Operating Manual Hotmelt Applicators Concept 4, 8, 12, 18

Operating Manual
Hotmelt Applicators
Concept 4, 8, 12, 18
Part No. 112532 / Edition 4.1
Program ICS-MAIN from version 3.04
Publisher:
Robatech AG
Pilatusring 10
CH-5630 Muri
Switzerland
Phone +41 (0)56 675 77 00

Fax +41 (0)56 675 77 01
Email info@robatech.ch
Internet www.robatech.com
Date of issue: May 2002
© Copyright by Robatech AG
All rights reserved. Without Robatech's written approval it is not permitted to copy and distribute this
manual or parts thereof in any form whatsoever, or to transmit it by means of electronic systems.
The illustrations and information contained in this Operating Manual are subject to technical altera-
tions necessary for the enhancement of the appliance.
Table of contents
1 Product description____________________________________________________________5
1.1 Use for the intended purpose....................................................................................................... 5
1.2 Improper use................................................................................................................................ 5
1.3 The operating manual.................................................................................................................. 6
1.3.1 How to use this manual.................................................................................................... 6
1.3.2 Program modifications ICS-MAIN....................................................................................7
1.3.3 Content and topicality...................................................................................................... 7
1.4 Appliance identification................................................................................................................ 7
1.5 Overview of the appliance............................................................................................................ 8
1.6 Technical data.............................................................................................................................. 9
1.7 Conformity, standards complied with........................................................................................ 10
2 Safety_____________________________________________________________________11
2.1 References contained in the operating manual.........................................................................11
2.2 Dangers of handling/operating the appliance............................................................................11
2.2.1 Danger of burns............................................................................................................. 11
2.2.2 Danger of splashing...................................................................................................... 12
2.2.3 Electrocution.................................................................................................................. 12
2.2.4 Irritations of the mucous membranes............................................................................12
2.3 General safety prescriptions...................................................................................................... 13
2.4 Safety features........................................................................................................................... 13
2.5 Qualified personnel.................................................................................................................... 13
2.6 Personal protective equipment.................................................................................................. 14
2.7 Procedure in case of an emergency.........................................................................................14
2.7.1 Skin burns...................................................................................................................... 14
2.7.2 Electrical accident.......................................................................................................... 14
2.7.3 Extinguishing hotmelt applicators on fire.......................................................................15
3 Transport and scope of supply__________________________________________________17

3.1 Packaging.................................................................................................................................. 17
3.2 Transport.................................................................................................................................... 17
3.3 Scope of supply......................................................................................................................... 17
4 Appliance overview and functions_______________________________________________18

4.1 Overview of the appliance......................................................................................................... 18
4.2 Functioning of the appliance..................................................................................................... 18
4.3 Tank with distributor................................................................................................................... 19
4.4 Piston pump............................................................................................................................... 19
4.5 Operating unit............................................................................................................................ 20
4.6 Control electronics..................................................................................................................... 21
4.6.1 Standard........................................................................................................................ 21
4.6.2 Options........................................................................................................................... 21
4.6.3 Wiring diagram............................................................................................................... 22
4.6.4 Specifications of the ICS-MAIN main control................................................................23
5 Installation and first commissioning______________________________________________25

5.1 Place of positioning.................................................................................................................... 25
Concept / 4.1 Table of contents 1

5.2 Installing the heated hoses........................................................................................................ 27
5.2.1 Installation examples..................................................................................................... 28
5.2.2 Electrical connection...................................................................................................... 30
5.3 Pneumatic connection............................................................................................................... 30
5.4 Electrical connection.................................................................................................................. 31
5.4.1 Checks prior to connection............................................................................................ 31
5.5 Higher-ranking system controls................................................................................................. 32
5.5.1 Data............................................................................................................................... 32
5.5.2 Signals........................................................................................................................... 32
5.5.3 Connection of PLC control............................................................................................. 34
5.5.4 Connection of relay control............................................................................................ 35
5.5.5 Wiring in compliance with EMC.....................................................................................36
5.6 Installation of accessories and options......................................................................................36
5.7 First commissioning................................................................................................................... 37
6 Operation__________________________________________________________________39
6.1 Filling in hotmelt......................................................................................................................... 39
6.2 Switching on and off.................................................................................................................. 39
6.3 Setting the feed quantity / glue pressure...................................................................................40
6.4 Draining the system pressure..............................................................................................................40
6.5 Operating concept...................................................................................................................... 41
6.5.1 Overview of the appliance functions.............................................................................41
6.6 Appliance status........................................................................................................................ 42
6.6.1 Overall status................................................................................................................. 42
6.6.2 Heating zone status.................................................................................................................43
6.6.3 Heating zone and system errors...................................................................................43
6.7 Access blockage........................................................................................................................ 44
6.8 Setting and checking the temperatures.....................................................................................44
6.8.1 Displaying temperatures................................................................................................44
6.8.2 Capturing the temperatures........................................................................................... 45
6.8.3 Checking the heating output......................................................................................... 45
6.9 Entering parameters.................................................................................................................. 46
6.9.1 Before you alter parameters.......................................................................................... 46
6.9.2 Capturing the parameters..............................................................................................47
6.9.3 Saving the program settings.......................................................................................... 48
6.9.4 Loading the program settings........................................................................................ 48
6.9.5 Putting back the program to the default setting.............................................................48
6.9.6 Parameter 1…18: Compensation factors......................................................................49
6.9.7 Parameter 20: Temperature differential tank - heated hoses.......................................49
6.9.8 Parameter 21: Temperature differential tank- application heads..................................49
6.9.9 Parameter 22: Heating-up order...................................................................................49
6.9.10 Parameter 23: Temperature - unit of measurement.....................................................50
6.9.11 Parameter 24: Standstill supervision, time until temperature lowering.........................50
6.9.12 Parameter 25: Standstill supervision, time until switch-off............................................50
6.9.13 Parameter 26: Activating the input H-ENABLE.............................................................50
6.9.14 Parameter 27: Configuration of input P-ENABLE1.......................................................50
6.9.15 Parameter 28: Number of heated hoses / application heads.........................................51
6.9.16 Parameter 29: Configuration of tank heating 2 (Premelter)..........................................51
6.9.17 Parameter 30: Maximum nominal temperature.............................................................51
6.9.18 Parameter 31: Waiting time after reaching of the tank nominal temp............................51
6.9.19 Parameter 32: Configuration of access blockage PAR-LOCHED2...............................51

6.9.20 Parameter 33: Melting time activating temperature......................................................52
6.9.21 Parameter 70: Resetting of the service messages A90…A92......................................52
6.9.22 Parameter 71: Operating hours until «Check filter»......................................................52
6.9.23 Parameter 72: Operating hours until «Clean complete system.....................................52
6.9.24 Parameter 73: Operating hours until «Free service message».....................................52
6.9.25 Parameter 80: Temperature inside the appliance.........................................................53
6.9.26 Parameter 81: Standstill time........................................................................................ 53
6.9.27 Parameter 82: Battery voltage.......................................................................................53
6.9.28 Parameter 90: Applied program....................................................................................53
6.9.29 Parameter 91: Program version....................................................................................53
6.9.30 Parameter 200: Existence of extra board ICS-EXT1....................................................53
6.10 Querying and setting the clock time..........................................................................................54
6.11 Time switch clock....................................................................................................................... 55
6.12 Temperature lowering................................................................................................................ 56
6.12.1 Determination of the lowered temperatures..................................................................56
6.12.2 Manual switching-on of temperature lowering..............................................................56
7 Maintenance________________________________________________________________57
7.1 References............................................................................................................................................57
7.2 Maintenance schedule............................................................................................................... 58
7.3 Flushing of the filter................................................................................................................... 59
7.4 Replacing the filter..................................................................................................................... 59
7.5 Cleaning of the appliance.......................................................................................................... 60
7.5.1 Cleaning agent............................................................................................................... 60
7.5.2 Complete cleaning......................................................................................................... 61
8 Repair_____________________________________________________________________63
8.1 References............................................................................................................................................63
8.2 Replacing heated hoses and application heads........................................................................64
8.3 Repairing the piston pump......................................................................................................... 65
8.3.1 Irregularities on pumping............................................................................................... 65
8.3.2 Removal and installation of the piston pump................................................................66
8.4 Replacing temperature sensors................................................................................................. 67
8.5 Resetting the temperature limiter.............................................................................................. 67
8.6 Checking the electrical connections.......................................................................................... 68
8.6.1 Checking the heated hose connection..........................................................................68
8.6.2 Checking the piston pump connection..........................................................................69
8.7 Connection assignment of boards ICS......................................................................................69
8.7.1 ICS-MAIN Main control.................................................................................................. 70
8.7.2 ICS-PWR1 Tank heating................................................................................................ 73
8.7.3 ICS-PWR2 Heating of heated hoses and application heads.........................................74
8.7.4 ICS-PUS Piston pump control.......................................................................................75
8.7.5 ICS-PWRD1 Power distribution.....................................................................................76
8.7.6 ICS-PWRD3 Power distribution.....................................................................................77
8.8 Pump disturbances.................................................................................................................... 78
8.9 Disturbances in the hotmelt application....................................................................................79
9 Putting out of operation and disposal_____________________________________________83

9.1 Putting out of operation............................................................................................................. 83
9.2 Disposal..................................................................................................................................... 83
10 Spare parts_________________________________________________________________85
10.1 Introduction................................................................................................................................ 85

10.2 Hand tools and auxiliary materials............................................................................................85
10.3 Exchange components.............................................................................................................. 86
10.4 Basic appliance.......................................................................................................................... 86
10.5 Electrical parts........................................................................................................................... 87
10.6 Piston pump HPC12.................................................................................................................. 88
10.6.1 Spare parts..............................................................................................................................88
10.6.2 Set of seals HPC12........................................................................................................ 88
10.7 Piston pump HPC5..................................................................................................................... 89
10.7.1 Spare parts..............................................................................................................................89
10.7.2 Set of seals HPC5.......................................................................................................... 89
10.8 Piston pump HPC16.................................................................................................................. 90
10.8.1 Spare parts..............................................................................................................................90
10.8.2 Set of seals HPC16........................................................................................................ 90
11 Accessories________________________________________________________________91
11.1 Heated hoses and accessories............................................................................................................91
11.1.1 Standard heated hoses, nominal width 8mm................................................................91
11.1.2 Screw fittings................................................................................................................. 91
11.1.3 Extension cables........................................................................................................... 92
11.1.4 Distribution cables......................................................................................................... 93
11.1.5 Accessories for heated hoses.......................................................................................93
11.2 Controls and accessories.....................................................................................................................94
11.2.1 Photoelectric cells and proximity switches....................................................................95
11.2.2 Valve cables................................................................................................................... 96
11.2.3 Power supplies ICS-PSUP............................................................................................ 96
11.2.4 Encoder.......................................................................................................................... 97
11.2.5 Proportional valves and accessories.............................................................................98
11.3 Pumps...................................................................................................................................................99
11.4 Level sensors........................................................................................................................................99
11.5 Pressure relief kit....................................................................................................................... 99
11.6 Maximum pressure valve......................................................................................................... 100
11.7 Installation kits for operating unit ICS-TRM............................................................................100
11.8 Various accessories................................................................................................................. 101
11.9 Plugs, cable sockets and cables........................................................................................................101
11.10 Operating instructions.............................................................................................................. 102
12 Appendix__________________________________________________________________103
12.1 Power distribution and admissible loading..............................................................................103
12.1.1 Supply 400 VAC 50Hz 3-phase with neutral conductor.............................................103
12.1.2 Supply 230 VAC 50Hz 1-phase....................................................................................104
12.2 Quick reference....................................................................................................................... 105
13 Key word index_____________________________________________________________107

1 Product description
1.1 Use for the intended purpose

The Concept units are hotmelt applicators and
serve to melt, feed and apply thermoplastic
hotmelts in an industrial environment. They are
hotmelt application systems of a modular
structure. Subject to the pertaining technical
data (see chapter 1.6) they are intended for the
The Concept applicators are intended for melt-

ing down and feeding thermoplastic hotmelts on
the basis of EVA (Ethylene-vinylacetate). The
application range reaches from dry (packaging)
to sticky (labelling, adhesive hotmelt).
following applications:
Robatech's specific approval must be obtained in
any case if polyamide or polyethylen are to be
processed. Unless Robatech's written approval
concerning the processing of special hotmelts has
been obtained beforehand, no liability will be
accepted in case of a damage to the system.
1.2 Improper use

Below are some examples, without limitation, of activities by the owner or operator of the appliance
which are considered to be improper use:
– Any other use than that for the intended use, without the manufacturer's written approval, or any
operation outside the technical limits are deemed to be improper.
– The Concept units are specifically not suitable for the processing of polyurethane hotmelts. This
material would crosslink inside the system after a few hours, form clots and solidify irreversibly.
– Adhesives containing solvents must not be used. A danger of fire and explosion exists on heating of
such materials.
– It is strictly prohibited to modify the appliance in any way without the prior written approval of Robatech.
– Operation of the appliance by unqualified personnel is prohibited.

– Failure to observe the safety and operating instructions and to comply with work protection, accident
prevention as well as particular local regulations is deemed to be improper practice.
Concept / 4.1 Product description 5

1.3 The operating manual
The information contained in this operating manual refers to:
All «Concept» hotmelt applicators of Robatech from program version 3.04 with piston pump
Without integrated pattern control ICS-IK4x and without gear pump
The operation of the pattern control ICS-IK and of the gear pump ZPC is not described in this
manual. Dedicated manuals are available for these options (see chapter 11.10).
Neither is the operation of the application heads described in this manual.

A dedicated manual is available for each type of application head.
This manual can be obtained in the languages English, German, French, Italian and Spanish; other
languages on request from the respective local representative.
The operating manual is a part of the appliance. Heep it ready for immediate use so that any item can
be looked up quickly whenever necessary.
The manual must be understood and complied with in every respect by all those persons who are
responsible for transport, installation, operation, maintenance and repair of the appliance.
1.3.1 How to use this manual

Chapters 1 to 4 provide the necessary basic knowledge which every user must acquire for his/her
work with the «Concept» appliance.
Chapter 6 includes information describing the operation of the appliance in the normal case, i.e. in
trouble- free running.
Chapters 5 and 7 to 11 include jobs which deviate from normal operation, i.e. maintenance,
commissioning, the elimination of disturbances or the ordering of spare parts.
At the end of the manual you will find information which facilitates the use of the operating manual,
e.g. a key word index and additional technical information.
Please read the manual carefully. Take particular note of chapter 2 «Safety» – so
that you can operate the appliance safely and without accidents.
1.3.2 Program modifications ICS-MAIN
Program ICS-MAIN from version 3.00 to 3.04:
– New operation status A90, A91 and A92 for service messages
– New parameters 70, 71, 72 and 73 for resetting and setting of the service messages
– Parameter 32: Extended blockage of «Loc1» or «Loc1+2»
– Resetting of the standstill supervision in parameters 24 and 25 via key
– Saving of all data (also glue patterns) via «2222» when switching on
Program ICS-MAIN from version 2.06 to 3.00:

– Support of the new ICS-MAIN board with modified layout. New inputs and outputs.
– Parameter 32 with new configuration
1.3.3 Content and topicality

This manual is complete and current , if it contains the following pages:
Documentation Content Edition

Operating manual, basic unit page 1 … 110 4.1
Table of parameters, basic unit page I … II from program 3.04
Wiring diagram page 1 … 9 of 03.05.02
1.4 Appliance identification

The type label is on the rear side of the appliance.
Typ Appliance version with installed options

Baujahr Year of manufacture [Year – week – serial number]
Art.Nr. Article number
Volt Electrical connection values
Ampère Maximum current consumption per phase
1.5 Overview of the appliance
The Concept appliances are of a modular design and available in different executions and with
various options. The overview below shows the subassemblies of the standard executions.
A. Basic appliances
– Concept 4 with a tank volume of 4 litres
B. Controls
– Temperature control (standard)
– Integrated pattern control ICS-IH4x
– Gear pump control ICS-PINT
C. Feed pumps
– Piston pump HPC12 (standard)
– Piston pump HPC5
– Piston pump HPC16
– Gear pump ZPC2.3 (standard)
– Gear pump ZPC 2.75
D. Connections for hoses and heads

– 2 heated hoses and 2 application heads
The operation of the integrated pattern control ICS-IK and of the gear pump
ZPC is not described in this manual. Dedicated manuals are available for these
options.
1.6 Technical data
Concept 4 Concept Concept Concept
8 12 18
Tank content 4 litres 8 litres 12 litres 18 litres
Tank lid opening 130 × 115 130 × 209 205 × 209 205 × 339
mm mm mm mm
Melting capacity 4 kg/h* 10 kg/h* 12 kg/h* 18 kg/h*
Piston pump types HPC12 (standard), HPC5 or HPC16
Pumping rate KPC 12 / KPC 5
max. 50 kg/h
KPC 16
max. 160 kg/h
Output pressure KPC 12
max. 72 bar
KPC 5
max. 30 bar
KPC 16
max. 96 bar
Viscosity 100…20,000 mPas
Compressed air supply 6 bar, not oiled, purified
Air consumption KPC 12 max. 27.5 l/min
KPC 5 max. 11.4 l/min
KPC max. 111 l/min
16
Heated hoses and application heads max. 4 max. 6 max. 8 max. 8
each each each each
Operating temperature 20…230° C / 68…446° F
Temp. feedback control accuracy ± 0.5° C
Operating voltages 230 V, 1
LNPE 400 V, 3 400 V, 3 400 V, 3
according to Euronorm EN60204-1** 400 V, 3 LNPE LNPE LNPE
LNPE
Mains frequency 50/60Hz
Power consumption Tank 1.8 kW 3.0 kW 3.0 kW 4.5 kW
Ambient temperature 0…45° C
Dimensions L×W×H [mm] 545 × 310 × 680 × 310 × 680 × 385 × 806 × 385 ×
601 570 570 570
Weight (with HPC12) 34 kg 44 kg 54 kg 59 kg
Sound pressure < 70dB(A)
* Guide value, melting capacity depends on the adhesive

** Admissible deviation from the permanent operating voltage: 0.9...1.1 of the rated voltage
1.7 Conformity, standards complied with
The Concept appliances satisfy all applicable basic safety and health requirements. The appliances have
been developed, designed and manufactured in compliance with the listed EU directives. In case of a
product modification without Robatech's approval this declaration becomes nul and void.
– Directive 98 / 37 / EC relating to machinery
– Directive 89 / 336 / EEC relating to electromagnetic compatibility
– Directive 72 / 23 / EEC relating to electrical equipment designed for
use within certain voltage limits (low voltage equipment)
– Euronorm EN 602040-1 Safety of machines - Electrical equipment of
machines
2 Safety
The Concept appliances can be operated easily and safely by the instructed user. Inadequately trained
users, on the other hand, can cause material and personal damage by incorrect behaviour. This chapter
informs you of the safety concept and the prerequisites which must be met for a safe and optimal
utilization of the appliance.
This chapter must be read by all persons authorized to commission, operate, maintain or repair the
appliance.
2.1 References contained in the operating manual

The framed reference boxes in this manual will show you different reference symbols which warn of possible
dangers and situations and which must be observed under all circumstances.
Consequences in case
Symbol Signal Meaning
of non-observance
word
Immediately threatening Death or most serious injuries
Dange
danger
r
Possibly Possibly death or most

Warni
dangerous serious injuries
ng
situation
Cautio Possibly dangerous Minor injuries
n situation
Material damage to product or

— Possibly harmful situation
the environment
Tips for application or No dangerous or harmful

—
other useful information situation
2.2 Dangers of handlingloperating the appliance

2.2.1 Danger of burns
Warnin Danger of burns
g There is a danger of suffering burns from parts of the heated-up appliance which
are not covered and in case of contact with the hotmelt (temperatures up to
230°C
/ 446°F). The heated-up unit must not be transported or moved. Failure to
comply might result in hot adhesive coming out.
Heat-resistant protective gloves must be worn for all adjustment or

maintenance jobs on hot parts of the unit or in case of possible contacts
with hotmelt. Parts of the unit remain hot for a longer period also after the
unit has been switched off.
– The hot areas on tank lid, feed pump and distributor block on the
rear side of the appliance are marked with the warning sticker on
the right.
Concept / 4.1 Safety 11
2.2.2 Danger of splashing
Warnin Danger of
g splashing
The hot adhesive in the lines is under a high pressure. At the application heads
or if the pressure system is opened there is a danger of hot splashes occurring.
If the pressure system has to be opened, the entire appliance must be relieved
of pressure beforehand (see chapter 6.4).
Protective goggles must be worn under all circumstances for all adjustment or
maintenance work on parts under pressure such as pump, distributor block,
heated hose or application head.
– A label on the rear side of the appliance warns of

the high pressure loads and temperatures which may
occur.
2.2.3 Electrocution
Danger Electrocution
Mortal danger exists on touching of live components (operating voltage
400Volt). The protective covers may only be removed if the power supply to the
appliance is interrupted.
Connection of the appliance to the power mains or other work on the power cir-
cuit may only be carried out by persons trained for the purpose, i.e. electricians
or electrical fitters.
– This sticker on the covers on the front and on both sides

warns of unauthorized opening and draws attention to the
correct procedure.
2.2.4 Irritations of the mucous membranes

Caution Irritations of the mucous membranes by vapours
Even if the prescribed processing temperatures are complied with, hotmelt
adhesives can emit annoying smells and might lead to irritations of the
mucous surfaces.
The appliance may be operated in sufficiently aerated rooms only. Keep the
tank lid closed! Do not exceed the recommended processing
temperature! The data sheet provided by the producer of the hotmelt must be
observed.
2.3 General safety prescriptions
The following general safety prescriptions must be observed as well:
– The Concept appliance may only be operated, maintained and repaired by authorized and trained
persons.
– If it must be assumed that an operation without danger is no longer assured, the appliance must be put
out of operation and protected against unintentional switching on.
– In addition to the information contained in the operating manual, you must comply with legal
requirements and the provisions on accident prevention and protection of the environment in your
country.
– Do not modify the appliance in any way without having received Robatech's written approval.
2.4 Safety features

