional Pressure (PSI/BAR) Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Use of the Optional Pressure (PSI/BAR) Programming Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Service Functions Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Service Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
High/ Low Temperature Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Standby Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Standby/ Sleep Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Setpoint Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Temperature Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Sequential Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Temperature Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Change Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Service Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Customer Zone Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Power On Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Keypad Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
PC Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
LCD Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
System Logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Change Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
c. 2001 Table of Contents Page v
Service Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Programming at Main Scheduler Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Use of the Main Scheduler Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Programming of 7-Day Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Use of the 7-Day Scheduler Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Up/ Downloading Instructions: Controller to Remote PC (PC Link) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Optional Dual (Split) Hopper Display & Keypad Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Chapter 6 Preventive Maintenence

General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Outlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Outlet Filter Manifold (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Replacing the Optional High Flow Outlet Filter Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Filter Shutoff Cleaning or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Pump Shaft Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Summary of Preventive Manintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Optional Panel Box Assembly Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Chapter 7 Troubleshooting
General Troubleshooting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hose/ Applicator Troubleshooting Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Motor Speed Control PC Board Re-set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
High-Temperature Redundant Overtemp Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pump Enable Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lithium Battery on PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CPU Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Display CPU Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Motor Control Interface Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Motor Speed Control & Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
48-Zone Power Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Optional Clutch Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Optional RS232/485 Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Optional Pressure (PSI) Printed Circuit Board & Layout Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Heater and Sensor Resistance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Resistance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Error Indication Alarm Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Adjustable Adhesive Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Operation of the ASU’s Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Troubleshooting the ASU Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Gear Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Page vi Table of Contents c. 2001
Chapter 8 Disassembly & Re-assembly Procedures
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

To Remove the Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
To Open the Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Sensor or Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
To Remove the Manifold Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
To Remove the Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
To Access the RTD Sensor in the Optional Drop-in Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
To Access the Electrical Components Inside the Panel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
To Access the Pump or Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Optional DC Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Pump Seal (O-ring) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Re-assembly Procedures & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Chapter 9 Available Options & Accessories
Pressure Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Pre-PSI and Post-PSI Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Drop-in Grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
High Temperature Heater Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Filter Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Pump Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Gear Motor Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Return (Re-circulating) Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Pneumatic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Dual Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
High Flow ASUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
DynaControl Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Recommended Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Chapter 10 Component Illustrations & Bills of Material
Chapter Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Pressure Relief & High Temperature Filter Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Hi-Volume Pressure Relief & Filter Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Typical Electrical Panel Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Cabinet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Melt & Grid Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Pump Adapter Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Pressure Gauge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Heater Control Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
In addition to the assemblies listed above, this chapter may also contain illustrations for other optional
assemblies ordered with your ASU.
c. 2001 Table of Contents Page vii
Chapter 11 System Schematics & Engineering Drawings

Hose Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Head Schematic: all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Flow Diagram, Outlet Filter Manifold/ Cross Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Typical Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Optional System Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Optional Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Grounding Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Pneumatic Clutch Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Instruction Sheet for Pump & Zone Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Dynamelt M ASU Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . end of chapter
Appendix
Optional Dynatec/ Zenith Standard Accuracy Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 1

Optional Dynatec/ Zenith High Accuracy Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 15
Optional Zenith Melt Spinning Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 29
High Accuracy Pump Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 34
Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 35
Optional TSHA Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 39
Page viii Table of Contents c. 2001
ITW Dynatec
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.
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 Safety ITW Dynatec c. 2010
Revised 8/12 ALL MODELS
Special Safety Considerations When Using Reactive HMPUR Adhesives

Reactive hot melt PUR (HMPUR) adhesives are known for superior adhesion to numerous substrates and their excep-
tional heat, cold and moisture-resistance qualities. They are an excellent choice for the difficult-to-bond substrates used
in a wide range of environments. HMPUR adhesives chemically cross-link (i.e., cure or thermal-set) to reach maximum
bond strength, typically over a period of 24 to 48 hours after being exposed to moisture and/or high temperatures.
The advantages of using HMPURs, however, come with special handling requirements. The adhesive must remain
sealed off from the environment and maintained at low temperatures until it is dispensed, otherwise there is a risk that
the adhesive will cross-link within the glue application equipment, rendering it impervious to melting when it is
re-heated. Most importantly, when over-heated, many HMPURs release gases that can be hazardous to humans. There-
fore, adequate ventilation must be available to prevent injury to personnel in the workspace.
Though the chemistries of individual adhesives differ, the following is a list of general operational considerations for
the use of HMPURs in ITW Dynatec equipment. In addition, it is important to contact your adhesive manufacturer to
discuss and verify precautions that must be implemented to prevent damage to equipment and injury to personnel who
are working with their products.
 Assure the workspace has adequate ventilation.
 Assure the entire adhesive delivery system is sealed from the environment to the greatest extent possible to
prevent moisture-related adhesive cross-linking.
 Assure all air is evacuated from the adhesive delivery system as soon as possible after it has been introduced
(i.e., when changing hoses, replacing filters, changing adhesive supplies, etc.) to prevent moisture-related cross-linking.
 The ITW Dynatec equipment should not be left dormant (sealed at ambient temperature) with PUR inside for
longer than recommended by your adhesive manufacturer. The ITW Dynatec system, especially applicators and nozzles,
should be thoroughly purged of adhesive using a PUR purge material if the system will be left dormant for extended
time periods.
 HMPUR viscosity increases the longer it remains molten within a system and can cross-link due to temperat-
ure exposure. Assure the molten adhesive does not sit within the ITW Dynatec equipment at operating temperature for
more than a cumulative total of 2 to 4 hours. Utilization of the Temperature Standby feature will ensure a temperature
drop occurs automatically.
 Turn off any gear pumps in the system if it will not be used for a period of five minutes or more. Doing so
will reduce potential glue degradation.
 When using spray applicators, the nozzles must be thoroughly cleaned on a regular basis to prevent the ad-
hesive from cross-linking inside or on the surface of the air passageways.
 The adhesive applicators must be either fully sealed or thoroughly cleaned with PUR purge material if the
system is to be idle for more than two hours. Otherwise, HMPUR adhesive present in the exposed orifices of the applic-
ator could potentially cross-link, clogging them.
 Recommended adhesive application temperatures should never be exceeded without first consulting with
your adhesive manufacturer. Higher application temperatures may result in higher adhesive viscosities and thermal-re-
lated cross-linking.
There are many advantages to using HMPURs. However, the proper handling of these unique adhesives is imperative to
assure success without damage to equipment or injury to personnel. ITW Dynatec equipment has been engineered to
minimize the effort required to assure safe and proper handling of HMPURs. ALLOWING PUR ADHESIVE TO
CURE IN A UNIT OR ITS COMPONENTS VOIDS ITW DYNATEC'S WARRANTY. Please consult with your ITW
Dynatec representative to discuss these topics in further detail, if necessary.
c. 2001 Description & Specifications Page 2-1
Chapter 2
DESCRIPTION AND SPECIFICATIONS
Description
The DYNAMELT M Series adhesive supply units (ASU) are computer-controlled hot-melt supply
units designed on metric standards. Utilizing ITW Dynatec’s DynaControl temperature controller,
their control panels, with choice of display languages, provide comparative data of all setpoints,
motors, etc. on a few convenient, comprehensive display screens.
The Dynamelt M Series ASUs are available in three cabinet sizes and offer four hopper sizes. The
Dynamelt 210 uses a microprocessor temperature control to closely control the temperature of hot-
melt adhesive for up to 12 hoses and 12 heads. Temperature setpoints are operator-selected for up to
48 zones and the system automatically provides warnings and alarms for operator errors and system
malfunctions.
The Dynamelt/ DynaControl system provides accurate, proportionate temperature control for the
hopper, hoses and applicators. Sequential heating delays may be programmed for turn-on of the
hoses and heads. A “standby” temperature may be programmed so that the temperature zones can
be maintained at a lower temperature when the ASU is not in active use, enabling rapid return to
normal operation. The seven-day scheduler allows programmable automatic startup and shutdown
of the ASU throughout the workweek.
With these flexible temperature programming features, the Dynamelt system increases adhesive life
by eliminating prolonged high adhesive temperatures. It reduces energy consumption and brings the
system up to normal operating temperatures in the shortest possible time.
A four-layered, shielded CPU printed circuit board protects the microprocessor from external inter-
ference. The temperature control can interlock the parent machine with preselected adhesive tem-
peratures so that production automatically begins when adhesive temperatures are correct for the
application. All system temperature values can easily and quickly be programmed. An optional re-
mote control panel gives control and monitoring flexibility.
Digital readout of system conditions is provided. A security code can restrict access to system pro-
gramming and parameters. The CPU monitors the electronic circuitry and provides alarms for error
conditions.
The Dynamelt M ASU uses an extremely dependable gear pump(s) to assure a smoother and higher
precision flow. The single or dual pumps are driven by individual drives.
The Dynamelt’s teflon-coated hopper accepts adhesive in all popular forms, including pellets, slugs
and blocks. The ASU can accommodate air-actuated automatic applicators (heads), electric applica-
tors, hand-held applicators and/or special applicators. Options available include pressure gauge,
additional drop-in grids, dual hopper, pneumatic clutches, digital pressure readout and adhesive lev-
el control. The DM210 is also available in a high flow model.
Page 2-2 Description & Specifications c. 2001
Revised 6/03 DYNAMELT M ASU Manual #20-38
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)
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 60 dbA at 1 meter (39 inches)
Physical:
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see dimensional layouts on following pages
Number of heads/ hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 12
Number of return hoses or auxillary zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 12
Number of hopper temperature zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 2
Number of pump/ motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 6
Number of (optional) drop-in grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Number of standard grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gear pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.92 cc/rev standard
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . styled, durable metal, dust and splatter resistant
Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . universal 15-pin Amphenol connectors at asu,
wrench-secured fluid fittings (#6 JIC)
Hopper (tank) capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 kg/ 420 lb
Hopper construction . . . . . . . . . . . . . . . . . . . . . . . . machined welded aluminum, Teflon impregnated
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hopper bottom screen, large pleated pump outlet filter
Weight, empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBD
Adhesive form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . accepts most forms
Electrical:
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-240 VAC/ 3p/ 50-60 Hz
380-400 VAC/ 3p (“Wye”, “Y” or 5-wire connection)/ 50-60 Hz
Minimum supply amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see circuit breaker size
Power consumption, hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,000 watts
Power consumption, 3 drop-in grids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,500 watts
Power consumption, 3 additional (optional) drop-in grids . . . . . . . . . . . . . . . . . . . . . . . . 7,500 watts
Hopper heater type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast in
Temperature control . . . . . . . . . . . . . . . microprocessor-based proportional integral derivitive (PID)
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ohm Platinum RTD standard
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Ohm Nickel RTD optional
Electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . durable, latching connectors
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 hp, alternating current motor, TEFC*, direct drive,
vertical orientation, right angle gearbox
Maximum current available for each hose or head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ampere
* totally enclosed, fan cooled

Performance:
Adhesive temperature control range . . . . . . . . . . . . . . . . . . . . . . . . 40°C to 232°C (100°F to 450°F)
Standby adhesive temperature range . . . . . . . . . . . . . . . . . . up to 80°C (150°F) lower than setpoint
Hopper ready adhesive temperature deviation (factory set/ field adjustable) ± 20°C (36°F) from setpoint
Over-temperature cutoff for hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232°C (450°F)
Adhesive viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 to 50,000 centipoise
Warm-up time, full hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 0.5 hour
Typical adhesive melt rate (depends on adhesive used) . . . . . . . . . . . . 45-145 kg/hr (99--319 lb/hr)
Adhesive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 68 bar (1000 psi) maximum
DynaControl Temperature Control:

Controller power board . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 zones per board, modular construction
Display type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . graphic, liquid crystal
Temperature control zones (DM210) . . . . . . . . . . . . . . . . . . . . . 48 maximum with solid state relays
Power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hopper: 15,000 watt
hose: 1200 watt
applicator head: 1200 watt
auxiliary: 2000 watt
Solid state relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 VDC
Line speed inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 6
Other:
Display languages . . . . . . . . . . . . . . English, French, German, Spanish, Swedish, Italian, Japanese,
Portugese and Dutch
Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . multi-zone, liquid crystal display with
alpha/numeric keyboard and function keys
Temperature standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
High and low temp alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Ready interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Password protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Sequential heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes (hopper, hose, head staged heating)
Sensor open alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
RS232 and RS485 communications capable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Seven-day scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
High temp capable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
Line speed tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
CE approval granted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes
F
E
D
A
G
C B
I
DYNAMELT M210 Installation Dimensions
DIMENSION A B C D E F G H I
mm 1506.4 1227.4 1301.6 1622.3 177.8 342.9 610 320.68 1377.7

inches 59.31 48.32 51.24 63.87 7.00 13.5 24 12.625 54.24
Total System Wattage Capacity
Maximum Wattage M210
Hopper + High Temp Heater 18,000 w
PreMelt 7,500 w
Optional Drop-in Grid 7,500 w
Up to 12 Hose Zones 14,400 w

(1200 w each)
Up to 12 Applicator Zones 14,400 w

(1200 w each)
Up to 12 AUX Zones 24,000 w

(2000 w each)
Maximum System Wattage: 85,800 w
Main Circuit Breaker Determination
Main circuit breakers vary depending on each unit’s system configuration. ITW Dynatec typically
determines the main circuit breaker by the mains load for a system, which, by codes, should be
125% to 150% of the maximum load. If a customer later modifies his system (by adding heads,
hoses, auxiliary outputs, etc.), the main breaker may need to be upgraded to reflect the increase in
load.
To determine your existing main circuit breaker, first determine if the ASU has been modified
and the breaker upgraded accordingly. If not, and the breaker is original to the ASU, you will find
the main circuit breaker listed in the Panel Box Assembly (PBA) section of the indented bill of
materials inserted at the back of this manual. The main circuit breaker is the largest amperage cir-
cuit breaker listed in that bill of materials.
Definition of Code: DYNAMELT DM 210 ASU w. DynaControl Controller

ASU Code: M XXX D X XXX XXX X D# - X X XX . . .
Example: M 21S D N ZLS SHS 2 D2 - D N V2
Code PN Base Unit Code Voltage
21S 106055 210kg (420 lb) Hopper 2 240V/ 3P Delta/ no neutral

21D 106054 210kg (420 lb) Dual Hopper 3 380V/ 3P Star/ neutral only
21H 106697 210kg (420 lb) Hopper, HiFlo
Motor/ Drive Groups (1 per pump)

# = total number of drives
D DynaControl Controller
Drive Setup
# Drives # Front # Rear
1 drive 1 0
Code PN Grids 2 “ 1 1
3 “ 2 1
N n/a Standard, first level of grids
4 “ 2 2
G 804634 add 2nd level of grids
Code PN Options
Code PN Pump(s) (quantity of pumps = 1 to 6) B 809030 Adhesive Fill Ball Valve
GAS 100860 Dynatec 1.54cc single C 815146 Harting Connector
GBS 100861 Dynatec 3.18cc single D Digital Pressure Readout
GCS 100862 Dynatec 4.5cc single F2 817809 Pneumatic Pressure Relief, 2 pos
GAD 100863 Dynatec 1.54cc dual F4 817397 Pneumatic Pressure Relief, 4 pos
GBD 100864 Dynatec 3.18cc dual F6 817535 Pneumatic Pressure Relief, 6 pos
ZLS 084E372 Precision 0.160cc single G 819685 Analog Pressure Gauge Kit
K N06642 Signal Isolator
ZDS 084E428 Precision 0.297cc single
L 810237 One-Point Level Control Assy (in tank)
ZES 084E374 Precision 0.584cc single
M 112224 EtherNet Interface
ZFS 084E430 Precision 1.168cc single
N 806573 Three-Point Level Control Assy (in lid)
ZGS 084E434 Precision 2.92cc single
R 108313 Digital RPM Kit
SHS 108875 Precision 8.5cc single
T add Temperature Zone(s)
ZLD 084E387 Precision 0.160cc dual
U Cooling Fan Kit (within panel box assy)
ZDD 084E388 Precision 0.297cc dual
V1 814008 80-mesh Easy-Spin Filtration
ZED 084E389 Precision 0.584cc dual
ZFD 084E432 Precision 1.168cc dual
SGD 108874 Precision 2.92cc dual W Cooling Air Conditioning Kit (within panel box assy)
ZIS 110289 Precision 20cc single, Large, HiFlo
ZJS 110290 Precision 30cc single, Large, HiFlo
ZKS 110291 Precision 45cc single, Large, HiFlo
ASU codes are typically compiled without
SPC Special Pump (see sales order)
spaces between categories.
The example shown above would be recorded

as M21SDNZLSSHS2D2- DNV2
c. 2001 Installation Page 3-1
Chapter 3
INSTALLATION
Placing the DYNAMELT M ASU
The DYNAMELTÒ M SERIES ASU can stand alone on flat surfaces. The main electrical power
and the serial communication connections come in from below the unit and connect under the Dy-
naControl keypad, so access is needed there.
For installation dimensions, see illustration on page 2-4.
Controller Keypad Access

Door
Keylock
Hopper Lid
Panel Box
Panel Box Hose/ Head
Keylock Electrical
Main Disconnect Connections
Switch
Manifold
Cover
The DYNAMELT M210 DCL ASU

Page 3-2 Installation c. 2001
Re-read Chapter 1 “Safety Precautions” before performing any installation procedures. All installa-
tion procedures must be performed by qualified, trained technicians.
“ON”
Position
To Open/ Close Panel Box Door
1. With the key supplied, unlock the panel box door.

“Reset”
Position
2. Turn the main disconnect switch counterclockwise
to “Reset” while pushing the tab clockwise with your thumb.
3. Pull door open.
4. To close: Turn switch to “ON”. Hold door closed

while turning swith to “Reset” and then back to “ON”.
Lockout Safety Tab
5. Lock the panel box door with the key.

ON
P
RI
Installation T
O
F
After the DYNAMELT M SERIES ASU has been properly F
R
positioned, the following general sequence should be followed E
for installation: S
E
T
1. Make sure that incoming line power to the ASU and
that the unit’s main disconnect switch are turned OFF.
Main Disconnect Switch
DANGER HIGH VOLTAGE

Disconnect and lock out input power to the application system, using the
lockout safety illustrated above, before starting any installation procedures.
Make sure there is no electrical power on the leads you will be connecting.
2. Within the panel box assembly: Connect 3 electrical leads with the appropriate voltage to the
main circuit breaker and connect one electrical lead to the ground (PE) terminal (see diagram
following).
380v ASUs only: In addition to above, connect one lead to the neutral terminal.
CAUTION: Grounding conductors never carry electrical current. The use of a neutral
conducting wire as earth ground is incorrect and may cause damage to the controller.
cont.
3. At installation, the customer must make the following terminal connections into the ASU’s
printed circuit boards (PCBs). The boards do not need to be removed from the ASU in order to
make connections.
See the detailed layout on the next page for locations, and refer to the detailed layout drawings
of the PCBs in Ch. 7, if needed.
Terminal Circuit Location
Required connections for standard 240 vac ASU:

Input Power from Main Power 240vac Main Power Switch/L1, L2, L3
PE Ground Terminal rail
Required connections for 380 vac ASU:
Input Power, from Main Power, 380 vac Main Power Switch/L1, L2, L3
N, PE Neutral, Ground Terminal rail
Non-essential connections; connect if feature is desired:
R1, R2 Normally Open Ready (parent machine interlock) Power PCB/ JS4/ pins 1 & 2 and
Power PCB/ JS2/ pins 1 & 2
A1, A2 Normally Closed Alarm (controller display alarms) CPU PCB/ X1/ pins 1 & 2
E1, E2 External Standby (controller standby mode) CPU/ X4/ connect 5 and 9 or 10
P1, P2 Program Select 1&2 (controller program selection) CPU/ X4/ connect 1 to 9 or 10**
P3, P4 Program Select 3&4 ” ” ” CPU/ X4/ connect 7 to 9 or 10**
Power On Output Power PCB/ JS1/ pins 1 & 2
Options: Make connections for the following if installed on your ASU:
S1, S2 Tachometer (line speed tracking) MCI*/ X3/ 0 (ground) & 10 (+)
H1, H2 Hand-Held Applicator, Footswitch MCI*/ X3/ TR
Low Adhesive Level (output alarm) CPU PCB/ X1/ pins 3 & 4
Dual Hopper: Low Adhesive Level (output alarm) same as above. CPU1 = Hopper 1 &
CPU2 = Hopper 2
Pressure Transducer(s) (1 to 4 transducers) PSI PCB/ X1, X2, X3, X4
Pressure Transducer(s) (high & low psi alarms) PSI PCB/ X6
Clutch Customer Enable (for motor 1) Clutch PCB/ JS1/ pins 1 & 2
Clutch Customer Enable (for motor 2) Clutch PCB/ JS1/ pins 3 & 4
Ribboncable RS232/485 Communication Display CPU PCB
* MCI = Motor Control Interface PC Board

** Program Selection Table
User Connections P1/P2 P3/P4 Program #

Pin 1 Pin 7
open open = Program 1

closed open = Program 2
open closed = Program 3
closed closed = Program 4
Printed Circuit Board Location Diagram
The printed circuit boards (PCBs) are located within the main panel box assembly.
Note: When multiple PCBs are installed to accomodate multiple components (ie, six motor speed
control PCBs and six motor control interface PCBs to accomodate six drives, as illustrated
below), make connections to all PCBs.
Main Circuit Main Ground

CPU Board Power (I/O) (PE)Terminal
Breaker
(3 shown) Board
Side Panel X4 X1 JS1

JS4 L1 L2 L3
JS2
CPU #1
CPU #2 CPU #3
RS232/485
Communication
Board
Pressure Contactor
Board Mtr1 Mtr2 Mtr3 Mtr4 Mtr5 Mtr6
(4 shown)
X3 Motor Control
interface Board
X1 X6 (6 shown)
X2
X3 Motor Speed
X4 Mtr1 Mtr2 Mtr3 Mtr4 Mtr5 Mtr6 Control
(6 shown)
Fuses
Circuit
Breakers
Circuit
Breakers
JS1 Single-Point Neutral (for 380v only)

Level Control
Clutch Board Signal Isolator Board
(3 shown)
Typical Panel Box Layout with Options

4. The adhesive hoses are connected at the rear cover (see illustration on page 3-6). Each hose is
connected at both an adhesive port and an electrical connect. Make your electrical hose
connections at the numbered connects above the filter manifolds. Route hoses so that there is at
least an eight-inch radius at any bend. Do not hang hoses without proper support. Do
not crimp, clamp, squeeze or tie hoses.
Two feed hose adhesive ports are located near the center of each filter manifold. When making
hose connections, use the numbered guides shown on the illustration to coordinate; ie. when
using one hose, make your hookup to electrical connection #1 and adhesive port #1. When
using two heads/ hoses, hookup hose/ head #1 to electrical connection #1 and adhesive port #1,
then hookup hose/ head #2 to electrical connection #2 and adhesive port #2, etc.
5. Auxiliary electrical connects (A1, A2, etc.) are provided for customer’s use, as needed.
6. Connect (optional) PSI transducers at the PSI ports labeled on the filter manifold. Position them
from left to right across the manifolds as shown in the lower illustration on page 3-6.
Transducers measuring adhesive pressure before it enters the filter use the ports stamped “Pre
PSI” and transducers measuring pressure after the filter use the ports stamped “Post PSI”.
Transducers must be wired into the pressure printed circuit board.
Units not using transducers may use either a PSI port or a feed hose port to mount a (optional)
pressure gauge. If all ports are in use, the pressure gauge may be installed in line with a hose.
Refer to the hose and applicator manuals for further details on these items.
Post-Filter
Transducer
Connection
Electrical
Connections
F1 Pressure Relief Valve
Filter Nut
#1
A1
Auxiliary
#1 Pre-Filter
Transducer
Connection
Hose
Connection
Heater Channel
Purge (Drain) Valve RTD Sensor Channel
Retainer Plate
Hose/ Head Electrical and Adhesive Connections

Electrical Connections F1 thru F12 are for Head/ Hoses
Electrical Connections A1 thru A12 are for Auxiliaries
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12
PSI 1 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 7 PSI 8 PSI 9 PSI 10 PSI 11 PSI 12
F1 F2 F3 F4 F5 F6 F7 F8 F9 F 10 F 11 F 12
Adhesive supplied Adhesive supplied Adhesive supplied Adhesive supplied Adhesive supplied Adhesive supplied
by motor/pump #1 by motor/pump #2 by motor/pump #3 by motor/pump #4 by motor/pump #5 by motor/pump #6
Up to six Filter Blocks with up to 24 Adhesive Ports
Note: Always connect Auxiliary #1 (A1) to Auxiliary Electrical Connect #1 (A1), Feed Hose #1 (F1) to Feed
Electrical Connect #1 (F1), etc. as described on page 3-3.
Dynamelt M210: Electrical Connection and Filter Manifold Arrangement for Maximum
Head/ Hose Configuration
This page is intentionally blank.

Adding Adhesive
The adhesive level in the melt tank should be maintained at 13mm to 100mm (1/2” to 4”) from the top of
the hopper. Where applications demand a high output volume of adhesive, add small amounts of adhe-
sive frequently. Adding large amounts of adhesive to an almost empty hopper will lower the tempera-
ture of the adhesive in the hopper and may cause the ASU to fall below its READY setpoint.
Changing the Adhesive Formula

If a different adhesive formulation from the one being currently used is needed, the system will have to
be flushed if the two formulations are incompatible. See Chapter 6 of this manual for the proper flushing
procedure. When in doubt about adhesive compatibility, flush your system.
Field Installation of Controller Options
Customers who choose to modify their adhesive supply unit with ITW Dynatec manufactured options
should assure that only qualified technicians perform such installations. The installation of options that
require specific procedures and/ or calibration are outlined in this chapter.
Before controller options are installed, always turn the controller’s main power switch OFF. In most
cases, turning the controller OFF will assure that the controller will retain its programmed parameters
and configuration. Re-booting is not necessary.
Adjusting the Pressure Relief Valve
The function of the pressure relief valve is to protect the gear pump(s) and the pump drive compo-
nents from overload and to protect other components from potentially damaging pressure levels.
The system will allow pressures up to 1000 PSI, however, typical factory settings are 500 PSI.
WARNING HIGH PRESSURE, HOT ADHESIVE

NOTE: The following procedure sleeved protective clothing must be worn
will require the hot melt adhesive to prevent the possibility of serious injury
to be at a high temperature and from the molten adhesive. Refer to
the application system to have Chapter 1 and the section entitled
substantial pressure. Safety “SAFETY PRECAUTIONS” for further
glasses, insulated gloves and long- details and First Aid information.
To Adjust Pressure Relief:

Note: This adjustment should be done with a melt pressure gauge or a pressure transducer
installed. Failure to use proper equipment can result in excessive pressure levels.
The pressure relief valves are located on the filter manifolds, which are located under the rear
manifold cover(s), near where the hoses connect to the ASU.
1. Turn the application system ON and raise the temperatures of all components to normal
operating temperatures.
Note: Position a heat-resistant bucket or other waste receptacle under the applicator(s) so that
adhesive will be collected during the adjustment procedure.
2. At the controller, set the motor speed to “0” so that the gearmotor is not turning.
Note: If using a single pump or if using a dual pump with both output streams combined into one,
adjust one of the pressure relief valves fully clockwise to close it off and use the other valve to
adjust that pump’s pressure setting.
Adjustment screw
If using a dual pump with separate glue streams, set the
pressure of each stream with its respective pressure relief
valve.
Turning the
Reference Note #7 on page 10-3 regarding the plug that adjustment screw
counterclockwise
separates the two pressure chambers, if using a dual pump. opens the outlet
This plug must be removed if combining dual streams into and decreases the
pressure to the
one or if using a single output pump. hose.
Turning the
3. The pressure relief valve’s adjustment screw is at the adjustment screw
top of the valve (see diagram). Turn the adjustment clockwise closes
screw counter-clockwise until it stops. the outlet and
increases the
pressure to the
4. At the controller, turn the motor ON to its maximum hose.
operating speed.
Pressure Relief Valve
5. Actuate (open) the valves on the applicator(s) in order to fill them with adhesive and purge air from
the system.
6. Close the valves (those opened in the last step) to stop the flow of adhesive.
7. Using a wrench, turn the adjustment screw clockwise to increase the pressure to the
applicator(s).
CAUTION: Approach desired pressure with caution. Be aware that the higher the
adjusted pressure, the more sensitive the adjustment is (i.e., at higher pressures,
smaller adjustments to the screw will make larger changes to actual pressure).
8. After desired pressure is achieved, stop turning the adjustment screw.
9. While the motor is operating at maximum speed and the applicators are valved on, observe the
adhesive flow from the applicator(s).
10. Reduce the motor speed, in increments of about 10%, until the adhesive flow begins to decrease.
Note: Though the speed of the motor is reduced, there will be no change in the amount of adhesive flow
coming out of the applicator. This is because the pressure relief is designed to allow only a maximum
adhesive pressure regardless of the motor speed past a certain point.
Then, increase motor speed in smaller increments (1 to 5%) until adhesive flow returns to the
desired amount.
Note: This is the optimum point of operation for the motor, pump and pressure relief. It will also facili-
tate the best system performance and reduce wear on these components.
The application system is now adjusted for normal operation.

Pump Enable (Ready) Thermostat Calibration
The Pump Enable (Ready) Thermostat is preset to 132°C (270°F), unless the customer has specified
a different preset temperature on his original ASU order. Generally, the pump enable thermostat is
set approximately 30°C (50°F) lower than the application setpoint. If a different temperature is de-
sired, use the following procedure to re-calibrate the thermostat.
CAUTION: DO NOT set the pump enable thermostat lower than the softening
point of your adhesive or pump damage may result.
As an example: the operator desires to lower the preset Pump Ready temperature to 107°C (225°F).
1. At the controller keypad, set the hopper temperature setpoint to the temperature at which you
want the pump to start, i.e. 107°C (225°F).
Hopper
2. Use the key to unlock the side door, then remove it, being carefull not
to pull out the ground wire attached.
3. Wait for the hopper temperature to stabilize at 107°C (225°F), then:

Pump EnableThermostat
a. For thermostats with purple & black wire leads or tan leads:
turn the thermostat’s adjustment screw counter-clockwise to increase
the temperature (or clockwise to decrease it) until the pump’s
mootor begins turning. Adjust no further.
b. For thermostats with tan (with tracer) wire leads: turn the thermostat’s adjustment screw
clockwise to increase the temperature (or counter-clockwise to decrease
it) until the pump’smotor begins turning. Adjust no further.
4. Replace the side door.
5. At the keypad, re-set the hopper temperature setpoint to its correct “run” temperature.
Calibration of the Optional Voltage Tachometer
A voltage tachometer allows the system operator to monitor gear pump motor speed from the
controller. This information is useful since the amount of glue dispensed per product can be var-
ied by adjusting the motor rpm (an increase in rpm = an increase in glue dispensed).
DANGER WARNING
HIGH VOLTAGE HOT SURFACE
Dynamelt systems use electrical power that can be life threatening and hot-melt adhesives that
can cause serious burns. Be sure to read and follow the safety procedures in Chapter 1 of this
manual. Only qualified persons accustomed to working with live electrical circuits should per-
form this procedure on the Dynamelt system.
Calibration Procedure
1. Turn the application system ON and raise the temperatures of all components to normal
operating temperatures.
2. Turn main power OFF and open the panel box door. Restore power to the ASU.
3. At the controller keypad, verify normal operation in AUTO, STOP and MANUAL modes
(refer to “Motor Control Programming” in Chapter 5 if needed).
4. At the controller keypad, set motor speed to MANUAL mode and to 100% full speed.
5. With an external tachometer, measure the motor RPM.
6. On the Motor Control Interface PCB, turn the MAX ADJUST potentiometer until the RPM of
the external tachometer reads 1800 rpm.
7. Calibration of this motor is complete. If additional motors are used on your application
system, repeat the above procedure for each motor.
8. Close the panel box door and restore application system to normal operation.
Installation of the Optional Tach Generator or a DC Tracking Signal
The installation of a tach generator or a similar DC tracking signal allows speed tracking of the
gear pump through voltage following. Multiple motor boards may be wired in parallel to the tach
generator. On the controller, voltage following is referred to as the “AUTO” Mode of the motor
control.
Installation Procedure
DANGER HIGH VOLTAGE

Dynamelt systems use electrical power that can be life threatening. Disconnect
and lock out input power to the application system before starting any
installation procedures.
1. Disconnect and lockout input power to the application system.
2. Open the panel box and locate the Motor Control Interface Board (see layout illustrtion in
Chapter 7). The device will be connected to the “0” and “10” terminals on X3.
3. A. To install a tach generator:

i. If, when facing the shaft on the tach generator, the rotation of the shaft is clockwise,
connect the black lead wire to the “0” terminal and connect the white lead wire to “10”.
or
ii. If, when facing the shaft on the tach generator, the rotation of the shaft is counter-clockwise,
connect the black lead wire to the “10” and connect the white lead wire to “0”.
iii. Verify that the gear pump motor is running at full speed when set to 100% in MANUAL
mode. The output of the tach generator can be adjusted, depending on the application, but it
must be at least 10 VDC to obtain full adhesive gear pump speed.
Note: under no conditions will the motor ever run faster than this speed (100% Manual).
B. To install a similar DC tracking device (not a tach generator):

Connect the DC tracking voltage signals to the terminals so that the negative lead is connected
to “0” and the positive lead is connected to “10”.
Note: the tracking voltage must be at least 0-10 VDC, but not more than 0-25 VDC.
4. Close the ASU’s panel box door.
5. Re-connect input power and restore the application system to normal operation.
Procede to “Calibration of the Optional Tach Generator or DC Tracking Signal”.