The Concept appliances are built to the current level of safety engineering and feature the following
safety and protection devices in standard execution:
– Appliance switch – interrupts the power supply to the control of the appliance
– Automatic switching-off of all heaters at an ambient temperature >65° C / 149° F
– Automatic switching-off of all heaters at a tank temperature >230° C / 446° F
– Connection for external emergency-off, the feed pump can be stopped immediately
– Monitoring of the program sequence – in case of errors all outputs are switched off within 250 ms
and the program is restarted
2.5 Qualified personnel

The appliance may only be operated, serviced and repaired by authorized and trained personnel. Based
on their physical disposition, training and experience, these persons are able to safely attend to operation,
service and repair of the appliance. This qualified personnel must be familiar with the safety and accident
prevention regulations and aware of the company-internal work instructions. The owner/operator of the
appliance is responsible for the personnel's training. The level of knowledge can be ascertained and
intensified with product- specific training by Robatech.
Appliance operator
The operator must be familiar with the appliance to the extent that he/she can run it including accessories
and periphery in trouble-free production. Prerequisite for this is a good technical understanding and at
least the reading and understanding of chapters 1, 2, 4 and 6 of this operating manual.
Technician
The technician must have a more extensive knowledge of the appliance. The person must have absolved
a basic training in mechanics/electrics and acquired elementary knowledge of pneumatics and hydraulics
to be able to put the machine in operation, to maintain and repair it. The person must read and
understand the chapters 1-9 in this manual.
2.6 Personal protective equipment
Working clothes covering arms and legs must be worn under all circumstances.
A pair of gloves and protective goggles must be worn under all circum-
stances for work on the hot and pressurized appliance components, in
particular for putting into operation, maintenance and repairs. Danger
of splashes and burns!
Robatech offers suitable protective equipment for this purpose: Maintenance kit Art.No.100660
consisting of a pair of protective gloves, protective goggles and a nozzle cleaning kit of 6 parts.
2.7 Procedure in case of an emergency

Please observe the information below. If an emergency occurs contrary to
expecta- tions, the information below will help you to proceed correctly in
keeping the damage within limits and in preventing possible further damage.
2.7.1 Skin burns

– The extent of an injury from burning cannot be assessed immediately after the accident. The body
must first react to the effects of the high temperature. Soft parts of the body injured by burns and
going dead are particularly endangered by infections. Only small, superficial burns may be treated by
the patient, otherwise a doctor's attention is necessary!
– In many cases burns will leave ugly scars which may interfere with movements. Burns in the face
and on the hands must always be treated by the doctor.
– Whenever possible, cool burns as quickly as possible under cold flowing, clean water. Then apply
sterile material, e.g. sterile gauze compresses. Do not use wound powder or oil, ointment or
similar. If no sterile bandage material is available, use freshly ironed hankerchiefs or linens. Do not
open or remove blisters.
2.7.2 Electrical accident

– Switch the power off immediately (e.g. switch to 0, pull out mains plug, remove fuse)
– If you are affected personally, you must apply all your strength to come free of the power circuit
(push yourself away, drop on the floor, pull out mains plug by walking away, etc.)
– Don't forget to protect yourself in a rescue operation. Stand on an insulated spot, touch a person
under electrical current with insulating dry objects only (clothes, wooden handle, etc.), tear or
push the victim away from the power circuit.
– Rest the injured person correctly. Give artificial respiration immediately if the person subject to the
accident stops breathing. In case of a circulatory collapse, give artificial respiration and apply
external heart massage immediately.
– Call a doctor right away.
2.7.3 Extinguishing hotmelt applicators on fire
– In case of a fire, use a CO2 extinguisher or dust extinguisher. Every person working on the
«Concept» hotmelt applicator must know the location of the next fire extinguisher.
Hotmelt applicators on fire must not be extinguished with water, otherwise
there is a mortal danger from electrocution. If no other medium but water is
available, the power supply to the appliance must be disconnected before
extinguishing.
Warnin Danger of burns

g On extinguishing the burning appliance with water there is an additional, in-
creased danger of burns from hot water vapours and splashes of hotmelt. Make
sure you observe the remarks on personal protection equipment in chapter 2.6.
3 Transport and scope of supply
3.1 Packaging
The Concept appliances are packed in a solid cardboard box:
Concept 4 Concept 8 Concept 12 Concept 18

Dimensions L×W×H [mm] 805 × 460 × 805 × 460 × 805 × 460 × 940 × 460 ×
670 670 670 670
Weight min. 40 kg* min. 50 kg* min. 60 kg* min. 65 kg*
* Weight of basic Concept appliance without accessories packed in same consignment
The handling symbols on the box must be observed:
Delicate
Do not djop
Instjume
nts
T Protect from Fragile Do not drop
o wet
Sensitive
p
appliance
Use only the original box for all transports.
3.2 Transport
Please observe the following points for transport:
– Transport the appliance carefully to prevent damage due to the application of force or careless loading
and offloading.
– Immediately after taking delivery, check the appliance for transport damage. Deficiencies must be
reported to Robatech immediately.
In case of transport after commissioning, watch the following points:

– The hotmelt applicator must not be packed or transported while it is still hot.
– Components which convey hotmelt material can only be dismantled in heated-up condition. Make sure
you observe chapters 8.2 and 8.3 in this context.
3.3 Scope of supply

– The scope of supply must be checked against the positions on the delivery documents. The delivery
papers are stuck to the top of the box.
– Missing items must be reported to Robatech immediately.
Concept / 4.1 Transport and scope of supply 17

4 Appliance overview and functions
4.1 Overview of the appliance
1. Appliance switch 14. Heated hose connection

2. Operating unit 15. Heated hose
3. Control electronics 16. Plug for heated hose
4. Power supply/electronic connection 17. Plug socket for application head
5. Tank lid
6. Melting tank Not described in this manual:
7. Heating elements 18. Application head
8. Feed pump 19. Heating part
9. Feed pump connection 20. Spray element
10.Coarse filter 21. Nozzle
11.Distribution block with drain 22. Valve
valve 23. Plug for application head
12.Filter cartridge
13.Plug sockets for heated hoses
4.2 Functioning of the appliance

After switching-on of the appliance, the hotmelt material in the tank is melted and heated up to
processing temperature. As soon as tank, heated hoses and application heads have reached their
temperatures, the feed pump is released for production, i.e. the pump can start feeding hotmelt.
The liquid hotmelt is drawn through the coarse filter into the feed pump and pressurized. The hotmelt
then flows through the fine filter to the heated hose connections and into the heated hoses which feature
the application heads at their ends. The hotmelt is applied to the product by spraying or airspraying.
4.3 Tank with distributor
1. Tank
2. Tank lid
3. Heating elements
4. Temperature sensor
5. Temperature limiter
6. Distributor block
7. Heated hose connections
8. Filter cartridge
9. Drain valve screw
10. Drain opening
4.4 Piston pump

The standard piston pump for the «Concept» appliances is of type HPC12 illustrated below. Two
further types, HPC5 and HPC16, are available to cover special requirements (see chapter 1.6, technical
data). Design and operation, however, are the same for all three types.
1. Piston pump
2. Fixation ring
3. Sight glass to check the stroke movement
4. Control electronics
5. Pressure gauge
6. Pressure controller
7. Compressed air connection
8. Cylinder
9. Type label with designation
10.Power supply connecting cable
Concept / 4.1 Appliance overview and functions 19

4.5 Operating unit
Actual operation of the appliance is by means of the operating unit. The temperatures, operating
stati, time switch clock and all appliance parameters are indicated/displayed and can be altered. All
functions are described in detail in chapter 6.
1 Appliance switch and the operating parameters. Light indication of the

selected function.
2 Light indications for the current operating
status. 6 LCD display showing the value of the function or
parameter selected in field 5. Light indications for
3 Light indications for the selected heating
zone. the units of measurement. Selection keys for
altering the values.
4 Selection keys for the heating zone and
heating zone number (if more than 1 heated
hose/head). LCD display of the heating zone
number.
5 Selection keys for the program functions
7 LCD display for the code of the
appliance status, the parameter
number or the current day of the
week. Light indication for the
selected function. Selection keys for
altering the values.
8 Switching on and off of temperature lowering
9 Switching on and off of the time switch clock
10 Operating field reserved for the
optional pattern control ICS-IH4x;
see the corresponding manual.
11 Operating field reserved for the
gear pump control; see the
corresponding manual.
4.6 Control electronics
The electronic control (ICS) of the «Concept» appliances is located under the operating front panel and cov-
ered. It is of a modular design and depends on the execution of the appliance.
4.6.1 Standard
Listed below are the electronic components of the standard version, i.e. without application control,
gear pump control, premelter heating and external operating unit:
ICS-MAIN Main control

ICS-TRM Operating unit
ICS-PWR1 Power control of tank heating
ICS-PWR2/2 Power control for 2 heated hoses
and application heads
ICS-PWR2/4 Power control for 4 heated hoses
and application heads
ICS-PWRD1 Single-phase power distribution
(only Concept 4/2 with 230 Volt)
ICS-PWRD 3 3-phase power
distribution 400 Volt
ICS-PSUP1 Power supply unit 24 Volt
with 40, 60 or 100 Watt power
4.6.2 Options
ICS-EXT1 Extension for the control of the
application heads / switch-off of
the heating zones
PROFIBUS Communication interface
ICS-PINT Control of the gear pump
ICS-TIM External installation of the TRM
panel at up to 100 metres distance
Dedicated operating manuals are available for all options.

4.6.3 Wiring diagram
For the electrical installation/structure the electric diagram in index 5 must be ob-
served.
Illustration in maximum execution for 8 heated hoses and application heads.

4.6.4 Specifications of the ICS-MAIN main control
1 Supply 20…28 VDC, max. 5 W (outputs without load)
2 Operating temperature 0…60° C, automatic switch-off at Ti >
65° C at 5…95% relative humidity of
air
3 Storage temperature –40…+85° C (avoid extreme temperatures!)
4 Number of tank heating zones 1 or 2 (with premelter)
5 Number of hoses/heads 2, 4, 6 or 8
6 Temperature sensors Robatech NTC
Monitoring of the sensor line for
interruption (R > 342 kOhm) and short circuit (R < 21 Ohm)
7 Resolution of temp. < 0.25° C
measurement
8 Accuracy of temp. feedback control Constancy < 0.5° C - absolute deviation depending on NTC
sensor
and its offset,
respectively.
9 Temperature range 20…230° C (tank: 210° C) setting range programmable
10 Activation of the heaters Pulse width-modulated output signal with 1.875 sec. period
duration (full wave control)
11 Order of heating up Programmable
All heating zones at the same time or sequential, order:
1. tank - 2. hoses - 3. application heads
Release of the heating zone in case of sequential heating if
one of the conditions below is met:
1. The reduced temperature of the heating zone is above
90° C and the heating zone's temperature is below the
reduced temperature by less than 10° C.
2. All preceding heating zones meet one of the following
conditions:
- Their temperature is below the nominal (setpoint)
temperature by less than 10° C, or
- the reduced temperature of the heating zone is above
90°C and its temperature is below the reduced
temperature by less than 10° C, or
- the heating zone is switched off.
12 Temperature lowering Lowered temperature programmable for each heating zone
Release of temperature lowering over keyboard, weekly
switch clock or input LOW-TEMP (X1/6) of the system
interface
Status message via output TEMP-LOW (X1/16) of the system
interface
13 Automatic switch-off in case of ma- Optional capture of the machine movements over input T-
chine standstill TRIGGER (X1/4) of the system interface or, if the
optional glue application control ICS-EXT1 exists, over the
release of glueing. Each edge on the input T-TRIGGER or
release of glueing (ICS- EXT1) resets the internal timer.
Impulse duration min. 9 msec.
The time until temp. lowering or switch-off is programmable.
14 System interface: outputs 4 DC-decoupled source outputs (PNP)
Status indication by LED - supply voltage: 11…
27 VDC Output current: max. 150 mA/output, short
circuit-proof Output voltage: supply voltage - 1.7
VDC
15 System interface: inputs 5 DC-decoupled inputs - status indication by LED
10…27 VDC, source (PNP), Rin = 2.7 kOhm
16 System interface: Power supply for the optional supply of the inputs and/or
outputs
Power supply output of the system interface = 24 VDC, Imax < 0.3 A
17 Temperature monitoring input Common for all heating zones
Input for temperature switch of heaters (no excess
temperature heating) Rin = 5.7 kOhm (24 VDC)
18 Release of airspray valve Input SSWITCH (X10/1, X10/2)
pos. signal - 20…27 VDC, Rin = 5.7 kOhm
19 Control of airspray valve Output SVALVE / TANH-EMPTY (twin function with tank fill
level output) switched on for as long as the input
«SSWITCH» is active and the appliance ready for
operation.
Output current: max. 0.5
A
Output voltage = supply voltage
20 Time switch clock operation (timer) Battery-buffered clock with weekly program
Up to two switching times can be programmed per day of
the week: Start of temperature lowering, start of normal
operation and switching-off of the appliance.
Optional switching-off of the time switch clock over control
input
P-ENABLE1 (X1/7a) of the system interface (parameter 27=
2).
21 Tank fill level supervision Inputs EMPTY-TANH, FULL-TANH
20…27 VDC, Rin = 5.7 kOhm
22 Tank fill level output Output SVALVE / EMPTY-TANH (twin function with airspray
valve control) is switched on for as long as the input signal
TANH- EMPTY is active. Output current: max. 0.5 A
Output voltage = supply voltage
23 Safety functions Monitoring of the correct program sequence with
"watchdog".
In case of error all outputs are switched off within 0.25
seconds and the program is restarted.
Monitoring of the logic supply voltage: all outputs are
switched off if the limit value is fallen short of.
Monitoring of the ambient temperature Ti with automatic
switching-off of all heaters at Ti > 65° C
Thermostat input with independent switching-off circuit
(switching-
off of the heating supply).
24 Pump emergency-off Connection for external contact
With open contact the supply to the pump is interrupted
directly. Contact load: 24 VDC, max. 0.8 A
25 Parameter storage EEPROM
26 Battery (clock supply) Lithium battery type CR 2430 - life span >10 years
5 Installation and first commissioning
The appliance must be installed and commissioned by a trained and experienced

technician. The information provided in this chapter must be read prior to
installation under all circumstances.
For all installation work, make sure you observe the safety references in chapter 2
and also the generally applicable safety and accident prevention prescriptions.
For all installation work on the heated appliance it is an absolute must to

wear clothes which cover arms and legs, as well as protective gloves and
pro-
tective goggles.
Proceed as follows for a successful installation:

• Remove the accessories from the cardboard box and put them to one side. Take the appliance from the
cardboard box and check all parts on the basis of the delivery documents.
• Open the tank lid and take out the wrapped, white cover plate. Remove the folder with the
Declaration of Conformity including the sticky tapes from the tank handle.
5.1 Place of positioning

The following requirements must be met:
– The appliance may be operated in sufficiently aerated rooms only
– Flat, stable positioning surface without vibrations
– Free-standing position to avoid an accumulation of heat
– Protect against humidity and splashing water
– The ambient temperature must be neither too high nor too low
– Provide sufficient space for optimal accessibility during operation and maintenance and for the
accessories.
Concept / 4.1 Installation and first commissioning 25

– The appliance must be bolted to the surface it is standing on. For this purpose it features four M8
fastening threads on its underside.
– Space requirement and dimensions:
Concept 4 8 12 1
8
Length A 545 680 680 806
Width B 310 310 385 385
Height Tank C 320 320 320 320
Height Unit D 601 570 570 570
Fastening E 381 432 581 646
Fastening F 249 249 323 323
Distance G 83 125 40 83
Fastening thread M8× M8×1 M8× M8×
15 5 15 15
Weight 34 44 kg 54 59
kg kg kg
All dimensions in [mm]
5.2 Installing the heated hoses
Warnin Danger of splashes and burns
g The hot adhesive within the system is pressurized up to 100 bar. On opening of
the pressure system there is a danger from hot splashes. Install heated hoses
only if the system has been relieved of pressure beforehand (see chapter 6.3)!
Always wear gloves and protective goggles!
• The heated hoses are connected to the

distributor block on the rear side of the
appliance. Up to 8 heated hoses can be
connected depending on the execution of the
appliance (see chap. 1.6).
• The hose connections are offset by 45° and
the different unions permit an optimal
adaptation on installation.
• Robatech recommends the use of heated hoses of
8 mm nominal diameter.
Heated hose connections
• A female thread 1/4" is available after

removal of the screw plug (1).
• A union (2) for connecting the heated hose
must now be screwed into this thread hole.
Unions are available in different versions (see
chapter 11.1).
• Next, screw the heated hose (3) with the end
fea- turing the cable with the connecting plug
onto the union.
Connecting the heated
hose
• Tighten the spigot nut with a fork spanner.
Don't tighten excessively! The delicate
heated hose must not twist, otherwise it will
be destroyed.
• Hold the heated hose firmly by hand or use e.g.
a second fork spanner to hold it in position.
Tightening the heated hose
Heated hoses are available in different executions and between 0.6 and 9.5 metres
long. You will find a complete list of all heated hoses, unions and other mounting
material under the accessories in chapter 11.1.
The heated hoses must not be laid in cable ducts or under covers without air circula-
tion. An accumulation of heat in certain sections damages the hose and the hotmelt.
5.2.1 Installation examples
Make sure you observe the following installation examples:
Wron Corr Remark

g ect
Strong bending must be
avoided.
Remedy:
Use an angled screw
connection.
Deflections present a danger of

kinking.
Remedy:
Use a saddle or a roller of a
suitable diameter.
Butted strains and movements in

the length axis as well as a
pendulum motions to the side
reduce the pressure
resistance.
Remedy:
Install the heated hose with a
bend. If the connections are
not in a straight line to the
heated hose, use suitably
angled screw connections.
Torsional strains will destroy
the heated hose.
Remedy:
The heated hose must run
parallel in its axis and the
course of movements must
not cause any torsional strains.
Wron Corr Remark
g ect
Pulling of rolled heated
hoses causes torsional
strains and the smallest
bending radius is not
complied with.
Remedy:
Unroll the heated hose
prior to pulling apart.
Too short a heated hose will

cause kinking at its ends.
Remedy:
A straight section of the
length of the hose's
diameter (x) must be
provided at both ends. The
minimum bending diameter
amounting to 8 times the hose
diameter must be complied
with.
Unfavourable installation
allows the hose to sag.
Remedy:
Support the hose with guide
elements or suspend it
over a roller.
5.2.2 Electrical connection
When connecting the heated hoses and the application heads please take note
of the chapter 12.1 - Power distribution and admissible loading. It guarantees a
equal power distribution on the three-phase mains.
The plug of the heated hose is plugged into the

numbered socket on the rear side of the
appliance. The plug of the application head is
plugged into the socket at the end of the hose.
Compensation factor
A ring with an indented number is located on the
connecting plug. This compensation factor must
be recorded in the list of parameters (in the
appendix of this manual) and programmed in the
appliance at a later stage (see chapter 6.9.6).
Heated hoses without a ring have always a
compensation factor of 8.2.
Connections at the heated hose
The plugs must not be pulled out or plugged in under load. Failure to comply might
damage the heated hose or the appliance.
5.3 Pneumatic connection

– The piston pump operates pneumatically and
must be supplied with compressed air at 6
bar.
– After removing of the cover the compressed
air hose with 8 mm outside diameter is
connected to the pressure controller.
– If another connection has to be used, a R 1/8"
connecting thread is available after removal of
the plugin connection.
The compressed air must be free of water and dust. No oiled compressed air may
be used. The oil would burn into the hot sliding surfaces of the piston pump and
thereby damage the pump.
5.4 Electrical connection
Mortal danger exists if live components are touched (operation voltage 400Volt).
The protective covers may only be removed if the appliance is disconnected
from the power supply.
Connection of the appliance to the power mains and other work on the power
circuit is reserved to suitably trained persons exclusively, e.g. electricians or
electrical fitters.
5.4.1 Checks prior to connection

• Check the voltage supply for compliance with the type label
230Volt single phase or 400 Volt 3-phase with neutral conductor
The appliance must not be connected to the mains supply if no neutral conductor
is available. In this case the neutral conductor must be created by a star circuit.
Make sure you contact Robatech Service before going ahead with this.
• Watch power consumption according to the type label.