Calibration of the Optional Tach Generator or DC Tracking Signal
After installation of a tach generator (or a similar DC tracking signal), the device must be cali-
brated at the DynaControl controller.
Prior to calibration, turn the application system ON and allow all components to warm up to nor-
mal operating temperatures (above ready temperatures).
1. Perform the following sequence at the controller keypad for each motor:
a. Go to Motors screen.
b. Choose AUTO mode. Press Enter.
c. Scroll to Min % and enter a value of “0”. Press Enter.
d. Scroll to Max % and enter a value of “100”. Press Enter.
2. Energize the parent line (tracking signal) to its full speed (at least 10 VDC at the “0” and “10”
terminals at X3 on the Motor Control Interface printed circuit board).
3. On the Motor Control Interface printed circuit board (see illustration in Chapter 7) locate and
adjust the web speed scaling potentiometer (VR1) clockwise until the “SET %” is below 99.8.
Then adjust counter-clockwise until it equals 99.8%.
4. The system is now calibrated so that full parent machine speed corresponds to full speed of the
gear pump.
The amount of adhesive dispensed can now be adjusted by trimming the pump RPM at the AUTO
menu of the controller by adjusting the “MAX %” value down from the factory default of 100%.
Adjusting the “MIN %” value corresponds to the pump speed when the parent line is stopped (0.0
volts at the “0” and “10” terminals). In most applications, the factory default (MIN % = 0) is
used.
Optional Level Controls
Single Point Level Control

The level control device informs the ASU’s operator, via a “Level Low” message on the Dyna-
control controller’s System Status display, that the ASU’s hopper needs to be refilled or that it is
overfull. It may also be wired to stop production. When the alarm activates, press “C” to reset it.
You then have five minutes to refill the hopper before the alarm reactivates and the ASU’s
pumps stop.
The single point level control monitors a low adhesive level.
The capacitive sensor is mounted in the hopper. The sensor cable is plugged into an amplifier.
DO NOT CUT the sensor cable.
Adjustment of the Single Point Level Control:

To adjust the adhesive level control’s sensitivity, access the control’s amplifier, located inside
the panel box assembly. On the amplifier (diagrammed below) is a sensitivity adjustment screw.
Turn the screw clockwise to increase sensitivity (or counter-clockwise to decrease). The yellow
LED lights to indicate the presence of adhesive. When the LED goes out, the alarm will acti-
vate.
1 2 3 4 5 6
Sensor Sensitivity Adjustment Screw
Connect min max
S
Yellow LED
7 8 9 10 11 12
Amplifier
Multi-Point Level Control

Refer to the level control manufacturer’s manual for complete instructions on its setup and op-
eration.
The multi-point level control is used with customer-controlled devices (not the Dynacontrol
controller). It has the capability for three separately calibrated outputs. However, for most ap-
plications, one output, calibrated with a high and a low level, is sufficient.
The two other outputs may be used as safeties (such as “critical high” and “critical low”) for
multi-ASU systems with bulk feeders.
Typical Start-Up and Shut Down of the DYNAMELT M Application System
The following simplified sequence assumes that the DynaControl Controller has been pro-
grammed.
Start Up Procedures
1. Fill the ASU’s hopper with clean hot-melt adhesive to within a couple of centimeters (inches)
of the top of the hopper. Close the hopper lid immediately to prevent contaminants from
falling in. (Cover your bulk supply of adhesive to prevent contaminants also.)
2. Switch ON the Main Disconnect (the circuit breaker located on the panel box).
3. At the DynaControl keypad, press the controller’s F1 button, if prompted to do so.
4. Allow adequate time (approximately 20-30 min.) for the adhesive to melt and the temperatures
of the temperature zones to stabilize. Monitor the System Status display to see when “Heat
Up” changes to “Ready”. Undertemp arrows will blink until the temperature zones are up to
ready temperature.
5. When temperatures are ready, the pump and motor are enabled to pump adhesive.
At the pump screen:
Select Auto or Manual Mode. Select desired pump, press Enter.
a. If Pump is in Auto Mode: Adhesive will begin to pump when the production line begins
to operate.
b. If Pump is in Manual Mode:

i. Press Manual (F1). Press Enter.
ii. Enter desired speed value. Press Enter.
iii. Scroll to select next pump (if applicable). Repeat steps i thru iii until all pumps are
programmed.
Adhesive will begin to pump once the pump enable thermostat closes and “Ready” condition
is attained.
Shut Down Procedures

At the pump screen:
1. If Pump is in Auto Mode:
a. Press STOP or STOP ALL (F3).
b. Turn OFF the Main Disconnect Switch.
2. If Pump is in Manual Mode:

a. Press STOP or STOP ALL (F3).
b. Turn OFF the Main Disconnect Switch.
3. If 7-Day Scheduler is in use: Turn ON and OFF with the Controller On/Off pushbutton.
Note: Except in the case of the 7-Day Scheduler, use of the Main Power Switch to turn the unit
OFF will avoid unexpected ASU activation in the event of a power outtage.
Storage and Disposal of the DYNAMELT M Application System
Temporary Storage of the Unit
1. Flush the adhesive application system with flushing fluid (PN L15653), following the
instructions detailed in chapter 6 of this manual.
2. Clean or replace both the outlet filter and the primary filter, following instructions detailed
in chapter 6.
3. Shut OFF all pressure and power sources.
4. Release residual air pressure (if applicable).
5. Remove all residual adhesive and wipe components clean.
6. Remove all air lines (if applicable) and all power supply cables.
7. Pack the unit in a corrosion-proof manner.
8. Store the unit in such a way that it is protected from damage.
Disposal of the Unit
1. Shut OFF all pressure and power sources.
2. Release residual air pressure (if applicable).
3. Remove all residual adhesive.
4. Remove all air and adhesive hoses and all power supply cables.
5. Dismantle all components and sort into mechanical and electrical components.
6. Arrange for all components to be recycled.

ITW Dynatec

ITW Dynatec c. 2000 Controller Setup Page 4-1
DYNAMELT M ASU Manual 20-36, 20-37 and 20-38 Revised 5/03
Chapter 4
DynaControl CONTROLLER SET-UP
Temperature Control Functions in General
The DynaControl microprocessor-based proportional temperature control in the ASU performs a

number of functions that help to maintain adhesive setpoints in all temperature zones of the DYNA-
MELT system. It maintains permanent system values (fixed proportional and integration values that
have been programmed at the factory, such as the maximum temperature setpoint). It enables the user
to program temperature settings and heater on/off sequencing that are appropriate to a specific ap-
plication. It displays all programmed values, and it includes self-diagnostic malfunction alerts and
failure alarms. Note: Some DynaControl functions are direct temperature conversions between de-
grees Celsius and Fahrenheit. Other parameters are independently selected values.
Defining DynaControl Temperature Control Terms
Adhesive Temperature Control Range

The temperature limits within which the ASU, hoses and applicators may be programmed and main-
tained.
CPU Module
The central processing unit (CPU) of the microprocessor temperature control.
Cold Start
When the ASU resets itself to default setting due to either a malfunction or to a deliberately initiated
cold start procedure. When the ASU is turned ON via the Main Power Disconnect Switch.
Default Settings
The factory-set programmable system values that will be in effect if the user does not enter new val-
ues. The controller will revert to its defaults whenever it is reset. The DynaControl controller’s de-
faults are listed in this chapter.
Error Indication Alarms

Alarms which indicate that the programmed over-temperature values have been exceeded for one or
more hopper, hose or head zones. Alarms may also indicate an open or short-circuited sensor.
EtherNet Serial Communication

A bi-directional data transfer connection to a remote PLC which enables system parameters to be
monitored and/ or controlled from the remote station.
Mechanical High-Temperature Protection

A mechanical, redundant thermostat located on the hopper which turns OFF the system at 232C
(450F).
Microprocessor-based Proportional Temperature Control

The built-in control system that controls, monitors and displays all system temperature values.
Page 4-2 Controller Setup ITW Dynatec c. 2000
Revised 10/00 DYNAMELT M ASU Manual 20-36, 20-37 and 20-38
Over-Temperature Setpoint
The programmable temperatures that will cause alarms (blinking up and down display arrows) to
occur when those temperatures are exceeded. Power is not disconnected, the READY contact opens
and the alarm contact opens. If an external alarm has been connected, it will activate. The over-temp
setpoint is the upper limit of the ready temperature range of each zone.
PC Link
Also referred to as remote I/O interface, this is a DynaControl controller option that allows monitor-
ing and programming from a customer-provided PLC (programmable logic controller) or a PC (per-
sonal computer).
P-I Loop
A temperature control loop which bases heater output proportional (P) to the difference betweeen
setpoint and actual temperature and combines it mathematically with a time (I = integral) factor.
Power I/O PCBs

The Power I/O printed circuit board (PCB) provides control signals to, and monitoring signals from,
all the temperature zones in the ASU’s system. The ASU’s hopper, hoses and applicators are con-
trolled by the Power I/O PCB.
Pump Enable Temperature

The pump enable temperature protects the pump, pump shaft, motor and motor control board from
damage by not allowing the pump to activate until a low limit (the programmed pump enable tem-
perature) is achieved.
RTD Sensors
The standard Dynamelt system uses 100-ohm platinum resistance temperature detector sensors for
all temperature controls. As an option, the unit can be configured for 120-ohm nickel sensors.
Ready Temperature
The programmable temperature, on gear pump models, which allows the ASU pump to turn ON.
The default ready temperature range is a deviation of ± 20°C (± 36°F) from the setpoint. The set-
point minus the deviation is the low limit of the range, and the setpoint plus the deviation is the high
limit of the range.
Recipe
A program recipe is a set of temperature setpoints and parameters which the user has programmed
and wishes to store in the controller for future use. Up to four recipes may be stored in the Dyna-
Control controller.
Sequential Heating
The heating sequence which allows the slower-heating hopper to reach operating temperature with-
out unnecessary use of electricity for faster-heating hoses and applicators. Sequential heating is the
time period during which the hoses and applicators remain OFF while the hopper (and optional
drop-in grids) heats up. Hoses and applicators may be independently programmed. If hopper tem-
perature is above ready temperature when the ASU is turned ON, the hose and applicator cont.
sequence is bypassed and they will be turned ON. The heat up sequence is restored after Standby
is turned from ON to OFF. Sequential heating is not needed for most applications and can delay
total system warm-up time.
Standby Condition
The system condition where the ASU, hose and head temperatures are maintained at predeter-
mined reduced temperature values. Standby temperatures are set lower than setpoint temperatures
in order to reduce adhesive degradation and energy consumption when the system is temporarily
inactive, and to permit rapid system warm-up when run condition is selected.
Setpoint
A programmable temperature that has been selected for hopper, hoses, applicators or auxiliary
zones.
Setpoint Limitation
This is a universal maximum temperature for all zones. The programmer cannot program a tem-
perature setpoint higher than the setpoint limitation.
System Logbook
This is the controller’s record-keeping function. It contains the DynaControl’s list of the last
1,000 controller events, its Data Logger which records the last 1000 lines of selected actual tem-
peratures and a counter which records the system’s elapsed hours.
Temperature Zone Enable

The temperature zone enable allows the operator to disable unused temperature zones in such a
way that they do not ever appear on the controller’s display and heating is switched OFF.
Temperature Zone Offset

Due to the separation between the heaters and sensors in some systems, the controller can be pro-
grammed to display a temperature for a zone which is different from the sensor’s actual tempera-
ture. The temperture zone offset mathematically corrects for these temperature differences. Each
zone may have an individual offset.
Error Indication & Alarms
Error Indication (Blinking Up and Down Arrows)

The following illustration shows the display screen when one or more error indication conditions
occur. The conditions that will trigger an error indication are:
a. When a hopper, hose, head or auxiliary zone has exceeded its selected over-
temperature setpoint, which is the setpoint plus its high/low alarm setting, or when it
is below its selected under-temperature setpoint, which is the setpoint minus its high/
low alarm setting. In these cases, heater power will not be switched off.
b. When a hopper, hose, head or auxiliary zone sensor has an open circuit. In this
case, heater power will be switched off.
Blinking up arrow indicates overtemp. Blinking down arrow indicates undertemp.
SYSTEM: Alarm Tue. 3:36 PM

Actuals ° F Next Page Press C
1.
1 2.
2 3.
3 4.
4 >
Premelt 300 310 SYM ABC DEF
Progmelt 299
Filterblock 300
Hose 274 273 251 ? GHI JKL MNO

Head HOLD HOLD HOLD
Aux Zone ? ?
Pump MANU MANU STOP STOP

% HOLD HOLD HOLD HOLD PRS TUV WXY
SETPOINTS PUMP PRESSURE HELP
<
C
Delete En- > ABC/123
ter
“?” indicates no sensor (open circuit).

Error Alarms (Message Window)

The display of a message window, as illustrated below, signifies an error alarm. The operator’s re-
sponse to an error alarm is to press “F4” and to troubleshoot.
If a sensor error alarm or an overtemperature alarm occurs during operation, the controller will
switch off internal power to the heaters and an appropriate error alarm display will appear.
Pressing the “F4” function key acknowledges the error. If several zones display alarms, each must
be acknowledged by pressing “F4”. The alarm display is switched off and the controller then
switches off the faulty zone until the ASU is ready for operation again.
When the actual temperature exceeds the setpoint limitation (plus a tolerance) the overtemperature
alarm window is displayed and main power is switched off.
Examples of Error Alarms

Overtemperature
The Overtemperature Alarm indicates that the named
zone has exceeded its programmed setpoint limitation. Zone Name ##
The controller will shut off power to the heaters. Press
F4 and troubleshoot the problem.
The Sensor Failure Alarm can indicate either a sensor

open or a sensor short. Sensor open is accompanied by Sensor Failure
a blinking up arrow on the actual temperatures display
screen. Sensor short is accompanied by a blinking down Zone Name ##
arrow. Press F4 to reset the error message and then either
a. manually turn the zone OFF (via Setpoints F1/ indi-
cated zone/ On/Off F3), or b. troubleshoot the problem.
The Hopper Overtemp Alarm indicates that adhesive

temperatures in the ASU’s hopper have exceeded the Hopper Overtemp
setting of the mechanical (redundant) thermostat.
Press F4 and troubleshoot the problem.
The Communication Error Alarm indicates an internal

failure, unrelated to zone temperatures. Call ITW
Dynatec for assistance. Communication error
Optional System Status Lights Audible

Alarm
This tri-color stack light eases remote monitoring of the system’s status. Red Alarm
The lower, white light illuminates when the system is turned ON. The
middle, green light indicates that the system has warmed up to temperature
setpoints (“ready”). The upper, red light illuminates only in an alarm Green System
Ready
condition and is accompanied by an audible alarm. The audible alarm is
housed within the upper (black) section of the stack. White Power
“ON”
The status lights may be wired to indicate either high/low temperature, low
adhesive level or open/short sensor. See Chapter 11 for wiring diagram.
Settings for a Typical Operation
Note: The values given here are approximate settings for a typical packaging operation. The values
you choose will be based on the type of equipment and adhesive you are using and the nature of
your particular operation.
If Application Temperature is 177°C (350°F):
∙ Hose and head temperature: 177°C (350°F).
∙ Hopper setpoint temperature: 163°C (325°F).
∙ Hi/ Lo limit deviation: 12°C (20°F).
∙ ASU operating range: 149°C to 177°C (300°F to 350°F).
∙ Standby condition temperature (deviation): 30°C (50°F).
∙ Hopper over-temperature setpoint : 177°C (350°F)
∙ Mechanical thermostat (for the hopper) over-temperature: 219°C (425°F)
For most operations, temperature fluctuations will be very small and of short duration. For these
reasons, the settings above are recommended.
System Values That Are Factory Programmed (not customer programmable)
∙ Minimum setpoint value: 10°C (50°F).
∙ Maximum setpoint value (Setpoint limitation): 218°C (425°F).

” ” ” for high temp mode enabled ASUs: 232°C (450°F)
∙ Maximum alarm deviation: 50° (C or F).
∙ Minimum alarm deviation: 5° (C or F).
∙ Maximum standby temperature: 150° (C or F) less than setpoint.
∙ Minimum standby temperature: 30° (C or F) less than setpoint.
∙ “Actual” temperature indication range: 0°C to 260°C (32°F to 500°F).
Customer Programmable Values Preset At The Factory
ITW Dynatec can set the controller’s system values to customer’s specs, if provided.
If customer’s specs are not provided, the following values will be entered into the DynaControl con-
troller at the factory. They may be changed by reprogramming through the keypad. (These are not
the “default” settings, see following section).
∙ Applicator (head) and hose setpoints: varies from 138 to 149°C (280 to 300°F).
∙ Hopper setpoint: 143°C (290°F).
∙ All zones are switched off, except for the hopper and the optional drop-in grid.
∙ Motor rpm: 0 in the “OFF” mode.
∙ Standby: 80°C (140°F) under setpoint.
∙ Hi and low alarms: ± 12°C (20°F) from setpoint.
∙ Pump enable temperature: 132°C (270°F).

Default Settings of the DynaControl Controller
Default settings are the manufacturer’s preset values to which the system will return if the Dyna--
Control is subjected to an internal memory reset (also referred to as a “re-boot”). While you can
change your programmed values to anything within the system’s limits, the default settings cannot
be changed.
Defaults
· Language: English
· Setting for Customer Access Code: “9999”.
· Temperature setpoint for each zone: -- -- --
· Hopper ready temperature: 135°C (270°F).
· Over-temperature limit: Your chosen setpoint limitation + 10° C or F.

For example: if your setpoint limitation is 218°C (425°F), then your over-temp limit = 228°C (435°F).
· Standby temperature for all zones: 80°C (140°F) lower than programmed setpoints.
· Hi/ lo limit deviation for all temperature zones: ± 20°C (36°F).
· Temperature zone offset: 0°C (0°F).
· Sequential heating: first hopper zones, then hose/ head zones and auxiliary zones.
· Setpoint limitation: 218°C (425°F).
· Minimum pump speed: 0% of full speed.
· Maximum pump speed: 100% of full speed.
· Proportional Integral values (P-I values): for Premelt, Hopper and Filterblock temperature
zones, P = 30F and I = 2. For all other zones, P = 20F and I = 2
Helpful Tips for the User
∙ When the ASU is turned ON, all temperature setpoints and other operating parameters will
be exactly where they were when the ASU was turned off.
∙ When the ASU is turned ON, all system heaters go ON if the automatic heater startup is
enabled and if setpoints are programmed unless sequential heatups have been set. However, if
hopper temperature is above ready temperature when the ASU is turned ON, all hose and
head sequential heatups will be bypassed and hoses and heads will be turned ON.
∙ If the system is turned OFF and then ON again, the standby condition will be disabled.
Revised 6/08 DYNAMELT M ASU Manuals 20-36, 20-37, 20-38
PN 112224 M Series DynaControl EtherNet/IP Adapter Option, V1.06
General
This optional adapter provides an EtherNet/IP connection for Dynamelt M Series hot melt ASUs.
This connection makes it possible to monitor and control the basic functions of the hot melt unit
from a remote PLC or PC.
This adapter uses an ODVA approved module. In order to fully operate, the Dynamelt M must
be equipped with firmware rev. V5.15M or later.
Basic Features:
- 10/100 Mbit/s
- DHCP/BootP
- Access to basic process parameters
- Local and remote access
- Watchdog signal
DYNAMELT M ASU Manuals 20-36, 20-37, 20-38 Revised 8/05
Installing the EtherNet/IP-Adapter in a ControlLogix5000 System
These installation steps assume that RSLogix5000 and ControlLogix5000 with an EtherNet/IP
module/bridge (1756 ENBT or similar) are set up and working properly.
1. Connect the Dynatec Hot melt unit (ASU) to the Ethernet network using a standard RJ45-
cable.
2. Start RsLogix5000 with a new or existing project. Set to “Offline” mode.
3. Add the EtherNet/IP-Adapter to the PLC Configuration:

- Start by right clicking the EtherNet/IP module/bridge in the configuration
- Select “New Module”
- Select “Generic Ethernet Module”
- Press OK
4. Configure the EtherNet/IP-Adapter:
- Enter the name of the module. (for example “Dynatec_Melter”. If you desire to import
the controller tags provided on the CD-ROM, the module name must be exactly
“Dynatec_Melter”. See step #6 following).
- Set Comm Format to “Data-INT”, since all data are 16-bit words
- Set Connection Parameter Assembly Instance to 100 for Input and 150 for Output
- Set Size for 180 input/ 80 output (16 bit)
- Set the Configuration Instance to 1 but the size to 0 since this instance is not supported
- Set the IP-Address to 192.168.23.180. For more details about IP-Address see the following
section, “Changing the IP-Address”
- Press Next >
- On next dialog, select Requested Packet Interval: 100ms
- Do not Inhibit Module
- Press Finish >>. On the main screen you should see the ETHERNET-MODULE under
the I/O Configuration
- Select “ Go Online” from the “Communications” menu
- Select “ Download” in the next window
- Confirm the Download
5. Checking the I/O Tags

After successful configuration of the EtherNet/IP-Adapter, it is possible to access the
input/output data. There are three Controller Tags: “Dynatec Melter: C”, “Dynatec Melter: I”
and “Dynatec Melter: O”. The input/output tags consist of 180/ 80 words each.
“Dynatec Melter: C” is the configuration tag (not used).
“Dynatec Melter: I” is the data coming from the Dynatec hot melt unit
“Dynatec Melter :O” holds the data going to the hot melt unit.
The definitions of the data tags are explained on the last pages of this section.
6. Importing Controller Tags
The CD-ROM that is provided with the EtherNet/IP option contains a pre-defined controller tag
table. In order to save time, this table may be imported.
- In the RSLogix5000 go offline
- Select Tools -> Import Tags
- Select the “Dynatec-Controller-Tags_DMM. CSV” from the CD-ROM
- Click Import
- If the import was successful, the Report Window in the lower part of the screen should
indicate 242 imported tags.
- Go online again
- Go back to the controller tag screen and verify the tags.
Details on the Communication
General Information
The In- and Out- data table (Controller Tags) contain all parameters for a maximum equipped
hot melt machine. In most of the cases, only parts of the parameters are needed.
The temperature zones are logically organized, first all premelt zones, progmelt zones (=
hopper), then filter blocks up to the auxiliary zones. The number of actually available zones
depends on the type of machine.
- Setting LocalAccessTemps to 1 allows the user to make changes to the temperature
setpoints on the hotmelt unit. The PLC can read the changes from the corresponding IN-
words but the temperatures in the OUT area will not be effective on the hot melt unit.
- Setting LocalAccessTemps to 0 switches the control back to PLC control. All

temperature OUT-words will be transferred to the hot melt unit. A local change of
temperature setpoints is not possible since the PLC will instantly overwrite the entry.
- LocalAccessMotors controls the access to pump settings analog to the description above.
- After a local change of setpoints, the PLC first must read the new setpoints before
switching back to PLC control.
- It is not possible to deactivate a temperature zone locally on the hot melt unit since the
PLC always sends the ZoneEnable/Disable information.
Zones Enabling/Disabling
Temperature zones that are temporarily not used can be remotely deactivated by setting a
corresponding value to OUT-word 70 to 75. Each bit of this word represents one temperature
zone. Bit0 = zone1, Bit1 = zone2 etc. Setting the bit will activate the zone. Resetting will
deactivate the zone.
Pump Control
There are several ways to control pump speed:
1. Manual Mode: the pump speed can be programmed locally on the hot melt machine. In
order to allow this mode, the OUT-word 50 (for pump 1) must be set to 77
(ASCII “M”). Local Access PUMP (OUT-word 63) does not have to be
set.
2. Automatic Mode: the pump speed is controlled via a 0 to 10V signal, connected to the hot
melt machine. In order to activate this mode, the OUT-word 50 (for pump
1) must be set to 65 (ASCII “A”).
The pump speed, which follows the line speed can be read in IN-word 134
(for pump 1). This value shows 0.1% resolution.
3. Stop Mode: The pump is stopped.
4. Bus Mode: the pump speed is controlled via OUT-word 56 (for pump 1). Out-word 50
(for pump 1) must be set to 66 (ASCII “B”). On the keypad of the hot melt
machine, the pump speed can be fine tuned by using the min. and max.
scaling, similar to the Automatic Mode.
The speed setting must be transmitted in increments of 0.1% (0 to 1000 =
0.0 to 100.0%).
Adhesive Level Indication

Word 142/ 143 (142 = single hopper/ 142 & 143 = dual hopper) shows the state of the optional
adhesive level control. A 0 indicates the level is O.K. and a 1 indicates a low-level situation.
This signal is an instantaneous non-latched indication.
In order to avoid local low-level indications, which have to be reset on the keypad, the low-level
detection should be disabled in the customer set-up menu of the Dynamelt M hot melt unit.
Zone Status Indication
The status of all temperature zones can be read in IN-word 146 to 175. This information is bit-wise
coded and organized in zone type.
Examples:
IN-word 146: 0003h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 1 1 premelt 1& 2 are switched ON

IN-word 150: 003Fh 0 0 0 0 . 0 0 0 0 . 0 0 0 0 .0 0 1 1 .1 1 1 1 6 heads are switched ON
IN-word 156: 003Fh 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 1 1 1 1 4 heads are in waiting position
IN-word 159: 0001h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 1 the progmelt (hopper) is heating
IN-word 167: 0020h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 .0 0 1 0 .0 0 0 0 hose 6 is ready
IN-word 175: 0011h 0 0 0 0 . 0 0 0 0 . 0 0 0 0 . 0 0 0 1 .0 0 0 1 auxiliary zones 1 & 5 show alarm
Identification Word
OUT-word 79 is used as an identification word. This word must be set to a certain value to
validate the communication. If this word is set differently, the hot melt unit will not accept the
OUT area although the IN-area will show proper values. Dynamelt M hot melt units require ID-
word set to 68 for unmonitored communication or a toggling word of 0/1 for monitored
communication. If toggle mode is used, the word should toggle once per second to validate
communication. Once toggle mode is used, the unmonitored communication can’t be used again.
In monitored communication, the Dynamelt unit switches off pumps after 4 seconds if
communication seems to be broken. Dynatec recommends use of the monitored communication
for security reasons.
Examples for a typical communication
Initializing: Set OUT 76 to 1 : Switches the controller on

Set OUT 79 to 68 : Identifies the communication
Set OUT 77 to 0 : No standby, normal mode
4-Hose Operation: Set OUT 73 to 15 : Hoses 1 to 4 are switched ON

Set OUT 74 to 15 : Heads 1 to 4 are switched ON
6-Hose Operation: Set OUT 73 to 63 : Hoses 1 to 6 are switched ON
Set OUT 74 to 63 : Heads 1 to 6 are switched ON
Check Ready Condition: Compare IN 146 with 164

Compare IN 147 with 165
Compare IN 151 with 169: If all comparisons are equal, the system
is ready
Check Alarm Condition: Read In 170 to 175 If any word does not equal 0, an alarm
is
present
Changing the IP-Address
The EtherNet/IP-Adapter will be factory set to 192.168.23.180 but the DHCP/BOOTP function is
enabled. That means the module will request a new IP-address after power up. If this request is not
serviced, the old IP-address will be valid.
There are several ways to change the IP-address. In any case, a PC must be connected to the
module, either directly via crossover cable or via hub/switch to the network with the module.
Configuration Program ‘Anybus IPconfig’
On the EtherNet/IP support disc you will find a configuration tool to change the IP-Address.
Start the Anybus IPconfig installation program. Follow the instructions on the screen.
Once the configuration tool is running, press the scan button to search for any Dynatec-
EtherNet/IP modules. If a module is detected, it will show up in the window. Double clicking on
it will allow changing the settings for this Module.
Using the Configuration File

The file ethcfg.cfg can be used to change the IP-address. This method is possible only if the
actual IP-address is known (e.g. the factory set 192.168.23.180), See also section “Configuration
File”.
- Open a FTP connection to the module (e.g. Windows Explorer™ FTP://192.168.23.180)
- Locate the ethcfg.cfg
- Copy this file to a folder on your PC
- Open the file with any text editor
- Change the IP-address
- Save the file using the same name
- Copy the file back to the module
- Re-cycle power on the module (hot melt unit)
Note: If the configuration file ethcfg.cfg is not found, the module will automatically activate a
DHCP/BOOTP request.
Using the BootP-Server Function

The BOOTP-Server comes with the RSLinx Tools of the Rockwell Automation™ Software or
can be downloaded as a stand-alone application. Version V2.3.2 or newer allows to change the
IP-address of the EtherNet/IP module.
Note: The EtherNet/IP module only requests an IP-address assignment for approx. 30 sec.
If this request is not serviced within this time (by entering the desired IP-address in the relation
list) the module’s power (hot melt machine) must be re-cycled.
Diagnostic LED’s
PN 112224 EtherNet/IP-Adapter
MAC-Addr.
1. Net Stat. = Network Status
State Summary Description

Steady Off No power or no IP The module has no power or no IP address has
address been assigned.
Steady Green Connected The module has at least one established

EtherNet/IP connection.
Flashing Green No connections There are no EtherNet/IP connections established to

the module.
Flashing Red Connection Timeout One or more of the connections in which this module
is the target has timed out. This state is only left if all
timed out connections are re-established or if the
module is reset.
Steady Red Duplicate IP Address The module has detected that its IP address is
already in use
Flashing Self-Test The module is performing a power on self test

Green/Red
2. Active
This led flashes green each time a packet is received or transmitted.
3. Mod. Stat. = Module Status
State Summary Description

Steady Off No power The module has no power.
Steady Green Device operational The module is operating correctly.
Flashing Green Standby The module has not been configured.
Flashing Red Minor Fault A minor recoverable fault has been detected
Steady Red Major Fault A major internal fault has been detected
Flashing Self-Test The module is performing a power on self test

Green/Red
4. Link = Link Activity
Color State Description

The module has a link
Green On
Off The module does not sense a link
Configuration File
The EtherNet/IP module contains a file (ethcfg.cfg) that is read by the module at start up. This
file defines the network properties of the module. Any text editor can be used to edit the
parameters.
Note: It is very important to follow the exact syntax specification, otherwise the module might
have problems interpreting it, which can result in a faulty or non-expected behavior.
The file can be uploaded and after modification, downloaded using the FTP function.
(e.g. open a Windows Explorer window. Type ‘FTP://192.168.23.180’)
The format of the file is shown as follows:
FORMAT EXPLANATION
[IP address] IP Address
192.168.23.180
[Subnet mask] Subnet mask
255.255.255.0
[Gateway address] Gateway address
0.0.0.
[DHCP/BOOTP] DHCP/BootP
ON ON - Enabled
OFF – Disabled
[SPEED] Speed
Auto Auto – Default. Auto Negotiation will be used.
100 – Forces the module to operate at 100Mbit/s only
10 – Forces the module to operate at 10Mbit/s only

FORMAT EXPLANATION
[Duplex] Duplex
Auto Auto – Default. Auto negotiation will be used.
Full – Forces the module to operate at full duplex only
Half - Forces the module to operate at half duplex only
[SMTP address] SMTP server/ login settings
0.0.0.0
[SMTP username] SMTP server/ login settings
username
[SMTP password] SMTP server/ login settings
password
[DNS1 address] Primary and Secondary DNS
0.0.0.0
[DNS2 address] Primary and Secondary DNS
0.0.0.0
[Domain name] Domain Name (Optional)
hms.se
[Host name] Host Name (Optional)

Date: 08.11.05
Dynacontrol - EtherNet/IP Data Table Page 1 of 5
IN-Area (Dynacontrol to PLC) Version: V5.18M
Word
Address
Function Zone Name Valid Range
0 Reserved
1 Reserved
2 Setpoint Premelt 1
8 Setpoint Progmelt 1
11 Setpoint Filterblock 1
14 Setpoint Hose 1
15 Setpoint Hose 2
16 Setpoint Hose 3
17 Setpoint Hose 4
18 Setpoint Hose 5
19 Setpoint Hose 6
20 Setpoint Hose 7
21 Setpoint Hose 8
22 Setpoint Hose 9
23 Setpoint Hose 10
24 Setpoint Hose 11
25 Setpoint Hose 12
100°F - 425°F
26 Setpoint Head 1
27 Setpoint Head 2
28 p
Setpoint Head 3
29 Setpoint Head 4
30 Setpoint Head 5
31 Setpoint Head 6
32 Setpoint Head 7
33 Setpoint Head 8
34 Setpoint Head 9
35 Setpoint Head 10
36 Setpoint Head 11
37 Setpoint Head 12
38 Setpoint Auxiliary 1
50 Motor Mode 1
51 Motor Mode 2 S' (83) = Stop
52 Motor Mode 3 'M' (77) = Manual ( Local manual speed)
53 Motor Mode 4 'A' (65) = Auto (0 to 10V)
54 Motor Mode 5 'B' (66) = Bus (EtherNet/IP: OUT 56 to 61)
55 Motor Mode 6
56 Motor Speed 1
57 Motor Speed 2
58 Motor Speed 3 0 to 1000 = 0.0 to 100.0% [500 = 50.0%]
59 Motor Speed 4 (Local manual speed)
60 Motor Speed 5
61 Motor Speed 6
Date: 08.11.05
Word
Address
62 Pressure Channel 1
67 Pressure Channel 6 0 to 1500 PSI
68 Pressure Channel 7 (requires digital pressure readout option)
74
75
76
77
78
79
80 Actual Temp. Premelt 1
86 Actual Temp. Progmelt 1
89 Actual Temp. Filterblock 1
92 Actual Temp. Hose 1
0 to 500°F (1999 = open sensor / 999 = shorted sensor)
104 Actual Temp. Head 1
116 Actual Temp. Auxiliary 1
Date: 08.11.05
Word
Address
128 Actual Pump Speed 1
130 Actual Pump Speed 3 0 to 1500 = 0.0 to 150.0 RPM
131 Actual Pump Speed 4 (requires RPM readout option)
134 Line Speed 1
135 Line Speed 2
136 Line Speed 3
0-1000 = 0 to 100.0% (0 to 10V)
137 Line Speed 4
138 Line Speed 5
139 Line Speed 6
140 Controller ON/OFF 0 = Controller is OFF / 1 = Controller is ON
141 Standby ON/OFF 0 = Normal Mode / 1 = Standby is active
142 Adhes. Level Status 1
0 = Level is OK / 1 = Level is low (requires level control option)
143 Adhes. Level Status 2
144
145
146 Premelts On/Off Bit0 to Bit 5
147 Progmelts On/Off Bit0 to Bit2
148 Filterblocks On/Off Bit0 to Bit2
0 = Zone is OFF / 1 = Zone is ON
149 Hoses On/Off Bit0 to Bit11
150 Heads On/Off Bit0 to Bit11
151 Aux. Zones On/Off Bit0 to Bit11
152 Premelts Waiting g
153 Progmelts Waiting
154 Filterblocks Waiting
0 = Zone is not waiting / 1 = Zone is waiting
155 Hoses Waiting
156 Heads Waiting
157 Aux. Zones Waiting
158 Premelts Heating
159 Progmelts Heating Each zone is
160 Filterblocks Heating represented by the
0 = Zone is not heating / 1 = Zone is heating
161 Hoses Heating corresponding bit in
162 Heads Heating these words
163 Aux. Zones Heating
164 Premelts Ready
165 Progmelts Ready
166 Filterblocks Ready
0 = Zone is not ready/ 1 = Zone is ready
167 Hoses Ready
168 Heads Ready
169 Aux. Zones Ready
170 Premelts Alarm
171 Progmelts Alarm
172 Filterblocks Alarm
0 = Zone has no alarm / 1 = Zone has alarm
173 Hoses Alarm
174 Heads Alarm
175 Aux. Zones Alarm
176
177
178
179 Watchdog Signal toggles every 0.5sec. (0/1)
Date: 08.11.05
OUT-Area (PLC to Dynacontrol) Version: V5.18M, 06/08
Word
Address
0 Reserved
1 Reserved
14 Setpoint Hose 1
15 Setpoint Hose 2
16 Setpoint Hose 3
17 Setpoint Hose 4
18 Setpoint Hose 5
19 Setpoint Hose 6
20 Setpoint Hose 7
21 Setpoint Hose 8
22 Setpoint Hose 9
23 Setpoint Hose 10
24 Setpoint Hose 11
25 Setpoint Hose 12 100°F - 425°F
26 Setpoint Head 1 only active if Local Access Temps. O.Data[62] is set to 0
27 Setpoint Head 2
28 p
Setpoint Head 3
29 Setpoint Head 4
30 Setpoint Head 5
31 Setpoint Head 6
32 Setpoint Head 7
33 Setpoint Head 8
34 Setpoint Head 9
35 Setpoint Head 10
36 Setpoint Head 11
37 Setpoint Head 12
50 Pump Mode 1
51 Pump Mode 2 S' (83) = Stop
52 Pump Mode 3 'M' (77) = Manual ( Local manual speed)
53 Pump Mode 4 'A' (65) = Auto (0 to 10V)
54 Pump Mode 5 'B' (66) = Bus (EtherNet/IP: OUT 56 to 61)
55 Pump Mode 6
56 Set Speed Pump 1
57 Set Speed Pump 2
58 Set Speed Pump 3 0 to 1000 = 0.0 to 100.0% [500 = 50.0%]
59 Set Speed Pump 4 only active when pump in in Bus-Mode
60 Set Speed Pump 5
61 Set Speed Pump 6
Date: 08.11.05
OUT-Area (PLC to Dynacontrol) Version: V5.18M
Word
Address
62 Local Access Temps. all temp. zones set to 1 enables setpoint changes on keypad set
63 Local Access Pumps all pumps to 0 enables setpoint changes via EtherNet/IP
64
65
66
67
68
69
70 Premelts On/Off Bit0 to Bit 5
71 Progmelts On/Off Each zone is Bit0 to Bit2
72 Filterblocks On/Off represented by the Bit0 to Bit2
each bit: 1 = zone enabled
73 Hoses On/Off corresponding bit in Bit0 to Bit11
74 Heads On/Off these words Bit0 to Bit11
75 Aux. Zones On/Off Bit0 to Bit11
76 Controller ON/OFF set to 0 to switch off / set to 1 to switch on
77 Standby ON/OFF set to o for normal mode / set to 1 for standby mode
78
79 Identification Word DM-M: has to be set to 68 or toggled 1/0 for monitored communication
Page 4-24 Troubleshooting ITW Dynatec c. 2005
ITW Dynatec

ITW Dynatec c. 2000 Programming Page 5-1
DYNAMELT M ASU Manual #20-36, 20-37, 20-38 Revised 5/01
Chapter 5
PROGRAMMING INSTRUCTIONS
FOR DynaControlä CONTROLLER WITH EXPANDED KEYPAD V.5.00c & UP
Controller Safety Consideration
DANGER HIGH VOLTAGE

Never open the control panel without switching off the main disconnect switch
to ensure that it is disconnected from its power source.
The printed circuit boards should always be carefully removed. DO NOT handle the boards except
by their edges. Read the section on PCBs in Chapter 7 of this manual for further cautions.
Software Version
You can determine the software version of your controller by noting it when it comes up on the
Help Screen or on the display at startup:
* * * ITW Dynatec * * *
M-Control V 5.00c
Current Software Version

Page 5-2 Programming ITW Dynatec c. 2000
Revised 12/02 DYNAMELT M ASU Manual #50-13, 20-36, 20-37, 20-38
Display & Keypad Reference

Scheduler Key:
Standby
System Status: Day/Date Clock
Ready Scheduler Active Indicator 7-Day Scheduler
Heat up Program Recipes
Alarm Day of Week
Standby Time of Day Service Key On/Off Key & LED
Numeric Entry Keys

1.
1 2.
2 3.
3 4.
4 >
Progmelt 299
Filterblock 300

Head HOLD HOLD HOLD
Aux Zone ? ?
Pump AUTO PRS TUV WXY

% HOLD
SETPOINTS PUMP PRESSURE CLEAR
<
C
> ABC/123
Delete En-
Delete En-
terter
Arrow Symbol = use to enter Enter

“%” or
“RPM” if optional actual Keys a space, colon, dash, 0 = toggle from nu-
RPM readout is installed dot, “Q” or “Z” into meric (1,2,3) to alpha-
text Continued betic (A,B,C) entry
< >
Display & Function Keypad Numeric
(Actual Temps Screen shown as example) Keypad
current software version

Program #: P# *** M-Control *** V5.00c C Flashing “C” indicates
P1, P2, P3 or P4 optional serial commu-
Press Enter to activate or confirm nication (PC Link) is ON
1, 2, 3 Enter a numeric value with 0 - 9 keys

A,B,C Enter a letter on the alpha-numeric
This item or this screen is locked
F This item is factory setup* only
< > Press button C to see more zones
* Factory Setup = can be
HELP Screen (F4 on Actual Temperatures Screen) modified by ITW Dynatec’s
technicians only
Display Reference, cont.

Condition of Pump Enable Thermostat
Black box = item is selected for programming
Numeric Entry Screen continues,

Keys press “C” to view
System Status Line SYSTEM: Alarm Lo Tue. 3:36 PM
SETPOINTS °F Next Page Press C Zone Status:
1 2 3 4 > ### = Temperature
Premelt 300 301 HOLD = In priority queue,
Progmelt 299--------------299 waiting for release
Filterblock 380 = Over temp
Zone Names
Hose 274 273 251 273 = Under temp
Head ------ ------ ------ ------ -- -- -- = Off
Aux Zone ------ ------ ? = no sensor
Information lines INFO: UPPER PREMELT GRID Zo: 1 Zo: # = this is the
Set: 300°F Act: 300°F Tol:±30°F 1, 2, 3 controller’s identifica-
RETURN tion # for each zone
Function keys:
Scroll Up, Down or Right Programming entry:
“Return” to last screen 1,2,3 = numeric only
Go to “Pressure” screen A,B,C = alpha only
Go to “Pump” screen
Toggle “On/Off”
“All _ _ _” = all in category Function keys:
“ABC/abc” = letter case F1, 2, 3, 4
“Clear” an alarm or message
“Copy” = copy word(s) to a clipboard
“Paste” = paste copied words into text Setpoint Programming Screen
“CLR Line” = clear entire line
Dashed line (------) indicates Progmelts are
linked (models M70/140/210 only)
For illustrations of the screens of the Dual Hopper ASUs, see pages 5-28 & 29.
SYSTEM: Ready Tue. 3:36 PM

Press Enter and Select Mode Actual RPM =
Set Min Max Actual optional display
Pump Mode % % % RPM (tach generator
required)
1 MANU. RUN 90.5
2 AUTO. 5.0 5.0 80.0 RUN 87
3 STOP RUN
User-chosen name INFO: RIGHT PUMP Mtr 1 Lock = this screen is

locked from further
Function key: MANUAL AUTOMATIC STOP Delete
RETURN
En- programming
“Manual”, “Automatic” or ter
“Stop” = pump modes
“Restart” pump
“All Stop” = stop all pumps
Arrow
Motor Programming Screen
Keys
Pump Programming Screen

Basic Programming Sequence: Quick Reference
Follow the screen-by-screen steps outlined in the remainder of this chapter for complete setup and
programming instructions. Thereafter, use this page as a “quick reference”.
Press
Turn Controller On
x2, 6 Language Selection
x1, 8 Temperature Scale Selection
F4 Actual Temperatures:
F1 To Program Setpoints
F2 To Program Pump/ Motor(s)
F2 To Program Optional Clutch(es)
F3 To Program Optional Pressure Transducers
x1 Service Page 1:
1 = High Low Temperature Deviation 6 = Temperature Offset
2 = Setback Temperature 7 = Sequential Heating
3 = Setback/ Sleep Setup 8 = Temperature Scale
4 = Setpoint Limitation 9 = Change Security Lock or Access Code
x2 Service Page 2:
1 = Customer Zone Names 6 = Language
2 = Power On Configration 7 = LCD Contrast
3 = Factory Defaults 8 = System Logbook
4 = Keypad Locking 9 = Change Security Lock
5 = PC Link
To Program Scheduler
1 = Manual Standby Activation 4 = Select Program Recipes
2 = Time & Date Clock 5 = Manual Scheduler Activation
3 = Program 7-Day Scheduler
End
Controller Setup
Below is the step-by-step process of setting up the controller.
Note: Whenever an Access Code is required, enter your individual code. The default code is 9999. If
you have lost your code, call ITW Dynatec Customer Service: 1-800-538-9540 (in the USA) or con-
tact your local repsentative.
Turn the Controller ON

Turn the controller ON using the ASUs main On/ Off switch.
Language Selection
English is the default language. If you desire another language (choices are German, French, Ital-
ian, Spanish, Swedish, Portugese, Japanese and Dutch), make your selection:
Press the Service Key two times to advance to Service Page 2.
Press #6 on the numeric keypad, followed by Enter .
Press the numeric key of your language choice, followed by Enter .
(OR Scroll to your choice, then press Enter .
Note: To quickly return to the English language, turn the controller OFF. Then press both Enter
and “9” and hold while turning the controller ON.
Temperature Scale Selection
Press the Service Key twice to advance to Service Page 1.
Press #8 on the numeric keypad, followed by Enter .
Toggle to make your choice between °C scale or °F scale. Press Enter.
Press Return (F4) to Go to the Actual Temperatures Screen

Revised 5/01 DYNAMELT M ASU Manual #20-36, 20-37, 20-38
Actual Temperatures Screen
The Actual Temperatures Screen serves as the controller’s main menu. From here you can go to
any other screen. The Actual Temperatures Screen is also the most useful screen to display for
monitoring purposes.
Scheduler Key Controller

System Status 7-Day Scheduler Active On/Off Key
Service Key

1.
1 2.
2 3.
3 4.
4 >
Progmelt 299
Filterblock 300

Head HOLD HOLD HOLD
Aux Zone ? ?
Pump AUTO
% 78.0 PRS TUV WXY
SETPOINTS PUMP PRESSURE HELP
<
C
> ABC/123
Delete En-
ter
Pump Info Lines
Use of the Actual Temperatures Screen
Press This To:

Function Key
On/Off Toggle display, pumps and heaters power ON or OFF
Setpoints (F1) Go to the setpoints programming screen
Pumps (F2) Go to the pumps programming screen
Pressure (F3) Go to the pressure screen
Help (F4) Go to the Help screen.
Service Go to the first of the three service screens
Scheduler Go the the Main Scheduler screen

Use of the Actual Temperatures Screen, cont.
Programming Sequence (details on following pages)

1. Press Setpoints. After programming all of your temperature setpoints, return to the Actual Tem-
peratures Screen.
2. Press Pumps. After programming all pumps and optional clutch(es), return to the Actual Tem-
peratures Screen.
3. Press Pressure if optional pressure transducers are installed on ASU. After setting limits for all
pressure transducers, return to the Actual Temperatures Screen.
4. Press Scheduler Key to program the following functions: Standby, Time & Date Clock, 7-Day
Scheduler and/ or Program Recipes.
5. Press Help to view the Help screen (illustrated on page 5-2).
Monitoring:
1. System Status display describes system status as one of the following:
a. System Heat up: power is ON but zone temperatures have not risen to setpoint range.
b. System Ready: all zones have reached setpoint temperatures.
c. Alarm: a temperature zone is out of its setpoint tolerance range. An overtemp alarm is indi-
cated by an upwards arrow next to a temperature. An undertemp alarm is indicated by a down-
wards arrow next to a temperature.
d. Alarm Lo: the pump enable thermostat (undertemp thermostat) is preventing operation due
to a low temperature condition.
e. Standby: the system is in a programmed standby state.
2. Actual Temperatures or Zone Status of all zones is displayed:
a. ###: a three-digit number indicates a zone’s actual temperature.
b. HOLD: zone is waiting for release. Temperatures have not risen to setpoint range.
c. Arrow up: zone is over temperature.
d. Arrow down: zone is under temperature.
e. ?: there is no sensor. Zone needs troubleshooting.
f. >: there are more temperature zones not seen on the current display. To view them, press C
on the numeric keypad (bottom row, first key).
3. 7-Day Scheduler Active display shows that the 7-Day Scheduler is programmed and in use.
4. Pump Info Lines indicate pump mode (”Auto” on the illustration on page 5-6) and external refer-
ence percent or set speed percent.
5. If the optional Actual RPM display (shown on page 5-3) is installed, actual pump rpm may be
monitored.
Setpoints Programming Screen
SYSTEM: Alarm Lo Tue. 3:36 PM

SETPOINTS
Arrow °F Next Page Press C
SETPOINTS
Keys
°F 11. 1 2.
2
2 3.
3
3 4
4.
4 >
Progmelt 350
Filterblock 380
Hose 275 275 275 275

Head 275 275 275 275 GHI JKL MNO
Aux Zone ------
INFO: UPPER PREMELT GRID Zo: 1

Set: 300°F Act: 300°F Tol:±30°F PRS TUV WXY
RETURN
<
C
> ABC/123
Delete En-
ter
Controller identification number for zone

Zone Info Lines
Use of the Setpoints Programming Screen
Each of the temperature zones is programmed individually by using the function keys as follows:
Press This To:
Function Key
Scroll Up, Down or Right (F1, 2, 3) Select each zone’s setpoint
Return (F4) Return to the Actual Temperatures Screen
(Enter) Enter a numeric value
All -- -- -- (F1) All zones in a category (ie, All Hoses, All Heads, etc.)
On/Off (F3) Toggle a zone on or off
Clear (F4) Eliminate an error message or alarm
Programming
1. Scroll to the first temperature zone setpoint you desire to program.
2. On the numeric keypad, enter the desired setpoint value.
3. Press Enter .
4. Scroll to the next setpoint to be programmed and repeat steps 2 and 3.
Notes:
a. To turn a zone OFF: scroll to zone, press Enter to select, press ON/OFF (F3).
b. When turning a switched-off zone back ON, it will retain its previous setpoint.
c. To change all zones in a category (ie, all hoses, or all aux zones, etc.): scroll to one item in
that category, enter desired value, then press F1 (this does not apply to zones which are turned
OFF).
Monitoring
1. “Zo #”: the number which appears here is the controller’s identification number for this zone.
This number cannot be changed by user.
2. The Zone Info Lines indicate the user-defined zone name (programmed on Service Page 2,
menu item 1), the zone’s setpoint, the zone’s actual temperature, the zone’s tolerance (programmed
on Service Page 1, menu item 1) and the zone’s identification number.
Pump Programming Screen
Optional
RPM
Display
SYSTEM: Ready Tue. 3:36 PM

Arrow Press Enter and Select Mode
Keys
Set Min Max Actual SYM ABC DEF
Pump Mode % % % RPM
1 MANU. 78.0 RUN 90.5
2 AUTO. 5.0 5.0 80.0 RUN 87 GHI JKL MNO
3 STOP HOLD
Mtr 1
INFO: RIGHT PUMP 1, 2, 3
PRS TUV WXY
MANUAL AUTOMATIC STOP RETURN

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Alternative programming function keys:

STOP ALL RETURN
CLUTCHES RE-START
DYNAMELT ASU Manual #50-13, 20-36, 20-37 and 20-38 Revised 4/06
Use of the Pump(s) Programming Screen
Each of the pump(s) is programmed individually by using the function keys as follows:
Press This To:
Function Key
Scroll Up or Down (F1, 2) Select a pump.
Stop All (F3) To stop all pumps in system
Re-Start (F4) To re-start all pumps
Manual (F1) Choose Manual Mode for the selected pump
Automatic (F2) Choose Automatic Mode for the selected pump
Stop (F3) Choose Stop Mode for the selected pump
Clutches (F2) Go to the Clutch Programming Screen (if clutches are installed)
(Enter) Enter a numeric value
Programming
1. Scroll to select a pump. Press Enter.
2. Press Manual, Automatic or Stop as desired pump mode. Press Enter.
3. If in Manual mode, enter pump speed ##.# in the Set % column:
a. Use numeric keypad to enter desired rpm value.
b. Press Enter.
4. If in Automatic:
a. Scroll to Min % to program minimum pump speed. Enter value as described above.
Note: typically, at 0 volts, this value will be between 0 and 10% (default = 0%).
b. Scroll to Max % to program maximum pump speed. Enter value as described above.
Note: typically, at 10 volts, this value will be between 0 and 100%, depending on motor
installed on ASU (default = 100%).
5. Scroll to select next pump to be programmed. Repeat steps 2 thru 5 until all pumps are pro-
grammed.
6. If clutches are installed on ASU, Press Clutches (F2) to program (see next page).
Monitoring
1. RUN indicates the pump/ motor is enabled.
2. HOLD indicates that the controller is preventing the pump/ motor from running, due to a low
temperature, a standby condition, etc.
2. The Info Line indicates the user-defined name for the selected pump (programmed on Service
Page 2, menu item 1).
3. If the optional Actual RPM display is installed, actual pump rpm may be monitored. With this
option, the RUN/HOLD column is eliminated. The Actual RPM display is also seen on the Actual
Temperatures Screen.
Optional Clutch Programming Screen
The Clutch screen is active, as a subset of the Pump Programming Screen, only if clutches are
installed on your ASU. It is reached by Pressing F2 “Clutches” on the Pump Screen (seen on pre-
vious pages).
The number of clutches on the ASU will equal the number of motors:
For DM 35: there is a maximum of two pumps/ clutches
For DM 70/ 140: there is a maximum of four pumps/ clutches
For DM 210: there is a maximum of six pumps/ clutches
SYSTEM : Ready Tue. 3:36 PM

ArrowPress Enter and Select Mode
Keys
Switch Clutches ON/OFF with button 1 . . 6 SYM ABC DEF
Pump - Clutch 1 ON
Pump - Clutch 2 ON GHI JKL MNO
Pump - Clutch 3 OFF
Pump - Clutch 4 OFF
Pump - Clutch 4 OFF
Pump - Clutch 6 OFF 1, 2, 3 PRS TUV WXY
RE-START STOP ALL RETURN
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Turn Clutch ON/OFF using numeric keys 1 thru 6

Use of the Optional Clutch Programming Screen
Press This To:

Function Key
Re-start (F2) Turn ON all clutches at once
Stop All Turn OFF all clutches
Return (F4) Return to the Pump Screen
Programming
1. To turn individual clutches On or Off, toggle individually on the numeric keypad.
Monitoring
1. On/ Off status of each clutch is indicated.
Optional Pressure (PSI/ BAR) Programming Screens
The two Pressure Programming screens are active only if pressure transducers (sensors) are
installed on your ASU. They are reached by Pressing F3 “Pressure” on the Actual Temperatures
Screen.
The number of pressure transducers on the ASU will vary per ASU:
For DM 35: there is a maximum of four pressure transducers
For DM 70/ 140: there is a maximum of eight pressure transducers
For DM 210: there is a maximum of twelve pressure transducers
Pressure Screen #1 cont.

Arrow
Keys
Pressure PSI (BAR) SYM ABC DEF
Sensor Act.
1 100 Pre Filter Pump 1 GHI JKL MNO

2 100 Post Filter Pump 1
3 ? Pre Filter Pump 2
4 100 Post Filter Pump 2
PRS TUV WXY
PR.LIMITS SETUP RETURN
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Optional Pressure (PSI/ BAR) Programming Screens, cont.
Pressing “Setup” (F3) on Screen 1 brings up a message screen:
Access Code: ________
Pressure Sensor Type: max. PSI/BAR
Bar/PSI Calibrat. RETURN
System depressurized ?
CONFIRM RETURN
Pressure Screen #2

Arrow
Keys
Pressure PSI (BAR) Alarm PSI (BAR) SYM ABC DEF
Sensor Act. Low High
1 100 10 500 GHI JKL MNO
2 100 10 90
3 ? 10 500
4 100 110 500
1, 2, 3 PRS TUV WXY
HI <--> LO RETURN
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Use of the Optional Pressure Programming Screens
Press This To:

Function Key
Pr. Limits (F2) Go to Pressure Screen #2 to set low and high alarms
Setup (F3) Enter access code in order to advance to calibration
Scroll Up or Down (F1 or F2) Select each sensor (transducer)
Hi <--> Lo ((F3) Select the screen’s high or low column
Bar/PSI (F1) Choose pressure scale
Calibrat. (F2) Calibrate all transducers
Programming
1. The names of the pressure transducers (shown on the preceeding page as “Pre Filter Pump 1”,
etc.) are programmed at Service Page 2, Function #1 (see page 5-19).
2. On Pressure Screen #1, press Pr. Limits (F2) to advance to Pressure Screen #2. Use the Scroll
keys to select a Low or High limit for the first pressure transducer (sensor) to be programmed. Use
the numeric keypad to enter your desired value. Press Enter. Repeat until all desired pressure
transducers are programmed with Low and High pressure limits. Use Hi<-->Lo (F3) to move be-
tween columns as necessary.
3. Press Return (F4) to return to Pressure Screen #1. Press Setup (F3). On the first message screen,
enter your four-digit access code. On the second message screen, enter the maximum Bar/PSI val-
ue of the pressure transducer(s) installed on your ASU.
4. Press Bar/PSI (F1) to choose display in Bar or PSI.
5. Press Calibrat (F2) to calibrate all the pressure transducers installed. The controller will ask,
“System depressurized ?”, press Confirm (F3).
Note: Before confirming, verify that all transducers are at “0” pressure. Pumps must be turned
OFF and time allowed for system pressure to drop to “0”.
The controller will display “Waiting”. After a few seconds, the Pressure Screen will appear and, in
its last column, will list if each pressure transducer has “Passed” or “Failed” the calibration.
(Note: “Failed” indicates a problem with the transducer or the Pressure PCB.)
6. Press Return (F4) to return to Pressure Screen.
7. Press Return (F4) again to return to Actual Temperatures Screen.
Monitoring
1. Actual pressure values may be monitored for each transducer on either screen.
2. Over pressure or Under pressure arrows indicate conditions.
3. A question mark ? indicates that no transducer is installed, or that installation is not complete
for this transducer position.
Service Functions Screens
The three Service Function Screens are designated Service Page 1, Service Page 2 and Service
Page 3. They are accessed by pressing the Service Key 1, 2 or 3 times.
Functions coded ---- are active and require no code to program.
Functions coded with a key are locked and require entry of a code before programming.
For example, as seen on the diagrammed screen below, Setpoint Limitation is locked from further
programming.
Functions coded F are ITW Dynatec factory setups and are not user accessible.
Program the Service Functions as described on the following pages. Many functions are pro-
grammed simply by a toggle or by a single numeric entry.
Service Page 1
Service Key

Service
Arrow Page 1 Press for Next Page
Keys CODE
Hi/Lo Temperature 1 ---- SYM ABC DEF
Standby Temperature 2 ----
Standby/ Sleep Setup 3 ----
Setpoint Limitation 4
N/A 5 ---- GHI JKL MNO
Temperature Offset 6 ----
Sequential Heating . 7 ----
°C / °F 8 ----
Change Security Lock 9 1, 2, 3 PRS TUV WXY

RETURN
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Alpha/Numeric Enter
Keypad
Service Functions Screens, Page 1 cont.

Function #
Press #1 to program High/ Low Temperature Deviation. Enter a numeric value for the first zone
selected. Press Enter to confirm. Scroll to next desired zone and repeat until all zones are pro-
grammed. Then Press Return (F4) to return to menu. Note: after entering one value in any catego-
ry, you may press All xxx. (F1) to change all the items in that category.
The High/ Low Temperature Deviation is a range (±) representing the high and low temperature
limits of each setpoint. During operation, these limits activate the error alarms which alert the op-
erator to over-temp and under-temp conditions in the temperature zones. The smallest deviation
programmable is ±5° (C or F) and the largest is ± 50°.
Press #2 to program Standby Temperature. Enter a numeric value for each category. Press Enter.
Press Return (F4). Note: if the same Standby Temperature is desired for all zones: enter the value
in the first row, then press Enter.
The Standby Temperature is a reduction in temperature by which all the temperature zones will be
reduced in a standby condition. For example, if the hopper setpoint is 275° and you program a 100
degree standby temperature, the controller will reduce the hopper temperature to 175°. Numerical-
ly, the controller will accept any standby temperature within the range of -30°C and -150°C (-30°F
and -150°F).
Press #3 to program Standby Time Delay and Sleep Mode. Enter a numeric value for the time
delay. Press Enter. Toggle (press F1 or F2) to Sleep Mode. Enter a numeric value for Sleep Mode
Delay. Press Enter. Press Return (F4).
The Standby Time Delay allows programming of a delay from the time the “external standby” ter-
minals (for connection, see Chapter 3) are connected until the ASU enters its standby mode. The
time delay selected must be in the range from 0:00 (which represents an immediate entry into
standby, i.e. no delay) to 18.0 hours.
The Sleep Mode may be activated only during Standby. It becomes activated after a programmed
length of time (0.1 to 18.0 hours). During Sleep Mode all heaters are turned OFF and the motors
are stopped. The display reads “F1 to Start Heating” when in Sleep Mode. To disable the Sleep
Mode, press Disable (F3).
Standby and Sleep Mode work together. For example, if you program a Standby of 1 hour and a
Sleep Mode of 3 hours, the ASU enters Standby one hour after the external contact is closed. The
ASU enters Sleep Mode three hours after entering Standby.
Press #4 to program Setpoint Limitation. Enter a numeric value. Press Enter. Press Return (F4).
The Setpoint Limitation is a universal maximum temperature for all temperature zones (ie, the
overtemperature limit). The controller will not allow the operator to program a higher setpoint
than the value of the setpoint limitation. The default setpoint limitation is 218°C (425°F). The se-
lectable range for the setpoint limitation is 40°C - 232°C (100°F - 450°F).
Function #5 is not active in the present controller configuration. No programming is possible.

Press #6 to program Temperature Offset. Enter a numeric value for the first zone selected.
Press Enter. Scroll to next desired zone and repeat until all zones are programmed. Press Return
(F4). Note: to enter a negative value, enter the value, then press Negative (F3).
The Temperature Zone Offset is a mathematical factor which compensates for differences in tem-
perature between the placement of the system’s heaters and sensors. An offset is often used for
large applicator heads, printrolls, printwheels or other custom devices. Usually no offset is re-
quired for standard heads. The offset may be programmed up to ± 50 degrees (C or F) of the
zone’s temperature.
Press #7 to program Sequential Heating. Scroll to choose one of the three selections: No sequence,
First all hopper zones or Hold electric head. Press Confirm (F3).
Sequential heating allows you to choose the heating order of the temperature zones, so that zones
requiring more time to heat up to temperature can be programmed to begin heating before others.
In the case of the “Hold Electric Head” selection, programming of a reduced temperature for ten
minutes allows for the stabilization of the electric valves.
a. A “No sequence” designation means that all temperature zones will begin to heat immediately
after the ASU is powered on.
b. “First all hopper zones” means that the hose/ head/ auxiliary zones do not begin heating until
all hopper zones have reached the low limit of their setpoints. Zones which are switched OFF are
not applicable.
c. “Hold Electric Heads at xxx F for 10 minutes” applies to systems utilizing electric applicators
only. After choosing this selection and programming the temperature (to the softening point of
your adhesive, see your adhesive manufacturer), the controller holds all electric heads at the oper-
ator-selected temperature for ten minutes before releasing them to operating setpoint.
The controller’s default heating sequence for the Dynamelt ASU is first all hopper zones. This al-
lows the larger mass of adhesive in the hopper to begin heating immediately.
Press #8 to program Temperature Scale. Program directly on the menu screen by pressing #8 key
to choose between Centigrade or Fahrenheit. Press Return (F4).
Press #9 to Change Security Lock for Service Page 1. Enter your access code. Press Enter. Scroll
F1 or F2 to select desired function. Press F3 to Lock or Unlock function from programming. Re-
peat for each desired function.
To Change Your Access Code: Scroll F1 or F2 to select “Change Access Code”. Enter your de-
sired new access code. Press Enter to Confirm. Press Return (F4).
Press Service Key to advance to Service Page 2.

Service Functions Screens, cont.
Service Page 2
Programming of the Service Functions on this screen is similar to the programming of Page 1.