Use a supply line of suitable line cross sections and fuses. Connect a main switch in series.
The appliance must be connected and fuse-protected in accordance with local

regulations. If the appliance is wrongly connected, there is a danger of
electrocution and the appliance might be destroyed.
• The electrical connection is made on the front

bottom of the unit on the orange terminal
block (1).
• Remove the cover (2) after loosening of the
two bolts (3) and pull out the cover plate (4) if
necessary.
• Place the end sleeves on the strands and
fasten them to the terminal block. At the orifice
the cable must be fastened with a cable tie (see
also chapter 5.5.5).
Terminal block connection assignment:

5.5 Higher-ranking system controls
The system interface on print ICS-MAIN permits to link the Concept appliance to a higher-ranking system
control which can monitor and check the functioning of the ICS control.
All inputs and outputs (except X10) are DC-decoupled from the control and wired over terminals.
5.5.1 Data
Outputs – 4 DC-decoupled source outputs (PNP) with a common supply
X1.13…X1.16 – Status indication with LED
– Supply voltage: 11…27 VDC
– Output currennt: max. 150 mA/output, short circuit-proof
– Output voltage: Supply voltage - 1.7 VDC
Inputs – 5 DC-decoupled source inputs with common 0V connection
X1.4…X1.7b – Status indication with LED
– 10…27 VDC, source (PNP), Rin = 2.7 kOhm
Power supply output – 24 VDC power supply for the optional supply of the inputs and/or
outputs of the system interface
– Max. load: Imax < 0.3 A
Tank fill level ouput – Only active if the optional tank fill level sensor exists and
TANH-EMPTY parameter 200: existence extra board ICS-EXT1 is put to OFF
– Twin function with spray valve output
– Status indication with LED
– 24 VDC, source, Imax < 0.5 A, short circuit-proof
Pump emergency-off – Connection for external emergency-off contact; with open contact the
P-EMOFF at X33 supply to the pump is interrupted directly
– Contact loading: 24 VDC, Imax < 0.8 A
5.5.2 Signals
The connection terminals are numbered and located at the bottom of control print ICS-MAIN.
X Designation I/O LE Function
1 D
1 0V Out Power supply 0 V
put
2 + 24 VDC Out Power supply 24 VDC
put
3 INPGND Inpu Common 0V connection of the inputs
t H-ENABLE, T-TRIGGER, LOW-TEMP and P-
ENABLE
4 H-ENABLE Inpu D16 If switched off and parameter 26 = On, all heaters
t are switched off
X1 Designation I/O LED Function
5 T-TRIGGER Input D 17 Standstill supervision, each edge (min. 9ms) resets the
su-
pervision
timer
6 LOW-TEMP Input D 18 Activation of temperature lowering
7a P-ENABLE1 Input D 19 If parameter 27 = 1 and input is switched off =
pump and optional pressure build-up valve are
switched off If parameter 27 = 2 and input is
switched on =
timer function switchs off and device switchs on
7b P-ENABLE2 Input D 30 no function
8 0V Output Power supply 0 V
9 + 24 VDC Output Power supply 24 VDC
10, 11 OUTGND Input Output supply 0 V
12 OUTVIN Input Output supply 12..24 VDC
13 ON Output D 23 Heaters released; inverse function of LED «0(off)»
14 READY Output D 24 Appliance ready for op.; same function as LED
«Ready»
15 ALARM Output D 25 Error; function like LED «Error» except for error
E102/E103
16 TEMP-LOW Output D 26 Temperature lowering active, same function as
LED «T low»
The connections 1+8, 2+9 and 10+11 are connected to each other in each case

1 D
0
1 SSWITCH Inpu D Release of the spray gun
t 22
put
put
4 SVALVE / Out D Tank fill level too low or activation of spray valve
TANH- put 29 (twin function!) Tank fill level display only active if
EMPTY the sensor exists and parameter 200 is set to
«OFF».
X11/X Designation I/O LE Function

12 D
put
put
3 EMPTY- Inpu D if input is switched on = Tank empty
TANH t 20
4 FULL-TANH Inpu D if input is switched on = Tank overcharged
t 21

2 D
3
put
put
3 PAR- Inpu D31 not active
LOCHED1 t
4 PAR- Inpu D32 if parameter 32 = «1 or 2» and input is
LOCHED2 t switched on = Blockage of data entry
X Designation I/O Function

3
3 LED
1 P-EMOFF1 Output Connection for an external emergency pump stop.
2 P-EMOFF2 Input Open contacts interrupt the 24VDC supply to the
pump drives.
5.5.3 Connection of PLC control
– Fuse 1AF Part No.111202; supplier e.g. Schurter type SP 0001.1004
– If activation is effected by a PLC control, the voltage supply of the PLC control must be wired to
print ICS- MAIN.
– GND of the PLC control is put on terminal X1, connection 10, the switching voltage of the PLC
control is put on terminal X1, connection 12.
– All connections on terminal X10 are not potential-segregated. Optocoupler or relay contact must be con-
nected in series under all circumstances.
– For wiring, please observe the remarks concerning electromagnetic compatibility (EMC) in chapter 5.5.5.
5.5.4 Connection of relay control
– If activation and evaluation are effected over relay contacts without potential, the voltage required
for switching can be obtained from connection 2 on terminal X1. In this case the connections 8 and 10
as well as 9 and 12 on terminal X1 are to be connected.
– All connections on terminal X10 are not potential-segregated. Optocoupler or relay contact must be con-
nected in series under all circumstances.
– For wiring, please observe the remarks concerning electromagnetic compatibility (EMC) in the next
chapter.
5.5.5 Wiring in compliance with EMC
The electromagnetic compatibility or abbreviated EMC refers to the ability of an appliance to correctly
operate in an environment with other electrical devices without itself generating any interferences. Correct
wiring of the control lines is an important part of this. Please observe the following points:
The appliance must be separated from the power mains before any connecting
cables are connected. Touching of live components means mortal danger.
• Use only shielded cables which are skinned as

illustrated on the right. The dimension X
depends on the position of the terminal.
Stripped connecting cable
• The cable is fed through the base plate into the

electrical cabinet.
• The free line shield is connected to the
appliance housing by means of a cable tie.
• The line shield must be earthed at the cable's
beginning and at its end. This is the only way
in which an attenuation of the electromagnetic
interference fields is provided. A shield
connected on one side only offers only poor
shielding, and a shield which is not connected
at all suppresses no interference fields.
Suitable EMC cable connection
5.6 Installation of accessories and options

Normally, accessories and options are installed at the Robatech works before the appliance is delivered.
How- ever, subsequent installation is also possible. The installation and operation of accessories and
options such as
– application control ICS-IH incl. control accessories like encoder, photoelectric cells, valve cables, etc.
– external installation of the operating unit
– gear pump
– tank fill level supervisions
– pressure relief
are described in the pertaining manuals. A detailed overview of the accessories can be found in chapter 11; Ac-
cessories.
5.7 First commissioning
To be able to work safely and perfectly and to avoid bodily and material damage,
the appliance must be in impeccable condition. The following items must be
checked prior to first commissioning:
• Fit the warning stickers in the local language. In standard execution the appliance is delivered with
warning labels in German. The plastic folder contains labels in English and French. The ones in the
appropriate language can be stuck over the existing labels.
• Adapt the tank lid if necessary. For optimal accessibility the tank lid can be turned by 180 degrees.
Unscrew the stop plate and press the securing ring off the shaft using a screwdriver. Remove the tank
lid and install it on the opposite side.
• Are power connection and all electrical connections correctly installed?
• Compressed air available and connected to the piston pump? Set the pressure controller to 0 bar.
• Heated hoses correctly fitted and application systems (application head, hand gun, etc.) installed in
accordance with the pertaining instructions? Are all glue exits locked which are not used?
If all above points are complied with, the appliance can be switched on for a short test run:
• Switch the appliance on. All indications must light up for two seconds and the display at the bottom
right shows the program version. Check the program version for concurrence with this operating
manual.
• If no temperatures are programmed yet (standard setting) LED «Ready» will then be lit. If temperature
values are already entered, LED «Tr<Tn» is lit and the display «A2 - nominal temperature not reached»
comes up.
• Next, switch the appliance off again. Programming of the appliance and the functions for production are
described in the next chapter, 6. Operation.
After initial heating of the appliance, the tensioning nut of the piston pump must be
tightened using a hook spanner (see also chapter 8.3.2).
The decision whether or not the system is ready for operation is reserved to
persons who have received the appropriate training and who are suitably
authorized.
6 Operation
If it must be assumed for any reason that operation without danger is not
assured, you must not switch on the appliance.
Make absolutely sure you comply with the safety instructions in chapter 2 before
you put the appliance in operation. The information on possible dangers in the
operation of the appliance, on the procedure in case of an emergency and on
training of the personnel are particularly helpful to operate the appliance safely.
6.1 Filling in hotmelt

Caution Danger of burns
Contact with the heated adhesive results in burns (temperatures up to
230°C/446°F). If a contact with hot hotmelt material is possible, it is an absolute
must to wear heat- resistant protective gloves.
• Fill the tank up to the tip of the red filling mark
maximum. The hotmelt expands during heating
up and might overflow if you don't comply.
• The melting ribs at the tank base must always
be covered with hotmelt.
• N e v e r ever mix two different types of hotmelt
material. If the type of hotmelt must be changed,
the hotmelt system must first be cleaned (see
chapter 7.5) before the new type of hotmelt is
filled in.
Vapours escape on heating up of the hotmelt. The emissions depend on the type of hotmelt. The tank lid
must remain closed if possible. Possible evaporations are reduced by the lowest possible tank temperature
and a high fill level. Observe the data sheet of the hotmelt producer in any case. It will tell you if the
vapours are a health hazard and if protective measures are required.
6.2 Switching on and off

Switching-on The appliance is switched on with the green appliance switch next to the operating unit.
After switching-on, all indications light up for two seconds and the installed program version is displayed.
Afterwards, the operating unit indicates the current operating status (see chapter 6.5) and the appliance
starts heating. As soon as all heating zones have reached their nominal temperatures, the entered waiting
time (parameter 31) is run down and no error has appeared, the device is ready for operation and the
display «Ready» lights green. The piston pump is released for production now.
With a full tank it takes approx. 45…90 minutes before the hotmelt material is
melted down and the appliance is ready for operation.
Switching-off: It is done with the main switch. The hotmelt material solidifies as the appliance cools down.
The appliance can be stored over a longer period of time without any problems.
Concept / 4.1 Operation 39

6.3 Setting the feed quantity I glue pressure
• The piston pump starts only to operate if the green LED «Ready» lights in the appliance status display.
There- fore all heating zones must have reached their programmed nominal temperatures and no errors
have appeared. Take note of the status messages on the operation unit (see chapter 6.6).
• The feed quantity is determined by the
pressure at the piston pump. The set pressure
can be read off the pressure gauge.
• To arrive at the hotmelt pressure, the value
shown by the pressure gauge must be
multiplied by the transmission factor of the
piston pump. Example: Pressure gauge
indication 2 bar with piston pump HPC12
results in a hotmelt pressure of 2 × 12 bar =
24 bar.
• To adjust, pull out the rotary knob. After the
pressure setting is made the knob must be
locked again by pressing inwards.
Piston pump with pressure gauge and rotary knob
6.4 Draining the system pressure

Warnin Danger of splashing and burns
g The hot adhesive in the lines (temperatures up to 230°C/446°F) is under high
pressure up to 100 bar. If the pressure system is opened not appropriate
there is a danger of hot splashes occurring.
All machine operators must be able to reliably drain the system pressure. The pressure must be drained
prior to all maintenance and repair work, but also after disturbances and defects. The reference label above
the distributor describes the correct procedure.
• Switch off the appliance at the appliance

switch and set the pressure controller at the
piston pump to 0 bar. Pressure gauge
indication 0 bar.
• Place a temperature-resistant container under
the drain opening (1) at the distributor block.
• Wear protective gloves and protective goggles!
• Carefully open the drain bolt (2) - hotmelt
must flow from the drain opening. The glue
pressure is completely relieved when no
more hotmelt flows out.
Distributor block with pressure drain
6.5 Operating concept
Actual operation of the appliance is effected by means of the operating unit
– All set values are maintained after switching off
- no special storage is required.
– An access blockage protects all inputs against
unintentional and unauthorized changes.
– Normally, the basic settings of the appliance
are made by Robatech. In this case the
programmed values are already recorded in the
table of parameters in register 6 of this
manual.
6.5.1 Overview of the appliance functions
The two selection keys serve to first select the

appliance function which is to be
indicated/displayed or changed. The following
functions can be selected:
Display Function
Display the real temperature of tank, heated hoses and application heads (see chapter
6.8).
Display and alter the nominal temperature of tank, heated hoses and application
heads (see chapter 6.8).
Display and alter the lowered temperature of tank, heated hoses and application
heads (see chapter 6.12).
P Display the heating output of tank, heated hoses and application heads. Unit of
measurement are % of the maximum heating output (see chapter 6.8.3).
Display and alter the clock time and day of the week (see chapter 6.10).
Display and alter the switch-on times (see chapter 6.11)

Display and alter the switch-off times (see chapter 6.11)
Display and alter the temperature lowering times (see chapter 6.12.3).
Select the feed quantity. Only with gear pump. See pertaining manual.
Display the pump speed (revs.). Only with gear pump. See pertaining manual.
V Display the machine speed. Only if encoder with gear pump or application control
are installed. See pertaining manuals.
Display the operating hours. The display shows units of 1,000 hours.
Parameter Select and alter parameters (see chapters 6.9).
6.6 Appliance status
The general operation status is indicated by LEDs as
soon as the appliance is switched on. The displays be-
low show the corresponding status code.
Rea The appliance is ready for operation.

dy
The appliance is in the heating-up phase - the nominal temperatures are not yet
reached.
Erro An error occurred. The error number is displayed in the right bottom display (see chapter
r 6.6.3). If the error originates from a heating zone, the corresponding LED flashes
additionally in red and the number of the heating zone is displayed.
0 The control is switched off. The code for the possible cause comes up in the left
(off) bottom display
(see chapters 6.6.1 and 6.6.2).
Temperature lowering is activated.
The tank is empty «| |» or filled «| |». Display only if optional fill level sensor exists).
6.6.1 Overall status

Displ Cause
ay
A2 Heating-up phase
A3 Temperature lowering activated via operating unit
A4 Temperature lowering activated via 'LOW-TEMP' (X1/6)
A5 Temperature lowering activated via the weekly switch clock
A6 Temperature lowering due to exceeding of the standstill time defined in parameter 24
A7 Appliance switched off via release input 'H-ENABLE' (X1/4)
A8 Appliance switched off due to exceeding of the standstill time defined in parameter 25
A9 Pump and pressure-buildup valve switched off via 'P-ENABLE' (X1/7)
A10 Nominal temperature exceeded by more than 12°C
A11 Only with gear pump. Pump switched off via operating unit.
A12 Pump switched off via external emergency-off contact 'P-EMOFF' (X33/1 and X33/2
interrupted)
A15 Waiting for expiry of the tank melting time defined in parameter 31
A16 Appliance switched off via time switch clock
A17 Gear pump: Manual operation mode is activated. Hey is lit
A18 PROFIBUS: Parameter 400 = On and no communication with bus master
A19 Control ICS-EXT1: Manual application mode is activated. Hey is lit
A90 Service message «Check filter cartridge», see in chapters 7.3 and 7.4
In default mode after 600 operating hours, time duration adjustable in
parameter 71 Resetting of the message in parameter 70
A91 Service message «Clean complete system», see in chapter 7.5
In default mode after 3,000 operating hours, time duration adjustable in
parameter 72 Resetting of the message in parameter 70
A92 Service message «Freely adjustable service message», in default mode
switched off Time duration adjustable in parameter 73, resetting of the
message in parameter 70
6.6.2 Heating zone status
Displ Cause
ay
H1 Heating zone switched off internally
H2 Heating zone switched off due to error in another heating zone
H3 Heating zone switched off by weekly switch clock
H4 Heating zone switched off due to exceeding of the standstill time defined in parameter
25
H5 Heating zone switched off via control input
H6 Heating zone switched off due to order of heating up
H7 Temperature lowering activated via control input
H8 Temperature lowering activated via operating unit
H9 Temperature lowering activated via weekly switch clock
H1 Temperature lowering due to exceeding of the standstill time defined in parameter 24
0
H1 Nominal temperature not reached
1
H1 Nominal temperature reached
2
H1 Nominal temperature exceeded by more than 12°C
3
H1 Heating zone switched off via ICS-EXT1 control inputs
4
H1 Premelter switched off by tank fill level sensor (only if options installed)
5
6.6.3 Heating zone and system errors

– If the error originates from a heating zone, the corresponding LED flashes in red and the number of the
heating zone is displayed.
– All heaters are switched off if the errors E01…E06 occur.
– The errors E01…E06, E08, E100 and E101 remain stored until the unit is switched off.
Displ Cause
ay
E01 Temperature limiter opened
E02 Temperature sensor line interrupted
E03 Temperature sensor line short-circuited
E04 Temperature too high. More than 12° C above the top temperature limit defined in
parameter 30
E05 Insufficient heating. Temperature rise is less than 5° C within 10 minutes. Possible causes:
Fuse defective, heater defective, sensor not in contact with heating, etc.
E06 Temperature inside appliance too high
E07 EEPROM write error (remedy: reset parameters to default values or exchange print
MAIN)
E08 Outputs of system interface X1 or X8…X10 overloaded
E09 Glue tank full
E10 Battery voltage too low
E11 Clock time invalid
E10 Control ICS-EXT1: Valve outputs overloaded
0
E10 Control ICS-EXT1: Outputs of the system interface overloaded
1
E10 Control ICS-EXT1: Glue pattern cleared due to lengths or intervals being too short
2
E10 Control ICS-EXT1: Speed (velocity) > Vmax
3
E30 Gear pump: Pump speed (revs.) too low (overload)
0
E30 Gear pump: Pump nominal speed (revs.) higher than rated speed (revs.)
1
E Gear pump: Error on the AC frequency converter (Note the error message on the
302 converter)
E PROFIBUS-DP interface: Error in the parameterization
400
E PROFIBUS-DP interface: Error in the configuration
401
E PROFIBUS-DP interface: Parameter value outside of the input range
402
6.7 Access blockage
To prevent unintentional or unauthorized alteration of the data, all values can only be altered after the access
blockage has been lifted. On alterting of the values the display shows «Loc1» or «Loc2».
Lifting «Loc1» Lifting «Loc2» Activating the access

blockages
Press these keys simultaneously: Press these keys simultaneously: Press these keys simultaneously:
– Lifting Loc2 lifts always Locl too.

– The access blockage is activated automatically if no key is actuated within two minutes.
– The data access can also be blocked via a key switch (see parameter 32).
– If the PROFIBUS board is installed, the access blockage LocE is displayed. The data input via operating
unit is blocked. To lift LocE set parameter 400 to OFF (see also Profibus manual).
6.8 Setting and checking the temperatures

The temperatures of the tank and of each individual heated hose and application head can be programmed
with an accuracy of 1° C within a range from 20…230° C (tank 210° C).
– Parameter 23 (see chapter 6.9.10) defines the temperature unit of measurement in ° Celsius or °
Fahrenheit.
– Parameter 30 (see chapter 6.9.17) defines the top temperature limit.
6.8.1 Displaying temperatures

• Select function Treal by means of the keys (1).
• Select the desired heating zone: tank, heated hose
or application head with the keys (2). The
corresponding LED (5) is lit.
• Additionally in the case of the heated hose and
the application head, the number has to be
selected with the keys (3). The selected heated
hose or application head number is shown in
the display (4).
• The display (6) shows:
– the actual temp.of the heating zone in °C or °F
– OFF if the heating zone is switched off
– a heating zone error E XX
• The display (7) shows the status of the heating
zone (see chapter 6.6.2 Heating zone status).
6.8.2 Capturing the temperatures
The temperature values are protected by the access blockage «Loc1» (see chapter 6.7).
If no heated hose or application head is connected, it is an absolute must that the corresponding heating zone is
switched to the OFF position.
• Select the function Tnominal with the keys (1).
the application head, the number must be
the display (4).
– the detected temperature in °C or °F
– OFF if the heating zone is switched off
• By means of the keys (7) the value is altered:
– the input range is 20…230° C (tank 210° C)
– OFF switches the heating zone off
To simplify the input it is also possible to set the temperatures jointly for all heating zones:
Condition: The heating zone must not be switched off with OFF.
• Select the heated hose or the application head with the keys (2).
• Select the value «A» in the display (4) by means of the keys (3).
• Determine the temperature of the active heating zones with the keys (7). After leaving the data input the
tem- paeratures are assigned as follows:
Heating zone Temperature setting
Tank Input value
Heated hoses Input value + value in parameter 20 (see chapter 6.9.7)
Application Input value + value in parameter 21 (see chapter 6.9.8)
heads
6.8.3 Checking the heating output

• Select function P with the selection keys (1).
the application head, the number must be
the display (4).
– the output of the heating zone in percent of
the maximum heating output.
6.9 Entering parameters
The basic settings of the appliance are made by means of the parameters.
6.9.1 Before you alter parameters

Answer the questions below and alter the parameters only if you can answer the questions with YES.
Adhere to the order in which the questions are listed.
Question Paramet Basic

er value
Check first the number of heated hoses / application heads that can be applian
28
connected. Works setting! → Chapter 6.9.15 ce
specif
ic
Have you installed a new heated hose or application head and/or have
1…18 8.2
you not yet entered the compensation factor of a temperature sensor? →
Chapter 6.9.6
On entering of all temperatures (tank, all heated hoses and application
heads), do you want to alter the basic settings with one single 20 10 [°C]
temperature entry? → Chapters 6.8.2, 6.9.7, 6.9.8
Tank temperature = entry value / Heated hose temperatures = entry 21 15 [°C]
value +
parameter 21 / Application head temperatures = entry value + parameter
22
Do you want to alter the standard sequence of heating up, i.e. first tank,
then hose and then head, to all heaters simultaneously? Alterations 22 1.2.3.
only after consulting the Robatech customer service department! →
Chapter 6.9.9
Do you want to change the unit of measurement for the temperatures
23 º Celsius
from
° Celsius to ° Fahrenheit? → Chapter 6.9.10
Do you want to automatically activate temperature lowering over the
OFF
machine interface input T-TRIGGER, after the time defined here, 24
(no function)
without input signals? → Chapter 6.9.11
Do you want to automatically switch off the appliance over the machine
OFF
interface input T-TRIGGER, after the time defined here, without 25
(no function)
input signals?
→ Chapter 6.9.12
Do you want to be able to switch all heaters on and off over the OFF
26
machine interface input H-ENABLE? → Chapter 6.9.13 (no function)
Do you want to switch the feed pump on and off over the machine
OFF
interface input P-ENABLE, or do you want to use it for switching the 27
(no function)
time switch clock on and off (timer functions)? → Chapter 6.9.14
OFF
Is an optional premelter attachment fitted in place? → Chapter 6.9.16 29
(no
Premelter)
Should the basic setting of the maximum nominal temperature be
30 210º C
altered?
→ Chapter 6.9.17
For how much longer should the tank be heated after reaching of its
nominal temperature (melting of the entire tank content) until heating of 0.30
31
the hoses is released? Note: Order of heating up under parameter [hh.min]
22 must be 1.2.3. → Chapter 6.9.18
Should the machine interface input PAR-LOCHED2 be used as data
32 OFF
input blockage? → Chapter 6.9.19
Should the works setting for the activation of the tank melting time
85 [%]
(parameter 33
of Tnominal
31) be altered? Alterations only after consulting the Robatech customer
service department! → Chapter 6.9.20
Question Paramet Basic
er value
Do you want to reset a service message «A90, A91 or A92»? → 70
6.9.21
Do you want to alter the number of operating hours until display of the
71 600
service messages «Check filter» and «Clean complete system»? (not h
72
recommended) → 3'000
6.9.22 and 6.9.23 h
Do you want to define an own service message in dependence of the
73 OFF
operating hours? → 6.9.24
6.9.2 Capturing the parameters

Access blockage Loc2 protects the parameters against unintentional or unauthorized alteration (see chapter 6.7).
It is an absolute must to record all parameters in the table of parameters in the

register 6 in this file.
The parameters are captured as follows:
• Select the function parameter with the

selection keys (1).
• The display (2) shows the parameter number
selected with the keys (3).
• The LEDs (4) and the display (5) confirm the
selected parameter optically to some extent.
• The display (6) shows the set value. After
lifting of the access blockage the value is set
with the keys
(7) and memorized automatically.
6.9.3 Saving the program settings
All entered settings and the 87 programs of the
pattern control ICS-IH4x are stored.
• Switch the appliance off.
• At the same time press the two marked keys and
switch on the appliance again. Hold the two keys
pressed during at least two seconds until
«2222» is shown in the display.
• All data are now stored and can be reloaded
after possible alterations (see next chapter).
6.9.4 Loading the program settings

After wrong revisions, for example, all data can be
put back again to the saved settings (see chapter
6.9.3).
• At the same time press the two marked keys and
switch on the appliance again. Hold the two keys
pressed during at least two seconds until
• The stored settings and the 87 programs of the
pattern control ICS-IH4x are loaded again.
6.9.5 Putting back the program to the default setting

All program settings can be put back to the default
value, the basic value of the ICS-control. All
recorded data, even the saved program settings are
deleted with it.