Arrow
Service
Page 2 Press for Next Page
Keys CODE
Customer Zone Names 1 --
PowerOn Configuration 2 --
Factory Defaults 3 --
Keypad Locking 4 --
PC Link 5 --
Language 6 --
LCD Contrast . 7 --
System Logbook 8 --
Change Security Lock 9 1, 2, 3
RETURN
Function #
Press #1 to program Customer Zone Names. This function allows the programmer to enter his de-
sired name for each temperature zone, pump and (optional) pressure transducer. This up-
to-20-character name will be the name displayed in the controller’s Info Lines. Program following
these rules:
a. use the Alpha/Numeric keypad to enter letters and numbers. When entering letters, use one,
two or three presses of a key to distinguish between the letters. Press Enter after each desired
letter or number is in place.
b. press the 0 (zero) key to toggle from letters to numbers,
c. press the SYM key to enter a space, colon, dash, dot, “Q”, “Z” or other special characters,
d. press F1 to toggle from upper to lower case,
e. you cannot back up. If an error is made, press Enter repeatedly to advance through the name
loop until you reach the point for correction and re-write as desired,
f. press CLR LINE to clear an entire line,
g. you may COPY (F2), PASTE (F3) and then modify to save time when names are similar,
h. press F4 to advance to the next motor or zone to be named.
To program Customer Zone Names: Press F1 to program Temperature zones, F2 to program

Pumps or F3 to program Pressure Transducers. Scroll to the first item to be named. Press Enter to
allow naming. Using the Alpha/Numeric keypad and following the rules given above, spell out
name as desired. Press F1, F2 or F3 to select another item to name. Repeat until all items are
named as desired. Press F4 again to Return to Service Page 2 screen.
Press #2 to program Power On Configuration. This function gives the user the choice of having the
heaters and pumps come on (or remain off) whenever the ASU is powered on. USA default is both
On. European default is Heaters On, Pumps Off. Note: programming here overrides programming
made at the next Service Function (Function #3 Factory Defaults).
Press 1 to toggle the heaters On or Off. Press 2 to toggle the pumps On or Off. Press 3 to toggle
the external inputs On or Off. Note: if you select heaters Off, the controller will remind you, at
power on, to press F1 to turn the heaters On.
Press #3 to program Factory Defaults.
CAUTION: Factory Default programming is not essential. If done improperly, it can cause re-pro-
gramming of setpoints to be necessary. If you are satisfied with your ASU’s setup, you may leave
Factory Defaults unprogrammed.
Upon entering this screen, the “ASU Type” (model) of your melter will be displayed. Use this
screen to program the quantity of hoses, quantity of premelt grids and quantity of pumps installed
on your ASU, if desired. It is o.k. to leave these items unchanged or with “?” selected.
Scroll (F1) to the line you wish to amend (ie, hose, premelt, pump). Press Change (F2) repeatedly
to view the list of possibilities for this line. Press Change until your desired quantity is displayed.
Repeat until all lines are programmed.
Then, Scroll (F1) to Configure EU/ US. Press Change (F2) to toggle between EU Setup or US
Setup for setpoints and parameters* if required.
Press Load (F3). Then press Confirm (F1). Press Return (F4) to return to menu.
*Choosing EU or US reloads all factory setpoints and parameters as follows:

EU (European) Setup = Temperature scale is Centigrade, pressure is measured in BAR, pumps are
in STOP mode at startup and heaters are active at startup.
US (United States) Setup = Temperature scale is Fahrenheit, pressure is measured in PSI, pumps
start in the mode they were left in at shutdown and heaters are active at startup.
Press #4 to program Keypad Locking. Scroll to either Temperature Settings or Pump Settings.
Press F3 to toggle Locked or Free. Scroll to other setting and press F3 to toggle Locked or Free.
Press F4 to Return to menu.
Selecting Locked prevents further programming to either temperature setpoints or pumps. Select-
ing Free allows further programming.
Press #5 to program optional PC Link (serial communication). Scroll to select either:

“Load: from Computer to this Controller” or
“Save: From this Controller to Computer.
Press F1 to Load. Press F2 to Save. Press F3 to Configure BAUD rate or FIFO. The message
“Waiting” indicates the controller/ computer is processing data. The message “Transmission
Done” indicates the computer/ controller has completed transmission. Press F4 to Return to menu.
The DynaControl is capable of bi-directional data transfer of all system parameters to a remote
computer. If this option is installed on your ASU, program it at this step. To program your remote
computer, see page 5-27. When PC Link is installed and the external serial communication is ON,
a flashing “C” appears at the upper right of the HELP screen.
Press #6 to program Language. Scroll to desired language. Press F4 to Return to menu.
Press #7 to program LCD-Contrast. Press F1 (+) to increase contrast or F2 (--) to decrease contrast
of display. Press F4 to Return to menu.
Press #8 to program System Logbook. The System Logbook has the following functions:
1. System Logbook: a list of the last 1,000 controller events. Use F1 and F2 to move forward or
backward thru the logbook. Use F3 Configuration to choose to log “all system data” or “errors
only”.
2. Data Logger: a list of the last 1,000 lines of actual temperatures for up to five selected zones.
The time interval at which these temperatures are recorded is programmable. The first screen of the
Data Logger is the actual data list. Move through the data by pushing F1 Forward or F2 Backward.
To program, press F3 Configure. The Data Logger programming screen is seen below. Use the ar-
rows to select a desired function. Use the numeric keypad to enter zone numbers or the time interval
(in 1/10ths of a minute). Press Enter to confirm your choices. Toggle to select Mode.

Arrow
Keys
Select Zones: 2 4 12 20 34
Enter Time Interval: 0.1 min.
Mode Run/Stop: RUN

.
Premelt 1 name of the selected zone (Zone #2)
RETURN
3. Elapsed Hours: the number of hours that the system has been running. Not resettable.
Press #9 to Change Security Lock for Service Page 2. Enter your 4-digit access code. Press Enter.
Press F1 or F2 to select desired function. Press F3 to Lock or Unlock function from programming.
Repeat for each desired function. Press Return (F4). Press Return (F4) again to go to Actual Temp
Screen.
Service Page 3
All of the functions on Service Page 3 are ITW Dynatec-accessible only. No operator programming
is possible.
Service
Arrow Page 3 Press for Next Page
Keys
CODE
Zone Arrangement 1 F
PI Loop Setup 2
Split Hopper Setup 3 F
Gear Ratio 4
F
F
RPM Display Yes/No 5 F
Pump/Clutch Yes/No 6
Level Control Yes/No . 7 F
I/O Troubleshooting 8 F
F
Change Security Lock 9 1, 2, 3
RETURN
Programming at Main Scheduler Screen
The Main Scheduler Screen functions include Standby, Date & Time Clock, 7-Day Scheduler and
Program Recipes.
Press the Scheduler Key to advance to the Main Scheduler Screen.
Main Scheduler Screen

Scheduler Key

Arrow
Keys
Activate/ Deactivate Standby 1 SYM ABC DEF
Change Time & Date 2
Program Scheduler 3
Select Recipes 4
Activate/ Deactivate Scheduler 5 GHI JKL MNO
.
1, 2, 3 PRS TUV WXY
RETURN
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Use of the Main Scheduler Screen
Function #
Press #1 to manually activate or deactivate Standby. Press Press F4 to return to the Main Scheduler
screen. Note: use of this key will override a programmed Standby.
Press #2 to program the time-of-day and date-of-year clock. Press F1 or F2 to change a selected
item, press F3 to select another item. Press Press F4 to return to the Main Scheduler screen.
Press #3 to program the 7-Day Scheduler. See programming details and screen on following page.
Press #4 to select an active recipe (1-4). Use F1 or F2 to select recipe #1, 2, 3 or 4. Press F3 to Con-
firm. Press F4 to return to the Main Scheduler screen.
Up to four separate setpoint recipes (programs) can be programmed and stored in the controller,
though only one recipe is active at any given time. Setpoints may differ from one recipe to another.
When switching between recipes, the new recipe’s setpoints take over, so there may be error alarms
if the new recipe’s unused temperature zones are turned on.
The program recipes are referred to as: Recipe 1, Recipe 2, Recipe 3 and Recipe 4.
To create a Recipe: advance to the Main Scheduler Screen and press #4. Use F1 or F2 to choose a
recipe number (for this example, say #2). Press F3 to confirm. Press F4, then press F4 again to go to
the Actual Temperatures Screen. Program all controller setpoints and functions as outlined on page
5-4. When all programming is completed, Recipe #2 is created.
Press #5 to activate or deactivate the 7-Day Scheduler. Press F4 to return to the Main Scheduler
screen.
Press F4 to return to the Actual Temperatures Screen.
Shortcuts
1. To activate or de-activate the Scheduler from the the Actual Temperatures Screen (Main Menu):
toggle by pressing and holding the Service (wrench) Key for five seconds.
2. To activate or de-activate Standby from the the Actual Temperatures Screen (Main Menu): toggle
by pressing and holding the Scheduler (clock) Key for five seconds.
Programming of 7-Day Scheduler
7-Day Scheduler
The Seven-Day Scheduler allows the operator to program main power ON and OFF times which
coincide with his daily production schedule throughout the work week. Up to ten “events” may be
scheduled. An event is a specific day and time or every day at the same time.
An ASU which has an active seven-day scheduler should be turned ON at the main power switch.
It should not be turned off by the main power switch while the scheduler is active. To turn the
ASU OFF (temporarily overriding the scheduler), use the DynaControl On/ Off keypad icon.
In the event of a power outage, or a manually switched main power ON, an active scheduler over-
rides the “Power On Heater Start” parameter. That is, if the scheduler is in “Switch ON” at the
time of a power ON, the heaters will be turned ON. Likewise, if the scheduler is in “Switch OFF”
at the time of a power ON, the heaters will be turned OFF.
When the seven-day scheduler is programmed and active, the scheduler icon on the controller
screen flashes continuously.
7-Day Scheduler Screen
7-Day Scheduler Active Indicator Keypad On/ Off

Event
#
Arrow Action Day Time
Keys
1 Standby Mon-Fri
Mon-Fri 5:00am SYM ABC DEF
2 Switch On Mon-Fri 6:00am
3 Standby Mon-Fri 11:30am
4 Switch On Mon-Fri 12:30pm
5 Switch Off Mon-Fri 6:00pm GHI JKL MNO
6 -- -- -- -- Everyday
7 -- -- -- -- Monday
8 -- -- -- -- Tuesday
9 -- -- -- -- Wednesday PRS TUV WXY
10 -- -- -- -- Thursday
RETURN
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Enter
Use of the 7-Day Scheduler Programming Screen
Press This To:

Function Key
Scroll Up, Down or Right (F1, 2, 3) Select an individual action, day or time
Return (F4) Return to the Main Scheduler Screen
(Enter) Enter a chosen selection
Programming
1. Press F3 to scroll to the Action column. Then scroll to the first event you desire to program.
2. Press Enter until the desired Action [ie, Standby, Switch On, Switch Off or -- -- -- (no event)]
is displayed.
3. Scroll (F3) to the Day column.
4. Press Enter until the desired Day (ie, Mon--Fri, Everyday or any individual day) is displayed.
5. Scroll (F3) to the Time column.
6. Press Enter to display the time you desire the event to start. Enter hour, minutes and am/ pm in-
dividually.
7. Repeat steps 1 through 6 for each event desired.
8. Press F4 to return to Main Scheduler screen.
Up/Downloading Instructions: Controller to Remote PC (PC Link)
The Upload/ Download functions are used to transfer system information and data from or to the
DynaControl. To do this, the DynaControl must be connected to an external PC or PLC via a se-
rial cable. The data format is an ASCII text with TAB-delimited data. This text can be created
with standard word-processing programs or spreadsheet applications and up or downloaded via
terminal programs. Both functions are ‘on--demand’-functions, i.e. they must be started on the
DynaControl keypad.
Hardware Hookup
Remove the controller mounting bracket from the ASU via four screws accessed from inside the
panel box assembly. Using a standard serial extension cable (Male/Female DB9) (if necessary,
utilize a DB25 to DB9 adapter), connect either of the DynaControl controller’s serial ports (on
the Display CPU PCB, see illustration on page 7-5) to the remote computer’s COM1 or COM2.
Download Instructions
Download = Transfer data from an external PC to DynaControl
1. DynaControl must be connected to a PC via a Null--Modem--Cable.

2. Start the terminal program on PC.
3. Start PC Link on DynaControl (Function #5 on Service Page 2).
4. If necessary, select Configuration (F3) and change baudrate, than re-enter Function #5.
5. Address setting is not used.
6. Press LOAD (F1).
7. Send ASCII file on terminal program.
8. DynaControl screen should list all received lines.
9. Press RETURN to exit service mode.
10. Customer zone text (command *Text) requires the zone number (temperatures: 1-48, pumps
49-54, pressure 55-66).
Download File Format
The downloaded ASCII text is line-oriented. Pages 29 and 30 show all possible line commands.
Each line starts with ‘*’ and the command, following a number of parameters, depending on the
command. Each parameter must be separated with a horizontal tab (char # 09h). A tab-character
must be placed after the last parameter in each line.
Examples:
1. Downloading data for the first filterblock zone
*Filterblock [tab] 1 [tab] 325 [tab] 30 [tab] 0 [tab] ON [tab]
This will set the first filterblock to a setpoint of 325 degrees, tolerance = 30, no offset, zone is
switched ON.
2. *Text [tab] 50 [tab] Pump 1, Factory Side
This will program the customer pump name for motor #2 (which could be pump #1!) with the
string: “Pump 1, Factory Side” cont.
Important Note: the last command in the download file must be *End#
Notes:
The command lines may be arranged in random order.

Maximum file length is 5000bytes.
Each data field may have a comment text ([tab] Setpoint:325F [tab] = [tab] 325 [tab]).
The DynaControl list screen indicates the commands in abbreviated form.
A ‘?’ after the command on the DynaControl list screen indicates a wrong parameter.
‘ER” indicates unknown command or syntax error.
If downloading system info using the *System command, the controller does not check
for validity of the parameters.
Upload Instructions
The upload function will send an ASCII file to the external PC/PLC. The file contains all
zone-related information. The size of the file depends on the number of zones, pumps
and pressure transducers.
The data format is similar to the download file.
Example:
…..
*PREME. 1 410 35 --5 ON
…..
*PUMP 2 M 850 100 900
Premelt #1: setpoint 410, tolerance 35, offset –5, zone is ON

Pump #2: manual mode with 85.0%, min. speed for automatic 10.0%, max. speed 90.0%
Customer zone names will be indicated with: *TXT--TE for temperature zones
*TXT--PU for Pumps
*TXT--PR for Pressure transducers
1. DynaControl must be connected to a PC via a Null--Modem--Cable.

2. Start terminal program on PC.
3. Start PC Link on DynaControl (Function #5 on Service Page 2).
4. If necessary, select Configuration (F3) and change baudrate, then re-enter Function #5.
5. Address setting is not used.
6. Start “Capture Textfile” at terminal program.
7. Press SAVE (F2).
8. Stop and close file on terminal program.
9. Press RETURN to exit service mode.
Line Commands (page 1 of 2)
*Premelt No# Setpoint Tolerance Offset On/Off
*Progmelt No# Setpoint Tolerance Offset On/Off
*Filterblock No# Setpoint Tolerance Offset On/Off
*Hose No# Setpoint Tolerance Offset On/Off
*Head No# Setpoint Tolerance Offset On/Off
*Aux Zone No# Setpoint Tolerance Offset On/Off
1--12 50--450 5--50 0--50 ON / OFF
*Pressure No# Min--Pressure Max--Pressure
1--12 0--1500 0--1500
*Pump No# Mode Manual% Automatic--Min% Automatic--Max%
1--6 Manu/Auto/Stop 0--100.0% 0--100.0%

0--100.0%
*Text No# Customer Name
Temp.:1--48 20 characters
Pumps: 49--54
Press.: 55--66
Line Commands (page 2 of 2)
*System 1 Setback Premelt Setback Progmelt Setback Filterblock Setback Hose Setback Head Setback Aux.Zone
*System 2 Setback General Setpoint Heat up Sequence Electr.Head Hold °C / °F Spare

Limitation (0,1,2) Temp. (°C=0, °F=1)
*System 3 Power--On Heater Power--On Motor Keypad Lock Keypad Lock Mo- Configuration Lock Configuration Lock
0/1 (1 = Start) 0/1 (1 = Start) Temp.Settings 0= tor Settings 0= Page 1 Bit0¼Bit7, Page 2 Bit0...Bit7,
free, 1= locked free, 1= locked 1= lock 1 =lock
*System 4 PI--Loop Premelt PI--Loop Progmelt PI--Loop Filterblo. PI--Loop Hose PI--Loop Head PI--Loop Aux Zone
(High= I Low= P) (High= I Low= P) (High= I Low= P) (High= I Low= P) (High= I Low= P) (High= I Low= P)
*System 5 Gear Ratio Mo- Gear Ratio Mo- Gear Ratio Mo- Gear Ratio Motor Gear Ratio Motor Gear Ratio Motor
tor. 1 tor 2 tor 3 4 5 6
*System 6 Rpm--Displayn Pump--Clutches Level Control Bar/PSI Pressure Sensor- Active Recipe
(0/1) (Bit0¼Bit5, Bit7) (0/1) (Bar=0, PSI=1) type (1¼4)
*System 7 Zone# Premelt 1 Zone# Premelt 2 Zone# Premelt 3 Zone# Premelt 4 Zone# Premelt 5 Zone# Premelt 6
*System 8 Zone# Zone# Progmelt Zone# Progmelt Zone# Progmelt Zone# Progmelt Zone# Progmelt
Progmelt 1 2 3 4 5 6
*System 9 Zone# Filterblo. 1 Zone# Filterblo. 2 Zone# Filterblo. 3 Zone# Filterblo. 4 Zone# Filterblo. 5 Zone# Filterblo. 6
*System 10 Zone# Hose 1 Zone# Hose 2 Zone# Hose 3 Zone# Hose 4 Zone# Hose 5 Zone# Hose 6
*System 11 Zone# Hose 7 Zone# Hose 8 Zone# Hose 9 Zone# Hose 10 Zone# Hose 11 Zone# Hose 12
*System 12 Zone# Head 1 Zone# Head 2 Zone# Head 3 Zone# Head 4 Zone# Head 5 Zone# Head 6
*System 13 Zone# Head 7 Zone# Head 8 Zone# Head 9 Zone# Head 10 Zone# Head 11 Zone# Head 12
*System 14 Zone# Aux.Zo. 1 Zone# Aux.Zo. 2 Zone# Aux.Zo. 3 Zone# Aux.Zo. 4 Zone# Aux.Zo. 5 Zone# Aux.Zo. 6
*System 15 Zone# Aux.Zo. 7 Zone# Aux.Zo. 8 Zone# Aux.Zo. 9 Zone# Aux.Zo.10 Zone# Aux.Zo. 11 Zone# Aux.Zo. 12
*System 16 Motor# Pump 1 Motor# Pump 2 Motor# Pump 3 Motor# Pump 4 Motor# Pump 5 Motor# Pump 6
Optional Dual (Split) Hopper Display & Keypad Reference

Description
Dual Hopper models (available on DM140 and DM210 only) contain two hoppers for the purpose
of applying two different adhesives or for applying adhesive at two different temperatures.
On Dual Hopper models, each of the ASU’s pump/ motors are assigned to one hopper or the other.
The DM210’s pump arrangement is 4/2 (illustrated in the following diagrams), meaning that hop-
per #1 (System 1) has 4 pumps and hopper #2 (System 2) has 2 pumps. A 2/2 arrangement is used
on the DM140.
Dual Hopper programming and monitoring is identical to the standard models, with the exception
of having more temperature zones divided among the two systems. The controller indicates the
active system in the upper status bar. The operator moves from system to system in the same man-
ner that the standard model controller moves from page to page, i.e. by pressing the “C” key.
If the operator desires to see the “Day/Date Clock”, press the Scheduler key, then press #2. Press
Return twice to return to the Actual Temperatures screen.
As indicated below, System 2 temperatures are
READY, but its low temperature thermostat is open.
System 1 Status:
Ready Displayed (active) System Scheduler Key:
Heat up Scheduler Active Indicator Day/Date Clock, etc.
Alarm
Standby System 2 Status
Numeric Entry
Keys
SYS 1: READY SYS 2: READY lo
Actuals ° F System 1 Next Page Press C
1.
1 2.2 3.3 4.4 >
Premelt 300 301 301 300 SYM ABC DEF
Progmelt 299 299
Filterblock 300 300
Hose 274 273 273 274 GHI JKL MNO

Head 274 273 273 274
Aux Zone ? ?
Pump Stop Stop Stop Stop PRS TUV WXY

% Hold Hold Hold Hold
<
C
Delete En-
ter
ter
Arrow All Keypad functions are

Keys identical to standard models
Dual Hopper Display & Function Keypad Numeric

(Actual Temps Screen shown as example) Keypad
Optional Dual (Split) Hopper Display & Keypad Reference, cont.
After Pressing “C”, the Display Changes to:
Displayed System
SYSTEM 1: READY SYSTEM 2: READY

5.
5 6.6 7.7 8.8 >
Premelt
Progmelt
Filterblock
Hose 275 275 273 274

Head 274 274 275 274
Aux Zone ? ?
Pump Stop Stop Stop Stop

On the screen shown above, additional System 1 temperature zones are displayed.
After Pressing “C” again, the Display Changes to:
Displayed System
SYSTEM 1: READY SYSTEM 2: READY

< 9.9 10.
10 11.
11 12.
12
Premelt 299 300
Progmelt 300 300
Filterblock 301
Hose 273 273 274 274

Head 274 275 273 273
Aux Zone ? ?
Pump Stop Stop Stop Stop

On the screen shown above, System 2 temperature zones are displayed.

ITW Dynatec

ITW Dynatec c. 2009 Preventive Maintenance Page 6-1
DYNAMELT M ASU Manual #20-38 & 20-57 Revised 11/12
Chapter 6
PREVENTIVE MAINTENANCE
Note: Re-read Chapter 1 “Safety Precautions” before performing any maintenance procedures. All
maintenance procedures must be performed by qualified, trained technicians.
General Cleaning
The DYNAMELT M SERIES ASU enclosure is finished with an extremely durable polyurethane
paint. The enclosure may be cleaned with a variety of industrial cleaners following manufacturers’
directions. To prevent discoloration or deterioration of the ASU’s finish, avoid prolonged contact
with strong solvents.
The molded plastic handles may be cleaned with mineral spirits.
Preventive Maintenence Schedule
The Dynamelt M ASU requires little maintenance. The hopper is fitted with a coarse screen to pre-
vent large debris from entering the system. Normally this screen does not require cleaning. The
ASU parts that require regular, periodic maintenance are as follows:
Replacing the Easy-Spin Outlet Filter

The outlet filter should be replaced monthly during the first few months of operation. After you
gain experience with your system, you can determine how often you need to replace it. The outlet
filter is located on the outlet filter manifold on the hose connection panel of the ASU. See illustra-
tion of theoutlet filter on page 6-2.
Use the following procedure to replace the standard outlet filter. cont.
WARNING HIGH PRESSURE

Turn the motor OFF and trigger the applicators to relieve adhesive pressure
before performing any outlet filter maintenance.
WARNING
Avoid splashing hot adhesive. The filter screen will be covered with hot
adhesive and must be handled with proper tools. Position a heat-resistant
container under the manifold before proceeding.
WARNING HIGH VOLTAGE

All electrical connections should be made by qualified electrical personnel. Care
must be taken to assure proper grounding prior to any disassembly. Lockout
and tag the electrical sources as required. When covers are removed, high
voltage sources create an electrocution hazard. Wear appropriate safety
equipment when working with high voltage sources.
Page 6-2 Preventive Maintenance ITW Dynatec c. 2009
Revised 8/09 DYNAMELT M ASU Manual #20-38 & 20-57
Filter Nut
O-rings:
(listed top to bottom)
PN 812816 #127
PN A69X133 #124
Pressure Relief Valve PN N00187 #020
Easy-Spin Filter:
PN 814008 80 mesh
PN 814009 100 mesh
PN 814010 150 mesh
Outlet Filter Manifold
Hose Connection
Purge Valve
Adhesive Drain
Easy-Spin Filter Manifold (located at the Hose Connection Panel)
1. The system should be at operating temperature before starting this procedure.
2. Before proceeding, verify that the motor(s) is turned OFF and the applicators have been
triggered to relieve pressure.
3. Position a heat-resistant container below the manifold. Wearing insulated gloves and using a
5mm wrench, slowly loosen the two purge valves (do not attempt to remove them) located on
the fitting side of the filter manifold. Allow adhesive and pressure to escape out of the
manifold. Adhesive will drain into the container.
4. After pressure has drained from the filter assembly, remove the filter from the filter block.
5. Inspect the filter nut and o-rings for defects or degradation and replace if necessary.
6. Install a new filter cartridge(s) onto the filter nut and reinstall the filter. Tighten to 10 lbs/ft.
The top of the nut should be flush with the top of the filter block when correctly installed.
cont.
7. Close the pressure bleed (purge) valve, return the equipment to service and check for leaks.
8. If leaking, it may be necessary to replace the filter nut o--rings.

Retainer
Plate
Screws
Replacing the Optional High Flow Outlet Filter Basket
1. The system should be at operating temperature before
Filter Plug
starting this procedure.
O-ring
2. Before proceeding, verify that the motor(s) is turned OFF
and the applicators have been triggered to relieve pressure.
Filter
Basket
3. Remove the Manifold Access Cover. Note: it is not
necessary to remove the Lower Manifold Cover.
4. Using insulated gloves and an allen wrench, remove the

retainer plate screws.
5. Lift out the retainer plate/ filter plug assembly.
6. Remove the clogged filter(s) and install a replacement filter.
Note: the filter(s) may be cleaned or replaced. If cleaning a filter, Outlet

Filter
use only solvents recommended by your adhesive supplier. Manifold
High Flow Filter Manifold

7. Inspect the o-ring. Replace if flat or damaged.
8. Apply a coat of silicone lubricant onto the filter plug before re-inserting it into the
manifold.
9. Apply a coat of anti-seize compound onto all screws before re-inserting.
10. Restore application system to normal operation.

Hose Fittings
All hose fittings should be checked for tightness after every three months of operation.
Fasteners
After the first ten hours of operation, check all set screws, socket head and cap screws for tightness.
Thereafter, re-check all fasteners after every three months of operation.
Filter Shutoff Cleaning or Replacement

See the illustrations in Chapter 10 (Melt & Grid Assembly) for location of the filter shutoff(s).
DM70, DM140 and DM210 models have two filter shutoffs.
1. Pump all the adhesive out of the hopper.
2. Lower the temperature of the application system to the adhesive’s softening point.
WARNING HOT SURFACE

The ASU will still be hot for this procedure. Use insulated gloves and protective
clothing when removing the filter shutoff.
3. Open the two access doors located at the sides of the ASU. Do not pull out the ground
wires attached. The filter shutoff assemblies are located on either side of the hopper. Repeat
this procedure for each assembly.
4. Wearing gloves, use a wrench to unscrew the filter shutoff nut and pull the filter shutoff out.
5. a. Replace the clogged filter shutoff assembly, or

b. Emerse the assembly in flushing fluid (PN L15653) to loosen contaminants. Remove
assembly from fluid and use a hot air gun (if necessary) and rags to clean all contaminants
from it.
6. Apply a coat of anti-sieze compound onto the threads of the filter shutoff nut before
re-inserting into the ASU.
7. Replace the filter shutoff o-ring. Lubricate the new o-ring with lube (PN N07588).
8. When re-installing the filter assembly, turn the filter’s cut out hole toward the pump.
Align the filter shutoff knob in its “open” position. Note: each filter shutoff is stamped “I”
(open) and “0” (closed) to show position.
9. Close the access doors. Restore the ASU to normal operation.

Pump Shaft Leak

There is a cutout in the baseplate, directly below the pump shaft(s), which will allow adhesive from
a leaking pump to exit the ASU. Inspect the area under the baseplate cutout every month for adhe-
sive. A leaking pump shaft indicates a worn pump seal. See instructions in Chapter 8 for replace-
ment of this seal.
Summary of Preventive Maintenance Schedule
Monthly (or as experience dictates)

1. Inspect outlet filter basket. Replace as required.
2. Check for leaking adhesive under the baseplate, caused by a worn pump seal. Replace as re-
quired.
Every Three Months (or as experience dictates)

1. Check all hose fittings for tightness.
2. Check all fasteners for tightness.
3. Inspect filter shutoff. Clean or replace as required.
Flushing the System
Contaminated adhesive, accumulation of residue in the system and hopper, or changing the adhesive
formulation may require the system to be flushed. To flush the system, have at least 6 liters (1.5 gal-
lons) of flushing fluid on hand (PN L15653) per hopper. Repeat this procedure for each hopper of a
dual hopper ASU.
WARNING
The flushing fluid will splash easily. Wear protective clothing, gloves and
a face shield to prevent severe burns.
1. Pump out as much of the molten adhesive from the hopper as possible.
2. Reduce the ASU’s pump pressure to zero.
Note: the hose used in the following process is merely for the convenience of depositing flushing
fluid. This procedure does not have to be repeated for each hose in the system.
3. Disconnect one of the supply hose’s adhesive feed from its applicator head. Do not
disconnect the electrical power to the head (since that would disable the pump). Put the hose
in a secured position within a container which will catch the used flushing fluid.
4. Add flushing fluid to the hopper and allow approximately fifteen minutes for it to reach
hopper temperature. Carefully stir the flushing fluid to mix with any adhesive remaining in
the hopper.
cont.
5. Slowly increase the pump pressure. Pump about half of the fluid through the hopper, pump
and adhesive supply hose into the flushing container.
WARNING
Avoid splashing the flushing fluid from the end of the hose.
6. Reduce the pump speed to zero.
7. Remove the outlet filter and replace the basket following the procedures outlined in the
”Outlet Filter” section of this chapter.
8. Add new adhesive to the hopper and allow it to reach application temperature.
9. Slowly increase motor speed to the pump.
10. Actuate each of the heads until all the flushing fluid is removed and a steady stream of new
adhesive flows.
11. Re-adjust the pump speed for the desired flow.
12. Re-fill the hopper with adhesive. The system is now ready for production.
Panel Box Fan Filter (Optional)
One to two air-circulating fans may be located within the electrical panel box assembly (PBA).
DANGER HIGH VOLTAGE

Disconnect and lockout/ tagout input power to the application system before
opening the panel box assembly’s door.
Replacement and/ or Cleaning of Fan Filter

1. Remove front grille and remove filter.
2. Wash filter in water up to 40C (104F) with a mild detergent added, if necessary.
Or vacuum, beat or blow the filter with compressed air.
To clean greasy substances:

Wash filter in benzine, trichloroethylene or warm water with a grease solvent added.
3. Do not wring or use a sharp jet of water or compressed air.

ITW Dynatec

ITW Dynatec c. 2000 Troubleshooting Page 7-1
DYNAMELT M ASU Manual #20-36, 20-37 and 20-38 Revised 8/09
Chapter 7
TROUBLESHOOTING
General Troubleshooting Notes
DANGER WARNING
HIGH VOLTAGE HOT SURFACE
Dynamelt systems use electrical power that can be life threatening and hot-melt adhesives that
can cause serious burns. Re-read Chapter 1 “Safety Precautions” before performing any
troubleshooting or repair procedures. All troubleshooting and repair procedures must be
performed by qualified, trained technicians.
CAUTION: Printed circuit boards (PCBs) are prone to damage from static
electrical charges during handling. Read “Handling Printed CIrcuit Boards” in
this chapter before handling or attempting service on Dynamelt’s PCBs.
The Dynamelt’s DynaControl includes malfunction self-diagnostics, alerts and error indication
alarms. The error indication alarms (the alarms displayed on the DynaControl readout) are triggered
whenever there is a sensor failure and whenever there is an over-temperature condition. The
operation of the error indication alarms is described in Chapter 4 of this manual.
Preliminary Checks: Verify the following before proceeding:

1. The ASU is switched on.
2. The ASU is supplied with power.
3. The ASU is supplied with pneumatic air.
4. Pneumatic and electrical connections are correct.
5. Adhesive is in the hopper.
Error Messages:
See Ch. 4 for complete instructions on Error Alarms and Messages.
Sensor Failure on Zone # = temperature zone “#” has an open or shorted sensor.
Overtemperature on Zone # = temperature zone “#” has exceeded setpoint limitation.
Communication Error = indicates a serious problem which requires service by Dynatec.
Hopper Overtemp = hopper temperatures have exceeded their thermostat’s setting.
Hose/ Applicator Troubleshooting Tip

Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an
alternate socket on the ASU. If the malfunction goes with the applicator and hose, the problem will
usually be in the applicator or hose that was moved. If the malfunction does not move with the
applicator and hose, the problem is probably in the ASU.
Revised 4/01 DYNAMELT M ASU Manual #20-36, 20-37 and 20-38
High-Temperature Redundant Overtemp Thermostat

The ASU includes a mechanical (redundant) overtemp thermostat that acts as a safety backup. If the
ASU’s hopper temperature should exceed 232°C (450°F), the thermostat will cause the ASU’s cir-
cuit breaker to open and power to the hopper and all hoses and heads will be cut off. The mechani-
cal thermostat must be manually re-set after the hopper temperature falls below 204°C (400°F).
The overtemp thermostat is located behind the motor access door (see Chapter 8). To reset: turn
OFF the ASU’s main power switch, push the center of the thermostat’s insulator to re-set, restart
the ASU.
Pump Enable Thermostat

The pump enable thermostat is a low-temperature safety feature of the Dynamelt ASU designed to
prevent the pump from powering on before the adhesive is molten. It is a cartridge thermostat and it
is factory set at 135°C (275°F). The thermostat is adjustable so that operators using adhesives with
extraordinarily high or low melting points can tailor the low-temp setting to their production’s
needs.
To access the pump enable thermostat, follow the instructions given in Chapter 8. Refer to Chapter
3 for instructions on calibration of this thermostat.
Lithium Battery on CPU PCB

The CPU Printed Circuit Board contains a lithium battery which serves no function in the Dynamelt
M Series controller configuration.
Lithium Battery on Display CPU PCB

The Display CPU Board contains a lithium battery. The normal life of this battery is about ten
years. When the battery needs replacement, the scheduler’s clock does not function, but other con-
troller features remain intact. Return the board to ITW Dynatec for battery replacement.
Handling Printed Circuit Boards (PCBs)

The Dynamelt ASU and DynaControl controller utilize several printed circuit boards (PCBs). These
boards are extremely sensitive to electrostatic charges. When working near or with any PCBs, the
following procedures must be followed to avoid damage to them.
DANGER HIGH VOLTAGE

Before unplugging connectors from the I/O PCBs, ground yourself to the
ASU by touching any available unpainted cool metal surface, mounting
screws, etc. This will avoid electrical discharge to the PCB assembly when you are remov-
ing and replacing connectors.
CAUTION: Printed circuit boards (PCBs) should be handled using the following
procedures:
1. Wear a wrist grounding strap. If a grounding strap is not available, frequently touch a
bare metal part of the ASU (unpainted frame, mounting screw, etc.) to safely discharge
any electrostatic buildup on your body.
2. Handle a PCB by its edges only. Don’t grip a PCB across its surface.
3. When removed from the ASU, each PCB must be individually packaged inside a
metallized, static drain envelope. Do not place the removed PCB on a table, counter,
etc. until it has first been placed in or on a static drain envelope.
4. When handing a PCB to another person, touch the hand or wrist of that person to
eliminate any electrostatic charge before you hand the PCB to him.
5. When unwrapping a PCB from its static drain envelope, place the envelope on a
grounded, nonmetallic surface.
6. To cushion PCBs for shipment, use only static-drain bubble pack. Do not use foam
peanuts or bubble pack not known to be static draining.
The following pages detail the Dynamelt M Series PCBs.

CPU Printed Circuit Board
The CPU board contains the controller’s CPU chip (built into the board) and optional 7-Day
Scheduler chip. The CPU chip (EPROM) can only be reprogrammed at ITW Dynatec’s factory.
The Low Level relay is fixed at normally open. The High/ Low Alarm relay is fixed at normally
closed. During normal operation, the two red indicator lights are always ON.
Triac control for Hopper, Head/ Hose 1 & 2
PC/PLC Serial Channel EPROM (not removable or programmable by user)
BT1
X5 X6 Audible + Battery
Connect to Operator Alarm
Panel PCB X9
+ 5D
+12D
+12A
--12A
Relay outputs: LEDs
1
1&2 = alarm contacts 2 X1 Optional Scheduler chip
3&4 = low level contacts 3
IC5
4
(Dynatec factory use)
Flat cable connect to
Auxiliary PCB or X16
Dip switches
Relay Output PCB S4
X11
J2
S3
S2 J1 Flat cable connect
S1 to optional motor board
ON
X4
1
(cutout)
Terminal connections: 2
3
1 = Program Select 1 (1/2) Input 4
2, 4, 6, 8 = +12V 5
3 = Low Level Detect Input 6
7
5 = External Setback Input
8
7 = Program Select 2 (3/4) Input 9
9&10 = Ground 10
Flat cable connect J6 (cutout)

to Power PCB X3
Sensor Inputs for X2
Head/ Hose 3 & 4
Sensor Inputs for X7
Head/ Hose 5 & 6
and Aux 1, 2 & 3
X14
Sensor Inputs for

Hopper &
Head/ Hose 1 & 2
Sensor Input for channel 16
Layout of Components on CPU Board

Display CPU Printed Circuit Board
The Display CPU PCB contains the controller’s CPU module, scheduler battery, serial ports and op-
tional connections. It is located directly behind the controller’s display panel within its mounting
bracket (or within the remote pendant assembly (option), if applicable).
When downloading software updates, use the download serial port seen at the lower right of the il-
lustration. While downloading, the J1 jumper is moved temporarily to its #1 position.
To configure the number of (optional) pressure transducers on an ASU, use the dip switches (shown
below beneath the expansion board) and the following chart. There are four transducers per PSI
PCB and a maximum of three PSI PCBs per ASU. Note: PSI not available on APS models.
# of PSI PCBs
On the RS-Com board, both the J1 and Switch # 0 1 2 3 Connect to opt.
Expansion Board
J2 jumpers must be in upper position for 1 off on off on (for Serial Commu-
485 and both in lower position for 232. 2 off off on on nication)
3 on = APS OFF = nornal CAUTION! FOR
EXPANSION
Dip Switches to configure
Optional RS232 Serial Connect Optional RS485 Serial Con- BOARD CON-
# of opt. PSI PCBs (only
(use for PLC/ PC Link) nect (use for PLC/ PC Link) NECT ONLY
switches #1 & 2 are used)
or APS model
Optional Expansion Board
J1 J2
Scheduler
Battery Reset
1 Download
Reset
ON
J1 SW2 SW1
Download Jumper
Software Download Port

Connect to
CPU PCB
Layout of Components on Display CPU PCB

Motor Control Interface Printed Circuit Board
For each motor on the ASU, there is a Motor Control Interface PCB and a Motor Speed Control
PCB. The Motor Control Interface PCB (diagrammed below) connects directly to the CPU PCB.
The Motor Speed Control (diagrammed on the following page) connects via a spade connector to
the Motor Control Interface PCB. Up to two motor’s pcbs may be connected to one CPU PCB.
Each Motor Control Interface PCB’s jumpers should be set as follows: the J1 and J2 jumpers should
always be set in the M1 position diagrammed below for motor #1, #3 and #5. For motor #2, #4 and
#6, jumpers J1 and J2 are set in the M2 position (opposite from those diagrammed below). The M/S
selection jumper must be set in the “M” position. The J3 jumper is always set as shown below.
“MAX” speed adjusting pot: This pot adjusts the maximum output voltage of the motor speed con-
trol board. It is factory preset to full pump motor rpm (100%). Normally, this pot does not need ad-
justment. Turning clockwise increases the voltage. To verify adjustment, set the motor to “manual”
mode and to 100% speed. Then adjust the pot to desired maximum speed (5%).
NOTE: Do not attempt to use the MAX pot adjustment to trim the line speed to a given value.
Proper automatic line speed following is accomplished with correct motor programming into the
controller (see Chapter 5).
“ENCODER” connections: the optional Digital RPM Readout’s encoder is installed onto these
board connections.
Voltage Selection (J3): UP position (for KB drive) = 0-5V, DOWN position = 10v (for Yaskawa drive)
MAX Speed Adjustment potentiometer
X2 connections are internal and not

Motor for customer’s use:
M1 M2 X2 10 Speed reference voltage set by J3
J2 0 Ground
Flat cable connect to
CPU PCB at J1 J1 not used
5V En Pump enable
10v En Pump enable
X1 J3
P Encoder pulse
M S not used
F1 X4
Transformer Fuse Web 0 Ground
5 Encoder supply voltage
Transformer
X5 Handgun trigger input &
L1 VR1 TR pump enable
TR Handgun trigger input &
240 VAC input 10 pump enable
X3
0 0-10 VDC input, web speed,
N max. 40v
Ground
Web Speed Scaling potentiometer

Factory Set, Do Not Adjust
Layout of Components on Motor Control Interface Board

Motor Speed Control Drive
The Motor Speed Control is located within the panel box assembly, mounted on the insert. This
variable-frequency drive is factory-set and normally does not require adjustments. The following is
a list of parameters that Dynatec programs which differ from the drive’s default parameters.
Parameter Value Description
B1-17 1 Starts the motor even when the enable signal precedes power up.
L1-01 2 Prevents false tripping at low speeds.
L2-01 2 Does not stop the motor when under-voltage is detected (power up after
short interruption).
E1-09 0.5 Allows the motor turn down to 1% minimum.
E2-01 1.5 Full load amperes, maximum motor current for DM35 ASU.
E2-01 3.6 Full load amperes, maximum motor current for DM70/140/210 ASUs.
E1-04 62* Calibrates the maximum speed. See note below for details.
E1-08 16.0 Stabilizes low-speed operation.
E1-10 9.5 Stabilizes low-speed operation.
* Due to component tolerances, the maximum speed of the

pump might vary. In order to calibrate the maximum speed,
parameter E1-04 can be fine-tuned. Valid range is 61 to 63.
Set motor speed to 100% and adjust parameter E1-04 so that
the pump is turning exactly 90rpm.
Corrupted Memory
If the memory becomes corrupted:
1. Restore the factory default settings by entering
2220 at parameter A1-03.
2. Re-enter the ITW Dynatec parameters specified in
the chart at the top of this page.
Acceleration/ Deceleration Times

The acceleration and deceleration
times are factory set to 10
seconds. If an application requires
faster acceleration/deceleration, S1 S2 S3 S4 S5 SC A1 +V AC AM AC
corresponding parameters can be BLU

BLU
changed: + OR
-- GRAY
Parameter Value Description
C1-01 10.0 The time it takes to ramp the

pump speed up from 0 to
maximum.
C1-02 10.0 The time it takes to ramp the
pump speed down from max-
imum to 0.
cont.
Layout of Motor Control Drive
Accessing, Programming and Monitoring Motor Control Parameters
To Access and Change Parameter Values
Step 1.
Step 2.
Step 3.
Note: On the Motor Interface PC board, change Voltage Selection jumper J3 to 10V (down
position).
To access other drive signals, refer to the Yaskawa technical manual, available at:
http://www.yaskawa.com/site/products.nsf/productGroup/ACDrives.html
48-Zone Power Printed Circuit Board
The 48-Zone Power PCB has the capacity to monitor adhesive temperatures for multiple hoses,
applicators, hoppers and auxillary zones.
The LEDs for each temperature zone (1 through 48 illustrated below) will flash on and off as their
heaters output to maintain setpoint temperature. The Power On and Hopper LEDs will light contin-
uously once the hopper(s) are up to temperature.
The settings of the JP1 and JP2 jumpers correspond to the number of hoppers on the ASU. For an
ASU with one hopper, both jumpers must be set to position 1-2 (shown). For two hoppers, JP1 must
be set at 1-2 and JP2 must be set at 2-3.
Jumper JP1 Jumper JP2:

1&2 = 1 or 2 hoppers 1&2 = 1 hopper
2&3 = 2 hoppers
Low temperature High temperature

thermostats for thermostats for Connect to
CPU 1 at Connect to Connect to
Hoppers 1, 2 Hoppers 1, 2 Connect to CPU 2 at
X16 CPU 3 at
H2 H1 H2 H1 Clutch pcb X16 X16
{
{
{
{
12 11 10 9 8 7 6 5 4 3 2 1
JF5 JF1 JF6 JF7
Power ON
for PLC { JS5 1
JP1
3 1
JP2
3
Power ON
contactor { JS1 LED Future
LED Hopper 2 Ready
System System 1 { JS4 CPU 1 CPU 2 CPU 3
Ready
outputs to
customer-
System 2 { LED Hopper 1 Ready
supplied LED Power ON 48
PLC
Future { 16
15
32
31 47 Solid state relay
14 46 driver outputs
30
System System 1 { JS2 13 29 45 (1 per zone)
Ready F1
12 28 44
(snubbed)
power
System 2 { 11 27 43
Transformer 10 26 42
outputs Future {
9 25 41
8 40 LED:
24
Green = zone
Input L1 7 23 39
is heating
Power { L2/N 6 22 38
240 VAC PE 5 21 37
4 20 36
JS3
3 19 35
2 18 34
1 17 33
JH1 JH2 JH3
JF2 JF3 JF4
Transformer Fuse
(5x20 1 amp)
Connect to Connect to Connect to
CPU 1 at CPU 2 at CPU 3 at
J6 J6 J6
Layout of Components on 48-Zone Power Board

Optional Clutch Printed Circuit Board
The Clutch PCB allows installation of up to six (optional) clutches on the ASU.
The dip switches (SW1) are turned ON to reflect the number of clutches on the system.
Relay Green LED = clutch is activated
Clutch 1 Clutch 2
JS2 JS1
#2 clutch
#1
Clutch 3 Clutch 4
#3
#4
Clutch 5 Clutch 6 Green LED = System Power ON

clutch #5
#6
Clutch Coil Leads Connects JF1

Connect to 48-Zone
Customer Enable Switches: ON Power Board at JF1
for a footswitch, hand-held 1
applicator, etc. Board F1
Fuse SW1
6
JS3
L1 L2
{
240 VAC Input Dip Switches:

1 clutch = switch #1 is ON
2 clutches = switch #1 & 2 are ON
3 clutches = switch #1, 2 & 3 are ON
Layout of Components on Clutch Board 4 clutches = switch #1, 2, 3 & 4 are ON
5 clutches = switch #1, 2, 3, 4 & 5 are ON
6 clutches = all switches are ON
Optional RS232/485 Printed Circuit Board
Pin Configuration:
RS232 RS485
5 9
2 RxD 3 TxB
3 TxD 4 TxA 4 8 Ribboncable connect to
5 Gnd 8 RxB 3 7 Display CPU PCB
S Shield 9 RxA 2 6
S Shield 1 Shield
(Pins not listed are not used)
Layout of Components on Communication Board

Optional Pressure (PSI) Printed Circuit Board
Each Pressure (PSI) PCB on the ASU allows the controller to monitor up to four pressure transduc-
ers. The DM35 ASU can accept one PSI PCB (four transducers), the DM70/140 ASUs can accept
up to two PSI PCBs (up to eight transducers) and the DM210 ASU can accept up to three PSI PCBs
(up to 12 transducers). Each CPU board can accomodate one PSI PCB.
The 8 pairs of terminals at the top edge of the board (as seen below) are for the high and low alarm
outputs of the relays. The eight jumpers for the high/ low alarm output relays (E1 thru E8) are facto-
ry set to Normally Open (default) and are illustrated below in default position.
The leads from the pressure transducers are connected at the left of the board (as seen below).
Note: the quantity of pressure transducers on an ASU is configured at the dip switches on the Dis-
play CPU PCB.
High & Low Alarm Outputs
4 High 4 Low 3 High 3 Low 2 High 2 Low 1 High 1 Low
X6
NC
NO Jumpers for
E8 E7 E6 E5 E4 E3 E2 E1
High/Low Alarms:
Normally Open (default)=
no alarm/ no continuity
Input connections Normally Closed =
from Transducers: no alarm/ has continuity
X1
Transducer #1
Flat cable to
CPU PCB
X2
Transducer #2
Green LED = Board
X3
logic power is OK
Transducer #3 X5
X4
Transducer #4
Layout of Components on Pressure Board

Heater and Sensor Resistance Values
The resistance values given in the four tables on the following page will aid in troubleshooting
when a sensor or heater malfunction is suspected. The “Temperature Sensor Resistance” table gives
values for various temperatures. If you know the approximate temperature of the suspected sensor,
you can check to see if the sensor resistance approximates the value given in the table by unplug-
ging the affected head or hose connection and measuring resistance across the affected pins (see
wiring diagram in Chapter 11 for pin numbers).
DANGER HIGH VOLTAGE

Disconnect input power to the application system before disconnecting/
re-connecting electrical connections. Make sure there is no electrical power on
the leads you will be connecting.
The “Nominal Hose Heater Resistance” table gives the heater resistance for hoses. A suspected hose
heater problem can be quickly isolated by measuring hose heater resistance and comparing it to the
correct resistance for your hose length and voltage as shown.
The “Nominal Head Heater Resistance” table gives values for several different head wattages. A
suspected head heater problem can be isolated by measuring head heater resistance and comparing
it to the resistance for the appropriate wattage of your system.
The “Nominal Hopper Heater Resistance” table gives heater resistance for the hopper heaters of
each Dynamelt M Series model and for the (optional) drop-in grids.
The “Nominal Filter Manifold Heater Resistance” table gives heater resistance for the heater located
in the (optional) filter manifold/ pressure relief block. The heater inside the manifold varies depend-
ing on the number of filter manifolds mounted on the ASU, therefore resistance varies also.
c. 2000 Troubleshooting Page 7-13
Resistance Tables
Temperature Resistance Hose Length Resistance

°F °C in Ohms Meters Feet in Ohms
(approximate)
32 0 100
50 10 104 1.2 4 515
68 20 108 1.8 6 343
86 30 112 2.4 8 257
104 40 116 3 10 206
122 50 119 3.7 12 171
140 60 123 4.9 16 128
158 70 127 7.3 24 86
176 80 131
194 90 135 Nominal Hose Heater Resistance
212 100 139 for #6 DynaFlex Hoses
230 110 142
248 120 146 Watts Resistance in Ohms
268 130 150
284 140 154 200 288
302 150 157 270 213
320 160 161 350 165
338 170 164 500 115
356 180 168 700 82
374 190 172 Nominal Head Heater Resistance
392 200 176
410 210 180
428 220 183 Note: Resistance is measured at
ambient temperature (20°C/ 68°F).
Temperature Sensor Resistance
(0.00385 PT 100 RTD)
Model : M35 M70/ 140 M210
Qty. Hopper Heaters 1 2 3

Max. # of Drop-in Grids 2 4 6
Resistance (Ohms) for each Hopper Heater 11.5 11.5 11.5
Resistance (Ohms) for each Drop-in Grid Heater 23 23 23
Nominal Hopper Heater Resistance in Ohms
No. Hose Outlets Model: M35 M70/ 140 M210

per Filter manifold
1-2 115.2 115.2 115.2

3-4 51.6 51.6 51.6
Nominal Filter Manifold Heater Resistance in Ohms

Page 7-14 Troubleshooting c. 2000
Error Indication Alarm Troubleshooting Guide
The operation of error indication alarms is described in Chapter 4. When checking for correct
equipment operation in the following guide, be aware that all heaters will go off immediately after
an error indication alarm occurs if the operator takes no action. With the exception of the fuses,
there are no user-replaceable parts on the printed circuit boards. If there is a non-fuse failure on any
of the PCBs, the PCB must be replaced.
DANGER HIGH VOLTAGE

Some of the procedures in the following Troubleshooting Guide require poten-
tially dangerous electricity to be present. Only qualified service personnel should
perform these procedures.
Problem Possible Cause Solution
Hopper (tank) 1. Setpoints have been 1. Re-program setpoints, allowing a

Overtemp programmed without larger deviation between the high
enough deviation. and low limits.
2. Hopper sensor 2. Replace hopper sensor if resistance

inoperative. does not comply with the resistance
table in this chapter.
3. Hopper control solid state 3. a. Verify that the relay is not shorted by
relay inoperative. removing all of its output wires and
verifying that resistance is greater than
zero.
Hopper Sensor
b. Verify condition of relay by discon-
necting, then re-connecting properly.
Then, when Temperature Zone is OFF,
use a VOM AC voltmeter to verify that
240 volts are not present at the heater
terminal.
Solid State
Relay
Solid State
Relay
Hopper Sensor Open 1. Sensor cable has become 1. Verify that hopper sensor cable is
unplugged from CPU PCB properly connected on X14 on the CPU
PCB.
2. Inoperative hopper sensor. 2. Replace hopper sensor if resistance

does not comply with resistance table
in this chapter.
Hopper Sensor
Hopper Sensor Short 1. Short-circuit caused by 1. Verify that sensor plug is clean and
debris where sensor plugs correctly connected on X14 on the CPU
into CPU PCB. PCB.
2. Pinched sensor lead wire. 2. Visually inspect sensor lead wire for
break, kink, damage, etc. If no obvious
damage, use an ohmmeter to measure
continuity from the sensor lead to the
CPU PCB plug at the CPU PCB. Repair or replace
any damaged wire.
3. Inoperative hopper sensor. 3. Replace hopper sensor if resistance

does not comply with resistance table
X14 in this chapter.
Hopper Heater Open 1.Disconnection in hopper 1. Inspect hopper heater wiring for
heater circuit. proper connections.
Hopper
Sensor 2. Disconnection between 2. Verify that all connections are properly
Power PCB and CPU PCB. made on the CPU PCB.
3. Hopper circuit breaker 3. Refer to the schematic in Chapter 11

tripped. to locate the hopper circuit breaker. If
it is tripped, do not re-set it without
checking for causes. Visually
and electrically inspect for a short-
circuit to ground in the hopper heater
Hopper circuit. This will be limited to between
Heater Wire
Thermostat
the hopper control relay and the hopper
heater.
4. Open hopper heater 4. At the terminal rail: use an ohmmeter

element. to measure resistance across H3A and
N (380v) or across H3A and H3B
(240v). See the resistance table
Hopper Circuit Breaker in this chapter for normal resistance
values. Infinitely high reisistance
values indicate an open heating element
which must be replaced.
NOTE A: DM70/140 models If the ASU has a second heater, measure

may have up to two hopper this heater’s resistance across H15A and
heaters. N (380v) or across H15A and H15B
(240v) as outlined above.
NOTE B: DM210 models If the ASU has a second heater, see Note
may have up to three hopper A. If the ASU has a third heater, measure
heaters. this heater’s resistance across H27A and
N (380v) or across H27A and H27B
(240v) as outlined above.
(Optional) Drop-in 1. Setpoints have been 1. Re-program setpoints, allowing a

Grid Overtemp Heater programmed without larger deviation between the high
Leads
2500w enough deviation. and low limits.
2. Grid sensor inoperative. 2. Examine grid sensor assembly

for intermittent break in sensor lead.
Grid Remove sensor bulb from grid.
Sensor Replace grid sensor if resistance does
not comply with the resistance table
in this chapter.
3. Grid control solid state 3. Use a clamp-on ammeter to monitor

relay inoperative. current. Replace inoperative solid state
relay.
(Optional) Drop-In 1. Sensor cable has become 1. Verify that grid sensor cable is
Grid Sensor Open unplugged from CPU PCB. properly connected at X14 on the
CPU PCB.,
2. Disconnection between 2. Verify that all connections are properly

Power PCB and the CPU made on the CPU PCB.
PCB.
3. Drop-in grid sensor 3. Replace sensor if resistance does

inoperative. not comply with the resistance table
in this chapter.
(Optional) Drop-in 1. Short-circuit caused by 1.Verify that sensor plug is clean and
Grid Sensor Short debris where sensor plugs correctly connected at X14 on the
into CPU PCB. CPU PCB.
2. Pinched sensor lead wire. 2. Visually inspect sensor lead wire for
break, kink, damage, etc. If no obvious
damage, use an ohmmeter to measure
continuity from the sensor lead to the
CPU PCB plug at X14 on the Power PCB. Repair
or replace any damaged wire.
3. Drop-in grid sensor 3. Replace sensor if resistance does

inoperative. not comply with the resistance table
X14 in this chapter
(Optional) Drop-in 1. Disconnection in grid’s 1. Inspect grid’s heater wiring for

Grid Heater Open heater circuit. proper connections.
2. Disconnection between 2. Verify that the Power PCB is properly

Power PCB and solid connected to the solid state relay.
state relay.
3 Drop-in grid circuit 3. Refer to the schematic in Chapter 11

breaker tripped. to locate the grid’s circuit breaker. If
it is tripped, do not re-set it without
checking for causes. Visually
and electrically inspect for a short-
circuit to ground in the grid’s heater
circuit. This will be limited to between
the grid’s control relay and the grid’s
heater.
Heater
Leads
4. At the terminal rail, use an ohmmeter
4. Open drop-in grid heater
2500w
element. to measure resistance as follows:
For 1 grid: H1A & N (380v)
NOTE: The DM35 ASU may H1A & H1B (240v)
have 1 or 2 grids. The For 2nd grid: H2A & N (380v)
Grid
Sensor DM70/140 ASU may have H2A & H2B (240v)
from 1 to 4 grids. For 3rd grid: H13A & N (380v)
The DM210 ASU may have H13A & H13B (240v)
from 1 to 6 grids. For 4th grid: H14A & N (380v)
H14A & H14B (240v)
For 5th grid: H25A & N (380v)
H25A & H25B (240v)
For 6th grid: H26A & N (380v)
See the resistance table in this chapter

for normal resistance values. Infinitely
high reisistance values indicate an open
heating element which must be
replaced.
Hose/ Head 1. Hose/ Head setpoints 1. Re-program setpoints to allow a

(No.) Overtemp incorrectly programmed. larger deviation.
2. Inoperative or shorted 2. Refer to the schematic in Chapter 11 to
Note: Vertical configuration is for
DM 35 only. Larger ASUs are hose/ head triac or dual locate the correct head/ hose triac or
arranged horizontally. solid state relay. relay. Use a clamp-on ammeter to mon-
Aux.
itor hose/ head current. If current does
#1
not cycle on and off, then the triac or
relay has failed and must be replaced.
Aux.
#2
3. Disconnection between the 3. Verify that all PCBs are properly
Power PCB’s and the CPU mounted inside the panel box.
board’s flat cables.
#1
4. Hose/ Head sensor circuit 4. a. Visually examine socket connect-

#2 inoperative. ion where hose/ head attaches to ASU.
Verify that pins are properly seated. If
pins or plug housing are damaged,
repair or replace hose. If socket
is damaged, repair or replace harness.
b. If hose-to-ASU plug and socket are

okay, hose may have intermittent short
or open circuit. Repair or replace hose,
hose harness or Power PCB as
appropriate.
Alternately, problem can be isolated
Sensor by connecting the effected hose to a
Heater
different ASU hose socket to tell
whether the problem is in the hose or
in the Power PCB.
c. If head-to-hose and hose-to-ASU

Plug
plugs and sockets are okay, head
Sensor & sensor may have an intermittent short
Heater
or open circuit. Examine connections
inside the service block area of the head
and monitor head sensor resistance
with an ohmmeter while flexing sensor
leads. Repair or replace as appropriate.
Hose/ Head (No.) 1. Disconnection between 1. Visually examine connection where
Sensor Open hose and ASU. hose plugs into ASU socket for proper
contact and seating. If pins or housings
are damaged, repair or replace hose or
hose harness (in ASU).
Note: Vertical configuration is for 2. Hose sensor harness 2. Verify that effected hose is properly
DM 35 only. Larger ASUs are unplugged from Power connected to Power PCB. Replace or
arranged horizontally.
PCB. repair damaged hose harness as necessary.
Aux.
#1
3. Disconnection between the 3. Verify that all PCBs are properly
Power PCB’s and the CPU mounted inside the panel box.
Aux.
#2
PCB’s flat cables.
4. Hose/ Head sensor circuit 4. Replace head sensor if resistance does

#1
inoperative. not comply with resistance table in this
chapter. Use hose schematic to check
hose sensor at ASU socket. Repair or
#2
replace hose, hose harness or Power
PCB as appropriate.
Hose/ Head (No.) 1. Debris at connection 1. Visually inspect hose plug and ASU
Sensor Short between hose/ head and socket for cleanliness and proper
ASU. contact and seating of pins.
2. Hose/ Head sensor circuit 2. a. Using the hose schematic, check hose
inoperative. sensor resistance at ASU socket. An
ohmmeter can be used to isolate a
pinched wire in the hose harness.
When cause is isolated, replace
hose, hose harness or Power PCB as
appropriate.
b. If head-to-hose and hose-to-ASU

plugs and sockets are okay, head
sensor may have an intermittent short
or open circuit. Examine connections
inside the service block area of the head
and monitor head sensor resistance
with an ohmmeter while flexing sensor
leads. Repair or replace as appropriate.
Hose/ Head (No.) 1. Disconnection between 1. Visually examine effected hose plug
Heater Open hose/ head and ASU. and ASU socket for cleanliness and
proper contact and seating. Refer to
the wiring diagram for pin identifica-
tion. The problem can be isolated by
plugging the effected hose/ head into
another ASU socket. If the new hose
number is then displayed as malfunct-
ioning, the problem is in the hose that
was moved. Repair or replace hose,
head or ASU hose harness as
appropriate.
2. Disconnection between 2. Check connection. Verify that solid
solid state relay and state relay is operative: check schematic
Power PCB or inoperative in Chapter 11 for relay location. Use a
relay. clamp-on ammeter to monitor hose/
Head current. If current does not cycle
on and off, the relay has failed and must
be replaced.
3. Disconnection between 3. Visually inspect wiring inside head.
cartridge heater and cable Verify that cartridge heater leads are
assembly inside head. properly connected in the service
block area.
Sensor
4. Inoperative hose/ head 4. Refer to schematic in Chapter 11 for
Heater circuit breaker. location of circuit breaker. If it is
found to be tripped, do not re-set it
without first finding cause. Visually
inspect and use an ohmmeter to check
Plug for a possible short circut to ground in
the hose/ head heater circuit.
Sensor &
Heater 5. Open hose/ head heater 5. Use an ohmmeter to measure hose/

element. head heater resistance. See resistance
table in this chapter for resistance
values. Infinitely high resistance indi-
cates an open heater element.
6. Open wiring inside ASU. 6. Visually inspect ASU wiring and use
an ohmmeter and the wiring diagram
to locate open wires in head heater
circuit. Repair or replace ASU hose
head harness or other ASU wiring as
necessary.
Adjustable Adhesive Pressure Relief Valve
Dynamelt pumps are outfitted with a high-pressure relief valve located on the outlet filter manifold.
The valve is adjustable and it does not affect adhesive pressure under normal operating conditions.
The adjustable pressure relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.
When adhesive pressure exceeds the set limit, the pressure forces the valve to move away from its
seat, compressing the spring and allowing adhesive to flow back to the hopper. This adhesive flow
reduces pressure. When the pressure falls below the set limit, the spring forces the valve against its
seat, cutting off adhesive flow.
The check valve, seen below, is not instrumental in pressure relief. It serves as an overflow valve,
preventing adhesive from flowing out of the hopper when the filter plug is removed.
Normally Closed (Unrelieved): Open (Relieved):
In the drawing below, the pressure In this drawing, pressure has

relief valve is closed. exceeded the setting of the valve,
causing it to open and discharge
adhesive to the hopper.
Pressure Pressure
Relief Valve Relief Valve
Filter Filter
Cartridge Cartridge
Spring
Check Check
Valve Valve
no adhesive adhesive
return return
to hopper to hopper
adhesive flow adhesive flow

to hose to hose
Purge Valve Purge Valve
Adhesive flow through Adhesive flow through

filter block to hose filter block to hose
Operation of the Adjustable Adhesive Pressure Relief Valve

Operation of the ASU’s Gear Pump
Manual or Automatic Pump Operation

Choose “Manual”, “Stop” or “Automatic” gear pump operation via the “Motor” pushbutton (see
icon above) on the controller’s keypad. When the Dynamelt’s pump is to be operated manually (that
is, without a line following signal), the manual mode is used to control pump speed (and adhesive
output). For the gear pump to be operated in the automatic mode, a tach generator, or equivalent (at-
tached to the parent conveyor line) must be provided and the following set-up procedure should be
performed:
1. The tach generator or the signal isolator must be adjusted so that the voltage from the speed
controller is 0 to 10 VDC (but not more than +10 VDC when the conveyor is at maximum
speed). This voltage is measured at either X3 on the Motor Control Interface PCB (for a tach
generator) or at terminals 9 (+) and 10 (-) of the Signal Isolator Board.
2. The “Automatic” setting then changes pump speed for any given 0 to +10 VDC incoming
tachometer signal. Voltage will vary given production speed.
The motor speed can be adjusted (trimmed) in automatic mode by setting maximum and minimum
percent of full speed values on the controller’s keypad. MAX % of Full Speed will be the true motor
speed at 10 volts input. This value cannot exceed 100%.
To make the motor speed adjustment, follow the programming instructions in Chapter 5.
Pump Output Adjustment

When the adhesive in the ASU’s hopper has reached a temperature high enough for the pump to op-
erate safely, the controller will place the hopper in “Ready” condition and power will be supplied to
the pump. The pump is self-priming.
Pump output is adjusted by the motor speed control on the controller’s keypad. However, if less
pressure is needed, maximum pressure of the pump can be decreased (or increased) by adjusting the
pressure relief valve installed on the pump output manifold. To change the setting of this valve, re-
fer to instructions in Chapter 3.
The relief valve is factory set at 34 bar (500 psi) for Dynamelt M gear pumps.
Troubleshooting the ASU’s Gear Pump
No special tools are needed for working on the ASU pump. See Chapter 8 of this manual for diaas-
sembly/ assembly procedures for the ASU pump, and Chapter 10 for locating pump parts on the
component illustrations (exploded-view drawings).
Gear Pump Priming/ Start-Up
The pump is self priming.
CAUTION: DO NOT continue to run the pump if no glue is coming out. This could
damage the pump since it uses the glue as a lubricant. Stop and troubleshoot.
Gear Pump Troubleshooting Guide
WARNING HOT SURFACE & ADHESIVE

Some of the procedures in the following Troubleshooting Guide require working
near hot adhesive. Be sure to wear protective gloves, safety glasses and clothing
and use proper tools for handling hot melt components.
Note: Each motor and Motor Interface PCB in the system can run independently (or dependent-
ly). Each Motor Interface PCB may have its own operating parameters. Therefore, each motor
and Motor Interface PCB should be troubleshot independently.
Pump doesn’t operate 1. Motor On/Off is OFF at 1. Check keypad setting.

in “Manual” mode, the controller keypad.
power light doesn’t
light. 2. Hopper temperature is 2. Pump cannot operate until hopper has
ON/OFF Led below ready setpoint. reached “ready” condition. Verify that
hopper has reached ready. Re-program
hopper operating setpoint and ready
setpoint if necessary.
3. No incoming electrical 3. Check to see if ASU temperature
power. control is operating. If not, check
for presence of incoming supply
voltage.
Pump doesn’t operate 1. “Manual” motor is set at 1. Re-program motor.

in “Manual” mode, zero (at the keypad).
power light is ON,
hopper is at “ready”
condition. 2. If pump On/Off is being 2. Check condition of the remote switch
controlled by a remote (the hand-held applicator).
switch (i.e., a hand-held,
applicator), the switch or
switch circuit may be open.
3. Low temp alarm. 3. Verify that ASU is warmed up and that

hopper temperature is above the factory-
set pump enable temperature.
4. Faulty Motor Control 4. If the board is faulty it must be
Interface Board. replaced.
Pump doesn’t operate 1. Parent machine is not 1. Check parent machine.