• At the same time press the four marked keys
and switch on the appliance again. Hold the four
keys pressed during at least two seconds until
• All recorded values are deleted and the basic
settings of the control are valid now.
In case of a program update or repeated write error in the memory (error E07) it may be necessary to
reset the data.
6.9.6 Parameter 1…18: Compensation factors
The compensation factor serves to correct the tolerance of the electronic temperature sensors. These factors must be
captured for the temperature feedback control of the appliance to function perfectly. The factor in question is
indented in a disc at each heated hose and application head. The value at the temperature sensor of the tank
has been set at the works. When there is no ring on the hose or head, the factor is always 8.2.
Paramet Heating zone Paramet Heating zone

er er
1 Tank (works setting) 1 Heated hose 5
2 Heated hose 1 0
3 Application head 1 1 Application head 5
1
4 Heated hose 2
1 Heated hose 6
5 Application head 2
2
6 Heated hose 3 1 Application head 6
7 Application head 3 3
8 Heated hose 4 1 Heated hose 7
9 Application head 4 4
Input Function Defa
range ult
1.0…9.0 Compensation factor of the selected heating zone 8
.
2
6.9.7 Parameter 20: Temperature differential tank - heated hoses

On entering of a joint temperature for all heating zones (see chapter 6.8.2), the heated hose temperatures
are set to «Input value + parameter 20».
Input U Function Defa

range ni ult
t
0…50 [° 10° C
Temperature differential tank – heated hoses
C
]
0…90 [° 18° F
F]
6.9.8 Parameter 21: Temperature differential tank- application heads

On entering of a joint temperature for all heating zones (see chapter 6.8.2) the application head
temperatures are set to «Input value + parameter 21».

range ni ult
t
0…50 [° 15° C
Temperature differential tank – application heads
C
]
0…90 [° 27° F
F]
6.9.9 Parameter 22: Heating-up order

The order of heating up of the heating zones is programmable.
Attention: The standard, sequential heating up order avoids extreme pressure peaks in the system. Only
change this setting after a consulation to the Robatech service!
Input Function Default
range
1.1.1. All heating zones are heated up simultaneously.
1.2.3.
1.2.3. Sequential order: 1st: tank - 2nd: heated hoses - 3rd: application
heads
6.9.10 Parameter 23: Temperature - unit of measurement
range
C Unit of measurement: Celsius
C
F Unit of measurement: Fahrenheit
6.9.11 Parameter 24: Standstill supervision, time until temperature lowering

If no edge is registered on the input T-TRIGGER (X1/5) or TRIGGERx of the extra board ICS-EXT1
during the time programmed in parameter 24, temperature lowering is activated until edges are registered
again or key is pressed.

range
OFF Function switched off
OFF
0.05… Time in [hours.minutes] until temperature lowering is activated
10.00
6.9.12 Parameter 25: Standstill supervision, time until switch-off

If no edge is registered on the input T-TRIGGER (X1/5), TRIGGERx of the extra board ICS-EXT or H-
ENABLE during the entire time programmed in parameters 24 and 25, the appliance is switched off until
edges are registered again or key is pressed.

range
OFF Function switched off
OFF
0.05… Time in [hours.minutes] until switching-off is activated
10.00
6.9.13 Parameter 26: Activating the input H-ENABLE

If the input H-ENABLE is activated, the appliance is switched off if the input signal (0V) is missing on
the input X1/4.

range
OFF Input H-ENABLE blocked
OFF
On Input H-ENABLE activated
6.9.14 Parameter 27: Configuration of input P-ENABLE1

range
OFF Input P-ENABLE1 at X1/7a is blocked
1 Pump release: The pump as well as the optional pressure buildup
valve are switched off in case the input signal on the input OFF
(X1/7a) is missing.
2 Switching off of the weeky switch clock (timer): If the input signal
is present on the input (X1/7a), the weekly switch clock is
switched off and the appliance is switched on independently of
the weekly program.
6.9.15 Parameter 28: Number of heated hoses I application heads
Input depends on the number of available connections on the back of the unit. For example Concept 4 / 8 (see
nameplate) = 8. By this parameter not used connectors can be switched off.
Input Function Defa

range ult
1…8 Number of connectable heated hoses and application heads 2
6.9.16 Parameter 29: Configuration of tank heating 2 (Premelter)

range
OFF Optional Premelter not existing
1 No function in Concept appliances
2 Optional Premelter existing. The heating zone is released for as OFF
long as the signal TANH-EMPTY from the optional tank fill level
sensor is present.
6.9.17 Parameter 30: Maximum nominal temperature

range ni ult
t
20… [° 210° C
Maximum value for all temperature settings
230 C
]
68… [° 410° F
446 F]
All heating zones are switched off automatically if this maximum temperature is ex-
ceeded by more than 12°C or 54°F. It appears error message «E04».
6.9.18 Parameter 31: Waiting time after reaching of the tank nominal temp.
After reaching of the tank's nominal temperature, expiry of the time defined here is awaited to melt down the
entire tank content; status message «A15» comes up in the display. Only then are the other heating zones
released.
Input range Function Defa

ult
0.00…10.00 Waiting time in [hours. minutes] 0.
30
6.9.19 Parameter 32: Configuration of access blockage PAR-LOCKED2

The input blockages «Loc1» and/or «Loc2» can be activated by means of a key switch at the input
PAR- LOCHED2. With switched-on input the access is blocked, with switched-off input the access
blockages as per chapter 6.7 can be removed.

range
OFF Input PAR-LOCHED2 inactive, no blockage via key switch
1 The access to all with «Loc2» protected data is blocked. OFF
2 The access to all with «Loc1 and Loc2» protected data is
blocked.
6.9.20 Parameter 33: Melting time activating temperature
If the tank temperature drops below the value defined here (i.e. in case of a temperature reduction),
the tank melting time defined in parameter 31 is activated automatically and the feed pump is blocked.

range
30… Activating of the melting time in [%] of the nominal tank 8
95 temperature 5
6.9.21 Parameter 70: Resetting of the service messages A90…A92

On completion of the work the counter of operating hours for the service messages A90 to A92 is reset with pa-
rameter 70. After entry of the reset code, resetting must be confirmed with the key or .

range
1794 Resetting of the service message «A90 – check filter»
233 Zurücksetzen der Servicemeldung «A91 – clean complete 0
system»
97 Zurücksetzen der Servicemeldung «A92 – free service message»
6.9.22 Parameter 71: Operating hours until «Check filter»

ult
200…1,000 Number of operating hours until the service message «A90 – check
6
filter» is displayed. Make changes only after consulting 0
Robatech. 0
6.9.23 Parameter 72: Operating hours until «Clean complete system

ult
1,000…9,999 Number of operating hours until the service message «A91 – clean
3'0
complete system» is displayed. Make changes only after consulting 00
Robatech.
6.9.24 Parameter 73: Operating hours until «Free service message»

range
OFF No freely definable service message
«A92» O
1…9,999 Number of operating hours until the messa «A – fr servi F
service message» is displayed. ge 92 e ce F
e
6.9.25 Parameter 80: Temperature inside the appliance
Display of the current temperature inside the appliance. All heaters switch off automatically if the temperature
exceeds 65° C / 149° F. It appears the error message «E06».
6.9.26 Parameter 81: Standstill time

Display of the time [hours. minutes] since the last edge on input T-TRIGGER (X1/5), or the last release of
glueing if the optional application control ICS-EXT1 exists.
6.9.27 Parameter 82: Battery voltage

Display of the battery voltage in Volts for the internal clock. The minimum is 2.6 Volt ± 5%. If this is
fallen short of, the battery must be replaced. It appears the error message «E10».
6.9.28 Parameter 90: Applied program

Display of the applied program: 1 = ICS-MAIN (Concept) , 2 = ICS-JUMBO, 3 = ICS-RMC
6.9.29 Parameter 91: Program version

Display of the program version [X.YY].
6.9.30 Parameter 200: Existence of extra board ICS-EXT1

range
OFF Extra board ICS-EXT1 not existing or no evaluation of the
inputs H-ENABLE1…3 on the EXT1 board
OFF
On Extra board ICS-EXT1 existing and evaluation of the
inputs H-ENABLE1…3 on the EXT1 board
6.10 Querying and setting the clock time
The Concept appliance features an internal, battery-buffered clock. Apart from displaying the current clock
time and the day of the week, it permits to:
– automatically switch the entire appliance on and off (see chapter 6.11 Time switch clock)
– automatically lower the operating temperatures (see chapter 6.12 Temperature lowering)
The clock time is queried and set as follows:

• Select function with the selection keys (1).
• The display (2) shows the current clock time in
hours and minutes.
• The display (4) shows the current day of the week;
e.g. 1 = Monday, 2 = Tuesday, etc.
• After lifting of access blockage Loc2 the
current clock time is set with the keys (3) and
the day of the week with the keys (5).
6.11 Time switch clock
The time switch clock permits to switch the appliance on and off on each weekday at up to two different
times.
• Select the function for entering the switch-on

times or for the switch-off times with the
selection keys (1).
• Display (2) shows the day of the week on which
the time is to be set. With the keys (3) you
select the corresponding day. The selection
possibilities are listed in the table below.
• Display (4) shows the switch-on or switch-off

time. After lifting of access blockage Locl the
corresponding time is set with the keys (5). In
case of display «----» this time circuit is
inactive.
• After entering of the switch-on or switch-off
times it is necessary to activate the time circuit
with key (6). The green LED is lit.
Overview of the weekdays and switching times
Display Description
X.1 The first switching time on any arbitrary weekday X [1…7]
X.2 The second switching time on any arbitrary weekday X [1…7]
A.1 The first switching time from Monday to Friday (1…5)
A.2 The second switching time from Monday to Friday (1…5)
F.1 The first switching time on Saturday and Sunday (6+7)
F.2 The second switching time on Saturday and Sunday (6+7)
By selecting A or F it is possible to put the switching times of several days to the same value by
means of just one entry. This simplifies entering; the specific switching times can be corrected
individually afterwards.
For your own benefit, please record the set switching times in the list of parameters
in register 6 in this file.
The time switch clock can be switched off via input P-ENABLE of the system
control. See also chapter 5.5, Higher-ranking system control and chapter 6.9.14,
Parameter 27.
6.12 Temperature lowering
The quality of the hotmelt is impaired by constant heating at high temperatures. This is why the temperature
must be lowered whenever the appliance is not used for some longer period of time such as e.g. for setup
or maintenance work on the machine on which the Concept appliance is installed (not on Concept itself).
The appliance is ready for operation again soon after temperature lowering is switched off.
6.12.1 Determination of the lowered temperatures

After selection of function ' ' , a specific lowered temperature can be assigned to each heating zone.
The lowered temperature is entered in exactly the same way as the nominal temperature, as described in
detail in chapter 6.8.2, Capturing the temperatures.
The ideal lowered temperature depends on the adhesive and must be determined
by trial. Please note that at a lowered temperature of less than 85% of the
nominal temperature (parameter 33), the waiting time in parameter 31 is
activated automatically.
6.12.2 Manual switching-on of temperature lowering

• Lowering of the temperature can be switched
on manually.
• After lifting of access blockage Loc2 the function
is switched on by pressing of the key shown on
the right.
• The LED on the key and the corresponding key
in the status display are lit and the feed pump
is blocked.
6.12.3 Temperature lowering over weekly switch clock

Activating of the temperature lowering:
The time switch clock permits to switch on temperature lowering on each day of the week at up to two
different times. The times can be assigned after selection of function ' . The entry is made in
exactly the same way as switching-on of the appliance over the time switch clock (see chapter 6.11).
Display Description
X.1 The first switch-on time on any arbitrary weekday X [1…7]
X.2 The second switch-on time on any arbitrary weekday X [1…7]
A.1 The first switch-on time from Monday to Friday [1…5]
A.2 The second switch-on time from Monday to Friday [1…5]
F.1 The first switch-on time on Saturday and Sunday [6+7]
F.2 The second switch-on time on Saturday and Sunday [6+7]
Deactivating of the temperature lowering:

To switch back to the normal operation mode, the appliance must be switched on via time switch clock .
Temperature lowering can also be switched on over the input LOW-TEMP of the
system control. The status message is provided over the output TEMP-LOW.
See also chapter 5.5 – Higher-ranking system control.
7 Maintenance
This chapter describes the most important checks and jobs required for a trouble-free operation. Carrying out the
described maintenance work guarantees a long service life and an operation without disturbances.
In case of maintenance problems please get in touch with your nearest Robatech
service company. You will find the addresses in the register «Communication».
7.1 References
Warnin Danger of injury or material damage
g The appliance may only be maintained by the authorized and trained service
technician. Apart from the remarks in this chapter, the prescriptions in chapter
2 must be complied with.
Warnin Danger of burns and splashes

g Maintenance work is carried out at operating temperature (up to 230°C/446°F).
A danger of burns exists if you touch appliance components which are not
covered and in case of contact with the hot adhesive. The hot adhesive in the
lines is highly pressurized. In case of inappropriate opening of the pressure
system there is a danger of injury from hot splashes. Correct drainage of the
system pressure is described in chapter 6.4.
Protective goggles and heat-resistant gloves must be worn under all

circumstances for all maintenance work.
– Robatech offers a special maintenance kit (order No.100660).

It consists of 1 pair of protective gloves, 1 pair of protective goggles and 1 nozzle cleaning kit.
– Maintenance of the application heads is not described in this manual. You will find it in the manuals
dedicated to the application heads.
Concept / 4.1 Maintenance 57

7.2 Maintenance schedule
The maintenance intervals apply to one-shift operation. In case of a higher workload the appliance needs
more frequent maintenance.
When What How
Weekly Flushing of dirt out of the filter Flushing out of contamination through the drain
hole; see chapter 7.3, Flushing of the filter
Visual checking of the Check all screwed connections at the distributor
screwed connections block, at the heated hoses and at the
application heads for emerging hotmelt. Untight
screw connections must be replaced.
Visual checking of the cables Check all power cables, connecting cables, the
and hoses pneumatic hose and the heated hoses for surface
defects. Replace damaged cables or hoses.
Monthly Visual checking of the coarse Check the coarse filter in the tank for deposits.
filter Remove contamination from coarse filter and
tank; see chapter 7.5, Cleaning of the appliance.
Cleaning of the tank lid Clean the tank opening and the seal with
cleaning oil.
Half-yearly
or Replacing of the filter See chapter 7.4, Replacing of the filter
message
«A90»
Yearly
Flushing and cleaning of the See chapter 7.5, Cleaning of the appliance
or
entire hotmelt system
message
«A90»
7.3 Flushing of the filter
Hotmelt contamination accumulated in the filter is flushed out through the drain opening. Removal of the
filter is not necessary. Condition: The appliance has reached its operation temperature.
• The appliance must be at operating
temperature. Set the pressure controller at
the piston pump back to 0 bar.
• Place a temperature-resistant container under the
drain opening (1) at the valve block.
• Open the drain bolt (2). Hot hotmelt will now
flow from the drain opening (1).
• Increase the pump pressure and drain
hotmelt until no more visible contamination
flows out of the drain opening.
• Close and tighten the drain bolt again.
Exchange the filter cartridge if it is heavily
contaminated.
Draining of contamination
7.4 Replacing the filter

Condition: The appliance has reached its operation temperature. It is not neccessary that the tank is
empty. Spare part number of the standard filter with o-ring is «100142».
• Set the pump pressure at the controller to 0 bar.

• Drain the system pressure. For this purpose you place a temperature-resistant container under the drain
opening (1) at the distributor block. Open the drain bolt (2) far enough for hotmelt to emerge. The
system is relieved of its pressure when no more hotmelt flows out. Let the drain bolt (2) open.
• Remove the screw plug (3). The filter cartridge
is still seated in the bore.
• Screw an M5 bolt (5) or the special filter key
(Art. No. 113264) into the thread of the filter
cartridge (4) and pull the filter cartridge (4)
including the O-ring
(6) from the bore.
• Clean the bore with a rag free of fluff and slide
the new filter cartridge with O-ring into the bore.
• Screw the screw plug (3) back in again.
• After the filter change there is air in the system.
In- crease the pump pressure slightly so that the
air can escape through the drain opening (1).
Close the drain bolt (2) as soon as only hotmelt
flows out any more. The appliance is now ready
for operation again.
Replacing the filter cartridge

7.5 Cleaning of the appliance
Contamination of the hotmelt tank or of the appliance is the most frequent cause of disturbances. A good reason,
therefore, to keep your appliance spotlessly clean at all times.
7.5.1 Cleaning agent

To clean the hot parts or to flush the entire system, use nothing but Robatech's cleaning oil or a cleaning
agent recommended by your hotmelt producer.
Warnin Danger of fire

g Use cleaning agents with a high flash point exclusively! Do not use cleaning
agents containing solvents under any circumstances, e.g. thinner, acetone, etc.
There is a danger of fire in case of contact with hot appliance parts.
The cleaning agent must feature an ignition point of minimum 280° C and must be non-toxic at processing
temperature. It must not lead to any chemical reactions with the adhesive or parts of the appliance and
must not cause any corrosive or otherwise harmful action on parts of the appliance.
Robatech's cleaning oil is available in the following 2.5 litres Part No.
quantities: 100664
5.0 litres Part No.
101515
10.0 Part No.
litres 101516
Concept / 4.1 Maintenance 60

7.5.2 Complete cleaning
The hotmelt system must be cleaned and flushed completely at least once per year. Consider the following con-
cerning more frequent cleaning:
The frequency of cleaning the appliance inside depends on the processing

temperature, the heat stability of the hotmelt and the processed quantity. The
shorter the residence and throughflow time and the lower the processing
temperature, the less is the danger of deposits buildung up in the tank and
possibly causing disturbances.
Make absolutely sure you wear protective goggles and heat-resistant

gloves for cleaning work.
1. Draining the hotmelt from the tank

Set the pressure controller back to 0 bar. Place a temperature-resistant container under the drain
opening at the distributor block. Increase the pump pressure until the hotmelt flows out steadily.
2. Switch the appliance off, set the pressure controller to 0 bar and close the drain bolt
3. Unscrew the nozzles at the application heads and clean them
Immerse them in hot cleaning oil and blow them out with compressed air.
4. Remove deposits inside the tank
Use a wooden spatula to remove contaminations in the tank.
5. Fill in cleaning oil
Fill the tank to above the ribs with cleaning oil, switch the appliance on and heat up to approx. 140°C.
6. Flush the system
Drain approx. 5 dl of cleaning oil from each application head so that pump, heated hoses and
application heads are flushed with cleaning oil.
7. Leave the heated appliance standing for approx. 45 minutes
Use a rag or wooden spatula to remove incrustations in the tank which do not come off of their own
accord.
8. Drain the cleaning oil from the tank
Empty the tank completly, then switch the appliance off.
9. Replace the filter cartridge (see chapter 7.4)
10. Flush the system once again
Fill a small quantity of cleaning oil into the tank, heat up the appliance and empty the tank over the
application heads. Then switch the appliance off again.
11. Clean the tank using a rag free of fluff
12. Fill new hotmelt into the tank
Heat up the hotmelt and release it through each application head until it emerges without showing any
trace of mixed-in cleaning oil.
13. Fit the nozzles. The appliance is ready for operation again.
8 Repair
If technical disturbances or defects occur, this chapter provides the necessary information to eliminate and
repair them.
In case of repair problems please get in touch with your nearest Robatech service company. You will find
the addresses in the register 'Communication'.
8.1 References
Warnin Danger of injury or material damage
g The appliance may only be repaired by the authorized and trained service
technician. Repairs of electrical components, in particular, may only be
carried by persons with professional training in electrics.
Warning Danger of burns and splashing

Repair work on the heated hoses/application heads or on the piston pump are
carried out at operating temperatures up to 230° C / 446° F. A danger of
burns exists at the blank parts and in case of contact with the hot adhesive.
The hot adhesive in the lines is highly pressurized. A danger of injuries from
hot splashes exists if the pressure system is opened improperly.
Use original Robatech spare parts exclusively. By this you can be sure of having an impeccable quality and
the right to claims under guarantee if applicable.
Concept / 4.1 Repair 63

8.2 Replacing heated hoses and application heads
Protective goggles and heat-resistant gloves must be worn for this work under all circumstances.
The connecting cables for the heated hoses and application heads must not be plugged in or pulled out
under load. Always switch the appliance off beforehand.
1. Switch the appliance off with the main switch

2. Drain the system pressure
Set the pressure controller back to 0 bar. Place a temperature-resistant container unter the drain
opening at the distributor block. Open the drain bolt until hotmelt flows out.
3. Unplug the connecting cables of application head and heated hose
4. Removal of heated hose or application head
Unscrew the spigot nut at the beginning and/or end of the heated hose. It is an absolute must to hold
the lock nut with a second fork spanner, otherwise the hose will be twisted and damaged.
5. Installing a new heated hose or application head
If the heated hose or the screw connection is filled with solidified hotmelt, it must be sufficiently heated
prior to installation. A hot air blower is useful for this purpose. First, screw the spigot nut by hand
onto the connecting thread, then screw it tight with a spanner while holding the lock nut in
position with a second fork spanner.
6. Plug in the connecting cable
Hereby the appliance must not be switched on!
7. Recording the compensation factors of the new heated hose or application head
Record the new values in the parameter list at the end of this manual and enter them in the appliance
(see chapter 6.9.6, Compensation factors).
8.3 Repairing the piston pump
Make absolutely sure you wear protective goggles and heat-resistant
gloves for this work.
8.3.1 Irregularities on pumping