in “Auto” mode, running.
power light is ON,
hopper is at ready 2. “Auto” motor is set at 2. Re-program motor.
conditon. zero (at controller keypad).
3. No incoming line 3. Check for presence of 0 to 10 VDC

following signal. control signal at X3 of Motor Control
Interface PCB. If signal is not present,
check connection at X3 and tachometer
drive connections. If control signal is
X3 present there, the problem is within the
ASU.
Motor Control Interface PCB
4. Internal ASU connections 4. Check for the presence of 0 to 10 VDC
or Motor Control Interface control signal at X3 of Motor Control
PCB inoperative. Interface PCB. Check ASU connections
(S1 & S2). If the signal is not present, the
problem is in the connection. If the signal is
present there, the problem is most likely a
faulty Motor Control Interface Board.
5. System is not ready, temp- 5. Verify that ASU is warmed up and that
eratures are too low. hopper temperature is above the low
temperature thermostat.
Pump runs but there is 1. ASU is out of adhesive. 1. Add adhesive to hopper.
no adhesive output.
2. If pump has been serviced 2. Check pump wiring to schematic.
and leads reversed, pump
will run with no output.
Low or inconsistent 1. Filter(s) clogged. 1. Remove and inspect filter cartridge

adhesive output. and primary filter.
2. Adhesive used is too 2. Verify that system components are

viscous. at appropriate temperatures and that
Filter the selected adhesive is correct for
the application.
3. Clogged hose. 3. Inspect hose for kinks or internal

plugs of debris or char. Clean or
replace hoses as necessary.
4. Clogged applicators. 4. Inspect applicators for plugged

nozzles or filters. Clean or repair
applicators as necessary.
5. The fixed pressure relief 5. When fully closed (clockwise) and

valve is opening. all applicators are off, adhesive
pressure should be around 34 bar
(500 psi). If it is significantly less,
the pressure relief valve should be
replaced.
6. Inoperative lower o-ring 6. Replace o-ring. Follow diagram and

in filter plug is allowing instructions in Chapter 6 for “Outlet
pressure to escape. Filter” to locate the o-ring.
Adhesive leak at pump 1. Pump seal is incorrectly 1. Remove seal and bearing from pump.
shaft seal. positioned inside the seal Verify that all components are
and bearing assembly. correctly positioned.
Seal Assembly
Rear Plate 2. Pump seal inoperative. 2. Remove seal from pump, inspect it
O-ring and replace it if worn or damaged.
Be sure there are no burrs or other
sharp edges on pump shaft or on
installation tools that could damage
a new seal.
Adhesive leak at pump- 1. O-ring in pump’s rear 1.Remove seal from pump, inspect it
to-hopper interface. plate is inoperative. and replace it if worn or damaged. Be
sure there are no burrs or other sharp
edges on the rear plate o-ring groove
that could damage a new o-ring.
2. Pump assembly screws are 2. Verify that all four pump screws are
missing or loose. tightly assembled to the hopper.
3. Helicoil insert pulled out 3. Remove pump and inspect hopper.

of hopper. Repair or replace hopper as necessary.
ITW Dynatec

c. 2001 Disassembly & Re-assembly Page 8-1
Chapter 8
DISASSEMBLY & RE-ASSEMBLY PROCEDURES
Note: Re-read Chapter 1 “Safety Precautions” before performing any disassembly procedures. All
disassembly and repair procedures must be performed by qualified, trained technicians.
Disassembly Procedures
Note: Use the exploded-view drawings referenced with each procedure in conjunction with the
instructions outlined in this chapter. Read the “cautions” on page 8-5 before re-assembling the
ASU.
To Remove the Access Doors

There are two access doors, one on either side of the ASU. Use the key to unlock the door, then lift
it off, being careful not to pull off the ground wire attached. Remove the ground wire and re-attach
when the door is re-installed. These doors allow access to: the motor, pump, junction boxes,
(optional) drop-in grids, filter shutoffs and (optional) ball valves.
To Open Junction Boxes

There are two junction boxes, one on either side of the hopper(s). A junction box cover is removed
by two screws at the bottom of the box. Within the juction boxes are thermostats, heater terminals
and the hopper sensor. See also the detailed illustration on the following page.
Panel Box
Access Assembly Filter Shutoff
Door Assembly
Keylock
Over-Temp Reset
Thermostat
Pump Enable
Thermostat
Filter Shutoff Assembly
Ball Valve Filter Manifold

Assembly
(option)
Pump Enable Thermostat Manifold Cover
Over-Temp Reset Thermostat

Page 8-2 Disassembly & Re-assembly c. 2001
Junction Hopper
Box cover
Junction
Box
Cutouts for conduit
connectors for filter
manifold heater and
sensor.
Over Temp
Reset
Thermostat
Cutouts for drop-in
grid assembly
Filter Shutoff
Pump Enable-
Hopper Sensor Heater Thermostat Port
Port Terminals
Junction Box
Side View
Sensor or Thermostat Replacement

Remove the junction box cover.
a. Over-Temperature Thermostat Replacement: Remove the two screws and slip the terminals and
the hopper ground wire off of the thermostat before removing the thermostat from the base of the
hopper.
b. Pump Enable Thermostat Replacement: Disconnect two wires from the terminal strip and slide
the thermostat out.
c. RTD Sensor Replacement: Disconnect two wires from the terminal strip and slide the sensor
out.
To Remove the Manifold Cover

Unscrew its captive screw and slide cover off. Cover allows access to the hose connections on the
filter manifold, outlet filters, heaters and the pressure relief.
Heater Replacement
Cartridge heaters are located underneath the filter manifolds:
For models DM70 & 140: Remove the manifold cover (see previous page). Remove the cover
located at the end of the heater retainer plate (4 screws). Disconnect heater wires from the terminal
rail. Loosen the heater retainer plate, then allow the cartridge heaters to slide out.
For model DM210: Replace heaters on the outer four manifolds as described above. To access
heaters on the two inner manifolds, remove the two manifold covers, then remove the cover located
at the end of the heater retainer plate (4 screws). Disconnect heater wires from the terminal rail. Re-
move the heater retainer plate, then remove the heater(s).
Heater plates are kocated underneath the hopper(s):

Remove the access door. Use a hex head socket wrench to remove the six heater plate bolts
through the holes drilled in the base plate. Disconnect the heater wires. Slide the old heater plate
out. Connect heater wires to new plate. Slide new plate in place and fasten with the six bolts.
Note: the DM70 & 140 models have two heater plates; the DM210 model has three heater plates.
To Remove Rear Cover

No customer replaceable components are behind the rear cover. To remove: remove the two ac-
cess doors in order to access and remove the five screws which hold the rear cover in place. Two
screws are located in the upper corners of the rear cover. Three screws are located across the bot-
tom of the cover.
To Access the RTD Sensor in the Optional Drop-in Grid

Remove the access door. Remove the screws on the drop-in grid’s junction box cover in order to
remove the cover. Disconnect the sensor from the terminal strip inside the junction box and slide
the sensor out of its adapter.
To Access Electrical Components inside the Panel Box
DANGER HIGH VOLTAGE

Dynamelt systems use electrical power that can be life threatening. Disconnect
and lock out input power to the application system before starting any
disassembly procedure.
Verify again that the main power is OFF. On the outside of the panel box, use the main disconnect
switch to open the panel box door (see Chapter 3 for instructions on opening door).
a. Fuse Replacement: Fuses are located in the upper right corner of the inside of the panel box
assembly. The following printed circuit boards are fused: Motor Control Interface, Power I/O and
the optional Clutch board.
b. Printed Circuit Board Replacement: Reference the section entitled “Handling Printed Cir-
cuit Boards” in Chapter 7. The PCBs are located in the panel box assembly. Refer to detailed lay-
out in Chapter 3.
The PCBs snap into and out of their standoffs. To remove: place your fingertips under one corner
of the PCB and pull out firmly from the standoff. Repeat for each corner of the PCB.
Note: aside from fuses and the Lithium battery on the M Series CPU PCB (see Chapter 7), there
are no replaceable parts on the PCBs.
To Access the Pump or Motor
DANGER HOT SURFACE & HIGH VOLTAGE

If the pump is not operable but the heating system will function, raise the
temperature of the application system to the operating temperature to aid in the
pump disassembly process. Otherwise, a heat gun or other controlled heating
method is recommended to melt hardened hot melt material. Never use a torch
or an open flame on any of the components of the application system. Once the
system is up to temperature, disconnect all incoming power before proceeding.
Remove access door(s) using the key, being careful not to pull off the ground wire attached. Turn
OFF the filter shutoff valve by turning it to its closed “0” position.
a. Motor Removal: Open the motor junction box cover (2 screws). Inside the junction box, dis-
connect the wires leading to the motor. On the outside of the junction box, unscrew the hex nut
conduit fitting. Slide the wires through the conduit fitting. Remove the four bolts which attach
the motor to the gear box. Lift the motor up and out of the ASU.
For re-assembly: torque should be approximately 1.8 Nm (16 foot/lbs) at room temperature.
With hopper at 177°C (350°F), the maximum allowable torque on screws is 4.1 Nm (36 foot/lbs).
Motor
Access
Door
Motor
Junction
Box
Gear Box
c. Pump Removal: Verify that the filter shutoff

is in its closed “0” position. Remove the release
pin and retainer clip, slide the shaft out of the
gear box. Slide the coupling off the pump shaft. Shaft
Remove the four pump mounting bolts.
Release pin &
Retainer clip
d. Pump Seal (O-ring) Replacement: Remove
the pump from the ASU (see instructions above, Coupling
“c”). Remove the external pump seal from its
groove on the back of the pump adapter plate
(this is the seal located between the adapter plate Pump
and the hopper). Install the new seal.
Re-Assembly Procedures
Unless noted, the M Series ASU’s re-assembly is simply the reverse sequence of the disassembly
procedures. However, the following precautions should be followed (whenever they apply) for
proper re-assembly:
WARNING HOT SURFACE

It order to protect personnel and equipment, it is important to replace all
insulation whenever it is removed from the ASU.
CAUTION: In general, all O-RINGS AND SEALS should be replaced whenever

hot-melt equipment is re-assembled. All new o-rings should be lubricated with
o-ring lube (PN N07588).
CAUTION: TAPERED PIPE THREADS are found on air line fittings used with the
pump air supply (if applicable) 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 the ASU 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 against the pump body (or other
surface). Excessive torque may damage straight-threaded parts and the use of
power wrenches is not recommended
CAUTION: HOT-MELT RESIDUE should 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 should always be
re-tightened at operating temperature.
ITW Dynatec

c. 2001 Options & Accessories Page 9-1
DYNAMELT M ASU Manual #20-37, 20-38 Revised 8/09
Chapter 9
AVAILABLE OPTIONS & ACCESSORIES
Pressure Gauge Assembly PN 805641

An optional analog pressure gauge can be mounted on the outlet filter manifold. Reading the
adhesive pressure at the manifold, rather than in-line on a hose, allows for more precise monitoring
of system pressure. It is also useful for troubleshooting and maintenance.
The gauge is installed at one of the adhesive ports on the manifold. Fittings and adapter are included
in the assembly.
Pre-PSI & Post-PSI Transducers PN 815969; Transducer Assembly PN 815970

A pressure transducer is an electronic probe that allows the melted adhesive’s pressure to be
processed by the ASU’s control system. They are used to monitor system operating pressures and
their limits. The Pre-PSI transducer measures adhesive pressure in the filter manifold before the
filter basket. The Post-PSI transducer measures the pressure after the filter basket. By comparing
the two readings, the operator can determine if the filter basket is clogged.
Drop-in Grids PN 104802

The drop-in grid is an extra heated grid(s) which is installed near the bottom of the ASU’s hopper.
The additional grid(s) allows faster melting of adhesive for applications requiring higher melt rates
and higher volumes of adhesive. When installed, the drop-in grid becomes an auxiliary temperature
zone on the controller.
High-Temperature Heater Groups

More accurate temperature control may be gained by using a High-Temp Heater Group in the filter
manifold/ pressure relief block. A heater and sensor are contained inside the block and become their
own temperature zone on the controller. Six groups are available depending on the number of filter
manifolds on the ASU.
Filter Options and Accessories:

40 Mesh Easy-Spin Filter PN 814007 100 Mesh Easy-Spin Filter PN 814009 (standard)
80 Mesh Easy-Spin Filter PN 814008 150 Mesh Easy-Spin Filter PN 814010
Level Control
Single-Point Level Control Kit: PN 810237 (DMM140 & DMM210 only)
Multi-Point Level Control Assembly: PN 084Q210 (DMM140 & DMM210 only)
Level control devices inform the operator, via a message on the controller, that the hopper’s adhe-
sive level is low. They may also be wired to stop production, turn on an alarm light or signal, or
signal a PLC.
Page 9-2 Options & Accessories c. 2001
Revised 9/07 DYNAMELT M ASU Manual #20-37, 20-38
Pump Options and Accessories:

Gear Pumps
For higher tolerances and precision, several gear pumps are available for the Dynamelt. Gear pumps
give better service for continuous applications or applications which require more control over the vol-
ume of adhesive pumped. Gear pumps available are:
Single Pumps:
PN 100860: 1.54 cc/rev single, standard accuracy gear pump
PN 109690: 10 cc/rev single, standard accuracy gear pump
PN 108875: 8.5 cc/rev single, high accuracy gear pump
PN 084E374: 0.584 cc/rev single, high accuracy gear pump
Dual Pumps:
Note: all dual pumps require PN 102049, see below.
PN 100863: 1.54 cc/rev dual, standard accuracy gear pump
PN 100864: 3.18 cc/rev dual, standard accuracy gear pump
PN 084E389: 0.584 cc/rev dual, high accuracy gear pump
PN 084E432: 1.168 cc/rev dual, high accuracy gear pump
PN 108874: 2.920 cc/rev dual, high accuracy gear pump
Hi-Flow Pumps:
PN 110289: 20cc/rev single, gear pump, TSHA
Feinpruf Gear Pumps

Feinpruf pumps are commonly used in the European marketplace.
Gear Pump Repair Kit PN 103151

Contains the following items needed to repair the PNs 100860 thru 100864 gear pumps:
PN Description Qty. PN Description Qty.
N00198 O-ring 2 069X064 O-ring 3

018X031 Ball Bearing 5 078F017 Ring, Clip 4
069X061 Seal 1 078I001 Key, Woodruff 1
c. 2001 Options & Accessories Page 9-3
DYNAMELT M ASU Manual #20-37, 20-38 Revised 10/12
Return (re-circulating) Hoses

Available on all models. Use of return hoses allows higher adhesive pressures from the head to the
substrate because the head is “overfed” adhesive. The overflow adhesive is re-circulated to the hop-
per.
Pneumatic Clutch PN 106877

A pneumatic clutch is available for the Dynamelt M70/ 140/ 210 ASUs. A clutch relieves adhesive
pressure quickly in applications where there are periods of time when adhesive is not being applied.
Dual Hopper
Available on DM M140 and M210. The adhesive hopper on the dual hopper models is divided into
two separate chambers to allow the application of two different adhesives simultaneously. Each
chamber is an independent temperature zone, allowing them to operate at different adhesive temper-
atures.
High Flow ASUs

These ASUs are available as DM M140 or M210 units for applications requiring a pump rate up to
2,625 cc/min per pump. The high flow models are equipped with high flow grid groups, including
high flow hoppers, filter shutoff assemblies, filter manifolds and filter baskets.
DynaControl Options:
Pendant Control Panel PN 107643
The pendant control option gives the DynaControl keypad mobility via a 9 meter (30 ft), 6 meter
(20 ft) or 3 meter (10 ft) cable. The Pendant Control Panel replaces the standard display panel.
Pressure Display PN 108389 = DM 70/140, PN 108390 = DM 210

The pressure board option enables the controller to read and display adhesive pressure PSI values in
the outlet filter manifold. The option consists of a PSI printed circuit board which is used with a
pressure reading device (transducer or gauge) mounted on the filter manifold.
Actual Digital RPM Readout PN 108313

This option provides a controller readout for actual motor or pump revolutions per minute. No addi-
tional programming is necessary. Installation of an encoder is required.
System Status Lights PN 104280

Remote monitoring of system status is made easier with this tri-color light. The stack light is
mounted on a 6”x 6” box, which is itself mounted on a stand with a 10’ cable. Wired into the con-
troller, the lights illuminate to indicate “Power On”, “Ready” and “Alarm”. An audible signal ac-
companies the “Alarm” light. The alarm may be wired to indicate either high/low temperature, low
adhesive level or open/short sensor.
cont.
Line Speed Tracking Options

Line speed tracking is a standard feature of the M Series ASUs which allows the speed of the motor
and ASU to follow the speed of a production line via a reference voltage input. When operated as
the standard feature, a 0-10v signal from a PLC or a similar line speed output device is utilized.
However, it may also be operated utilizing one of the following optional devices:
PN 015D050 Tach Generator: a mechanically operated device which produces a reference voltage
that allows the ASU’s gear pump to track a parent machine’s production line speed.
PN N06642 Signal Isolator: a device which conditions a parent machine’s production line’s DC
speed reference voltage to allow the ASU’s gear pump to track line speed.
Serial Communication (PC Link / Remote I/O Interface) PN 108475

Bi-directional data transfer to a remote computer is available for the controller. The ASU’s standard
RS232 serial port connection allows remote interface up to 50 meters from the DynaControl con-
troller. The RS485 serial port connection offers remote interface over a much longer distance. Either
connection enables all system parameters to be monitored and/ or controlled from the remote sta-
tion.
Ethernet/ IP Adapter Kit: PN 112224

This kit adapts the DMM ASU for an Ethernet network so that all system parameters can be trans-
mitted and received, allowing full remote operation of the ASU.
c. 2001 Optional & Accessories Page 9-5
Recommended Service Parts List

Category Part No. Description Qty.
Electrical: 102762 Fuse, 1 amp (motor control interface pcb) 5

108566 Fuse, T6.3ALx 5x20 (pcbs) 5
103184 Fuse GDC4 (terminal rail) 10
804535 Fuse 15a, LP-CC 3
N07958 RTD Sensor, PT 1
036B103 RTD Sensor, PT 2
104166 Over-Temp Thermostat & Insulator 1
036B015 Pump Enable Thermostat 1
048H384 Solid State Relay, Dual 9 to 24
109857 CPU Printed Circuit Board, V5 1
108256 Control Assy. (w. PCB) 1
107440 48-Zone Power (I/O) PC Board 1
106149 Auxiliary RTD PC Board (optional) 1
816341 Motor Speed Control Kit, 1HP, Y 1
110090 Motor Control Interface PC Board 1
107438 Clutch PC Board (optional) 1
106147 Pressure PC Board (optional) 1
036A170 Heater, 500w (for 1 filter block) 1
036A079 Heater, 1000w (for 2 filter blocks) 1
102149 Heater, 1500w (for 3 filter blocks) 1
036A077 Heater, 2000w (for 4 filter blocks) 1
O-rings: N00181 O-ring 014 (outlet filter/ manifold) 12 + 14 per manifold

A69X133 O-ring 124 (outlet filter/ manifold) 2 per manifold
N00187 O-ring 020 (outlet filter/ manifold) 2 per manifold
812816 O-ring 127 (outlet filter/ manifold) 2 per manifold
N00192 O-ring 032 6
807729 Pump Shaft Seal (Zenith/ TSHA pump models) 2 per pump
069X061 Pump Shaft Seal (ITW Dynatec pump models) 2 per pump
069X289 Pump Shaft Seal (Hi Flow pump models) 2 per pump
069X064 O-ring 041 (optional pump block off assembly) 1
see IBOM Pump Adapter O-rings 1 of each per pump
Filters: 814007 Easy-Spin Filter, 40 mesh (optional) 2 per manifold

814008 Easy-Spin Filter, 80 mesh (optional) 2 per manifold
814009 Easy-Spin Filter, 100 mesh (standard) 2 per manifold
814010 Easy-Spin Filter, 150 mesh (optional) 2 per manifold
105968 Filter Shutoff Assembly, Right 1
105969 Filter Shutoff Assembly 1
Misc: N07588 Lubricant, O-ring 2

L15653 Kit, Flushing Fluid, 1 gallon 1
001U002 Hi-Temp Lubricant, tube 1
808217 Adjustable Relief Valve, 0-750psi 1
814018 Filter Nut 1
102717 Check Valve 1
ITW Dynatec

c. 2000 Component Illustrations Page 10-1
Chapter 10
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.
Chapter Format
This chapter contains the component illustrations (exploded-view drawings) for each assembly of
the DYNAMELT M SERIES ASU. These drawings are useful for finding part numbers as well as
for use when maintaining or repairing the unit.
Note: most common nuts, bolts and fasteners can be obtained locally at your hardware store. Spe-
cialty fasteners are available by contacting Dynatec’s Customer Service.
Page 10-2 Component Illustrations & BOM’s ITW Dynatec c. 1999
Revised 6/10 DYNAMELT M ASU Manual, ALL MODELS
Bill of Materials for PN 814016 Easy-Spin Filter Assembly
Item No. Part Number Qty. Description
808349 SCR, SHC, M6-1.00X20,ZP

ITW Dynatec c. 1999 Component Illustrations & BOM’s Page 10-3
DYNAMELT M ASU Manual, ALL MODELS Revised 2/10
Component Illustration: PN 814016 Filter Assembly

Revised 8/05 DYNAMELT M ASU Manual
PN 809534 Hi Volume/ Hi Flow Filter & Pressure Relief Assembly

Item No. Part Number Description Qty.
1 N00185 O-ring, #018 6
2 003D105 Heater Plate 1
3 006B043 Heat Isolator 1
4 809533 Block, Filter 2
5 806182 Filter Nut 2
6 807796 Large Filter Basket (20 Mesh, option) 2
807797 Large Filter Basket (40 Mesh, option) 2
7 806188 Filter Retainer Plate 2
8 006G064 Block, Pressure Relief 2
9 006G078 Spring, Pressure Relief 2
10 012G001 Relief Piston 2
11 012G010 Pressure Relief Screw 2
12 048D141 Junction Box 1
13 048D142 Cover 1
14 N00220 Snap-In Hole Plug 1
15 048J022 3/8” St, Conduit Fitting 1
16 806206 O-Ring #333 2
17 104733 1/2 NPT Level Seal Plug 4
18 006G112 Cap, Adjustment Screw 2
19 078A005 10-24 x 1/2 SHCS 4
20 N04458 1/4 Dowel Pin 4
21 N00838 3/8-16 x 1 1/4SHC Screw 8
22 N00839 3/8-16 x 1 3/4 SHC Screw 4
23 078A164 10-24 x 1/2 HHSM Screw 1
24 N07790 3/8-16 x 4 1/4 SHC Screw 4
25 078A337 3/8-16 x 5 1/2 SHC Screw 4
26 078A379 1/4-20 x 4 1/2 SHC Screw 6
27 078D027 3/4-16 Jam Nut 2
28 078C005 Flat Washer, #8 SAE 4
29 078C021 Flat Washer, .88 x 1.0 x .13 1
30 101833 10-32 Tamper Proof Screw 2
31 807188 Plug, Drain 2
32 N00754 Level Seal Plug, 1/4 4
33 N00755 3/8-18 NPT Level Seal Plug 2
807179 Heater Control Section 1
34 036A079 Heater, 5/8 x 10, 240v, 1000w 3
35 036B013 T’Stat, Cartridge, N.C., 1/2 Dia. 1
36 106174 Sensor Adapter 1
37 N07958 Temperature Sensor 1
38 807543 Hi Volume Filter Nut Cover Assembly (option) 2
39 807542 Cover Plate 1
40 N00817 1/4-20 x 1.25 SHC Screw 4
c. 1999 Component Illustrations & BOM’s Page 10-5
DYNAMELT M ASU Manual All Models Revised 8/05
18
40 27
21 22
8 11
39
9
5 1
10
7
22
16
23 1
1
28
13 3
19
12 14
6
34
37
36
35 20
29
Optional
15 2
24 32
17 33
30
25 31
32 4
32
26
Note: The junction box can be mounted either side of the

filter block depending on the application set-up.
Component Illustration:Hi Vol. Filter & Pressure Relief Assembly # 809534

Page 10-6 Component Illustrations & BOM’s c. 2001
Bill of Materials for Typical Electrical Panel Box Assembly, M210 DCL V5
1 804469 Mounting Bracket 1

2 107625 Bezel 1
3 802626 Heat Sink 2
4 102328 Panel Box Lock Kit 2
5 103377 Wire Duct, 1.5” W x 3” H
103378 Wire Duct, 2” w x 3”H
6 103439 Wire Duct Cover, 1.5.”
103438 Wire Duct Cover, 2.25”
7 104382/ 104383 Rotary Handle & Shaft 1
8 107641 Block-off Plate (used with pendant control) 1
9 104384 Mechanical Operator, Circuit Breaker 1
10 Circuit Breaker (part number varies, see your bill of materials) 1
11 802679 Panel Box 1
12 804426 Insert Panel 1
13 048H384 Solid State Relay, Dual 40A, 240VAC 6--24
14 109770 Pendant Control Assembly (option) 1
continued on pages 6 thru 7

8 2
14
Optional Pendant Control
7
11
13
3
9
7 10
12
5 6
Bill of Materials for Typical Electrical Panel Box Assembly, M210 DCL V5 (cont. from pg. 4)
Quantities depend
Item No. Part Number Description on model
15 102762 Fuse, 1A 4
16 103183 Fuse Block, Lever Open 12
17 103184 Fuse, GDC4, 250VAC 4
18 104167 Terminal Rail, 15.75 1
19 109857 Control Processor Board (CPU) 1--3
20 103069 Circuit Breaker, CB,16A,1P,63F,415V,WE (used on 400v system) 33
806424 Circuit Breaker, CB,16A,2P,415V,WE (used on 240v system) 33
21 103070 Circuit Breaker, CB,20A,415V,2P,WE (used on 400v system) 3
806425 Circuit Breaker, CB,20A,2P,415V,WE (used on 240v system) 3
22 104193 Ground, Small Dual 1
23 108306 Side Insert Panel 1
24 107856 Filter, RFI, 240v, 10A 1--4
25 106111 M4 x 12 Button Head Screw 4--16
26 107466 Fuse, 2A 1
27 104761 2ND MAIN CB, 50A 3
28 Contactor (part number varies, see your bill of materials) 1
29 108144 Snap-on Stand-off 29
30 048I126 Fuse Holder 4
31 104780 Ground Block, Main 1
32 804535 Fuse, 15A LP-CC 1
33 805198 Ground Bar 1
34 107440 Power Board 1
35 106147 Pressure Board (option) 1
36 804691 Bus, 65A, CB, L1, L2, L3 1
37 804696 Endcap, Bus, PSB12N, 65A 1
38 107893 Eprom Chip 1
39 107922 Ribbon Cable Assy., 15PinM, 9 PinF Serial, 8 conductor crimp-on 1
40 108256 Control Assembly 1
41 Key Pad Label 1
42 107891 Cable Assembly Bracket 1
43 110090 Motor Control Interface PC Board 1--6
44 078A164 Screw, HWH 10-24x1/2, F 2-12
45 815223 Motor Speed Control, 1HP, Yask 1--6
46 108143 Stand Off, Brass 4--16
47 107438 Clutch PC Board (option) 1--4
48 N06642 Signal Isolator KBSI Board (option) 1-3
49 804890 Neutral, Term 1
19 29
49
34
Back side of Control Panel 15 31

or Pendant Control
42
39
19 29
38
38
40
46 24
41
25
2
43
45
32 30 33
44 10
17 22
7
16
18 37 36 9
23
35 20
21
28
48
47 27
26
Page 10-10 Component Illustrations ITW Dynatec c. 2013
Revised 9/13 M SERIES DCL ASU Manuals
DYNAMELT M210 Series Cabinet Assembly, PN 106047
1 101843 Handle, Side Panel 4

2 105981 Panel, Top, Bracket 1
3 105887 Access Cover 2
4 105980 Rear Cover 1
5 106897 Wire Box 6
6 105974 Base Plate 1
7 105982 Top Panel 1
8 105977 Heat Barrier, Panel Box 1
9 820416 Manifold Cover, ES, new style 3
107890 Manifold Cover, old style (used with PN 102710 manifold) 3
108128 Manifold Cover, Hi-Flow Only 3
10 802679 Panel Box 1
11 802102 Mounting Bracket 1
12 106110 M5 Hex Nut 12
13 009E006 Rigid Caster 2
14 009E009 Swivel Caster 2
15 101074 Receptacle up to 24
16 103866 Bracket, Connector Bank, Amphenol up to 1
17 108296 M8-1.25 x 16mm HHC Screw 24
18 M8 Star Washer 16
19 078C008 5/16 Flat Washer 16
20 106111 M4 x 12 BHC Screw 48
21 101304 Blank Plate, Dual up to 11
22 104279 Blank Plate, Single 0 or 6
23 105111 M3 Hex Nut up to 24
24 107392 M8 Nut 4
25 107390 M6 nut 4
26 108295 M8-1.25 x12mm HHC Screw 3
27 106048 Lid Assembly 2-3
28 N01788 10-32x0.375 BCH Screw 4
29 N04302 Lock Washer w. ext. tooth 4
30 809489 Fan Filter, 5” (not shown) 1
31 815007 Exhaust Grill Kit 1
32 107390 M6 Hex Nut w. washer 2
33 116939 Hinge, Left 2
34 116940 Hinge, Right 2
35 106198 M4 Lock Washer 4
36 105937 M4x2mm SHC Screw 4
37 105101 M6 x 16mm HHC Screw 2
38 not used
39 106770 Heat Deflector 1
40 106771 Collar, Hopper 1
41 101842 Handle, Hopper, Lid 1
42 106769 Lid Hopper 1
43 806400 Lid (with level control mntg.) (807141 Level Cnt. Assy.) (option) 1
44 107890 Ground Screw Filter 3
45 101156 M6 x 20mm SHC Screw 6
46 107390 M6 Nut 10
ITW Dynatec c. 2013 Component Illustrations Page 10-11
M SERIES DCL ASU Manuals Revised 9/13
42 28 29
11
2
43 37
41
39
10 12
45
7
34 40
33 46
35
31 36
27
16
3 15
23
8
25 20
22 21
25
5
1
13 9
44
14
19 18 17
26
DM210 Cabinet Assembly

Revised 12/04 DYNAMELT M ASU Manual All M210 Models
Bill of Materials for DYNAMELT M210 AC Drive Assembly 106660 &106663.
1 106874 Coupling Half, Pump Side (Option, not part of this assembly) 1
2 106875 Coupling Center 1
Drive Assembly, M70/ M140/ M210 1
3 104663 M6‘--1,0 x 25mm 4
4 106714 Coupling, Half, Motor Side 1
5 106658 Shaft, Gearbox, 20:1 (Front Drive Assembly 106660) 1
108018 Shaft, Gearbox, 20:1 (Front Drive Assem. 106660,4.5cc pump) 1
106661 Shaft (Rear Drive Assembly 106663)
6 106662 Gear Box, 20:1, Boston 1
7 109226 Key, 1/4 Sq. x.75 3
8 106754 Ring Clip 2
9 106659 Motor Mounting Bracket 1
10 107602 Bolt M8 x 40mm HHC, Ser fl, Screw 2
11 105060 nut 2
12 801679 Motor, AC, 3P, 240v, 1HP, K256
13 106324 Flat Washer, M6 8
14 106319 External Tooth Lock Washer, M6 4
15 N00732 5/16-18 x 3/4 SHC Screw 8
16 N00933 5/16 Lock Washer 8
17 N00687 5/16 Flat Washer 8
18 106342 Adapter Plate 1
19 106438 Pin, Release 1
20 078A183 3/8-16 x 1 HHC Screw‘ 4
21 106341 M8-1.25 x 40mm SH Set Screw 4
22 108313 Ring Kit 1
23 808916 Optional Pneumatic Clutch Assembly 1
24 030A014 Solenoid, 240V, 3--way 1
25 048J184 Cord Grip, 1/8 --1/4 1
26 072X004 1/8 Hex Nipple 1
27 106877 Clutch Kit, 56C, In line 1
28 N00099 Fitting, Elbow, 90deg., Brass 1
29 N02745 Muffler, Pneumatic Exhaust, 1/8 NPT 1
30 N07677 Tubing, TFE, .25 OD x .125 ID 4’
31 N08236 cable, 18ga, 3C, SV 10’
32 110504 Optional Clutch Air Manifold Assembly 1
33 110503 Air manifold 1
34 N00093 Fitting, 1/4 tube x 1/8 NPT 7
35 N00753 1/8 NPT Level Seal Plug 1
36 101692 M4-0.7 x 35mm SHC Screw 4
37 106198 Lockwasher, 4mm 4
Note: When using a 30cc pump you will need coupling #104269 and Pump Adapter 084E419
DYNAMELT M ASU Manual All M210 Models Revised 12/03
22 To Heat
34 33
Barrier
12 37 36 Panel
20
31 35
27 34
26 25
6
8
19
8 24
30
5 29 28
4
7
1
3 14 13
To Melt 15
Section
16
17
10
11
NO TAG
21
18
106660 Front 106663 Rear
to Base Plate
Component Illustration: DYNAMELT AC Drive Assembly 106660 & 106663

Revised 9/10 DYNAMELT M ASU Manual, All M210 Models
Bill of Materials: DYNAMELT M210 Single 106043, Hi Temp. 804947 & Dual 106042, Grid Assemblies
1 036B015 Pump Enable Thermostat 3
2 036B103 Temperature Sensor 2
3 105999 Hopper Support 6
4 106000 Heater Spacer 1
5 105884 Hopper, Weldment, Dual, M140 2
6 105890 Hopper, Weldment, M140, Single 1
7 106617 Hopper, Weldment, M210, Single 1
804930 Hopper, Weldment, M210, Single (Hi-Temp) 1
106621 Hopper, Weldment, M210, Single (High Flow) 1
8 105881 Heater Plate 3
9 105135 Spacer 12
10 803945 M8 x 60mm HHC Screw 6
11 108297 M8 x 20mm SHC Screw 12
12 107602 M8 x 40 HHC Screw 24
13 N00686 Flat Washers, 1/4 72
14 N00697 Lock Washer, 1/4 72
15 072X093 Filter Shut-off Plug (used in place of or opposite Filter Shut-off) 2-4
16 N00210 O-ring, -912 2-4
17 106719 Junction Box (small) 1
18 105113 M4 x 8mm SHC Screw 2
19 106103 Ball Valve Assembly (option) 2
Junction Box Assembly 2
20 105885 Junction Box, Prog-Melt, M70/ M140/ M210 1
21 106001 Cover, Junction Box 1
22 048J064 Bushing, 3/4* Insulating 2
23 048J088 3/4” Str. Conduit Fitting 8
24 048F125 Terminal Rail, 11.5” 2
25 048F136 Block, Terminal 35 Amp 44
26 048F137 Cover End 6
27 048F021 Ground Terminal 2
28 048F069 End Clamp 2
29 048J049 1/4 Conduit Fitting 5
30 N06883 Jam Nut 8
31 107645 / 107646 5/16 Conduit, 12” / 24” 4
32 048J014 3/4 45° Conduit Fitting 2
33 108831 Conduit, 3/4”Sealtite, 36” 1
104166 Over Temp. Switch Assembly (sold as an assembly only) 3
34 104165 Insulator, Over Temp Thermostat 3
35 104164 Overtemp Reset Thermostat 3
36 103538 M4 X 6mm Pan Head Screw 8
Grid Group 1
37 N00181 O-ring, -014 12
N07081 O-ring, -014 (Hi-Temp) 12
38 104696 Flange 3
39 003E023 Cover 3
40 N07958 Temperature Sensor 3
41 106174 Sensor Adapter 3
42 104802 Cast Heater 3
43 107645 5/16 ID Conduit 4’
44 N00192 O-ring, -032 3
069X285 O-ring, -032 (Hi-Temp) 3
45 102446 M4-0. 70 x 10mm SHC Screw 6
46 N07429 M8 x 35mm SHC Screw 12
47 078A055 10-24 x 3/16 SHS Screw 3
48 Filter Block (see your order for part number) 2--6
084Q465 Pump Block-off Assembly
49 069X064 O-ring, #-041 1
50 012G009 Block-off Plate 1
51 N00834 3/8-16 x 1.25 SHC Screw 4
52 N00754 1/4 Level Seal Plug 2
53 105968 Filter Shutoff Assembly (Right) 1
54 105969 Filter Shutoff Assembly (Left) 1
804465 Filter Shutoff Assembly (Left Hi-Temp) 1
804948 Filter Shutoff Assembly (Right Hi-Temp) 1
805216 Grid Block Off Assembly 3
55 105149 Block off Plate 3
56 N00192 O-ring, #-032 3
57 108297 M8 x 20mm HH Flange Screw 4
58 N00181 -014, O-ring 4
59 069X274 Seal Dual Pump To Progmelt (not shown) 4
60 102411 Cap, Hi Temp. 6
61 108564 Heater Block 1
62 108565 Cover Heater Block 1
63 805728 M8 x 55mm SHC Sctrew 210
64 107751 5/16 Conduit Fitting 5
c.1999 Component Illustrations & BOM’s Page 10-15
DYNAMELT M ASU Manual All M210 Models Revised 1/03
36
62
58 57 56 55 42
34 35 1
40
61 37
41
64
63 30
45 39 31 44 54
46
38
or
6
43 19
47 5
49 1
50
51
35 36 34
2
15 16
48
53 19
36
35
65 34
67 4 60
30 29 2
52
22
1
23 31 20
8
33 64 65
32
29 60
30 60
31
64 12
21 13
14 10
7
22 9 66 17
11 30 18
64 3
68 14
13
12
11 14
24 25 13
14
26 27 28
13 3
13 14
11
Note the Single progmelt for the
to base plate
M210 is identical to the dual with
only one melting compartment.
Revised 6/99 Rev. C Eng: JW DYNAMELT M ASU Manual All Models
Bill of Materials for 1.54 cc / Rev. , Single Gear Pump Assembly # 100860
#100860 / #100861
1 012D079 / 012D077 Drive Shaft 1
2 078I001 Key, Woodruff 1
3 101626 M5 x 12 SHC Screw 4
4 069X160 Seal Retainer & Bearing Housing 1
5 069X061 Lip Seal 1
6 018X041 Bearing Sleeve 2
7 100866 / 100867 Front Plate Assembly 1
8 012D080 / 012D078 Driven Gear Shaft 1
9 018X031 Ball, 1/8” Diameter ( See illustration for quantity) 2-4
10 012C020 / 012C019 Drive Gear, 1.54 cc/rev 2
11 069X064 Pump Seal 2
12 078F017 Shaft Retaining Ring 4
13 018X041 Bearing Sleeve, Rear Plate 2
14 100865 Rear Plate Assembly 1
15 100908 M4 x 25 SHC Screw 2
16 104775/ 104776 M10-1.5 x 75mm/ 80mm 4
17 NPN M10 Flat Washer 4
Pump # 100860 has one bearing in this shaft

Pump # 100861 has two bearing in this shaft
9
2
1
7
3 12
6
8
10
4 13
5
11
14
16
17 9 10
Pump # 100861 has two bearings in this shaft 11

Pump # 100860 has one bearings in this shaft
15
In some cases the pumps are mounted

with the following hardware:
104158 M10 Flange Nut
104072 M10-1.5 x 100 All Thread
Component Illustration: PN 100860 & 100861 Single Gear Pump Assemblies

Revised 6/99 Rev. C Eng: JW DYNAMELT M ASU Manual All Models
1 012D072 Drive Shaft 1

3 101626 M5 x 12 SHC Screw 4
4 069X160 Seal Retainer & Bearing Housing 1
7 100868 Front Plate Assembly 1
8 012D073 Driven Gear Shaft 1
9 018X031 Ball, 1/8” Diameter 4
10 012C018 Drive Gear, 4.5 cc/rev 2
11 069X064 Pump Seal 2
13 018X041 Bearing Sleeve, Rear Plate 2
15 100908 M4 x 25 SHC Screw 2
16 104776 M10-1.5 x 80mm 4
17 NPN M10 Flat washer 4
2
9
1
7
3 12
6
8
10
4 5 13
11
14
16
9 10
17
11

with the following hardware: 15
104072 M10-1.5 x 100 All Thread
Component Illustration: PN 100862 4.50 cc/ rev Single Gear Pump Assembly
Revised 6/99 Rev. D Eng: JW DYNAMELT M ASU Manual All Models
Bill of Materials for 1.54 cc / Rev. , Dual Gear Pump Assembly # 100863

3 101626 M5 x 12 SHCS 4
4 069X160 Seal retainer & Bearing Housing 1
9 018X031 Ball, 1/8” Dia. 3
10 012C020 Pump Gear, 1.5 cc/Rev 4
11 069X064 O-ring, -041 3
13 018X041 Bearing Sleeve, rear Plate 2
15 101692 M4 x 35 SHCS 2
16 NPN M10-1.5 x 85mm SHC Screw 4
17 100869 Middle Plate 1
18 N00198 O-ring, -113 2
DYNAMELT M ASU Manual All Models Rev. D Eng: JW Revised 8/99
7
3 12
6
8
11
17
10
4 5
18 10
13
11
14
16 19 9 10
10
11

104073 M10-1.5 x 105 All Thread
15
Component Illustration: 1.54 cc / Rev, Dual Gear Pump Assembly #100863

Revised 8/02 DYNAMELT M ASU Manual All Models
1 9

104073 M10-1.5 x 105 All Thread
7
3 12
6
8
11
17
10
4 5
18
10
13
11
14
16
9 10
19
10
11
15
Bill of Materials for 3.2 cc / Rev. ,
Dual Gear Pump Assembly # 100864

3 101626 M5 x 12 SHCS 4
4 069X160 Seal retainer & Bearing Housing 1
9 018X031 Ball, 1/8” Dia. 5
10 012C019 Drive Gear, 4.5 cc/Rev 4
11 069X064 O-ring, -041 3
13 018X041 Bearing Sleeve, rear Plate 2
15 101691 M4 x 40 SHCS 2
16 NPN M10-1.5 x 85mm 4
17 100870 Middle Plate 1
18 N00198 O-ring, -113 2
DYNAMELT M ASU Manual ALL MODELS Revised 8/10
2 10
5
1
11
12 9
3
5
13 8
Bill of Materials: PN 109690 10cc Single Gear Pump Assembly

1 018X031 Ball Bearing, 1/8 Dia. 6
2 078F017 Snap Ring, 1/2” 4
3 078I001 Key Woodruf, #404 1
4 069X061 Shaft Seal 1
5 069X064 O-ring, -041 2
6 108588 M4x25mm, Blk SHC Screw 2
7 101626 M5-0.8 x 12mm SHC Screw 4
8 109685 Pump Body 10cc/rev 1
9 109686 Rear Bearing Plate 10cc/rev. 1
10 109689 Gear 10cc/rev 2
11 109687 Drive Shaft 10cc/20cc 1
12 109688 Driven Shaft, 10cc/20cc 1
13 069X160 Shaft Seal Retainer 1
14 001U002 Dow Corning 112 Lubricant (not shown)
Revised 5/10 DYNAMELT M ASU Manual, ALL MODELS
Bill of Materials for Assorted Pump Adapter Assemblies

084E406 TSHA Pump Adapter Assembly 1
1 012G024 Pump Adapter 1
2 069X058 O--ring, -028 1
3 N00179 O--ring, -012 2
4 069X274 Seal Dual Pump to Progmelt (not part of this assembly) 1
5 N00190 O-ring -024 1
6 078C130 3/8 Washer, 3/4 OD 4
7 NPN M10 x 85mm SHC Screw 4
8 Zenith Pump (shown for reference only)
084E428 THSA .297cc Single Outlet
084E374 THSA .584cc Single Outlet
084E430 THSA 1.168cc Single Outlet
108875 THSA 8.5cc Single Outlet
084E389 THSA .584cc Dual Outlet
084E432 THSA 1.168cc Dual Outlet
108874 THSA 2.292cc Dual Outlet
084E419 Zenith Pump Adapter Assembly 1
9 012G027 Adapter, Z Pump 1
10 069X064 O-ring, -041 1
11 N01010 O-ring, -021 1
12 069X270 O-ring, -025 2
13 078A618 Screw, Pump Mounting 4
14 078C141 7/16 ss Washer, 3/4 OD 4
15 808680 Drive Shaft Seal (shown for reference only) 1
16 THSA Pump (shown for reference only)
110289 THSA 20cc Single Outlet
103923 Feinpruef Pump Adapter Assembly 1
17 103624 Adapter Plate 1
18 103924 O-ring Plate 1
19 N00181 O-ring, -014 4
20 069X270 O-ring, -025 1
21 102927 O-ring, -133 1
22 Feinpruef Pump
103917 Feinpruef Pump .3cc
103918 Feinpruef Pump 1.2cc
103919 Feinpruef Pump 2.4cc
104351 Coupling Half (not shown, see Drive Section)
THSA Pump Adapter Assembly 084E406

5
3
1
2
8 6
7
THSA Pump Adapter Assembly 084E419
11 16
12
9
10
15
14
13
Feinpruef Pump Adapter Assembly 103923
21
17
19 18
20
19
22
Revised 7/03 DYNAMELT M ASU Manual All Models
4
or 3
4
6
Pressure Gauge Assembly-805641

1 806883 Fitting, 1/4 NPTM x #6 JIC x 90 1
2 101174 Pressure Guage, 1000 PSI 1
3 104325 Fitting Adapter, Swivel, 6J x 1/4 MPT 1
4 805632 Fitting, 1/4 NPT 1/2-20 Tranducer 1
5 102987 Insulator 1
6 N00104 Fitting, 1/4 NPTM x #6, ST 1
ITW Dynatec.com c. 2000 Component Illustrations Page 10-27
Heater Control Groups #103571, 103572, 103573, 103574
9
6 8
10
2
Filter Block Heater 3
Retainer Plate
(shown for reference, not
in heater control group) 7
103571 Heater Control Group (HCG) 240v, 1 block

103572 Heater Control Group 240v, 2 block
1 036A170 Heater, 5/8 x 5”, 240v, 500w (used in PN 103571 HCG) 1

036A079 Heater, 5/8 x 10”, 240v, 1000w (used in PN 103572 HCG) 1
102149 Heater, 5/8 x 15”, 240v, 1500w (used in PN 103573 HCG) 1
036A077 Heater, 5/8 x 20”, 240v, 2000w (used in PN 103574 HCG) 1
2 106174 Sensor Adapter (used in PN 103571 & 103572 HCGs) 1
036E032 Sensor Adapter (used in PN 103573 & 103574 HCGs) 1
3 N07958 Temperature Sensor, PT100 (used in PN 103571 & 103572 HCGs) 1
036B103 Temperature Sensor, PT100 (used in PN 103573 & 103574 HCGs) 1
4 107754 Cover, Hi-Temp Sensor & Heater Group 1
5 107645 Conduit, 10” 1
6 106156 M4 x 6mm SHS Screw 1
7 104163 M6 x 25mm SHC Screw 2
8 107751 Conduit Fitting (located in junction box) 1
9 N06883 Jam Nut (located in junction box) 1
10 103570 M5 x 8 x 6, CUD SH Set Screw 1
Page 10-28 Component Illustrations
Revised 8/09
ITW Dynatec

c. 2001 Schematics Page 11-1
Chapter 11
SCHEMATICS &
ENGINEERING DRAWINGS
Drawing: Found on:
Hose Schematic, ASU to Applicator page 11-2
Applicator Head Schematic page 11-3
Flow Diagram, Outlet Filter Manifold page 11-4
Typical Hydraulic Schematic page 11-5
Optional System Status Lights Schematic page 11-5
Optional Level Control Schematic page 11-6
Grounding Diagram, CE Mark Page 11-7
Pneumatic Clutch Schematic Page 11-8
Instruction Sheet for Pump & Zone Configuration page 11-9
ASU Schematics end of chapter

Page 11-2 Schematics c. 2001
HOSE SCHEMATIC PN 101082 REV. G

ASU to Applicator
Notes:
1. ALL WIRE MIL-W-22759/10 OR 12, MINIMUM 600 VOLTS, 260 DEG. C
2. SOLENOID(S) VOLTAGE AND TIMING METHOD DEPENDS ON APPLICATION.
3. RTD WILL BE PLATINUM 100 OHM.
HEAD SCHEMATIC PN 103117 REV. B

Function of Outlet Filter Manifold’s Closeable Cross Channel
A Closeable Cross Channel Plug is located inside the Outlet Filter Manifold to prevent adhesive
flow between the two outlet filters when a dual pump is in use.
When a single pump is used, ITW Dynatec removes the Cross Channel Plug.
When changing an ASU from a single to a dual pump, or vice versa, consult ITW Dynatec for
complete instructions.
Check Valve
Adhesive Return Port*
Adhesive In Port*
When Cross
Channel Plug is
removed, one
adhesive outlet
must be plugged.
Cross Channel
Plug is removed thru
port on side of manifold.
Closeable Cross
Channel Plug
Adhesive
Outlet To
Hose
Adhesive
Outlet To
Hose
* The second Adhesive In and Adhesive

FLOW DIAGRAM, OUTLET FILTER MANIFOLD Return ports are not shown.
Filter
Transducer
Basket
Gauge
Bypass
Pump Motor
TYPICAL HYDRAULIC SCHEMATIC: Single Pump, Motor, Bypass, Filter, optional Transducer & optional
Pressure Gauge
WIRING DIAGRAM FOR PN 108266 OPTIONAL SYSTEM STATUS LIGHTS

LEVEL CONTROL SCHEMATIC PN 802972 REV. C

GROUNDING DIAGRAM, CE MARK, PN 804704 REV. E

PNEUMATIC CLUTCH SCHEMATIC PN 108410 REV. A

PN 108534 Rev. C INSTRUCTION SHEET FOR PUMP & ZONE CONFIGURATION, Page 1 of 3
ITW Dynatec

c. 2000 Appendix 1
DYNAMELT M ASU Manual 20-36, 20-37, 20-38 Revised 3/01
DYNATEC/ ZENITH STANDARD ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL
PN 084E427, 084E429, 084E431, 084E433, 084E435, 084E437
Part Number Material Type/Accuracy Output/Rev Shaft Seal PN
084E427 Nodular Iron Single/ Standard 0.29cc 069X251

084E431 Nodular Iron Dual/ Standard 1.17cc 069X251

084E435 Nodular Iron Dual/ Standard 2.92cc 069X251
Thoroughly read and understand this entire manual before installation and
operation of pump.
Note: The instructions given herein cover the description, installation, operation and
maintenance of subject equipment. Dynatec and Zenith reserve the right to make engi-
neering refinements that may not be reflected in this bulletin.
Manual revised 8/94

Appendix 2 c. 2000
Revised 10/00 DYNAMELT M ASU Manual 20-36, 20-37, 20-38
INTRODUCTION
In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to
provide a precise, pulseless, repeatable flow and assure better quality control. The options
then were the same as those in the chemical process industry today: diaphragm, lobe, coarse
gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccura-
cies, multiple seal areas and slippage, which required constant calibration, high maintenence
and extended downtimes.
Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci-
sion and simplicity. Manufacturing techniques were developed to hold tolerances to
.00005”, and an internal pressure relief mechanism assured reliable precision metering. The
pump’s simple design of only three moving parts - two metering gears and a drive shaft -
provided long life and easy maintenance.
For years since, chemical engineers have relied on Zenith to provide precision fluid han-
dling solutions for their most difficult pumping applications. Zenith gear pumps can be
found wherever precise, pulseless, repeatable metering of fluids is required.
BENEFITS
High Accuracy
Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and
temperature.
High Temperature Capability

Operating temperatures to 450 degrees F (232 degrees C).
Maximum Life
Only three moving parts; components are through-hardened tool and die steels to 56 HRc or
better. The bodies are cast nodular iron. Replaceable sleeve bearings for low-cost rebuilds.
High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under
pressure by built-in alignment pins.
Minimum Pulsation
Unique design offers virtually pulseless flow without valves or flexible elements to hinder
performance.
Precision Construction
Ground and lapped components for close control of operating clearances.
c. 2000 Appendix 3
SPECIFICATIONS
Pump Type: Rotary external spur gear, single stream.
Rotation: Clockwise
Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.
Temperature: To 450 degrees F (232 degrees C)
OPERATION
All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a
port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the ex-
posed gear tooth volumes and is transported around the outer diameter of the gear pocket.
As the gears mesh together, the fluid is displaced in a very precise amount out through the
discharge port that is drilled alongside the inlet port in the rear plate.
Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pres-
sure required. However, when high-viscosity fluids are used, more time is required to fill the
tooth volumes. As a result, the inlet pressure must be increased, or the gears must rotate at a
slower speed to ensure complete volume filling and to prevent cavitation.
Dynatec/ Zenith pumps rely on the metered fluid for lubrication of internal bearing areas.
The pump should never be allowed to run dry or be allowed to run with non-lubricating
fluids such as water. Because of the close clearances in the bearing areas, lack of sufficient
lubrication can cause pump seizure or some other catastrophic failure.
Slippage will occur across the faces of the gears from the high-pressure side to the low-pres-
sure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential
pressure and pump clearances. Under reasonably stable operating conditions, slippage is re-
peatable and predictable and pump operation can be adjusted to compensate.
The Standard Accuracy Pumps are designed for high-temperature and high-pressure opera-
tion. As such, operating temperatures to 450 degrees F can be achieved.
INSTALLATION
Pumps should be carefully unpacked to make sure that the shipment is complete. If any
items are missing or damaged, the freight carrier and Dynatec should be notified immediate-
ly.
While the pump is composed of steel, it is a precision instrument. Dropping the pump or hit-
ting with a non-yielding material can cause serious damage to the components. All materials
are through-hardened to maximum hardness resulting in brittle material. Treat cont.
Appendix 4 c. 2000
them as you would any other precision gauging instrument.
Dynatec/ Zenith pumps are shipped filled with a rust preventive oil. Flush the oil throughly
with a cleaning solvent. It may be necessary to disassemble the seal arrangement to remove
all traces of the oil, but disassemble only if necessary.
After flushing, the pump should be lubricated internally for start-up purposes. Pour a suitable
high-temperature lubricant (silicone oil) into the inlet port. Rotate the metering gears until
lubricant appears at the discharge port.
Mount the pump to a block with a flatness of true flat to .0001” convex and a surface finish of
4 to 8 rms to prevent leakage between the pump and block. Mounting bolts should be a Grade
8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize com-
pound such as DAG Dispersion #154. Bolts should be alternatively torqued in even incre-
ments up to Dynatec’s recommended limit for the bolt size used. See Table 1 on page 10 for
torque values.
The following is a brief “standard” installation procedure. For any special applications, con-
siderations or simply to ask our advice, please contact Dynatec.
TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.
2. Filters should be installed prior to the pump inlet that filter ideally to half the pump run-
ning clearances.
3. Turn pumps by hand before running. Pumps should turn freely.
4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the
coupling* and that it is aligned within one degree angular and .005” parallel with the true
pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the
internal operating pressure of the pump to force it forward and effect a seal against the carbon
or metal seal plate.)
5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque
at room temperature.
6. Make sure fluid is in the pump before starting.
7. Start pump slowly and, if possible, run it with a lubricating fluid.
8. When satisfactory operation is achieved, the pump and system may be gradually brought
up to normal process speeds and pressures.
9. If at any time during operation the pump does not appear to be running smoothly, stop the
pump immediately to avoid any serious internal damage.
CLEANING, INSPECTION AND REPAIR
REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to devel-
op the high pressure demanded, the clearance between the metering gears and their housing
must be as small as possible, yet large enough to allow adequate lubrication. All parts are ma-
chined to extreme accuracy; critical dimensions are held between one and two ten-thousanths
of an inch (.0001”/ .0002”). Because of these close running clearances, cont.
c. 2000 Appendix 5
these pumps require careful maintenence and handling, especially of component parts. The
slightest burr, nick or particle of foreign matter can cause scoring or even seizure. These
pumps are precision instruments; you can’t keep them too clean. Please treat them with care,
and if it’s at all possible, set aside a separate clean area for pump maintenance.
To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat
in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temper-
ature will be related to the pump size and the degree of polymer contamination and should be
determined by trial. Note: Careful control of he furnace temperature (700 degrees F max.)
and atmosphere is critical. Should the temperature exceed the original tempering temperature,
the steel hardness will draw back and the dimensional stability of the pump may be upset.
Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.
The bath shold be heated to a temperature that is sufficient to carburize the polymer. The car-
burization process usually takes between 3 and 12 hours, depending on the polymer type,
temperature, pump size and furnace load.
CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.
After gradually cooling to room temperature, the pump should be thoroughly flushed in a
clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer
ash.
If present, always replace the carbon seal plate after pump burnout. If the pump was perform-
ing satisfactorily when removed from service and still turns freely after burnout, pressure test
it and add a high-temperature lubricant to prepare it for return to service. To store for future
use, simply add a rust preventative oil.
It is recommended that pump users institute a program of dimensional inspection of critical

parts in order to keep maintenence and operting costs at a minimum. By noting the perfor-
mance of a pump immediately before removing it from service and correlating the perfor-
mance to measured component wear, the user can establish the maximum wear limits for the
pump’s critical components. Further, he can predict the service life of the pump and schedule
his down-time accordingly.
As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for com-
plete rehabilitation as necessary. This procedure may be desirable if only a few pumps are
involved. If a large number of pumps are to be maintained at the user’s plant, it may be
worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view
the manufacturing, gauging and assembly techniques involved in producting the pumps.
Please contact Dynatec (at 1-800-538-9540) for further information on these items.
Appendix 6 c. 2000
STANDARD ACCURACY PUMP DISASSEMBLY
If pumps are to be disassembled on a regular basis, we recommend that you establish a pump
room with all the necessary tools and equipment for disassembly and cleaning with a separate
“clean” area for assembly, testing and storing of rebuilt pumps.
If maintenence is required due to low delivery or seizure, the following procedure is recom-
mended for disassembly.
NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.
Refer to assembly drawing (located in the back of this manual) for your correct pump type.
1. Remove the seal arrangement.

2. Remove all binder screws.
3. Remove pins (10) and arbor (5) with an arbor press in the direction which
disengages the press fit in the shortest distance.
NOTE: Dowels and arbors for the standard accuracy pumps are press fit in the gear/ rear
plate.
4. Separate the plates by pry slots that are available in the pump. Great care should be
taken not to scratch or damage the internal pump surface when prying the plates apart.
5. After disassembly, clean all components in a non-destructive solvent.
6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang
parts together.
7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and
faces of the gears may be hand blocked on 600 grit paper and any nicks, burrs or sharp edges
can be lightly removed with a honing stone. Be careful not to round off the edges of the gear
teeth while lapping.
CAUTION: Since the thickness relationship between the metering gears and the gear/
rear plate is critical to metering performance, and the gear/ rear plate is non-wearing on its
sides, lapping these components is not necessary and should not be done under any circum-
stances.
Place a layer of 600 Grit Emery Cloth on a lapping block or plate-a granite flat is suit-
able. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Fig-
ure 1) approximately five times until a smooth finish appears. Turning in a circular fashion,
or other non-uniform motion, may cause the ground holes to lose their perpendicularity to the
faces.
Always use clean, lint-free rags and compressed air to clean components. Paper towels
are not acceptable; they may leave small pieces of paper and dust on the components. Use
chemical brushes to clean between gear teeth, bores and reliefs.
8. Replace sleeve bearings as necessary and hone in the plate to the original new part
specifications.
9. After each resurfacing, carefully gauge the area between the inlet and discharge ports
at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical
part of the plate. Scoring or wear marks here will allow increased slippage from the cont.
c. 2000 Appendix 7
high-pressure discharge port section across the throat to the lower inlet port, reducing effi-
ciency. Therefore, carefully gauge this area for flatness after each resurfacing.
10. After all components are “hospital clean”, the pump is ready for assembly.
Figure 1
STANDARD ACCURACY PUMP RE-ASSEMBLY
NOTE: During and between each re-assembly step, manually turn the metering gears to en-
sure that they are free turning. If binding occurs at any time, determine the cause and correct
it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump
component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned,
the pieces will fit easily into place and the pump will turn freely. Re-assemble as follows:
1. After all worn parts have been re-finished or replaced, all parts should be throughly
cleaned in a solvent and dried.
2. Using the driven gear (5) as an up-righting fixture, carefully locate the arbor (7) over
its press-fit hole in the gear/ rear plate. Smoothly drive the arbor into its hole with the help of
an appropriate arbor press.
3. Place the gear/ rear plate (1) with the arbor in position in a soft-jaw vise or holding
fixture.
4. Slip together the driving metering gear (6), drive shaft (4), key (8) and retaining rings
(21). Position in the front of the gear/ rear plate.
5. Place the driven metering gear on its arbor and carefully mesh with the drive metering
gear.
6. NOTE: Repeat steps 3 through 5 for four-gear pumps.
7. Position the front side plate (3).
8. Rotate the gears to ensure free rotation.
9. Press the roll pins (41) into place.
10. Lubricate the binder screws (23) with DAG dispersion #154 or a similar heat resist-
ant lubricant and install. Torque the screws in even increments to the manufacturer’s recom-
mended limit. It is especially important to rotate the gears frequently during this operation.
11. Re-assemble the seal arrangement, making sure the sealing surfaces are perfectly
clean and free of scratches, nicks or burrs. When a carbon seal plate is used, always use a new
carbon seal that has been lightly polished on 600 grit paper. When using a carbon seal, the
coupling housing screws (27) should be torqued to the manufacturer’s recommended limit.
For pumps with a compensation packing seal, be sure all old packing is removed cont.
Appendix 8 c. 2000
from the packing housing.

12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or
worn. Worn shafts will result in premature seal leakage and should be replaced.
13. Inspect lip seals for wear, cracks and abrasions. Replace if needed.
14. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-O-
Lubricate or an equivalent silicone-based oil.
15. Install lip seals (15) into seal housing (9) as shown.
16. Tighten seal housing screws (22) in a cross pattern to 60 lbs./in. Check for free rota-
tion.
SCREW TORQUE VALUES (Standard Alloy Steel)*
Screw Size & Thread Torque (Lubricated Threads)

(UNC Alloy Steel) Lbs.-in. Nxm Lbs.-ft.
#10-24 (w/ carbon seal gasket) [50] 5.7 [4.2]

#10-24 (w/o carbon seal gasket) [64] 7.2 [5.3]
#12-24 [120] 13.6 [10]
1/4-20 [150] 16.9 [12.5]
5/16-18 [305] 33.9 [25]
3/8-16 into aluminum [360] 40.6 [30]
7/16-14 block (hopper) [480] 54.2 [40]
Table 1
*In critical applications where control of bolt preload is important, the torque-tension relation should be
determined by experimenting on the actual parts involved (including thread lubricants). At elevated
temperatures, it is often desirable to reduce screw stress because of deformation (creep) under sustained
loading. Screws constructed of type H-11 high-temperature alloy steel provide extremely high creep
resistance.
c. 2000 Appendix 9
TROUBLESHOOTING GUIDE
Trouble Probable Cause Remedy
Pump will not turn. 1. Low pump temperature. Check temperature sensor
and control loop for
proper setting/ operation.
Allow sufficient heat-up
time.
2. Drive malfunction. Verify drive is powered.