Uneven pumping
If the piston pump runs unevenly, it may be contaminated. Such contamination can often be eliminated by
flushing of the appliance (see chapter 7.5.2, Complete cleaning). If this does not improve things, the pump
must be cleaned or, better still, replaced by an exchange pump (see chapter 10.3).
Delayed starting
If the piston pump starts with a delay although the
operating temperature is reached, check first
whether or not the temperature is set too low.
If this is not the case, the stripper ring is probably
defective, permitting hotmelt to reach the piston rod
in the pneumatic part. This can be checked through
the bore (pos. 4 in the illustration overleaf). The
pump must be dismantled and cleaned, the stripper
ring and further seals must be replaced. However,
we do not recom- mend you to carry out this
repair. With an exchange pump the disturbance is
eliminated easily and quickly.
Defective piston pumps can be replaced in exchange. By this you can be sure of
having an impeccable quality at a very attractive price; see chapter 10.3.
8.3.2 Removal and installation of the piston pump
Removal
• Heat the unit to operating temperature, switch it off at
the main switch and drain the glue pressure (see
chapter 6.4).
• Remove the cover (1) after loosing the union nut. Pull
out the plug (2) of the pump control and the air hose
(3).
• Fully loosen the fastening nut (4) counterclockwise
using a hook spanner.
• Pull the piston pump vertically upwards and out of its
holder.
Installation
• Switch the appliance off at the main switch.
• Insert the journal of the piston pump in the bore at the
tank base.
• Apply a temperature-resistant lubricant to the fastening
thread and tighten the fastening nut (4) with a hook
spanner.
• Plug in the connector (2), connect the air hose (3)
and place the pump cover – the appliance can now be
switched
on again. Installation of the pump
8.4 Replacing temperature sensors
Danger Electrocuti
on
A mortal danger exists if live components are touched (operating voltage 400
Volt). The protective cover may only be removed if the appliance is
disconnected from the power supply.
Temperature sensors are located in the tank of the appliance, in the heated hoses and in the applaction
heads.
– Replacement of the temperature sensor at the application head is described in the dedicated manual.
– The sensor in the heated hose cannot be replaced. The entire hose must be exchanged.
– Proceed as follows to replace a defective tank temperature sensor:
• After loosening of the two fastening screws,

pull the left-hand protective cover
downwards and away.
• Lift the tank insulation mat (1) in the left
bottom corner. The temperature sensor (2)
and a safety thermostat become visible.
• Loosen the retaining bolt (3) and pull out the
temperature sensor.
• Cut the two stranded wires of the old and
new sensor, skin them and twist them
together. Next, screw a ceramic bunched
terminal (pos.4, Part No.100692) over the
two stranded wires.
• Insert and fasten the new sensor, fit the
protective cover and enter the different
compensation factor if appropriate (see
chapter 6.9.6).
Replacing the tank temperature sensor
8.5 Resetting the temperature limiter

At a tank temperature of more than 230° C or in case of severe impact (e.g. if the appliance is dropped) the
temperature limiter switches off all heating zones for safety reasons. After cooling down of the appliance
the temperature limiter is reset as follows:
• Gerät von der Stromversorgung trennen. Remove

the left-hand protective cover after loosening
of the two fastening screws.
• Lift the tank insulation mat in the left bottom
corner. The temperature limiter (1) becomes
visible.
• The temperature limiter is reset by pressing
with a screw driver.
Temperature limiter
8.6 Checking the electrical connections
Danger Electrocuti
on
Mortal danger exists if live components are touched (operating voltage 400V).
The work described below may only be carried out if the appliance is
disconnected from the power supply.
8.6.1 Checking the heated hose connection

Defective cartridge heaters and temperature sensors lead to a corresponding disturbance message. A possible er-
ror source can be identified by measuring the connection values at the connectors.
Resistance values of the heating elements (see chapter
11.1) Heated hose heating element Pin 7+5 = 53…587
Ohm Appl. head heating element Pin 7+2 = 53…587
Ohm
Resistance value of the temperature sensors at

25°C Heated hose temperatur sensor Pin 4+6 = 110
kOhm Application head temp. sensor Pin 1+3
= 110 kOhm
Heated hose connection
Connection assignment of the heated hose plug and the appliance socket:
8.6.2 Checking the piston pump connection
You can measure at the pin contacts whether the supply voltage for the pump change-over control is
switched free or present. Attention: the appliance must be switched on for this measurement.
Connection assignment of the piston pump connector:

Cont Function I/O Wire color
act
1 0 VDC Output white
2 24VDC Output brown
Piston pump connection
8.7 Connection assignment of boards ICS

Danger Electrocuti
on
Mortal danger exists if live components are touched (operating voltage 400V).
The protective covers may only be removed if the appliance is disconnected
from the power supply.
The electronic circuits are electrostatically sensitive. Before touching the circuits, discharge yourself from
static loads by touching the earth connection at the appliance.
8.7.1 ICS-MAIN Main control
X1 System interface
X1.1 A 0V
X1.2 A 24 VDC
X1.3 E INPGND (common 0 V of all inputs)
X1.4 E H-ENABLE D16
X1.5 E T-TRIGGER D17
X1.6 E LOW-TEMP D18
X1.7 E P-ENABLE1 D19
a
X1.7 E P-ENABLE2 D30
b
X1.8 A 0V
X1.9 A 24 VDC
X1.1 E OUTGND (- supply of the outputs)
0
X1.1 E OUTGND
1
X1.1 E OUTVIN (+ supply of the outputs)
2
X1.1 A ON D23
3
X1.1 A READY D24
4
X1.1 A ALARM D25
5
X1.1 A TEMP-LOW D26
6
X2 Supply
X2.1 E 0V
X2.2 E 24 VDC
X3 Connection to print ICS-PWRDx (control signal for contactor)
X4 Connection to print ICS-PWR1 (tank 1)
X5 Connection to print ICS-PWR2 (hoses/heads 1..4)
X6 Connection to print ICS-PWR2 (hoses/heads 5..8)
X7 Connection to print ICS-PWR1 (tank 2)
X8 Connection pump 1 / valve pressure build-up
X8.1 A 0V
X8.2 A PUMP1 (supply pump change-over control) D27
X8.3 A PVALVE1 (valve pressure build-up) D28
X9 Connection pump 2 / valve pressure build-up
X8.1 A 0V
X8.2 A PUMP2 (supply pump change-over control) D37
X8.3 A PVALVE2 (valve pressure build-up) D38
X10 Connection airspray gun / output tank fill level too low
X10. E SSWITCH (release of airspray gun) D22
1
X10. A 24 VDC
2
X10. A 0V
3
X10. A SVALVE / TANH-EMPTY D29
4 (valve airspray gun / tank fill level too low)
X11, Connection tank fill level sensors / parameter input blockage
X12 X11. A 0V
1
X11. A 24 VDC
2
X11. E EMPTY-TANH D20
3
X11. E FULL-TANH D21
4
X13 Connection operating unit ICS-TRM
X16 RS232 interface
X17 RS485 interface (optional)
X18 Jumper: bridge excess temperature switch to X4
X19 Jumper: bridge excess temperature switch to X7
X20 Additional inputs and outputs (not active)
X20. A 0V
1
X20. A 24 VDC
2
X20. A AUX-OUT1 D35
3
X20. E AUX-IN1 D33
4
X20. A AUX-OUT2 D36
5
X20. E AUX-IN2 D34
6
X20. A S-VALVE / TANH-EMPTY D29
7
X20. E SSWITCH D22
8
X21 Pressure sensor pump 1 (not active)
X21. A 0V
1
X21. A 24 VDC
2
X21. E 4…20 mA
3
X21. E 0…5 V
4
X22 Pressure sensor pump 2 (not active)
X22. A 0V
1
X22. A 24 VDC
2
X22. E 4…20 mA
3
X22. E 0…5 V
4
X23 Connection for data entry blockage
X231 A 0V
X232 A 24 VDC
X233 E PAR-LOCHED 1 (not active) D31
X234 E PAR-LOCHED2 D32
X33 Connection for external pump emergency-off contact (link between connections X33.1
and X33.2 interrupted -> supply to pump interrupted)
X33. A P-EMOFF1
1
X33. E P-EMOFF2
2
IC3 EPROM
IC5 EEPROM (only with optional hotmelt application control ICS-IH)
BAT1 Battery 3V minimum voltage 2.6Volt, Art. No. 111359
A = output, E = input, Dxx = luminous diode, Xxx = connector or terminal
– After a short circuit the supply voltage switches itself off automatically. The 24V supply voltage on
the MAIN print is switched on again by switching off and on again after at least 10 seconds.
– If the supply voltage does not switch itself on automatically, check the supply from the power
supply unit at connector X3. Next, the fuse F2 on print PWDR3 must be checked before finally
checking the fuse of the power supply unit. The power supply unit is behind the MAIN print. For
checking and replacing of the power supply unit's fuse it is necessary to remove the entire MAIN
print.
8.7.2 ICS-PWR1 Tank heating
Heating function
LED D1 is lit if the tank heating zone is
switched on by the control ICS-MAIN. If the
LED is lit permanently and the tank heating
has not reached the nominal temperature
after 60 minutes, it is possible that the fuses
F1…F3 or the heating elements are
defective.
Fuses
The fuses F1, F2 and F3 protect the power
outputs L1, L2 and L3 to the 3 heating
elements. A defect of the fuses is not
indicated by the LED.
X1, X2 Supply
X1.1 E N
X1.2 E W
X1.3 E V
X1.4 E U
X3 Connection to print ICS-MAIN
X4 Connection heater
X4.1 A N (optional)
X4.2 A T (W-wired)
X4.3 A S (V-wired)
X4.4 A R (U-wired)
X5 Connection temperature sensor
X5.1 – NTC –
X5.2 – NTC +
X5.3 empty
X5.4 empty
X6 Connection excess temperature switch (contact open = excess temperature)
X6.1 – OTMP1
X6.2 – OTMP2
D1 LED Heating on
F1 Fuse heating output T 12.5AF Part No.113808
F2 Fuse heating output S 12.5AF Part No.113808
F3 Fuse heating output R 12.5AF Part No.113808

8.7.3 ICS-PWR2 Heating of heated hoses and application heads
Two executions exist:
ICS-PWR2/4
For 4 heated hoses and 4 application heads
ICS-PWR2/2
For 2 heated hoses and 2 application heads
Missing are F5 to F8, D5 to D8 as well as
X2, 6, 7, 10 and 11.
Fuses and LED function checking

One fuse and one LED are assigned to
each heated hose and application head.
LED ”D4" indicates, for example, that the
application head 2, or application head 6 in
case the second PWR2 is installed, is
switched on.
If one of the LEDs is switched on

continuously, the heating zone is
– in the heating-up phase, or
– the heating element in the heating zone
is defective,
– the supply line is interrupted, or
– the fuse is defective
X1, X2 Supply
X1.1 E N
X1.2 E W
X1.3 E V
X1.4 E U
X3 Connection to print ICS-MAIN
X4 Connection heaters 1, 2 (heated hose 1(5), application head 1(5))
X4.1 A N
X4.2 A N
X4.4 A HEATER 1 (W-wired)
X5.1 A N
X5.2 A N
X6.1 A N
X6.2 A N
X6.4 A HEATER 5 (V-wired)
X6.3 A HEATER 6 (V-wired)
X7.1 A N
X7.2 A N
X7.4 A HEATER 7 (U-wired)
X7.3 A HEATER 8 (U-wired)
X8 Connection temperature sensors 1, 2
X8.1 – NTC1 –
X8.2 – NTC1 +
X8.3 – NTC2 –
X8.4 – NTC2 +
X9.1 – NTC3 –
X9.2 – NTC3 +
X9.3 – NTC4 –
X9.4 – NTC4 +
X10.1 – NTC5 –
X10.2 – NTC5 +
X10.3 – NTC6 –
X10.4 – NTC6 +
X11.1 – NTC7 –
X11.2 – NTC7 +
X11.3 – NTC8 –
X11.4 – NTC8 +
D1… LED Heating 1…8 on
D8
F1…F8 Fuse heating 1…8 5AF Part No. 112568
8.7.4 ICS-PUS Piston pump control

X Supply
X1.1 E 0 VDC
X1.2 E 24 VDC
X2 Connection valve 1 (bottom valve)
X2.1 A 0 VDC
X2.2 A 24 VDC-wired
X3 Connection valve 2 (top valve)
X3.1 A 0 VDC
X3.2 A 24 VDC-wired
D2 LED «Piston at bottom»
D3 LED «Piston at top»
D4 LED «Valve 2 on»
D5 LED «Valve 1 on»
8.7.5 ICS-PWRD1 Power distribution
Supply
1LNPE, 230VAC, 50/60Hz,
2
I<20A
Supply line max. 4mm
External fuse protection of the supply
line with 20A
X Mains connection
X2…X5 Supply ICS-PWR1, ICS-PWR2
X2.1 A N
X2.2 A W (L-wired)
X2.3 A V (L-wired)
X2.4 A U (L-wired)
X6 Connection mains switch
X6.1 A L (L protected with F1))
X6.2 A N
X6.3 E LS (L-wired)
X6.4 E NS (N-wired)
X7 Connection supply unit ICS-PSUP1
X7.1 A NS
X7.2 A LS
X8 Connection to ICS-MAIN (control signal for contactor)
X8.1 A 0V
X8.2 A PWRON (24 V signal)
X9 Connection PE with carrier plate
X12 Connection supply to pump drive
X12.1 A NP
X12.2 A LP (protected with F2)
F1 Fuse for supply unit ICS-PSUP1 2AT Art.No.102944
F2 Fuse supply pump drive (X12) 3,15AT Art.No.114642

8.7.6 ICS-PWRD3 Power distribution
Supply
3LNPE, 400VAC, 50/60Hz
I (L1,L2, L3) < 20A
2
Supply line max. 4mm
External fuse protection of the supply
line with 3×20A
X Mains connection
X2…X5 Supply ICS-PWR1, ICS-PWR2
X2.1 A N
X2.2 A W (L3-wired)
X2.3 A V (L2-wired)
X2.4 A U (L1-wired)
X6 Connection mains switch
X6.1 A L (L1 protected with F1)
X6.2 A N
X6.3 E LS (L-wired)
X6.4 E NS (N-wired)
X7 Connection supply unit ICS-PSUP1
X7.1 A NS
X7.2 A LS
X8 Connection to ICS-MAIN (control signal for contactor)
X8.1 A 0V
X8.2 A PWRON (24 V signal)
X9 Connection PE with carrier plate
X12 Connection supply pump drive
X12.1 A NP
X12.2 A LP (protected with F2)
F1 Fuse for supply unit ICS-PSUP1 2AT Part No.102944
F2 Fuse supply pump drive (X12) 3.15AT Part No.114642

8.8 Pump disturbances
Disturbance Cause Remedy
The feed pump generates Pump defective Replace pump
no or insufficient
pressure Pump does not build up Flush or replace filter. Check compressed
sufficient pressure air line and pressure controller of the
pump.
Filter cartridge
Clean or replace the filter
blocked Coarse
Remove pump and coarse filter - clean the
filter blocked coarse filter. If tank heavily contaminated,
remove the cover and clean the tank.
No pump reaction Control or appliance Check switching on, release switching
is switched off and parameter setting. Eliminate
disturbances.
Supply voltage for
piston pump is Check fuse F2 on supply print PWRD.
missing Switch appliance off and switch it on
again after 10 sec.
Short circuit?
A disturbance exists
Check disturbance message and eliminate
Release message missing
fault. Check machine contact and
Heating out of eliminate fault.
operation Temperature
Check disturbance messages, eliminate
limiter opened faults.
Switch the appliance off and let it cool

down. Check temperature limiter at the tank
and reset it. Switch appliance on again.
Uneven pump operation The piston pump feed Check suction valves of piston pump for
only in one direction contamination, flush or replace pump.
8.9 Disturbances in the hotmelt application
Hotmelt jumps or splashes Hotmelt temperature too Reduce the
from the substrate
high Pressure in system temperature Reduce
too high Hotmelt the pump pressure
viscosity too low Lower the temperature, use a nozzle with

a smaller orifice. Change the nozzle
application an-
gle. Use hotmelt of higher viscosity.
Hotmelt clogs in the tank Temperature too high Reduce the tank temperature
Temp. sensor defective Replace temperature sensor. Set

or wrong temperature compensation values correctly.
sensor compensation
Fill level too low Fill up tank
Hotmelt oxidizes Don't open tank lid unnecessarily, equip

appliance with premelter option.
heavily
Hotmelt steams or Tank temperature too Reduce tank temperature. Stick to data
fumes high of the hotmelt producer under all
circumstances.
Unstable hotmelt (clots Use a more stable hotmelt. Don't open

easily) tank lid unnecessarily.
Hotmelt jellies (thickens) Overheating, residence Empty system and flush it, lower the
time in tank too long. temp. or switch the appliance off when not
in production.
Incompatible hotmelts
have been mixed Empty the system and flush it. Check
compatibility by mixing in separate
Unstable hotmelt container.
Use a better hotmelt quality

Hotmelt does not Temperature too low Increase temperature slightly
penetrate
the product
Substrate features a Increase temperature slightly, try another
coating hotmelt
(flush the system first).
Surface too smooth Check whether application is made on the

right
side. In case of film substrate, check whether
sur-
face is corona discharge treated.
Insufficient quantity Use a nozzle with a bigger orifice, slightly

in-
crease the temperature, increase the pump
pres-
sure.
Hotmelt bead too cold Tank temp. too low Newly set the temperature
Distance excessive Go closer to the product (ideal are 1-5mm)

between spray nozzle
and product
Fit protective device in front of nozzle
Air blows on nozzle
and cools it down
Set temperature correctly
Wrong temperature
Insufficient hotmelt at Nozzle orifice too small Install a bigger nozzle
the point of
application
Nozzle partly blocked Clean or replace the nozzle
Nozzle opens only Insufficient air pressure at pneumatic valve

hesitantly on application head (4.5 - 5.5 bar)
Feed quantity too small Increase pump pressure, replace filter,

check overpressure valve (option), set
higher if necessary
Hotmelt is stringing Application head is too Go closer to the appl. surface (appr. 1-5
far away from mm), as close as poss. with permanently
substrate sticky hotmelt
Application head does Replace spray element or application head
not close correctly
Hotmelt is too cold Increase the temperature slightly
Hotmelt is too viscous Increase temp. slightly or use a hotmelt of a

lower viscosity
Cold air blows on Protect the appl. head, slightly increase temp.,
application head or the preheat substrate, heat ambient air
ambient temperature is
too low
Old or wrongly stored Change the hotmelt
hotmelt material
Air in the hotmelt Tank empty or not Fill tank and actuate application head until
enough hotmelt air bubbles disappear. Check the tank
melted down temperature and increase it if appropriate.
Use new hotmelt which was stored correctly

Hotmelt absorbed too (dry)
much moisture during
incorrect storage
Irregular nozzle Blocked nozzle(s) Clean nozzle(s). Increase pump pressure and
application in case of use nozzle with smaller orifice or increase
multi-head instal- tempera- ture.
lations
Drooling (dribbling) of Nozzle pin of appl. Clean and/or replace worn parts. Better: replace
the application head head and/or valve spray element by an exchange unit
seat worn or
contaminated.
Piston of appl. head Clean nozzle pin, renew set of seals or
stiff (sluggish) due to replace spray element by exchange
burnt hotmelt on unit.
nozzle pin.
Moisture bubbles in Humidity in substrate Dry out the product beforehand
applied hotmelt on the evapo- rates through
substrate hot hotmelt
Bursting open of the Hotmelt does not cool Reduce pump output or use nozzle with a
glued areas after down fast enough (open smaller orifice. Slightly reduce the
leaving of the time too long). temperature. Reduce the machine speed.
compression section Increase the pressure on the substrate.
Increase time/path length from application
to compression. Cool the substrate. Change
bead pattern from constant to
intermittent.
Hotmelt cools down too Increase temperatures and applied quantity or
quickly (open time too use a hotmelt with a shorter open time.
short).
Applied hotmelt sheared Take care that the product is not twisted,
off, cut shifted or subjected to other unfavourable
movements during the compression time.
9 Putting out of operation and disposal
9.1 Putting out of operation

Normal switching-off
Normal switching-off of the appliance is done with the main switch. The hotmelt material solidifies as the
appliance cools down.
In case of a longer interruption

The appliance can be stored over a longer period of time without any problems.
Hotmelts sensitive to humidity must be pumped from the system and the appliance must be cleaned (see
chapter 7.5.2, Complete cleaning, without filling-in of new hotmelt).
In storage, the appliance must be kept dry, at approx. room temperature and protected against dust.
Putting back in operation after a longer interruption

After a longer interval and/or if parts of the system were removed, the appliance must be put back in operation in
accordance with the instructions given in chapter 5.
9.2 Disposal
The owner/operator is responsible for correct disposal of the appliance and of the hotmelt material.
The national provisions of the law concerning disposal must be complied with.
Danger Electrocuti
on
Touching of live components means mortal danger (operation voltage 400V).
Before dismantling the appliance, make absolutely sure that all electrical
connections are interrupted.
The appliance must be disposed of by dismantling and correct sorting of the components into the different
material categories.
Frame Steel plate/sheet

Tank Aluminium
Control Electronic components and cables
Tank content To be disposed of as directed by the adhesive producer
Concept / 4.1 Putting out of operation and disposal 83

84 Putting out of operation and disposal Concept / 4.1
10 Spare parts
10.1 Introduction
– By using original Robatech spare parts you can be sure of having the best quality and of protecting your
rights in case of possible claims under guarantee.
– A stock of the most frequently required spare parts is an important prerequisite for permanent readiness
for operation of your appliance.
– Repair work may only be carried out by persons who can safely operate the appliance and who have the
necessary professional knowledge.
– In case of orders for spare parts under guarantee the serial number must be stated on the order.
– Your order can be processed faster if it contains the following details:
- Ordered quantity - Article number - Article designation - Type of appliance
10.2 Hand tools and auxiliary materials

Part No. Designation Quantity
112635 Tool kit «Concept» consisting of: -
112636 Hook spanner for piston pump 1
113264 Filter key M5 1
112793 Allen key SW12 1
112794 Fork spanner SW10 1
100660 Maintenance kit consisting of: 1
100299 1 pair of protective gloves 1
100602 Protective goggles 1
100661 Nozzle cleaning kit Ø 0.2 mm 1
113895 Pin key TORX TX20 for valve of piston pump 1
100664 Cleaning oil 2,5 litres 2.5 l
107574 Silicone grease 100g 100 g
105797 High temperature metall paste 1,200 g
100665 High temperature metall paste 3g
118221 Nozzle cleaning kit sextuple Ø 0.08 mm 6
Concept / 4.1 Spare parts 85

10.3 Exchange components
The following subassemblies are available in exchange. They are parts overhauled by Robatech, their
quality is impeccable and their price very attractive. For exchange parts please get in direct contact with
your local representative.
Part No. Designation
A112392 Exchange piston pump HPC5
A125124 Exchange piston pump HPC12 to Concept 4
A125145 Exchange piston pump HPC12 to Concept 8,
12, 18 A112393 Exchange piston pump HPC16
10.4 Basic appliance

10014 Filter cartridge with O-ring seal, 130µm, sintered bronze
2 (Standard) Filter cartridge with O-ring seal, 260µm, sintered
10014 bronze
4 Filter cartridge with O-ring seal, 125µm, woven
12120 filter Filter cartridge with O-ring seal, 265µm,
1 woven filter Filter cartridge with O-ring seal,
12120 400µm, woven filter Screwed sealing plug Filter
2
3/4" cpl. with sealing ring
12120 Sealing ring single to sealing plug
3
10175
4
10278
1
112453 Coarse filter in the tank for piston pump
111894 Tank lid seal Concept 4
111960 Drain cock complete
107332 Pos. 15 O-ring seal 6.75×1.78
107213 Pos.20 O-ring seal 2.57×1.78
100072 Pos.40 O-ring seal 10.78×2.62
113480 Pos.45 Back-up ring
101948 Drain tube cpl. on the glue distributor
10.5 Electrical parts
102120 Tank temperature limiter 230° C
112050 Tank temperature sensor with cable Concept 4
112056 Main switch with connection cable
122186 ICS-MAIN board with flash memory
111359 Battery 3V (ICS-MAIN)
112370 ICS-EXT1 board
112782 Programmable logic device ICS PLD-IH for 2 application channels
112783 Programmable logic device ICS PLD-IH for 4 application channels
113469 ICS-PINT board Gear pump control
111733 ICS-PUS board Piston pump control
112400 ICS-PWR1 board cpl. Tank
113808 Fuse 12.5 AF to PWR1
112398 ICS-PWR2/2 board cpl. 2 hoses / 2 heads
112399 ICS-PWR2/4 board cpl. 4 hoses / 4 heads
112568 Fuse 5 AF to PWR2
112405 ICS-PWRD1 board
102944 Fuse 2 AT to PWRD1
112406 ICS-PWRD3 board
102944 Fuse 2 AT to PWRD3
118293 Fuse 6.3 AT to PWRD3
112541 ICS-PSUP power supply 40 Watt
100588 Fuse 2.5 AF to power supply 40 Watt
107572 Fuse 3.15 AF to power supply 60 Watt
123226 Fuse 4 AF to power supply 100 Watt
112394 ICS-TRM1 operating terminal TEMP
112395 ICS-TRM2 operating terminal TEMP + IH
112396 ICS-TRM3 operating terminal TEMP + ZP
112397 ICS-TRM4 operating terminal TEMP + IH + ZP
10.6 Piston pump KPC12
Defective piston pumps can be replaced in exchange. By this you can take
advantage of an impeccable quality at a very attractive price; see chapter 10.3.
10.6.1 Spare parts

Position Designation Part No. Quant
ity
– Pressure controller 112427 1
– 3/2-way valve 112034 2
– Pressure gauge 112428 1
– Print pump change-over control ICS-PUS 111733 1
– Set of seals HPC12 112757 1
10.6.2 Set of seals KPC12

The set of seals for the piston pump HPC12 Art.No.112757 consists of:
Positi Designation Part Quan
on No. t.
5 O-Ring 37.47x5.33 10044 1
1 Teflon ring 1 1
0 d=50/47.4x5.8 V-slot 10044 1
1 ring 21,5/11,5x7 2 2
5 O-ring 6.07x1.78 10043 2
2 Sealing ring d=55/50x0.5 9 2
0 Sealing ring 1/8 10036 4
2 8
d=10/13.5x1.5 U-seal / 1
5 10044
Megu-ring D=6,7/10x1 O- 1
3 9
ring 11.91x2.62
0 10062
Shaft seal 24/15x7 8
3
5 11198
4 8
0 10206
4 3
5 10043
1
10.7.1 Spare parts

ity
– 3/2-way valve 112034 2

The set of seals for the piston pump HPC5 Art.No.115731 consists of:
Positio Designation Part Quan

n No. t.
5 Spacer ring 10298 2
1 d=36x32x0,5mm Piston 0 1
0 seal 10227 1
1 Slot ring AX300 H 6 2
5 Sealing ring 1/8 10534 2
2 d=10/13.5x1.5 O-ring 6 2
0 6.07x1.78 10062 1
2 8
O-ring 11.91x2.62
5 10036
Shaft seal 24/15x7
3 8
0 10206
3 3
5 10043
1
10.8.1 Spare parts

ity
– 3/2-way valve 113058 2

The set of seals for the piston pump HPC16 Part No.113803 consists of:
Positio Designation Part Quan

n No. t.
5 Piston seal 50 10205 1
1 Bar seal 20 1 1
0 U-seal / Megu-ring 10204 4
1 D=6,7/10x1 Sealing bush 8 1
5 HPC16 11198 1
2 O-ring 11.91x2.62 8 1
0 Back-up ring BHS 11296 1
2 0
16x2.1x1.5 Bar seal 25 1
5 10206
O-ring 29.82x2.62
3 3
0 11317
3 2
5 10204
4 1
0 10179
6
11 Accessories
Only a part of the «Concept» accessories are listed in this document. For further accessories please get in
touch with your Robatech representative.
11.1 Heated hoses and accessories
11.1.1 Standard heated hoses, nominal width 8mm

Positi Part No. Len Power fi Thre
on gth ad
– 100781 0.6 m 90 W 587 M16 ×
1.5
– 100782 1.0 m 130 407 M16 ×
W 1.5
– 100658 1.2 m 160 330 M16 ×
W 1.5
– 100657 1.5 m 210 251 M16 ×
W 1.5
– 100783 1.8 m 240 220 M16 ×
W 1.5
– 100784 2.0 m 270 196 M16 ×
W 1.5
– 100785 2.5 m 320 165 M16 ×
W 1.5
– 100786 3.0 m 370 143 M16 ×
W 1.5
– 100932 4.0 m 450 117 M16 ×
W 1.5
– 100933 5.0 m 530 100 M16 ×
W 1.5
– 104515 6.0 m 610 85 M16 ×
W 1.5
– 115632 7.0 m 750 74 M16 ×
W 1.5
– 104517 8.0 m 850 66 M16 ×
W 1.5
– 122518 10.0 m 1,000 53 M16 ×
W 1.5
– 123085 12.0 m 1,000 53 M16 ×
W 1.5
Concept / 4.1 Accessories 91

Further heated hoses like water resistant types, with integrated spray air hose, with non-
return valve or with different nominal widths etc. are available on request.
11.1.2 Screw fittings
P Part No. Designation Thread

os
.
1 100637 Screw fitting HM straight 1/4" – M16 × 1.5
1 117310 Screw fitting HM straight FEP 1/4" – M16 × 1.5
2 100641 Screw fitting HM 45° 1/4" – M16 × 1.5
2 117311 Screw fitting HM 45° FEP 1/4" – M16 × 1.5
3 100639 Screw fitting HM 90° 1/4" – M16 × 1.5
3 117312 Screw fitting HM 90° FEP 1/4" – M16 × 1.5
4 103808 Screw fitting HM A1/4" – I1/4"
– 101755 Screwed sealing plug for bore 1/4"
– 105034 Screwed sealing plug for M16 × 1.5
fitting
– 100072 Spare O-ring seal 10.78×2.62 For all 1/4"
– 100077 Spare back-up ring screw fittings
d=20/16×1.7
FEP = special coating with better cleaning attributes
Concept / 4.1 Accessories 92

11.1.3 Extension cables
Extension cable for head and hose:
Extension cable for head:
Part Designation Length

No.
1205 Extension cable for head and hose 0.4 m
29
1011 Extension cable for head and hose 1m
25
26
27
67
68
42
66
67
1154 Extension cable for head and hose 8.5 m
65
68
1170 Extension cable for head and hose 10 m
69
1176 Extension cable for head 0.4 m
84
1005 Extension cable for head 1m
12
13
14
81
82
69
62
63
1185 Extension cable for head 8.5 m
72
64
1170 Extension cable for head 10 m
65
11.1.4 Distribution cables
Position 1 Position 2
Position 3 Position 4
Part Designation Len Positi

No. gth on
1034 Distribution cable to 1 ×head and 1 × 250 1
19 hose
1155 Distribution cable to 2 × hose 250 2
17
1012 Distribution cable to 2 × head 250 3
45
1181 Distribution cable to 2 × head 100 3
78 0
1012 Distribution cable 2 × head to head/hose 250 4
44
11.1.5 Accessories for heated hoses

Position 1 Position 2 Position 3
Part Designation Position

No.
1096 Hose holder Ø 40 mm for 8, 13 and 16 mm hoses 1
88
1001 Hose clamp Ø 40 mm 2
39
1066 Hinking protection spring, D= 43 mm, L = 725 mm 3
06
1053 Heated distributor, 250W, 1 inlet / 4 exits, 1/4" –
55 each
11.2 Controls and accessories
Various control accessories permit to extend the application range of the
Concept appliances. For comprehensive advice please contact your nearest
Robatech representative.
Pattern control ICS-IK4x The integrated pattern control «ICS-IH4x» enables the precise activation of
up
to eight applicator heads for the application of freely programmable
patterns of adhesive. A subsequent extension is possible at any time.
Switch-off of heating zones The extra print permits switching-on and -off as well as preheating of each in-
dividual heating zone (tank, hoses and heads) by a higher-ranking control.
Up to seven combinations can be activated.
Profibus-DP interface Profibus-DP is an open communications fieldbus system. The extra print per-
mits reading and writing of all data of the ICS control. Data, operator
inputs and machine events can be collected and evaluated.
11.2.1 Photoelectric cells and proximity switches
Connector assignment of all sensors:
– Objects are detected in front of a changing background, practically

independent of their colour and surface properties.
– The background is suppressed to a large extent.
– Object detection virtually independent of colour. Scanning range 5…50
mm
– Not suitable for differentiation between light and dark.
Part Designation
No.
11412 Photoelectric cell PNP, 5…50 mm, cable 2 m without
1 plug Photoelectric cell PNP, 5…50 mm, cable 2 m
11412 with plug
2
1141 Mounting angle (optional)
27
– For applications at high temperatures up to 250°C.

– The scanning range depends largely on the reflective properties of the object
surface. Scanning range approx. 240 mm.
– Suitable for differentiation between black and white objects.
– Differentiation and sorting e.g. by size, degree of reflection, etc.
– Counting of objects.
– Checking for presence of e.g. a stack of paper.
Part Designation
No.
11412 Photoelectric cell PNP, up to 1.2 m, cable 2 m without
3 plug Photoelectric cell PNP, up to 1.2 m, cable 2 m
11412 with plug
4
11412 Light conductor 0,5 m (required) or
6 Light conductor 0,5 m 90° (required)
11728
6

112992 Adapter cable light barriers at ICS-IH, 1m (for all photo cells
with plug) 100668 Connection cable extension 2 m
120843 Connection cable extension 4 m
Further sensors like photoelectric cells, light barriers, proximity switchs etc. on request.
11.2. Valve cables
2
Pos.2
Pos.1
Pos.3
Pos.5
Positi Part Designation

on No.
1 11299 Valve cable MAC, 3 m
1
0
6
1 11300 Valve cable Bürkert, 3 m
0
1 11300 Valve cable Bürkert, 5 m
1
2 11303 Connection cable ICS/IH distribution box, 3 m
8
3 10807 Distribution box, 2 valve inputs, 2 × 3 valve outputs
6
4 10774 Valve cable MAC with plug, 3 m
5
6
8
0
0
4 11055 Valve cable Bürkert with plug, 2 m
4
5 10807 Valve cable extension with plug, 2 m
1
5 11562 Valve cable extension with plug, 5 m
8
11.2.3 Power supplies ICS-PSUP

Stronger power supply units are available if the consumption of the connected users (e.g. valves of
application heads) exceed the maximum capacity of the ICS-PSUP power supply unit.
Position Part No. Designation

– 112408 Power supply ICS-PSUP 24VDC 60Watt
– 117180 Power supply ICS-PSUP 24VDC 100Watt
11.2.4 Encoder

on No.
1 10082 Encoder 1'000 Imp./r, AB-signal
4
– 10082 Encoder mounting angle
5
– 10082 Encoder measuring wheel, 200/205 mm circumference
6
– 10082 Encoder coupling
7
2 11298 Encoder cable, 3 m
8
9
7
3 11266 Encoder cable 3 m
1
0
5
4 11266 Encoder extension cable, 2 m
2
5 11423 Encoder distribution box, 1 input, 2 outputs
0
6 11462 Encoder adaption cable 1 m
7
– 11298 Encoder sets ICS-IH complete with cable, consisting of:
7
1 10082 Encoder 1'000 Imp./r, AB-signal
4
9
Encoder kits for ICS-IK4x

Quantity Part Designation Position
No.
– Encoder set with coupling complete,
consisting of: Encoder 1'000 Imp./r, AB-
112985 signal
1 Endoder mounting
angle Encoder
100824 coupling
1 Encoder cable, 3 m, without plug
100825
1
100827
1
112988
– Encoder set with measuring wheel cpl.,
consisting of: Encoder 1'000 Imp./r, AB-
109646 signal
1 Endoder mounting angle
Encoder measuring wheel, 200/205 mm circumference
100824 Encoder cable, 3 m, without plug
1
100825
1
100826
1
112988
11.2.5 Proportional valves and accessories
Proportional valves translate an electrical signal into an analog pneumatic pressure. They are available in
current- controlled (I/P) and as voltage-controlled (U/P) executions. Their range of application is the
regulation of the piston pump pressure depending on the measured machine speed.
11.2.5.1 Pneumatic plates

119102 Pneumatic plate with manual valve, air filter, micro filter, pressure gauge and precision
pressure controller. Without converter!
119104 I/P converter 0…9 bar / 4…20 mA / 24 VDC / G3/8" with plug, 3 m
119113 U/P converter 0…9 bar / 0…10 V / 24 VDC / G3/8" with plug, 3 m
119101 U/P converter 0…5 bar / 0…10 V / 24 VDC / G3/8" with plug, 3 m
119128 Pneumatic plate complete with I/P-converter 0-9 bar / 4-20mA
11.2.5.2 Component parts and accessories
Pos.2 1 brown 0V
2 white + Control signal
3 green + Current supply
Part No. Designation Positi

on
108152 Air filter coarse 1
0
100936 Micro air filter 2
0
108959 Pressure gauge 0…10 bar 3
0
108153 Manual valve 4
0
112523 Precision pressure controller, pilot-controlled 1
0
0
101523 Manometer for precision pressure controller 1
1
0
101528 Manometer for pressure gauge 1
2
0
119114 Sound absorber 1
3
0
119445 Converter connection cable with plug, 3 m 1
4
0
113002 Adaption cable IP-converter, 1 m (required for connection to ICS-IH) 2
109067 Distribution box for UP converter signal (1 × IN, 2 × OUT) -
11.3 Pumps
Position Part No. Designation Pump Pumping
pressure rate
– 112392 Piston pump HPC5 max. 30 bar 5…50 kg/h
– 125124 Piston pump HPC12 to Concept 4 max. 72 bar 5…50 kg/h
– 125145 Piston pump HPC12 to Concept 8, max. 72 bar 5…50 kg/h
12, 18
– 112393 Piston pump HPC16 max. 96 bar 16…160
kg/h
– 113090 Gear pump ZPC2.3 max. 80 bar 17…170
g/min
g/min
g/min
– 117225 Gear pump ZPC0.3 max. 80 bar 2…20 g/min
11.4 Level sensors

The level sensor reports the glue level in the tank. The level is displayed on the operating unit and an
output at the system interface permits further processing of this parameter.
1 112367 Level sensor capacitive, fill level min.
2 113478 Level sensor mechanical, fill level min.
– 112786 Tool to capacitive level sensor (screw in and out)
11.5 Pressure relief kit

The pressure relief feature permits to automatically relieve the entire pressure system of hot melt pressure
in case of an interruption of production. Pressure relief is activated if the supply to the pump is
switched off, the pump emergency-off is switched on, if an application head is blocked over the input
G-ENABLE or if the minimum speed is fallen short of.

3 111924 Pressure relief kit compl. (automatic pressure relief in case of prod. stops)
– 112040 Closing plate compl. (after removal of the pressure relief feature)
11.6 Maximum pressure valve
The maximum pressure valve limits the maximum system pressure. Setting range 30…80 bar.

4 113117 Maximum pressure valve cpl. (System pressure 30...80 bar)
– 112040 Closing plate compl. (after removal of the max. pressure valve)
11.7 Installation kits for operating unit ICS-TRM

– 112368 Inst. kit complete for external mounting of the operating unit, consisting of:
– 112407 1 set of printed circuit boards ICS-TIM and ICS-TIT
– 112798 1 cable 15 m
5 112706 1 blanking plate TRM
– 101767 4 M6 nut
– 111983 1 cable bushing
– 112799 1 installation instructions
6 112781 Housing for external mounting of the operating unit, green
– 112369 Inst. kit complete for front installation of the operating unit for Concept 4/8,
con-
7 112127 sisting of:
5 112706 1 cover for electrical cabinet
– 101767 1 blanking plate TRM
– 113105 4 M6 nut
1 cable 800 mm
– 112780 Inst. kit complete for front installation of the operating unit for Concept
12/18, con-
7 112800 sisting of:
5 112706 1 cover for electrical cabinet
– 101767 1 blanking plate TRM
– 113105 4 M6 nut
1 cable 800 mm
11.8 Various accessories
Pos.1 Pos.2 Pos.3

on No.
1 12070 Cover cap, plug socket for heated hose
. 1
1
1 10006 Socket housing with pad
. 7
2
1 10004 Female connector insert
. 4
2
1 10011 Female plugin sleeve, gold-plated
. 3
2
– 10603 Releasing tool for contacts 100267 / 100113
8
2 11275 Antistatic matting complete with placement tools
8
3 11483 Squeezer bar Concept 4 / Fastening of the cable shields to the ICS
0 8
3 11483 Squeezer bar Concept 12 ICS electronic part. With ICS-IH standard
1 / 18
11.9 Plugs, cable sockets and cables
Pos.1 Pos.2 Pos.3
Positi Part Designation Application

on No.
1 10077 Cable plug, two-pin Valves, M-Stop
3
1 10075 Cable plug, three-pin Proportional valve
9
1 10076 Cable plug, four-pin Light barrier
7
1 10075 Cable plug, five-pin Encoder
4
2 10218 Cable socket, two-pin Valves, M-Stop
2
2 10047 Cable socket, three-pin Proportional valve
6
2 10076 Cable socket, four-pin Light barrier
8
2 10075 Cable socket, five-pin Encoder
5
3 10061 Magnet valve plug with LED MAC valves
8
3 10062 Magnet valve plug Bürkert valves
0
– 10774 Cable, shielded 2×0.75 mm By the metre
7
– 10075 Cable, shielded 4×0.25 mm By the metre
6
11.10 Operating instructions
Part No. Designation Langua
ge
112531 Operating manual Concept basic device, with file German
112532 Operating manual Concept basic device, with file English
112533 Operating manual Concept basic device, with file French
112534 Operating manual Concept basic device, with file Italian
112535 Operating manual Concept basic device, with file Spanish
112536 Operating manual Pattern control ICS-IH 4x German
112537 Operating manual Pattern control ICS-IH 4x English
112538 Operating manual Pattern control ICS-IH 4x French
112539 Operating manual Pattern control ICS-IH 4x Italian
112540 Operating manual Pattern control ICS-IH 4x Spanish
113482 Operating manual Gear pump ZPC 2.3 German
113483 Operating manual Gear pump ZPC 2.3 English
113484 Operating manual Gear pump ZPC 2.3 French
113485 Operating manual Gear pump ZPC 2.3 Italian
113486 Operating manual Gear pump ZPC 2.3 Spanish
118156 Operating manual Pressure tank to Concept 4 German /
English
117991 Modification manual Pressure release German /
English
113546 Modification manual Maximum pressure valve German /
English
112801 Mounting manual EXT1 board for Heating zone cutoff German /
English
112799 Mounting manual External operating unit German /
English
116531 Description PROFIBUS-DP interface German /
English
Further languages are available on request at the corresponding representation.
12 Appendix
12.1 Power distribution and admissible loading
12.1.1 Supply 400 VAC 50Hz 3-phase with neutral conductor
Current L1 Current L2 Current L3 Condition

Heated hose 1 ––––––– ––––––– <5A
– –
Application head ––––––– ––––––– <5A
1 – –
Heated hose 2 ––––––– ––––––– <5A
– –
2 – –
Heated hose 3 ––––––– ––––––– <5A
– –
3 – –
Heated hose 4 ––––––– ––––––– <5A
– –
4 – –
I1 Total: < 16 A

Heated hose 5 ––––––– ––––––– <5A
– –
5 – –
Heated hose 6 ––––––– ––––––– <5A
– –
6 – –
Heated hose 7 ––––––– ––––––– <5A
– –
7 – –
Heated hose 8 ––––––– ––––––– <5A
– –
8 – –
I2 Total: < 16 A

Conc. 4 I = 2.6 A
Tank < 10 Conc. 8 I = 4.3 A
A Con. 12 I = 4.3 A
I3 Total: < 10 Con. 18 I = 6.5 A
A