Check to assure all alarm
circuits are clear.
Check drive motor current
and speed settings.
Check all drive couplings.
3. Process conditions changed. Check process conditions

for proper melt tempera-
ture, pressures, viscosities
and materials.
4. Entrained particle. Return pump to ITW Dynatec

for repair.
5. Possible internal damages. Return pump to ITW Dynatec

for repair.
Excessive seal 1. Worn seal plate. Return pump to ITW Dynatec

assembly leakage for repair.
2. Insufficient inlet pressure. Increase inlet pressure.
3. Worn lip seal.* Replace lip seal.
Reduced pump efficiency 1. Worn gear(s). Return pump to ITW Dynatec.

for repair.
2. Worn bearings. Return pump to ITW Dynatec.

for repair.
3. Process conditions changed. Consult factory for

clearance recommended
on new process conditions.
* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.
Appendix 10 c. 2000
c. 2000 Appendix 11
Appendix 12 c. 2000
c. 2000 Appendix 13
Appendix 14 c. 2000
ITW Dynatec

c. 2000 Appendix 15
DYNATEC/ ZENITH HIGH ACCURACY GEAR PUMPS

INSTALLATION, CARE & MAINTENANCE MANUAL
PN 084E428, 084E430, 084E432, 084E434, 084E436
Part Number Material Type/Accuracy Output/Rev Shaft Seal PN
084E428 Tool Steel Single/ High 0.297cc 069X251

084E432 Tool Steel Dual/ High 1.168cc 069X251

084E436 Tool Steel Dual/ High 2.920cc 069X251
Thoroughly read and understand this entire manual before installation and
operation of pump.
Note: The instructions given herein cover the description, installation, operation and
maintenance of subject equipment. Dynatec and Zenith reserve the right to make engi-
neering refinements that may not be reflected in this bulletin.
Manual revised 8/94

Appendix 16 c. 2000
INTRODUCTION
In 1926, Zenith Pumps was appoached by the synthetic fiber industry to design a pump to
provide a precise, pulseless, repeatable flow and assure better quality control. The options
then were the same as those in the chemical process industry today: diaphragm, lobe, coarse
gear, piston, plunger and screw pumps. Each had problems with pulsation, flow inaccura-
cies, multiple seal areas and slippage, which required constant calibration, high maintenence
and extended downtimes.
Zenith Pumps met the challenge and designed a rotary external gear pump of unique preci-
sion and simplicity. Manufacturing techniques were developed to hold tolerances to
.00005”, and an internal pressure relief mechanism assured reliable precision metering. The
pump’s simple design of only three moving parts - two metering gears and a drive shaft -
provided long life and easy maintenance.
For years since, chemical engineers have relied on Zenith to provide precision fluid han-
dling solutions for their most difficult pumping applications. Zenith gear pumps can be
found wherever precise, pulseless, repeatable metering of fluids is required.
BENEFITS
High Accuracy
Stable, repeatable flows are assured even under varying conditions of pressure, viscosity and
temperature.
High Temperature Capability

Operating temperatures to 550 degrees F (288 degrees C).
Maximum Life
Only three moving parts; components are through-hardened tool and die steels to 62 HRc or
better. Replaceable sleeve bearings for low-cost rebuilds.
High Volumetric Efficiency

Maximum efficiency is achieved with optimum operating clearances and assured under
pressure by built-in alignment dowels.
Minimum Pulsation
Unique design offers virtually pulseless flow without valves or flexible elements to hinder
performance.
Precision Construction
Ground and lapped components for close control of operating clearances.
c. 2000 Appendix 17
SPECIFICATIONS
Pump Type: Rotary external spur gear, single stream.
Rotation: Clockwise
Operating Speed: 3 - 120 rpm depending upon application conditions and fluid viscosity.
Temperature: To 550 degrees F (288 degrees C)
DESIGN
Dynatec/ Zenith High Accuracy Metering Pumps consist of two gears rotating in mesh with-
in a closely fitted housing that is comprised of three plates. The center gear plate fits closely
around the outside diameter of the metering gears. The front and rear plates sandwich the
center plate and restrict axial movement of the gears. Power is transmitted to the gears by
the drive shaft which is a through shaft. Shaft sealing is accomplished with a high tempera-
ture cup seal.
High-accuracy pumps are precision instruments requiring skilled and careful maintenence.
Constructed of high-quality tool and die steels such as AISI D2, M2, M4 and CPM-M4, or
other high-performance alloys, they are tempered after heat treatment to hardnesses ranging
from HRc 58 to HRc 64. Since the thermal expansion rates for all three steels are almost
identical and are otherwise entirely compatible, it is possible to combine them so as to take
advantage of their best qualities in the most economical way.
The Type D2 tool steel is often selected for the side and center plates as it offers good abra-
sion resistance and it is the most economical of the three steels we most commonly use.
Type D2 will also provide a higher degree of corrosion resistance than M2 or M4.
The portion of the side plate subject to the most wear is the shaft bearing hole, which has an
easily replaceable, inexpensive sleeve bearing that can be made of the extremely wear resist-
ant Type M4 tool steel. Types M2 and CPM-M4 steels are commonly used for the metering
gears, drive shaft and universal seal coupling, due to their superior torsional strength and
abrasion resistance for these items that are the most critical to proper metering performance.
OPERATION
All Dynatec/ Zenith High Accuracy Pumps are rear ported. Fluid enters the pump through a
port drilled into the rear side plate (the side opposite the drive shaft). The fluid fills the ex-
posed gear tooth volumes and is transported around the outer diameter of the gear pocket.
As the gears mesh together, the fluid is displaced in a very precise amount out through the
discharge port that is drilled alongside the inlet port in the rear plate. cont.
Appendix 18 c. 2000
Since these pumps are not self-priming, a flooded suction is usually the minimum inlet pres-
sure required. However, when high-viscosity fluids are used, more time is required to fill the
tooth volumes. As a result, the inlet pressure must be increased, or the gears must rotate at a
slower speed to ensure complete volume filling and to prevent cavitation.
Dynatec/ Zenith pumps rely on the metered fluid for lubrication of internal bearing areas. The
pump should never be allowed to run dry or be allowed to run with non-lubricating fluids
such as water. Because of the close clearances in the bearing areas, lack of sufficient lubrica-
tion can cause pump seizure or some other catastrophic failure.
Slippage will occur across the faces of the gears from the high-pressure side to the low-pres-
sure side. The amount of slippage depends on four factors: fluid viscoisty, speed, differential
pressure and pump clearances. Under reasonably stable operating conditions, slippage is re-
peatable and predictable and pump operation can be adjusted to compensate.
The High Accuracy Pumps are designed for high-temperature and high-pressure operation.
As such, operating temperatures to 550 degrees F can be achieved.
INSTALLATION
Pumps should be carefully unpacked to make sure that the shipment is complete. If any items
are missing or damaged, the freight carrier and Dynatec should be notified immediately.
While the pump is composed of steel, it is a precision instrument. Dropping the pump or hit-
ting with a non-yielding material can cause serious damage to the components. All materials
are through-hardened to maximum hardness resulting in brittle material. Treat them as you
would any other precision gauging instrument.
Dynatec/ Zenith pumps are shipped filled with a rust preventive oil. Flush the oil throughly
with a cleaning solvent. It may be necessary to disassemble the seal arrangement to remove
all traces of the oil, but disassemble only if necessary.
After flushing, the pump should be lubricated internally for start-up purposes. Pour a suitable
high-temperature lubricant (silicone oil) into the inlet port. Rotate the metering gears until
lubricant appears at the discharge port.
Mount the pump to a block with a flatness of true flat to .0001” convex and a surface finish of
4 to 8 rms to prevent leakage between the pump and block. Mounting bolts should be a Grade
8 or better. Make sure mounting bolts are lubricated with a high-temperature anti-seize com-
pound such as DAG Dispersion #154. Bolts should be alternatively torqued in even incre-
ments up to Dynatec’s recommended limit for the bolt size used. See Table 1 on page 26 for
torque values.
The following is a brief “standard” installation procedure. For any special applications, con-
siderations or simply to ask our advice, please contact ITW Dynatec. cont.
c. 2000 Appendix 19
TO PREPARE THE PUMP FOR USE:

1. Always flush out the plumbing system before connecting the pump.
2. Filters should be installed prior to the pump inlet that filter ideally to half the pump run-
ning clearances.
3. Turn pumps by hand before running. Pumps should turn freely.
4. Engage the outer drive shaft carefully, making sure that it does not bottom in the slot of the
coupling* and that it is aligned within one degree angular and .005” parallel with the true
pump drive axis. (*Note: the coupling is the rotating member of the seal and depends on the
internal operating pressure of the pump to force it forward and effect a seal against the carbon
or metal seal plate.)
5. Tighten the mounting bolts and coupling housing screws to Dynatec recommended torque
at room temperature.
6. Make sure fluid is in the pump before starting.
7. Start pump slowly and, if possible, run it with a lubricating fluid.
8. When satisfactory operation is achieved, the pump and system may be gradually brought
up to normal process speeds and pressures.
9. If at any time during operation the pump does not appear to be running smoothly, stop the
pump immediately to avoid any serious internal damage.
CLEANING, INSPECTION AND REPAIR
REMEMBER: Dynatec/ Zenith metering pumps are made for exacting duty. In order to devel-
op the high pressure demanded, the clearance between the metering gears and their housing
must be as small as possible, yet large enough to allow adequate lubrication. All parts are ma-
chined to extreme accuracy; critical dimensions are held between one and two ten-thousanths
of an inch (.0001”/ .0002”). Because of these close running clearances, these pumps require
careful maintenence and handling, especially of component parts. The slightest burr, nick or
particle of foreign matter can cause scoring or even seizure. These pumps are precision in-
struments; you can’t keep them too clean. Please treat them with care, and if it’s at all pos-
sible, set aside a separate clean area for pump maintenance.
To clean High Accuracy Metering Pumps, place them in a suitable furnace and gradually heat
in an inert atmosphere for the initial hour to prevent flashing of the polymer. Time at temper-
ature will be related to the pump size and the degree of polymer contamination and should be
determined by trial. Note: Careful control of he furnace temperature (950 degrees F max.)
and atmosphere is critical. Should the temperature exceed the original tempering temperature,
the steel hardness will draw back and the dimensional stability of the pump may be upset.
Another acceptable cleaning method is to immerse the pump in a fluidized bed cleaning bath.
The bath shold be heated to a temperature that is sufficient to carburize the polymer. The car-
burization process usually takes between 3 and 12 hours, depending on the polymer type,
temperature, pump size and furnace load. cont.
Appendix 20 c. 2000
CAUTION: Avoid exposing the pump to thermal shock when using this method of cleaning.
After gradually cooling to room temperature, the pump should be thoroughly flushed in a
clean solvent. It may be necessary to disassemble the seal arrangement to remove polymer
ash.
If present, always replace the carbon seal plate after pump burnout. If the pump was perform-
ing satisfactorily when removed from service and still turns freely after burnout, pressure test
it and add a high-temperature lubricant to prepare it for return to service. To store for future
use, simply add a rust preventative oil.
It is recommended that pump users institute a program of dimensional inspection of critical

parts in order to keep maintenence and operting costs at a minimum. By noting the perfor-
mance of a pump immediately before removing it from service and correlating the perfor-
mance to measured component wear, the user can establish the maximum wear limits for the
pump’s critical components. Further, he can predict the service life of the pump and schedule
his down-time accordingly.
As with any other Dynatec pump, high accuracy pumps may be returned to Dynatec for com-
plete rehabilitation as necessary. This procedure may be desirable if only a few pumps are
involved. If a large number of pumps are to be maintained at the user’s plant, it may be
worthwhile to have key personnel attend a maintenance seminar at the Zentih factory to view
the manufacturing, gauging and assembly techniques involved in producting the pumps.
Please contact Dynatec (at 1-800-538-9540) for further information on these items.
HIGH ACCURACY PUMP DISASSEMBLY
If pumps are to be disassembled on a regular basis, we recommend that you establish a pump
room with all the necessary tools and equipment for disassembly and cleaning with a separate
“clean” area for assembly, testing and storing of rebuilt pumps.
If maintenence is required due to low delivery or seizure, the following procedure is recom-
mended for disassembly.
NOTE: Be sure to note the location and orientation of all parts to ensure correct re-assembly.
Refer to assembly drawing (located in the back of this manual) for your correct pump type.
1. Remove the seal arrangement.

2. Remove all binder screws.
3. Remove dowels (10) and arbor (5) with an arbor press in the direction which
disengages the press fit in the shortest distance.
NOTE: Dowels and arbors for the high accuracy pumps are press fit in the rear front plate (1)
and slip fit in the center (2) and side plates (3). cont.
c. 2000 Appendix 21
4. Separate the plates by pry slots. Great care should be taken not to scratch or damage
the internal pump surface when prying the plates apart.
5. After disassembly, clean all components in a glass bead blast cabinet to remove any
debris remaining after heat cleaning. Alternative, non-destructive cleaning methods such as
water jet or solvents are also acceptable.
6. Wash components in an ultrasonic cleaning tank and air dry. Be careful not to bang
parts together.
7. Inspect all parts for nicks, burrs, score marks and other signs of wear. The plates and
faces of the gears may be hand blocked on 400/600 grit paper and any nicks, burrs or sharp
edges can be lightly removed with a honing stone. Be careful not to round off the edges of the
gear teeth while lapping.
CAUTION: Since the thickness relationship between the metering gears and the center
plate is critical to metering performance, and the center plate is non-wearing on its sides, lap-
ping these components is not necessary and should not be done under any circumstances.
Place a layer of 400 Grit Emery Cloth on a lapping block or plate-a granite flat is suit-
able. Apply light pressure to the component and turn it in a figure-8 fashion (as shown in Fig-
ure 1) approximately ten times until a smooth finish appears. Turning in a circular fashion, or
other non-uniform motion, may cause the ground holes to lose their perpendicularity to the
faces.
Always use clean, lint-free rags and compressed air to clean components. Paper towels
are not acceptable; they may leave small pieces of paper and dust on the components. Use
chemical brushes to clean between gear teeth, bores and reliefs.
8. Replace sleeve bearings as necessary and hone in the plate to the original new part
specifications.
9. After each resurfacing, carefully gauge the area between the inlet and discharge ports
at the mesh of the gears. This area, commonly referred to as the “throat”, is the most critical
part of the plate. Scoring or wear marks here will allow increased slippage from the high-
pressure discharge port section across the throat to the lower inlet port, reducing efficiency.
Therefore, carefully gauge this area for flatness after each resurfacing.
10. After all components are “hospital clean”, the pump is ready for assembly.
Figure 1
Appendix 22 c. 2000
HIGH ACCURACY PUMP RE-ASSEMBLY
NOTE: During and between each re-assembly step, manually turn the metering gears to en-
sure that they are free turning. If binding occurs at any time, determine the cause and correct
it immediately. A tiny nick, burr or foreign particle can extensively damage a valuable pump
component. Never use force in re-assembling or turning a Dynatec pump. If properly aligned,
the pieces will fit easily into place and the pump will turn freely. Re-assemble as follows:
1. After all worn parts have been re-finished or replaced, all parts should be throughly
cleaned in a solvent and dried.
2. Using the driven gear (7) as an up-righting fixture, carefully locate the arbor (5) over
its press-fit hole with the help of an appropriate arbor press.
3. Place the rear side plate (3) with the arbor in position in a soft-jaw vise or holding fix-
ture.
4. Slip together the driving metering gear (6), drive shaft (4), key (8) and retaining ring.
Position in the front of the side plate by installing the drive shaft through the bearing (49).
5. Place the driven metering gear on its arbor and carefully mesh with the drive metering
gear.
6. Carefully lower the center plate (2) over the gears.
NOTE: Repeat steps 5 and 6 for four-gear pumps, placing the middle plate between gear
plates.
7. Position the front side plate (1).
8. Rotate the gears to ensure free rotation.
9. Press the dowels (10) into place moving in the direction of the shortest press distance.
(Usually from the rear side of the pump.)
10. Lubricate the binder screws (47, 48) with DAG dispersion #154 or a similar heat re-
sistant lubricant and install. Torque the screws in even increments to the manufacturer’s rec-
ommended limit. It is especially important to rotate the gears frequently during this operation.
11. Re-assemble the seal arrangement, making sure the sealing surfaces are perfectly
clean and free of scratches, nicks or burrs. When a carbon seal plate is used, always use a new
carbon seal that has been lightly polished on 400/600 grit paper. When using a carbon seal,
the coupling housing screws (27) should be torqued to the manufacturer’s recommended lim-
it. For pumps with a compensation packing seal, be sure all old packing is removed from the
packing housing.
12. Inspect the drive shaft at the seal area making sure that it is not scored, shouldered or
worn. Worn shafts will result in premature seal leakage and should be replaced.
13. Pack lip seals (15) with a silicone-based grease and lubricate with Parker Super-O-
Lubricate or an equivalent silicone-based oil.
14. Install lip seals into seal housing (22) as shown.
15. Tighten seal housing screws to 60 lbs./in. Check for rotation.
c. 2000 Appendix 23
SCREW TORQUE VALUES (Standard Alloy Steel)*
Screw Size & Thread Torque (Lubricated Threads)

(UNC Alloy Steel) Lbs.-in. Nxm Lbs.-ft.
#10-24 (w/ carbon seal gasket) [50] 5.7 [4.2]

#10-24 (w/o carbon seal gasket) [64] 7.2 [5.3]
#12-24 [120] 13.6 [10]
1/4-20 [150] 16.9 [12.5]
5/16-18 [305] 33.9 [25]
3/8-16 into aluminum [360] 40.6 [30]
7/16-14 block (hopper) [480] 54.2 [40]
Table 1
*In critical applications where control of bolt preload is important, the torque-tension relation should be
determined by experimenting on the actual parts involved (including thread lubricants). At elevated
temperatures, it is often desirable to reduce screw stress because of deformation (creep) under sustained
loading. Screws constructed of type H-11 high-temperature alloy steel provide extremely high creep
resistance.
TROUBLESHOOTING GUIDE
Pump will not turn. 1. Low pump temperature. Check temperature sensor
and control loop for
proper setting/ operation.
Allow sufficient heat-up
time.
2. Drive malfunction. Verify drive is powered.

Check to assure all alarm
circuits are clear.
Check drive motor current
and speed settings.
Check all drive couplings.
3. Process conditions changed. Check process conditions

for proper melt tempera-
ture, pressures, viscosities
and materials.
4. Entrained particle. Return pump to ITW

Dynatec for repair.
cont.
Appendix 24 c. 2000
TROUBLESHOOTING GUIDE, continued
5. Possible internal damages. Return pump to ITW Dynatec

for repair.
Excessive seal 1. Worn seal plate. Return pump to ITW Dynatec

assembly leakage for repair.
2. Insufficient inlet pressure. Increase inlet pressure.
3. Worn lip seal.* Replace lip seal.
Reduced pump efficiency 1. Worn gear(s). Return pump to ITW Dynatec

for repair.
2. Worn bearings. Return pump to ITW Dynatec

for repair.
3. Process conditions changed. Consult factory for

clearance recommended
on new process conditions.
* A minor seal leak or weep is not abnormal and may be desirable for lubricating the seal surfaces.
c. 2000 Appendix 25
Appendix 26 c. 2000
c. 2000 Appendix 27
Appendix 28 c. 2000
ITW Dynatec

c. 2000 Appendix 29
ZENITH MELT SPINNING PUMPS MANUAL
Covers ITW Dynatec part numbers:
084E374 0.584cc, single pump

084E376 1.752cc, single pump
084E388 0.297cc, dual pump
084E389 0.58cc, dual pump
084E411* 20cc, single, high flow

*available on models DM 70/140/210 only
Pump PNs 084E374 thru 084E389 use PN 069X251 pump shaft seal.
Pump PNs 084E411 thru 084E413 use PN 069X289 pump shaft seal.
Appendix 30 c. 2000
c. 2000 Appendix 31
Appendix 32 c. 2000
c. 2000 Appendix 33
HIGH ACCURANCY PUMP PERFORMANCE
c. 2000
DYNAMELT M ASU Manual 20-36, 20-37, 20-38
100
90
084E434
80 084E436
2.92 cc/rev
70
084E376
1.752 cc/rev
60
084E430
084E432
50 1.168 cc/rev
VOLUMETRIC EFFICIENCY %
40
30
084E388 084E374
084E387 084E428 084E389
.160 cc/rev .297 cc/rev .584 cc/rev
20
10
Revised 10/00
Appendix 34
.01 .02 .05 .10 .2 .5 1.0
VOLUMETRIC EFFICIENCY FACTOR

DP D P = DIFFERENTIAL PRESSURE (PSI)
mN m = APPARENT VISCOSITY (CENTIPOISES)
N = RPM
c. 2000 Appendix 35
OIL- FILLED
MELT PRESSURE TRANSDUCERS
W3 SERIES mV/V output
PN 800225 Pressure Transducer
MV, 1.5/30NHG
The W3 series of Gefran, are pressure transducers for
using in High temperature environment.
The main characteristic of this series is the capability to
read temperature of the media up to 315C.
The constructive principle is based on the hydraulic tra-
smission of the pressure.
The fluid- filled system assures the temperature stability.
The phisical measure is transformed in a electrical mea-
sure by means the strain- gauge technology.
FEATURES
 Pressure ranges from:

0- 35 to 0- 1000 bar / 0- 500 to 0- 15000 psi
 Accuracy: <0.25% FSO (H); <0.5% FSO (M)
 Fluid- filled system for temperature stability
 Oil filling meets FDA requirements CFR 178.3620 and
CFR 172.878
 Oil filling volume:
W30 (30mm 3); W31- W32- W33 (40mm3)
 1/2- 20UNF, M18x1.5, standard threads; other types avai-
lable on request
 Standard diaphragm is a 17- 7 PH stainless steel GTP
coating corrugated diaphragm
GTP (advanced protection)

Coating with high resistance against corrosion, abrasion
and high temperature
Appendix 36 c. 2000
W30
15 [0.59I]
ø26.5 [1.04I]
15 [0.59I]
W32
ø26.5 [1.04I]
76.5
ø7.5 [0.30I]
76.5
15.7 [0.62I]
D1 1/2 - 20UNF
26 [1.02I]
ø7.8 - 0.05
100 [3.94I]
D2
457 [18I]
[ ø0.31” - 0.002 ]
259.6 [10.22I]
12.7 [0.5I]
Ch.
ø10.5 - 0.025
D3
[ ø0.41” - 0.001 ]
771.1 [30.4I]
45.2 [1.78I]
D5
ø28 [1.10I]
D4 ø10.67
[ ø0.42 ]
152.4 [6I]
12.7 [0.5I]
D5 ø12.7 Ch.
[ ø0.5 ]
D4
45
A 5.56 - 0.26 D5
D1 [ 0.22” - 0.01 ]
C
152.4 [6I]
11.2
B
A
B
D2 [ 0.44 ]
D3
15.74 D4
C
W31 [ 0.62 ]
D1
45
C
Ch 16
15 [0.59I]
[Hex] [ 5/8 ]
A
ø26.5 [1.04I]
D2
D3
W33
D1 M18x1.5
15 [0.59I]
ø10 - 0.05 ø26.5 [1.04I]

D2
[ ø0.394 - 0.002 ]
76.5
26 [1.02I]
ø16 - 0.08
D3
[ ø0.63” - 0.003 ]
D4 ø16 - 0.4
76.5
[ ø0.63” - 0.016 ]
ø7.5 [0.30I] ø18

D5
[ ø0.71 ]
457 [18I]
25.5 [1I]
6 - 0.26
752.4 [29.62I]
A
[ 0.24” - 0.01 ]
26 [1.02I]
14.8 - 0.4 ø7.5 [0.30I]

440 [17.32I]
B
[ 0.58” - 0.016 ]
12.7 [0.5I]
Ch.
19
C [ 0.75 ]
ø9 [0.35I]
D5
Ch 19 ø1.6 [0.063I]
15 [0.59I]
152.4 [6I]
[Hex] [ 3/4 ]
Ch.
255 [10I]
D4
NOTE : dimensions refer to rigid stem D1
C
45
length option “4” (153 mm – 6”)
D1 45
C
WARNING : For installation use a

B
maximum tightening torque of

A
B
A
D2
D3 56 Nm(500 in- lb) D3
D2
c. 2000 Appendix 37
ELECTRICAL CONNECTIONS 6- pin 8- pin

mV/V OUTPUT +
Supply Voltage
C A
Supply Voltage - D C
Signal - B D
Signal + A B
Calibration shunt
E- F E- F
R- Cal
n.c. G- H
Connect the cable sheathing
to the side of the instrument.
6 pin connector
VPT07RA10- 6PT2
8 pin connector
(PT02A- 10- 6P)
PC02E- 12- 8P Bendix
ACCESSORIES
Connectors
6- pin mating connector (IP65 protection degree) CON300
8- pin mating connector CON307
Extension cables
6- pin connector with 8m (25ft) cable C08W
Other lengths consult factory
Accessories
Mounting bracket SF18
Dummy plug for 1/2- 20UNF SC12
Dummy plug for M18x1.5 SC18
Drill kit for 1/2- 20UNF KF12
Drill kit for M18x1.5 KF18
Cleaning kit for 1/2- 20UNF CT12
Cleaning kit for M18x1.5 CT18
Thermocouple for W32 model
Type “J” (153mm - 6” stem) TTER601
Appendix 38 c. 2000
ORDER CODE W 000

000 = Standard version
Special or customized versions
OUTPUT SIGNAL
available on request
2.5 mV/V 2
3.33 mV/V 3
FLEXIBLE LENGTH (*)
(mm / inches)
VERSION Standard (W30)

Rigid stem 0 0 none
Rigid stem + flexible 1 Standard (W31, W32)
With thermocouple 2 D 457mm 18”
Exposed capillary 3 E 610mm 24”
F 760mm 30
Standard (W33)
CONNECTOR L 711mm 28
Standard Available on request
6 pin 6 A 76mm 3”
8 pin 8 B 152mm 6”
C 300mm 12
ACCURACY CLASS RIGID STEM LENGTH (*)

0.25% FSO (mm / inches)
H
(ranges ≥ 100 bar/1500 psi) Standard (W30, W31, W32)
4 153mm 6”
0.5% FSO M
5 318mm 12.5”
Standard (W33)
0 none
Available on request
RANGE 1 38mm 1.5”
bar psi 2 50mm 2”
35 B35U 500 P05C 3 76mm 3”
50 B05D 750 P75D 6 350mm 14”
70 B07D 1000 P01M 7 400mm 16”
100 B01C 1500 P15C 8 456mm 18”
200 B02C 3000 P03M
(*) Note : maximum combined
350 B35D 5000 P05M
stem/flex length is
500 B05C 7500 P75C 914mm - 36
700 B07C 10000 P10M
1000 B01M 15000 P15M THREAD
Standard
Examples 1 1/2 - 20 UNF
4 M18 x 1.5
W32- 6- M- B07C- 1- 4- D- 000
Melt pressure transducer with type “J” thermocouple, 3.33 mV/V output, 6- pin connector, 1/2- 20UNF thread, 700bar full scale,
0.5 % accuracy class, 153 mm (6”) rigid stem, 457mm (18”) flexible capillary.
W20- 8- M- P03M- 1- 4- 0- 000

Melt pressure transducer, rigid stem, 2.5 mV/V output, 8- pin connector, 1/2- 20UNF thread, 3000psi full scale, 0.5 % accuracy
class, 153 mm (6”) rigid stem
GEFRAN reserves the right to make any kind of design or functional modification at any moment without prior notice.
GEFRAN spa
via Sebina, 74
25050 PROVAGLIO D’ISEO (BS) - ITALIA
tel. 0309888.1 - fax. 0309839063
DTS_W3_09- 2010_ENG
Internet: http://www.gefran.com
c. 2000 Appendix 39
DYNAMELT M ASU Manual 20-37, 20-38 Revised 4/06
TOOL-STEEL HIGH ACCURACY GEAR PUMPS

USER’S GUIDE
Pump # Identifier Displacement Type # Gears # Plates Shaft Seal #
108863 TSHA* 0.160 cc rev. single 2 3 807729

108864 TSHA* 0.160 cc rev. dual 4 5 807729
108866 TSHA* 0.297 cc rev. dual 4 5 807729
108868 TSHA* 0.584 cc rev. dual 4 5 807729
108870 TSHA* 1.168 cc rev. dual 4 5 807729
108873 TSHA* 4.500 cc rev. dual 4 5 807729
108874 TSHA* 2.920 cc rev. dual 4 5 807729
* Tool Steel, High Accuracy
Customer should read and thoroughly understand this

manual before installation and operation of pump.
If necessary, any Dynatec pump requiring maintenance can be returned

to the factory for complete repair and overhaul. Please contact our Rebuild
Department for further details.
Appendix 40 c. 2000
Revised 3/05 DYNAMELT M ASU Manual 20-37, 20-38
Description
ITW Dynatec’s metering gearpumps are manufactured to precise tolerances. To retain their high
performance, these pumps must be carefully installed and maintained. These pumps are CE (Dec-
laration of Conformity) rated.
Health & Safety
Dismantling
Internal components are precisely machined and have sharp edges and corners. These features are
essential to the accurate metering performance. Particular care must be exercised when handling
these components.
Cleaning
Cleaning fluids and methods are subject to strict Health and Safety regulations. Avoid contact
with skin, do not inhale fumes and protect eyes.
Operation
Pump outlet pressure and speed limits are dependant on fluid viscosity and throughput. Pump in-
let pressure is an important feature for lubrication and fluid homogeneity. Materials for pump
construction are important for corrosion and wear resistance. Consult ITW Dynatec for detailed
applications. Normally the pumps are single or dual output. Typical speed ranges are 10-90 rev/
min.
Flushing
To avoid contamination of process fluid, the pump should be flushed out to remove test oil. Pre-
caution must also be taken to flush out pumps at plant shutdown, since congealed fluid can cause
seizure.
Filtration
Unless fluid purity can be guaranteed (especially from metal fragments), filtration must be
installed before pump inlet, to avoid damage to pump internals.
Note: The following guide is for general purposes only. Due allowance must be made for any spe-
cial features.
Installation
Ensure pump is free from protective packing materials and rotates freely.
Pump Drive
Drive alignment is very important. Ensure backlash is 0.1mm (0.004”) to avoid shock or radial
load. In the event of driveshaft connection, two flexible components must be incorporated into
each driveshaft to allow for misalignment. These flexible components must have the capacity to
distort over the misalignment range while ensuring that any radial load is minimal. Do not allow
c. 2000 Appendix 41
shaft to put end thrust on the pump.
Rotation
Ensure drive rotates in correct direction (generally counter-clockwise at the pump drive spindle).
The pump must be checked for smooth operation by hand.
Fixing and Lubrication

The pump must be fixed securely to maintain position and alignment. When secured by lubricated
bolts, torque them evenly to the suggested torque (see Maintenance).
Start drive and bring up to speed slowly. Flush with process fluid.
Note: motor baseplate assemblies should be pre-checked in case the drive alignment has been dis-
turbed.
Gland Leakage
If oil seal is fitted, there should not be any fluid leakage.
Problem-finding Chart
Problem Remedy
LEAKAGE
Screws not tight Re-torque
Seal scratched or worn Replace seal
FLOW RATE ERROR
Gear worn on diameter Return to ITW Dynatec

or width
Gear teeth damage Return to ITW Dynatec
Plates worn, scratched or not Return to ITW Dynatec

flat
Low inlet pressure (cavitation) Check process
High outlet pressure (slippage) Check process

Appendix 42 c. 2000
Cleaning
Before removal from machine, the pump should be rotated for a short period (with inlet supply
shut off) to discharge process fluid. Care should be taken, when removing and stripping the pump,
to allow for any residual fluid. Pump components can be solvent or ultrasonically cleaned by im-
mersion, using a compartmentalized wire baset. Dry in air. Stubborn residues may be removed
with a brass wire brush. Avoid burnishing the sharp edges of gear and gear races.
Fluid immersion in rust inhibitor is advised. If components are to be stored for some time, they
should be lightly smeared with oil.
Maintenance
Tightening Torque
for High Tensile ISO 12.9 Lubricated Bolts (300C max)
Bolt Size & Qty. Bolt Location Torque Nm/ Ft.lbs.

M5 (4) retainer cap 7.1/ 5.2
M10, 12 (4) mounting bolts 41/ 30 at ambient temperature

M10, 12 (4) mounting bolts 24/ 18 at production temperature
Notes: If mounting bolts are torqued at production temperature, they should be re-torqued (to 41
Nm/30 Ft lb.) when machine is at ambient temperature.
1 Nm = 8.85 in/lbs. Torques given above are for Metric and UNF threads. Multiply by 0.8 for
UNC and BSF threads.Multiply by 0.8 for BSVV threads (multiply by 0.67 for stainless steel)
ITW Dynatec frequently provides special features at their customer’s request. Please consult with
ITW Dynatec, quoting job and pump references, if questions arise.
c. 2000 Appendix 43
Reconditioning
Should reconditioning (overhauling) become necessary, return the pump to ITW Dynatec.
Pump Shaft Seal Replacement
The ITW Part Number for all Standard Tool Steel High Accuracy Pump Shaft Seals (8.5cc and
smaller) is PN 807729.
DANGER HOT SURFACE & HIGH VOLTAGE

If the pump is not operable but the heating system will function, raise the
temperature of the application system to the operating temperature to aid in the
pump disassembly process. Otherwise, a heat gun or other controlled heating
method is recommended to melt hardened hot melt material. Never use a torch
or an open flame on any of the components of the application system. Once the
system is up to temperature, disconnect all incoming power before proceeding.
Pump Shaft Seal (O-ring) Replacement:
In most cases, the pump does not have to be Pump

removed from the ASU in order to replace the
shaft seal.
1. Disconnect the drive coupling so that the

Cap
pump may be accessed.
2. Remove the four screws in the pump “cap”

and remove the cap.
3. Within the cap is the pump shaft seal. Re-

move the old seal. Shaft
4. Clean all pump parts, paying particular

attention to the pump shaft seal groove.
5. Lightly lubricate the shaft seal before inserting it in the shaft seal groove.
6. Before re-assembling, wrap a small piece of paper around the shaft so that the shaft’s
woodruff key seat does not damage the new seal.
7. Re-assemble. Remove paper.
8. Re-tighten four screws.
9. Re-connect drive coupling.
10. Return ASU to operation and check pump for leaks.

Appendix 44 c. 2000
Rebuild Kit for 8.5cc TSHA Pump, PN 111939
The rebuild kit for the PN 108875 8.5cc TSHA pump consists of the following parts:
PN Description Qty. PN Description Qty.
111699 Drive Shaft 1 111707 Retaining Ring 1

111699 Idler Shaft 1 111709 Screw, 10-24 4
111701 Bushing, Front Plate 1 807729 Pump Shaft Seal 1
111702 Bushing, Back Plate 1 111705 Key 1
111704 Dowel 2 078I001 Key, Woodruff 1

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OPERATIONS & SERVICE MANUAL

DYNAMELT M SERIES ADHESIVE SUPPLY UNIT

Model DM M210 DCL

IMPORTANT ! - READ ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT

ITW Dynatec Service Parts Direct Dial: 1-800-538-9540

Adhesive Application Solutions

Chapter 2 Description & Specifications

Chapter 3 Installation & Start Up

Chapter 4 DynaControl Controller Set-Up

Default Settings of the DynaControl Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Helpful Tips for the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Chapter 5 Programming of DynaControl Controller

Controller Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Service Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Chapter 6 Preventive Maintenence

Chapter 8 Disassembly & Re-assembly Procedures

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Chapter 9 Available Options & Accessories

Pressure Gauge Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Chapter 10 Component Illustrations & Bills of Material

Chapter Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Chapter 11 System Schematics & Engineering Drawings

Optional Dynatec/ Zenith Standard Accuracy Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 1

power is on. Disconnect, lockout and tag external

A secure connection to a reliable earth ground is

A disconnect switch with lockout capability must be

Severe burns can occur if unprotected skin comes in

IMPORTANT NOTE: Even when a system’s pressure

To prevent serious injury from molten adhesive under

Keep all guards in place!

Eye Protection & Protective Clothing

Wear safety glasses with side shields which conform to

Always wear steel-reinforced safety shoes.

Safe Installation and Operation

Treatment for Burns From Hot Melt Adhesives

Call a physician and/or an emergency medical

Explosion/ Fire Hazard

Use of PUR (Polyurethane) Adhesives

Special Safety Considerations When Using Reactive HMPUR Adhesives

 Assure the workspace has adequate ventilation.

* totally enclosed, fan cooled

DynaControl Temperature Control:

DYNAMELT M210 Installation Dimensions

mm 1506.4 1227.4 1301.6 1622.3 177.8 342.9 610 320.68 1377.7

Total System Wattage Capacity

Maximum Wattage M210

Hopper + High Temp Heater 18,000 w

Optional Drop-in Grid 7,500 w

Up to 12 Hose Zones 14,400 w

Up to 12 Applicator Zones 14,400 w

Up to 12 AUX Zones 24,000 w

Maximum System Wattage: 85,800 w

Main Circuit Breaker Determination

Definition of Code: DYNAMELT DM 210 ASU w. DynaControl Controller

Code PN Base Unit Code Voltage

21S 106055 210kg (420 lb) Hopper 2 240V/ 3P Delta/ no neutral

Motor/ Drive Groups (1 per pump)

The example shown above would be recorded