I1 + I2 + I3 Total < 20 A
Concept / 4.1 Appendix 103

12.1.2 Supply 230 VAC 50Hz 1-phase
Only Concept 4/2 and Concept 4/4 units!
Current Condition
Heated hose 1 <5
A
Application head <5
1 A
Heated hose 2 <5
A
Application head <5
2 A
Heated hose 3 <5
A
Application head <5
3 A
Heated hose 4 <5
A
Application head <5
4 A
I1 Total: < 16
A
Current Condition
Tank 7.8 A < 16
A
I3 Total: 7.8 A < 16
A
Current Condition
I1 + I2 + I3 Total < 20 A
12.2 Quick reference
General production sequence Appliance status
1. Switch on with main switch or autom. time switch Ready Appliance is ready for operation
clock Tr < Tn Heating-up phase, nominal temps. not
2. Display of program version, all LEDs are lit reached
3. Tank starts heating => temperature is reached Error Error occurred
4. Waiting time in parameter 31 must expire 0 (off) Appliance switched off
5. Hose starts heating => temperature is reached Tlow Temperature lowering is
6. Appl. head starts heating => temperature is activated Tank empty (with
reached optional sensor)
7. When all temperatures reached and no
Program functions Appliance status messages
Selection with the keys 3.0 and 3.1 A 2 Heating-up phase
Treal Display actual temperatures A 3 Temp. lowering active via operating unit
Tnominal Display and enter nominal A 4 Temp. lowering active via 'LOW-TEMP'
temperatures Tlow Display and enter A 5 Temp. lowering active via weekly switch
reduced temperatures P Display heating clock A 6 Temp. lowering, standstill time too
output long (P 24) A 7 Appliance switched off via 'H-
Display and enter clock time / day of the ENABLE'
week Display and enter switching-on A 8 Appl. switched off, standstill time too long (P
times 25)
Display and enter switching-off A 9 Pump switched off via 'P-ENABLE'
times Display and enter temp. A 10 Nominal temp. exceeded by more than
lowering times Gear pump: enter 12°C A 11 Gear pump switched off via
speed (revs.) operating unit A 12 Pump switched off via
Gear pump: display speed (revs.) 'P-EMOFF'
V Display machine speed A 15 Waiting for expiry of tank melting time (P
Display operating hours [1,000 hours] 31) A16 Appliance switched off via time switch
Parameter Display and enter operating parameters clock A17 PINT: Manual pump mode active
A18 Profibus: Para.400 = On and no communication
A19 EXT-1: Manual application mode
active A90 Service message « Check filter
Heating zones status messages Error messages
H 1 Heating zone switched off internally E 01 Temperature limiter opened
H 2 Heating zone switched off, error on other heat. E 02 Temperature sensor line interrupted
zone H 3 Heating zone switched off by E 03 Temperature sensor line short-circuited
weekly switch clock H 4 Heatg. zone sw. off, E 04 Temperature too high, >12°C above Tmax (P
standstill time too long (P 25) H 5 Heating zone 30)
switched off via control input E 05 Heating insufficient, temp. rise < 5°C/10min
H 6 Heating zone sw. off due to order of heating up
E 06 Temperature inside appliance too high
H 7 Temp. lowering active via control input
E 07 EEPROM write error
H 8 Temp. lowering active via operating unit
E 08 Outputs of system interface X1 overloaded
H 9 Temp. lowering active via weekly switch
E 09 Glue tank full
clock H 10 Temp. lowering, standstill time too
long (P 24) H 11 Nominal temperature not E 10 Battery voltage too low
reached E 11 Clock time invalid
H 12 Nominal temperature reached E 100 EXT1: valve outputs overloaded
H 13 Nominal temp. exceeded by more than 12° C E 101 EXT1: system interface outputs
H 14 Heating zone switched off via EXT1 inputs overloaded E 102 EXT1: glue pattern cleared,
H 15 Premelter switched off by tank fill level sensor lengths too small E 103 EXT1: speed > Vmax
E 300 Gear pump: speed (revs.) too low
E 301 Gear pump: real speed > nominal speed
E 302 Gear pump: Error on AC frequency converter
E 400 Profibus: Error in the parameterization
E 401 Profibus: Error in the configuration
E 402 Profibus: Parameter value out of the input
Access blockage Calling up parameters
Lifting Loc1 Press keys 2.3 / 4.1 / 4.2 1. Select function Parameter (3.14) with keys 3.0 /
Lifting Loc2 Press keys 2.1 / 2.2 / 2.3 / 2.4 3.1
Activating Loc Press keys 2.4 / 4.1 / 4.2 2. Select number (display 4.0) with keys 4.1 / 4.2
3. Value in display 5.0, alter value with 5.1 / 5.2
Displaying and entering temperatures Saving all data settings
1. To display select Treal (3.2), to enter select – Heep keys 2.1 / 2.4 pressed on switching-on
Tnominal – Confirmation by display «2222» in display 5.0
(3.3) or Tlow (3.4) with the keys 3.0 or 3.1. Loading the saved data settings
2. Select heating zone Tank 2.7 / hoses 2.9 or heads – Heep keys 2.2 / 2.3 pressed on switching-on
2.10 with the keys 2.1 / 2.2 – Confirmation by display «5555» in display 5.0
3. Select hose and head number with the keys 2.3 / All data back to default values
2.4 – Heep keys 4.1 / 4.2 / 5.1 / 5.2 pressed on
4. Temperature in display 5.0 switching-on
5. Altering the nominal temp. with the keys 5.1 / 5.2 – Confirmation by display «8888» in display 5.0
Parameters
1 Temp. sensor correction factor tank 3 Waiting time after reaching of tank nominal
1 temp.
2- Temp. sensor correction factors hoses/heads 3 Configuration of input PAR-LOCHED2
18 2
20 Temp. difference tank - heated hoses 3 Activating temp. for waiting time (P 31)
3
21 Temp. difference tank - application heads 7 Resetting the service messages A90…A92
0
22 Order of heating-up (maintain basic value 7 Working hours till «Check filter cartridge»
1.2.3) 1
23 Temp. display in °Celsius or °Fahrenheit 7 Working hours till «Clean complete system»
2
24 Time until automatic temperature lowering 7 Working hours till «Free service message»
3
25 Time until automatic switch-off of appliance 8 Control-internal temperature (max. 65°C)
0
26 Switching-off heaters via H-ENABLE? 8 Standstill time
1
27 Switching-off pump or timer via P-ENABLE? 8 Battery voltage (minimal 2.6 Volt)
2
28 Number of existing heating zones (2 / 4 / 6 / 9 Programme
8) 0
29 Premelter existing? 9 Programme version
1
30 Upper temperature limit 2 Extra print ICS-EXT1 existing ?
0
0
Displaying and entering clock time / day of Activating temperature lowering
week Press key 2.6, green LED is lit
1. Select function (3.6) with keys 3.0 / 3.1 Activating the switch clock
2. Display of weekday in 4.0 and clock time in 5.0 Press key 2.5, green LED is lit
3. Altering of values with keys 4.1 / 4.2 or 5.1 / 5.2,
13 Key word index
A
Acces blockage configuration.........................51 Disposal..........................................................83
Access blockage.............................................44 Distributor block..............................................19
Accessories....................................................91 Disturbances in the hotmelt application...............79
Admissible loading........................................103 Disturbances of the pump....................................78
Air connection.................................................19 Drain opening.................................................19
Air connection.................................................30 Drain valve......................................................19
Air consumption................................................9 Draining of contamination...............................59
Air supply..........................................................9 Draining the glue pressure...................................40
ALARM output................................................33
Ambient temperature........................................9 E
Appendix.......................................................103 Electrical accident................................................14
Appliance design............................................18 Electrical connection............................................31
Appliance functions.........................................41 Electrical connections checking...........................68
Appliance identification.....................................7 Electrocution........................................................12
Appliance overview...........................................8 Electromagnetic compatibility..............................36
Appliance status.............................................42 Encoder and accessories........................................97
Applicance switch...........................................18 Error messages.......................................................43
Application head.............................................18 Exchange components............................................86
Extinguishing applicators on fire..........................15
B
Battery voltage................................................53 F
Battery............................................................24 Feed pump connections......................................18
Feed pump...........................................................18
C Feed quantity.......................................................40
Check stroke movement.................................19 Filling in hotmelt..............................................39
Cleaning agent...............................................60 Filter cartridge.................................................19
Cleaning the appliance...................................60 Filter flushing...................................................59
Cleaning, complete.........................................61 Filter replacing................................................59
Clock time.......................................................54 First commissioning.............................................37
Coarse filter....................................................18 Fixation ring....................................................19
Commissioning...............................................25 Free service message.............................................52
Compensation factor.......................................30 FULL-TANH input...........................................33
Compensation factors.....................................49 Functioning of the appliance................................18
Conformity......................................................10
Connection assignment of boards ICS...........69 G
Connection of PLC control..............................34 Glue pressure.......................................................40
Connection of relay control.............................35
Content of the manuals....................................7 H
Control electronics ........................................... 18, 21 Heads / hoses replacing......................................64
Controls and accessories....................................94 Heated hose fitting...............................................18
Copyright..........................................................2 Heated hose installation......................................27
Cylinder..........................................................19 Heated hose.........................................................18
Heated hose, electrical connection.........................30
D Heated hose, installation examples.........................28
Danger by vapours.........................................12 Heated hoses and accessories...............................91
Danger of burns..............................................11 Heating element...................................................19
Danger of splashing........................................12 Heating elements.................................................18
Dimensions.....................................................26 Heating output checking......................................45
Directives........................................................10 Heating part....................................................18
Heating up order.............................................23 Heating-up order.............................................49

Heating zone status........................................43 H-ENABLE activating......................................50
Concept / 4.1 Key word index 107
H-ENABLE input.............................................32 N
Hoses / heads replacing.................................64 Nominal temperature...........................................41
Hotmelt application disturbances....................79 Nozzle.............................................................18
Number of hoses/heads..........................................51
I Number of hoses/heads............................................9
ICS-EXT1 existence.......................................53
ICS-EXT1 location..........................................21 O
ICS-MAIN connection assignment..................70 ON output........................................................33
ICS-MAIN location..........................................21 On/off switch...................................................20
ICS-MAIN specifications.................................23 Operating concept................................................41
ICS-PINT location...........................................21 Operating hours until...........................................52
ICS-PROFIBUS location.................................21 Operating hours...................................................41
ICS-PSUP1 location.......................................21 Operating temperature..............................................9
ICS-PUS connection assignment...................75 Operating unit...................................................18, 20
ICS-PWR1 connection assignment................73 Operating voltages.................................................9
ICS-PWR1 location.........................................21 Operation.............................................................39
ICS-PWR2 connection assignment................74 Output pressure.....................................................9
ICS-PWR2 location.........................................21 Outputs...........................................................32
ICS-PWRD 3 location.....................................21 Overall status.......................................................42
ICS-PWRD1 connection assignment..............76 Overview.......................................................105
ICS-PWRD1 location......................................21
ICS-PWRD3 Connection assignment.............77 P
ICS-TIM location.............................................21 Packaging............................................................17
ICS-TRM location...........................................21 Parameter entering..................................................46
Improper use....................................................5 Parameters 1…22................................................49
Inputs..............................................................32 Parameters 23…27.................................................50
Installation......................................................25 Parameters 28…32.................................................51
Intended use..........................................................5 Parameters 33…73.................................................52
Interface of the system...................................32 Parameters 80…200...............................................53
Parameters capturing..............................................47
L Parameters, before altering.....................................46
Loading program settings...............................48 PAR-LOCHED input........................................33
Loc1 / 2...........................................................44 PAR-LOCHED2 configuration.............................51
LocE...............................................................44 PAR-LOCHED2 input......................................33
Longer interruption..........................................83 P-EMOFF........................................................33
Lowering of temperatures...............................56 P-ENABLE1 configuration...................................50
LOW-TEMP input...........................................33 P-ENABLE1 input............................................33
Personnel, qualified.............................................13
M Phase distribution..............................................103
Mains frequency...............................................9 Piston pump design.............................................19
Maintenance schedule....................................58 Piston pump installation.......................................66
Maintenance...................................................57 Piston pump removal...........................................66
Manual, how to use..........................................6 Piston pump repairing..........................................65
Maximum nominal temperature......................51 Piston pump seal sets..........................................88
Melting capacity................................................9 Piston pump types.................................................9
Melting tank....................................................18 Place of positioning.........................................25
Melting time activating temperature................52 PLC control.....................................................34
Messages.............................................................42 Plug sockets for hoses/heads..................................18
Pneumatic connection.............................................30
Power distribution..........................................103
Premelter configuration........................................51
Pressure controller...............................................19
Pressure gauge.......................................................19

Pressure peaks in system...................................49 Symbols for dangers.......................................11
Procedure in case of an emergency...............14 System control.....................................................32
Product description...........................................5 System errors.................................................43
Program modifications......................................7 System interface..................................................32
Program setting to default...............................48
Program version.............................................53 T
Program..........................................................53 Tank and distributor design.................................19
Protective equipment......................................14 Tank content..........................................................9
Publisher...........................................................2 Tank heating 2 configuration...............................51
Pump disturbances.........................................78 Tank lid opening...............................................9
Pump emergency-off......................................24 Tank lid ............................................................18, 19
Pumping rate....................................................9 Tank temperature waiting time............................51
Putting out of operation...................................83 Tank................................................................19
TANH-EMPTY output......................................33
Q Technical data........................................................9
Qualified personnel.........................................13 Temperature - unit of measurement....................50
Quick reference............................................105 Temperature accurancy.............................................9
Temperature differential Tank – heads...............49
R Temperature differential Tank – hoses................49
READY output................................................33 Temperature inside the appliance...........................53
Real temperature............................................41 Temperature limiter resetting...............................67
Relay control...................................................35 Temperature limiter..............................................19
Repair.............................................................63 Temperature lowering..........................................56
Resetting program..........................................48 Temperature sensor resistance value.....................68
Resetting service messages...........................52 Temperature sensor................................................19
Temperature sensors replacing...............................67
S Temperatures capturing..........................................45
Safety features...............................................13 Temperatures displaying.........................................44
Safety functions..............................................24 TEMP-LOW output..........................................33
Safety prescriptions........................................13 Test run...........................................................37
Safety.............................................................11 Time switch clock............................................55
Saving program settings.................................48 Topicality of the manuals..................................7
Scope of supply..............................................17 Transport..............................................................17
Screw fittings..................................................91 T-TRIGGER input............................................33
Seal sets piston pump....................................88 Type label.........................................................7
Sensors replacing...........................................67
Service messages resetting................................52 U
Setting the feed quantity.................................40 Use for the intended purpose................................5
Signals, system interface................................32
Skin burns.......................................................14 V
Sound pressure.....................................................9 Valve...............................................................18
Spare parts..........................................................85 Viscosity............................................................9
Spray element................................................18
Standstill supervision, switch-off.....................50 W
Standstill supervision, temperature lowering. .50 Weight...............................................................9
Standstill time.................................................53 Wiring diagram................................................22
Switching-on and -off......................................39

Table of parameters «Concept»
Valid for hotmelt applicators Concept ICS; from program version 3.04
On commissioning, the parameters set must be pencilled into the tables below. This means that in case of a
disturbance or after an exchange of the control, the correct values are reentered again quickly.
Date:
Initials: Program: ICS-MAIN Program version:
Typ Baujahr Art.Nr.

On type label
Volt Ampère
On ICS back panel SERIE NR. ICS ART.NR.
General parameters
Weekly switch Temperature Operating hours
clock lowering
D on / D D on / D [1,000 h]
off off
Temperature setting
Nominal Lowering Actual Heat.
Heating zone Unit
temp. temp. temp. power
«T nominal» «T low» «T real» «P»
Tank
Heating hose 1
Applicator head 1
Heating hose 2
Applicator head 2
Heating hose 3
Applicator head 3
Heating hose 4
Applicator head 4
Heating hose 5
D [°C]
Applicator head 5
D [°F]
Heating hose 6
Applicator head 6
Heating hose 7
Applicator head 7
Heating hose 8
Applicator head 8
Tank 2 (Premelter)
Weekly switch clock

Day of the week 1 2 3 4 5 6 7 Unit
Switch-on time 1
Switch-on time 2
Switch-off time 1
Switch-off time 2 [hh.min
Temp. lowering 1 ]
Temp. lowering 2
Concept ICS-MAIN 3.04 Table of parameters I

Temperature sensor compensation factors
Paramet Heating zone Value Paramet Heating zone Value
er er
1 Tank 1 10 Heating hose 5
2 Heating hose 1 11 Applicator head 5
3 Applicator head 1 12 Heating hose 6
9 Applicator head 4 18 Tank 2 (Premelter)
From programme 2.06 default value of all compensation factors = 8.2 / up to programme 1.11 default value = 7.0
Setup parameters
Pa Function Setting Input range Default
ra.
2 Differential temp. tank – heated [°C] / [°F] 10°C /
0 hoses 18°F
2 Differential temp. tank – applicator [°C] / [°F] 15°C /
1 heads 27°F
2 Order of heating up 1.2.3. = tank, hose, head
1.2.3.
2 1.1.1. = all heating zones
simult.
2 Temperature - unit of measurement C = Celsius / F = Fahrenheit C
3
2 Standstill time until temperature OFF Function off
OFF
4 lowering [hh.min] Time until
lowering
2 Standstill time until switch-off OFF Function off
OFF
5 [hh.min] Time until switch-off
2 Input H-ENABLE (X1/4) active OFF = inactive
OFF
6 On = active
2 Fucntion of input P-ENABLE (X1/7) OFF = Input
7 inactive 1 = Pump OFF
release
2 = Switch off timer function
2 Number of hoses / applicator heads [1…8] 2
8
2 Configuration of tank OFF = Premelter not
OFF
9 heating 2 (optional existing 2 = Premelter
premelter) existing
3 Maximum nominal temperature 20…230° C / 68…446° F 210° C
0
3 Waiting time after reaching of the
[hh.min] 0.30
1 nominal tank temperature
3 Configuration of access blockage OFF = no data access
2 on input PAR-LOCHED2 blockage 1 = Blockage of OFF
(X23/4) Loc2
2 = Blockage of Loc1 and
Loc2
3 Melting time activation temperature [30…95%] of Tnominal tank 85
3
7 Resetting of service messages A90… see manual 0
0 92
7 Operation hours till «Check filter» 200…1,000 h 600
1
7 Operation hours till «Clean cpl. 1'000…9,9999 h 3,000
2 system»
7 Operation hours till «Free message» OFF, 1…9,999 h OFF
3
8 Display, temperature inside the [°C] / [°F] max. 65° C / 149° F
0 appliance
8 Display, standstill time [hh.min]
1
8 Display, battery voltage [Volt] min. 2.6 Volt ± 5 %
2
9 Display, program 1=Concept, 2=Jumbo, 3=RMC
0
9 Display, program version [X.YY]
1
2 Existence of extra board ICS- OFF = without EXT1
0 EXT1, Evaluation of the or no evaluation OFF
0 release inputs On = with EXT1 and
H-ENABLE 1…3 evaluation
Parameter 80…82, 90, 91 only display
Concept ICS-MAIN 3.04 Table of parameters II

1 2 3 4 5 6 7 8
A
Inhaltsverzeichnis Drahtfarben A
Blatt 2 : Hauptanschluss+Energieverteilung
L1/L2/L3 400V AC : Schwarz
Blatt 3 : Heizung Tank
N Neutralleiter : Hellblau
Blatt 4 : Heizung Schläuche + Köpfe 1-4 PE Schutzerde : Grün-Gelb
Blatt 5 : Heizung Schläuche + Köpfe 5-8
B B
Blatt 6 : Zahnradpumpen
Blatt 7 : ICS-Main + ICS PUSF
Blatt 8 : Struktur ICS
C C
D D
Index Wire Color

Page 2 : Power-Supply
Page 3 : Heater Tank L1/L2/L3 400V AC :
Page 4 : Heater Hoses + Heads 1-4 N Neutral Blac
E
PE/GND k E
Page 5 : Heater Hoses + Heads 5-8
: Light-Blue
Page 6 : Gear Pumps Earth/Ground : Green-
Page 7 : ICS-Main + ICS PUSF Yellow
Page 8 : Structure ICS
F F
Creat : 24.04.01
ed
M.Räber
Robatech AG Concept
Art. Nr. Revision Sheet
Modified : 02.05.02 M.Räber Pilatusring 10

Approved : 03.05.02 M.Weber CH - 5630
Muri
12120 A 1 of 9
0
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
2A5
A MOUNTINGPLATE
MONTAGEPLATTE X9 A
X2
U
3x400/230VAC MAIN CONNECTION

X1 4 X2-U 3.1
Tank Heater Tank

V
PE 3 X2-V 3.1
W
POWER 3x400/230VAC FOR ICS-PWR1, ICS-PWR2

N 2 X2-W 3.1
N
L3 1 X2-N 3.1
B L2 B
10-17Zone 2-9Heizung ZoneHeizung

X3
L1 U
2-9
4 X3-U 4.1
PUMP-DRIVE
V
L 6.1 X12 3 X3-V 4.1
AC/DC CONV.230VAC
LP W
L. 6.3 2 2 X3-W 4.1
NP N
N 6.1 1 1 X3-N 4.1
C C
N. 6.3
X7 ICS-PWRD3 X4
230VAC
U
2 4 X4-U 5.1
Heater
V
1 3 X4-V 5.1
Heater Zone 10-17 Heizung Zone

2S5 0-1 W
grün 2 X4-W 5.1
MONTAGEPLATTE MOUNTINGPLATE
N
ON/OFF-SWITCH
green 2 X6 1 X4-N 5.1
D 2a
1 D
1 3
1a X5
230V 24V U
2 4
AC DC V
4 3
W
L1 L2 L3 N PE / GND 2
3 x 400/230V 50Hz/60Hz ov +24V X8 1
N
E E
Fuse / Vorsicherung max. PWRON
24VDC CONTACTOR
AT/IM ICS-MAIN 24V 7.5 2
20A
OV
0V 7.5 1
- +
7.1 7.1
F F
Hauptanschluss Netzgrät Leistungsverteilung

Main-line Regulated Power Power Distribution
Supply
Created : 24.04.01 M.Räber Concept Art. Nr. Revision Sheet
Modified : 02.05.02 M.Räber

Robatech AG
Approved : 03.05.02 M.Weber Pilatusring 10
CH - 5630 Muri 121200 A 2 of 9
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X2-U 2.8
X2-V 2.8
X2-W 2.8
A X2-N 2.8 A
KABEL TO ICS-MAIN, X4
12.5A 3A1
N W V U X3
X1/X2
1 2 3 4
B B
POWER 3X400/230VAC ICS-PWR1
TANK-HEATER TEMP.SENSOR OVERTEMP.

NTC PROTECTION
1 2 3 4 31 2 4 1 2
X4 N W V U X5 - + X6 OTMP1 OTMP2
C C
Schwarz/Black
Braun/Brown
Rot/Red
Grau/Grey
Grau/Grey
Grau/Grey
Grau/Grey
V1
230V
D D
3E21
HEATER
V2
W1 U1
HEATER 230V
HEATER 230V
3E2
NTC
3E22 3S5
3R3 230°C
E W2
Blau/Blue
E
Blau/Blue
U2
F
F
Heizung Tank
Temp. Fühler Tank Uebertemperatursicherung
Heater Tank Temp.Sensor Tank Overtemp.Fuse
Created : 24.04.01
Modified : 02.05.02
M.Räber
M.Räber
Robatech AG Concept Art. Nr. Revision Sheet

CH - 5630 Muri 121200 A 3 of 9
1 2 3 4 5 6 7 8
HE
BLUE/BLAU BLUE/BLAU
7
AT
BROWN/BRAUN 5-BLACK/SCHW.
ER
HOSE/SCHLAUCH HOSE
1
230V
5 1+
H H
HEATER
BLACK/SCHW. 2-BLACK/SCHW. 1 E 2
230V A
HEAD/KOPF 1 2 H
HEATER D 1
M.Rä 2
ber WHITE/WEISS WHITE/WEISS X8 TE
-
M.Rä 4 HOSE M Für
ber NTC1 P.
WHITE/WEISS BROWN/BRAUN
1 2
Con X3-U 2.8
HOSE/SCHLAUCH 6 SE
1
NTC + cept X3-V 2.8
NS
Robat
GREY/GRAU GREEN/GRÜN
1 HEAD O 2 X3-W 2.8
-
ech GREY/GRAU YELLOW/GELB NTC2 R Schl 2
3 4
3 + 1+ äuch
AG HEAD/KOPF 1
NTC
A
X5HOSE e/2
Pil M
N H HE
atu P
EB AT Köpf
BLUE/BLAU
H.
sri
ng
8P
N
AL
ER e7
DU
10 HO 1 E
HOSE 3+ For5-BLACK/SCHW.
/
3
SE/ H HB 4 Con
5 3
SC
3 EL
HL
AU A cept
DU
CH
2
2
B
R
O
W
N
/
B
R
A
U
N
230V
HEATER
HE C
AD/ 23
KO 0V
6 PF HOSE/S
2 HEA
CHLAUC
H TER
HO HEAD/K
SE/ OPF 3 NT
SC C
4 HL
AU
CH
2
NT
C
HE
C AD/
KO
on PF
2
23
ce 0V
pt HEA
TER
230
5 V
HO
SE/ HEA
SC TER
HL
AU
CH
3
HE NT
AD/ C
KO
PF
3
NT
F E D C B A
Appro Creat AA HOSE
HOSE
ved : ed : MM
PP HEA
H
03.05.
BL 24.04
U S 2- BLUE/BLA
5- 5
H. H HOSED E
HE 7
02A .01 BLACK/ U BLACK/SC H.
8P AT
C SCHW. 7 HW. 8P 7 1 2A
M.We Modifi N N H
K/
ber
S 2 HEAD/KOPF
BLA 4
2-
X4
H
N
D
E ER
S ed : 1 A
1
C 02.05 CK/ BLAC 4 7+
H Revision
BL W
.02
SCH
HEATE K/SC X9 D TE X1/X2 N 1
8
WHITE/ W. HW.
W. -
R M
AU
WEISS HOSE
2 H
H 4
8 NTC3 P.
BROWN X11 2 SE
TE P
W /BRAUN WHI WHIT
HOSE/SCHLAU O
1- 8
E/ I
Sheet
6
CH E/WEI HOSE NS
M W
SS + ER
TE/ NTC7 O
P.
HI
4 BLof T GREEN/
GRÜN
NTC 4
BRO
1
HEAD
2 R
SE
3X W 2
40
0/2
4
TE 9
1 WEI WN/B - NTC4 3+
NS 30
E
A YELLO RAUN
HEAD/KOPF 4 3 4 O VA
V3
W/GELB 6
/W SS
NTC
+ R
/ 3 GREE +
U F E N/GR 7+
HEAD
X6HOSE
WHI ÜN A U4
EI
W M N NTC8
B 1
P - 3 H4 HE
BLUE/B TE/ YELL H. E AT
SS
R E LAU OW/G 8P A
ELB D ER
7 N
W
I 5-
WEI 3 +
5+ 5
O HOS
BLACK/ D C 4 E B 6 IC A
SCHW. SS
HI
W S 5 H
H S-
E
2- GR 5 A
P
TE
N/ S BLACK/
SCHW.
W
/W 2 EY/
H R2 K
B G X3
6 TE A
X1 B
EI
R
WHITE/ GR
0-
M EL
R WEISS 1 P. T
4
SS AU HOS SE O
A E
BROWN E Für IC
/BRAUN NS S-
6
G 6
GR NTC5
O Con M
U Y +
GREEN/ R cept AI
EY/
R
N /
GRÜN HEAD 5+ 4
1 - NTC6
E YELLO GR 3 4 Schl
BL G W/GELB äuch
3
Y/
R
AU + e/4 4A
A
X7 Köpf 1
G N
C A e
R For
K/ U
Con
A
S G cept
U
4
C R
G
H E
R
W. Y
E
/
W
Y/
G
HI
G
R
TE
R
A
/W
A
U
EI
Art. Nr.
V
BLUE/BLAU
1212 HEATER
00HOSE/SC
HLAUCH
BROWN/BRAU
N
2
7 3
0
HE
BLUE/BLAU BLUE/BLAU
7
AT
BROWN/BRAUN 5-BLACK/SCHW.
ER
HOSE/SCHLAUCH HOSE
5
230V
5 1+
H H
HEATER
BLACK/SCHW. 2-BLACK/SCHW. 1 E 2
230V A
HEAD/KOPF 5 2 H
HEATER D 1
M.Rä 2
ber WHITE/WEISS WHITE/WEISS X8 TE
M.Rä 4
-
HOSE M
Für
ber
WHITE/WEISS BROWN/BRAUN NTC1 P. Conc
HOSE/SCHLAUCH 6 +
1 2
SE ept 6 X4-U 2.8
NTC
5
NS Schlä X4-V 2.8
Robat
GREY/GRAU GREEN/GRÜN
X4-W 2.8
1 -
HEAD O uche
ech GREY/GRAU YELLOW/GELB
3
NTC2
4
R /6 2
3 + 1+ Köpf
AG HEAD/KOPF 5
NTC
A
X5HOSE e
Pil M
N H HE
P
atu
H. EB AT ForBLUE/BLAU
sri
ng
8P
N
AL
U
ER Conc
7
D
10 HO 1 E
HOSE 3+ ept 5-BLACK/SCHW.
6
/
3
SE/ H HB 4 Hose
5 3
SC
3 E
HL
A
L
s/6
AU
CH DU Head
6
B
R
O
W
N
/
B
R
A
U
N
230V
HEATER
HE C
AD/ 23
KO 0V
6 PF HOSE/S
6 HEA
CHLAUC
H TER
HO HEAD/K
SE/ OPF 7 NT
SC C
4 HL
AU
CH
6
NT
C
HE
C AD/
KO
on PF
6
23
ce 0V
pt HEA
TER
230
5 V
HO
SE/ HEA
SC TER
HL
AU
CH
7
HE NT
AD/ C
KO
PF
7
NT
F E D C B A
Appro Creat A
A HOSE
HOSE
ved : ed : M
M
P HEA
H
03.05.
BL 24.04
U S 2- BLUE/BLA
5- 5 P
H. H HOSED E
HE 7
02A .01 BLACK/ U BLACK/SC H.
8P AT
C SCHW. 7 HW. 8P 7 1 2A
M.We Modifi N N H
K/
ber
S 2 HEAD/KOPF
BLA 8
2-
X4
H
N
D
E ER
S ed : 1 A
1
C 02.05 CK/ BLAC 4 7+
H Revision
BL W
.02
SCH
HEATE K/SC X9 D TE X1/X2 N 1
8
WHITE/ W. HW.
W. -
R M
AU
WEISS HOSE
2 H
H 4
8 NTC3 P.
BROWN X11 2 SE
TE P
W /BRAUN WHI WHIT
HOSE/SCHLAU O
1- 8
E/ I
Sheet
6
CH E/WEI HOSE NS
M W
SS + ER
TE/ NTC7 O
P.
HI
5 BLof T GREEN/
GRÜN
NTC 4
BRO
1
HEAD
2 R
SE
3X W 2
40
0/2
4
TE 9
1 WEI WN/B - NTC4 3+
NS 30
E
A YELLO RAUN
HEAD/KOPF 8 3 4 O VA
V3
W/GELB 6
/W SS
NTC
+ R
/ 3 GREE +
U F E N/GR 7+
HEAD
X6HOSE
WHI ÜN A U4
EI
W M N NTC8
B 1
P - 3 H4 HE
BLUE/B TE/ YELL H. E AT
SS
R E LAU OW/G 8P A
ELB D ER
7 N
W
I 5-
WEI 3 +
5+ 5
O HOS
BLACK/ D C 4 E B 6 IC A
SCHW. SS
HI
W S 5 H
H S-
E
2- GR 5 A
P
TE
N/ S BLACK/
SCHW.
W
/W 2 EY/
H R2 K
B G X3
6 TE A
X1 B
EI
R
WHITE/ GR
0-
M EL
R WEISS 1 P. T
4 AU HOS SE O
SS
A E
BROWN E
Für IC
/BRAUN NS Conc S-
6
GR NTC5
G
U Y 6 + O ept 8 M
R AI
GREEN/
EY/ Schlä
R
/
GRÜN HEAD 5+
N 1 - NTC6 uche
E YELLO GR 3 4 /8
BL G W/GELB
3
Köpf
AU +
Y/
A R e 5A
X7 1
G N For
A
C
Conc
R
U ept 8
K/
Hose
A
S G s/8
Head
U
C R
G
H E
R
W. Y
E
/
W
Y/
G
HI
G
R
TE
R
A
/W
A
U
EI
Art. Nr.
V
BLUE/BLAU
1212 HEATER
00HOSE/SC
HLAUCH
BROWN/BRAU
N
2
7 3
0
1 2 3 4 5 6 7 8
Variante Zahnradpumpe und / oder Kolbenpumpe

Variation Gearpump and / or Pistonpump
6A4
X6 1 NPN
A ICS-PINT X8 2
3
PNP
A
ENC. PUMP CONTROL PUMP 1 ENC. PUMP 2 CONTROL PUMP 2 ENC. MACHINE SPEED
-0V +24V N L -0V. +24V. N. L. 1
SHIELD GND 0V OUT 0-10V
SHIELD GND 0V OUT 0-10V
+24V 0V 0V
7.6
7.6 2.4 2.4 7.8 7.8 2.4 2.4
+24V P/N-INP 0V
+24V P/N-INP 0V
1 2 3 1 2 3 4 5 6 7 1 2 3 1 2 3 4 5 6 7 12345 6
X2 X4 X3 X5 X1
Gelb-Grün 9 / Yellow-Green Braun 7 / Brown
Gelb-Grün 9 / Yellow-Green Braun 7 / Brown

B B
Braun 11 / Brown
Braun 11 / Brown
Weiss 10 / White
Weiss 10 / White
Schwarz / Black Violett / Violet Rot / Red
Schwarz / Black Violett / Violet Rot / Red

Weiss / White Braun / Brown Grün / Green Gelb / Yellow Grau / Grey Rosa / Pink
Weiss / White Braun / Brown Grün / Green Gelb / Yellow Grau / Grey Rosa / Pink
Weiss / White
Grün / Green
Blau 6 / Blue
Blau 6 / Blue
C C
D D
1 2 5 6 1256 5 6 7 8 9 10 11 12 13 14 5 6 7 8 9 10 11 12 13 14
Amph.7-Pol - + N L PE Amph.7-Pol - + N L PE
E E
Amph.15-Pol Amph.15-Pol
Pumpe 1 Pumpe 2 Pumpe 1 Pumpe 2
6B8 0V +24V A B
Pump 1 Pump 2 Pump 1 Pump 2 24
VDC
Option Option
Option
F F
Speisung KP =24V / ZP =24V/230V Speisung KP =24V / ZP =24V/230V Steuerung Zahnradpumpe + Rückführung Steuerung Zahnradpumpe + Rückführung Encoder
Power Supply KP =24V / ZP =24V/230V Power Supply KP =24V / ZP Control Gearpump Control Gearpump
=24V/230V
Created : 24.04.01
Modified : 02.05.02
M.Räber
M.Räber
Approved : 03.05.02 M.Weber Pilatusring 10 CH - 5630 Muri

121200 A
6 of 9
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
- + Füllstandüberwachung
2.3 2.3 Level Sensor
7B7
Bedieneinh -+ Option
eit Operator Blau/Blue 3142
Terminal
A X Braun/Brown Weiss/White
A
X2 1 2
7A1
X1 X2 1 2 3 4 X22 1 2 3 4 X21 1 2 3 4 X20 1 2 3 4 5 6 7 8 X10 1
3 2 3 4 X11 1 2 4 1 2 3 4 X12 1 2
3 3
AUX-OUT1
AUX-OUT2
X33
P.-LOCK.1
P.-LOCK.2
FULL
P-EMOFF2
+24V
0V
24VDC
AGND
SSWITCH
TANK-LEVEL
EMERG.-STOP
AUX-IN1
AUX-IN2
SVALVE
+24V
POWER
4..20mA
4..20mA
0V
24VDC
24VDC
24VDC
AGND
0..5V
0..5V
EMPTY
0V
+24V
0V
B
ICS-MAIN
CONTROL-V. F.CONTACT.
TEMP-LOW
0V, OUT
0V, OUT
PWRON
PVALVE1
PVALVE2
OUTVIN
ALARM
READY
0V, INP
PUMP1
PUMP2
+24V
0V
PUMP
P-ENABLE2
P-ENABLE1
T-TRIGGER
LOW-TEMP
H-ENABLE
1 X1
+24V
ON
0V
0V
2 3 4 5 6 7a 7b 8 9 10 11 12 13 14 15 X3 1 2 X8 X9
16
C C
Brown/Braun
Brown/Braun
White/Weiss
White/Weiss
2.4 2.4
D 0V 24V 1 2 1 2 D
AMPH.7P X115 6.1 6.1 AMPH.7P X115 6.2 6.2
-0V +24V -0V. +24V.
Brown/Braun
Brown/Braun
Blue/Blau
Blue/Blau
Option
E 7A6 7A E
INPUT INPUT 7
X1 1 2 X1 1 2
Nur Kolbenpumpen 1+2 0V +24V ICS-PUSF 0V +24V ICS-PUSF

Only Pistonpumps 1+2 0V VALVE 0V VALVE 0V VALVE 0V VALVE
1 2 2 1 2 2
X2 BELOW X3 1 ABOVE X2 BELOW X3 1 ABOVE
A1 A1
F A1 A1
F
A2 A2 A2 A2
Created : 24.04.01
Modified : 02.05.02
M.Räber
M.Räber

CH - 5630 Muri 121200 A 7 of 9
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Tank-Level Control OPERATOR TERMINAL/BEDIENEINHEIT

Tankfüllstandsüberwachung
Tank-Level Control
Tankfüllstandsüberwachung X1
ICS-TRM
Tank-Level Control Safety Contact
A Tankfüllstandsüberwachung Sicherheitskontakt A
X11 X33 X13
Option
HOSE & X12 HOSE & HEAD
HEAD X4 X11 SCHLAUCH + KOPF
SCHLAUCH+KO
PF X8 X14 ZONE 8 + 9
X3 X5 X3 X7
ZONE 10 + X
B HOSE & HEAD B
11 6
X ICS-MAIN X10 SCHLAUCH + KOPF
5 X4 ZONE 6 + 7
HOSE & X6
HEAD
SCHLAUCH+KO X ICS-PWR2/4
7 HOSE & HEAD
PF X9 SCHLAUCH + KOPF
X X3 X15 X6
ZONE 12 +
13 ZONE 4 + 5
X5
C 9 C
X ICS- PUMP /
2 Pump 1
HOSE & ICS-PWR2/4 PUMPE
HEAD
PINT
X VALVE EVACUATE
SCHLAUCH+KO X8
PF X2 X4 X3 X5 X1
6 Pump 2
ZONE 14 + ENTLUEFTUNGSVENTIL
15
Sensor Sensor
Encoder ZONE 2 + 3
X4
D HOSE & Pump 1 D
Pump 2 X1 X2
HEAD Mach.Speed
X
SCHLAUCH+KO 24VDC
PF CONTROL
1 POWER
ZONE 16 + SUPPLY
17 0 CONTROL PUMP 1
PUMP
2
X
E E
7 X12 X8
X OVERTEMP.
7 PROTECTION
X6
UEBERTEMP.SCHALTE
X2 R
X X2
X
4 ICS-PWRD3 TEMP. SENSOR
1 X5
ICS-PWR1 TEMP. FUEHLER
F X3 F
1
HEATER MELTING
X1 X X1 X9 PLATE
X2 5 X4
X1/X2 HEIZUNG
SCHMELZPLATTE
ZONE 1
3 x 400/230VAC
MOUNTINGPLATE
Speisung / Power
X
6 3 x 400VAC/230VAC
POWER/SPEISUNG
Created :
24.04.01
M.Räber
Robatech AG Concept
Art. Nr. Revis
ion
Sheet
Modified :
02.05.02
M.Räber Pilatusring 10
CH - 5630 12120 A 8 of
Approved : 03.05.02 M.Weber Muri
0 9
1 2 3 4 5 6 7 8
PROJEKT 122850.prg
Refere Art. Bezeichnung Typ

nz Nr.
2A5 112406 PWRD3 max.20A

2T3 112408 Netzteil/Power-Supply 230V/24V 60W
2S5 112056 Netzschalter/Switch Robatech
3A1 112400 PWR1 12.5A
3E1 111802 Heizpatrone/Heater 600W
3R2 100187 Temperaturfühler/Temp.Sensor d=8mm
3S4 102120 Übertemp.Schalter/Overtemp.Swit 162 021 E1 - 3707
Concep 4: ch
t 111802 600W
3E2 Heizpatrone/Heater
Concep 8:
t 120100 Heizpatrone/Heater 100
3E2 0W
Concep 12:
t 120100 Heizpatrone/Heater 1000W
3E2
Concep 18:
t 120101 Heizpatrone/Heater 1500W
3E2
C 4/2 C 4/4
C 8/2 C 8/4 C 8/6 C 8/8
C 12/2 C 12/4 C 12/6 C 12/8
C 18/2 C 18/4 C 18/6 C 18/8
4A1 112398 PWR2/2 Pos.1 x
4A1 112399 PWR2/4 Pos.1 x x x
5A1 114445 PWR2/2 Pos.2 x
5A1 114446 PWR2/4 Pos.2 x
6B8 100824 Encoder BDT
03.24K1000/403386
6A4 113469 ICS-PINT ICS-PINT
7A1 122186 ICS-Main ICS-Main
7A6 111733 ICS-PUS ICS-PUS
7A7 111733 ICS-PUS ICS-PUS
7B7 111705 Initiator/Prox.Switch M30x1,5

Operating Manual Hotmelt Applicators Concept 4, 8, 12, 18

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operating Manual Hotmelt Applicators Concept 4, 8, 12, 18

Uploaded by

Copyright:

Available Formats

Operating Manual

Phone +41 (0)56 675 77 00

Date of issue: May 2002

3 Transport and scope of supply__________________________________________________17

4 Appliance overview and functions_______________________________________________18

5 Installation and first commissioning______________________________________________25

Concept / 4.1 Table of contents 1

6.9.19 Parameter 32: Configuration of access blockage PAR-LOCHED2...............................51

Concept / 4.1 Table of contents 2

9 Putting out of operation and disposal_____________________________________________83

Concept / 4.1 Table of contents 3

13 Key word index_____________________________________________________________107

Concept / 4.1 Table of contents 4

1.1 Use for the intended purpose

The Concept applicators are intended for melt-

1.2 Improper use

– Operation of the appliance by unqualified personnel is prohibited.

Concept / 4.1 Product description 5

Neither is the operation of the application heads described in this manual.

1.3.1 How to use this manual

Program ICS-MAIN from version 2.06 to 3.00:

1.3.3 Content and topicality

Documentation Content Edition

1.4 Appliance identification

Typ Appliance version with installed options

D. Connections for hoses and heads

* Guide value, melting capacity depends on the adhesive

2.1 References contained in the operating manual

Possibly Possibly death or most

Material damage to product or

Tips for application or No dangerous or harmful

2.2 Dangers of handlingloperating the appliance

Heat-resistant protective gloves must be worn for all adjustment or

– A label on the rear side of the appliance warns of

– This sticker on the covers on the front and on both sides

2.2.4 Irritations of the mucous membranes

2.4 Safety features

2.5 Qualified personnel

2.7 Procedure in case of an emergency

2.7.1 Skin burns

2.7.2 Electrical accident

Warnin Danger of burns

Concept 4 Concept 8 Concept 12 Concept 18

The handling symbols on the box must be observed:

Use only the original box for all transports.

In case of transport after commissioning, watch the following points:

3.3 Scope of supply

Concept / 4.1 Transport and scope of supply 17

4.1 Overview of the appliance

1. Appliance switch 14. Heated hose connection

4.2 Functioning of the appliance

4.4 Piston pump

Concept / 4.1 Appliance overview and functions 19

1 Appliance switch and the operating parameters. Light indication of the

ICS-MAIN Main control

Dedicated operating manuals are available for all options.

Illustration in maximum execution for 8 heated hoses and application heads.

The appliance must be installed and commissioned by a trained and experienced

For all installation work on the heated appliance it is an absolute must to

Proceed as follows for a successful installation:

5.1 Place of positioning

Concept / 4.1 Installation and first commissioning 25

– Space requirement and dimensions: