Save on labor and improve plant safety

The 3D system automatically vacuum transfers hot melt adhesives via a vibrating wand and hose from any shipping or storage container directly to a melt unit. It is a compact machine that operates on plant compressed air and installs in minutes on your existing melter. The 3D system operates continuously, so there's no need for operator interface.

Because the 3D fits directly on the top of your machine, it improves your operation in several ways. First, it operates automatically, so your machine operators can be freed up to handle other tasks, instead of manually scooping adhesive into the machine. This also improves workplace safety - less exposure to high temperatures - and plant housekeeping because opportunities for adhesive spills are eliminated.

Second, the 3D system seals over the existing melter filling port, so it prevents contaminants from reaching the molten adhesive, eliminating a major cause of char, which can lead to equipment maintenance problems. And lastly, it saves money through reduced labor cost.

Unlike manually filled operations, a 3D automated system prevents a hot melt unit from running out of adhesive. An adhesive level detector ensures continuous flow of fresh hot melt. And a low-level alarm sounds if there is any interruption in product supply. Because the hot melt is replenished continuously without opening the lid, the temperature is maintained, ensuring constant performance of the hot melt adhesive.

Need help installing your 3D Autofill unit?

National offers three different models of the 3D Autofill unit. Please select your 3D model and manual from the pictures below.

The installation, maintenance and operation manual for the 3D unit is available as a download file, in pdf format. 3D users can replace lost or worn copies of their manual by simply clicking on the link offered below. While all sections of the manual are important, we especially urge users to become familiar with the safety section (section 1.2) as well as the installation, operation, maintenance, and trouble shooting sections.

• Installation Manual
  Model MK1
• Installation Manual
  Model MK2
• Installation Manual
  Model MK3

Installation has never been easier!

What clearance do I need to install a 3D Autofill unit?

The original 3D Autofill unit, Model MK1, requires 21 inches (53 cm) of clearance for installation.

The unit itself stands 18 inches (46 cm) tall but you must allow 3 inches (8 cm) of added clearance for removal of the filter housing and air filter for routine cleaning and replacement.

The newer 3D Autofill units, Model MK2 and Model MK3, require 20 inches (51 cm) of clearance for installation.

Although these models are shorter than 20 inches (33 cm) tall, they require 20 inches (51 cm) of overhead clearance to allow for maintenance and removal of the air filter.

What power source is required to operate a 3D Autofill unit?

3D Autofill units are designed to run on either 110 or 220 volt power source.

The units are delivered with a standard North America 3 prong plug for connection to a 100 volt outlet.

If it is desired to connect to a 220 volt line, simply replace the standard plug with a 220 volt plug.

How much compressed air is required to run a 3D Auto fill unit?

The 3D Auto fill requires 60-80 psi (4-6 Bars) compressed air from a supply capable of maintaining 3 cubic feet per minute (5 cubic meter/hour) air flow at that pressure level.

Note that the 3D Auto fill unit does not place a constant draw on the plant compressed air supply.

It draws compressed air only when the unit runs to replenish the hot melt tank. This is usually only a few minutes per hour for most installations.

Over what distance will a 3D Auto fill unit convey hot melt "chips"?

The 3D Auto fill will convey hot melt "chips" over a max. distance of 50 feet (15m) from supply container to hot melt unit.

This distance can also include up to a 10 foot (3m) vertical run.

Does the 3D Auto fill come with sufficient hose to handle 50 foot (15m) max. delivery run?

The normal delivery of a 3D Auto fill includes 10 feet (3m) of both vacuum hose and compressed air tubing.

If longer lengths are required, this should be specified by your National Adhesives representative.

If longer hoses are needed after the initial installation, they can be ordered via the on-line order form.

Can we fit a remote alarm to the 3D Auto fill, instead of the local alarm in the control panel?

Yes, a remote audible or visual alarm, or both, can be installed.

Connect this in place of the existing alarm inside of the control panel.

24v DC and a max of 100 ma resistance are allowed.

What should be used as the supply container for the 3D Auto fill?

The vacuum wand of the 3D Auto fill can be inserted into any of National's standard packages: 50 pound box, corrugated bin box, Big Bag sack, or our VERSI-BOX™ collapsible bin.

National also supplies an optional COOL-BIN® storage container, which holds approx. 160 pounds (60Kg) of hot melt, for use as the supply container for the 3D Auto fill installations.

Request a COOL-BIN container when planning a 3D Auto fill installation with your National Adhesives representative.

What tools are needed to install a 3D Auto fill on existing hot melt application units?

For most installations, just 2 standard screwdrivers (supplied with your 3D Auto fill) are needed for installation.

The known exceptions are Nordson problue units which require a 4mm Allen wrench (not supplied) for the original mounting bolts.

Are there any tips for adjusting the level sensor?

Adjusting the level sensor is not a required step in the installation process for model MK3 and late model MK2s, which have the metal post attached beside the sensor.

Sensor adjustment is required at installation for earlier models.

After the initial installation, it may be necessary to readjust the sensor if your 3D Auto fill unit shows signs of overfilling or under filling the hot melt tank.

The procedure for adjusting the sensor is clearly described in the installation and Maintenance Manual, Section 9.2.

One valuable tip is to stand directly in front of the control box while adjusting the sensor.

This will position you to easily see the indicator light change color from amber to green to amber.

If you happen to stand off to the side of the control box, you could easily miss the color change.

What is the maximum temperature rating for the level sensor on a 3D Auto fill unit?

The level sensor on 3D Auto fill units has a maximum temperature rating of 250¡c (482¡ F).

Will I need to provide any parts for the installation of a 3D Auto fill unit?

Be aware that the tank-top screws on most hot melt applicators may not be long enough to accommodate the added 1/4 inch thickness (6mm) of the 3D Auto fill mounting plate.

It's a good idea to have 1/4 inch (6mm) longer screws available, in case they are needed for the installation.

What is the function of the round metal rod packed with he 3D unit?

3D Model MK3 and late model MK2s include a metal rod that serves as the calibration target for the sensor.

Each 3D unit is calibrated with the metal rod at the factory.

The rod is then removed and taped to the back of the heat shield mounting bracket for shipping.

For installation of a new 3D unit, find the metal rod and secure it to the mounting plate with the hex bolt provided in the installation hardware bag.

Failure to attach the metal rod for a new installation will result in sensor malfunction, overfilling or under filling, and premature controller failure.

Adjusting the sensor only takes a few steps

The fill-level sensor may need to be re-set if the probe is moved up/down in its mounting collar, if the probe is removed from its collar, or if the 3D unit is removed/replaced on the hot melt tank.

Signs that the sensor needs adjustment would include:

• Unit does not fill when needed
• Unit does not fill sufficiently
• Unit overfills the melt tank.

The latest procedure for adjusting the level sensor is offered via the link to the right.

If the sensor adjustment fails to solve your operating problem, use the 3D Fault Report (second link to the right) to troubleshoot your 3D unit. If operating problem persists, complete the Fault Report and contact your National Adhesives representative for instructions.

3D Auto fill Maintenance Tips

Save on labor and improve plant safety

Air Filter Cleaning and Replacement

The air filter on a 3D Auto fill unit requires cleaning and occasional replacement. Many of National's hot melt adhesives are coated with "poly dust" to prevent blocking of the slats. The "poly dust" may build-up on the inner surface of the air filter, requiring cleaning or replacement of the filter. To clean the filter, simply remove the filter from its housing and blow the filter clean with compressed air. If replacement is necessary, refer to Air Filter Replacement entries in the left menu column for the information needed to purchase filters for your model of the 3D Auto fill.

Level Sensor Adjustment

After installation, it may be necessary to readjust the level sensor if your 3D Auto fill unit begins to overfill or under fill the hot melt tank. The sensor adjustment is a simple process - just follow the steps in the Installation, Operation, and Maintenance Manual, Section 9.2.

Secure the level sensor adjustment screwdriver.

Here's a handy tip to prevent loss of the level sensor adjustment screwdriver. This tiny screwdriver is small enough to lose - even inside a maintenance toolbox! To secure the adjusting screwdriver for future use, store it inside the 3D control box. Use some tape to secure it to the inner surface of the control box so that when the box is reopened, the screwdriver remains in place. This way you'll always have the tiny tool available if you need to readjust the level sensor.

How can I replace the tiny screwdriver used to adjust the level sensor?

Each 3D Auto fill unit is delivered with a screwdriver for adjusting the level sensor. If you happen to lose this tiny screwdriver, you can purchase sets of small "precision screwdrivers" at most hardware/tool stores. You could also purchase an eyeglass repair kit at most drugstores, convenience stores, or many supermarkets. The eyeglass kit usually contains one or more small screwdrivers which can fit the 3D Auto fill adjustment slot. If you happen to have a "Dollar Store" nearby, they commonly sell a packaged set of tiny screwdrivers which work well for the 3D Auto fill adjustment. Of course, your National Adhesives representative can also arrange to obtain a replacement screwdriver for you.

Pick-up Wand

The vacuum pick-up wand should be checked periodically for proper operation of the built-in vibrator and to insure that the air jet holes remain clear and open. The vibrator operates on compressed air, so the air line should always be secured in the fitting. Vibration should be felt in the wand when the unit is operating. The air jets can be checked by removing the compressed air sleeve from the wand and visually inspecting. The air jets can be cleaned by blowing compressed air through the holes. Check that the "O" ring seals are not damaged before reattaching the sleeve.

Air Moisture Filter

The 3D Auto fill unit includes a small air moisture filter (trap), intended to act as a secondary filter. Plant compressed air lines should include a primary air moisture filter (trap). Both the plant air line primary filter and the 3D Auto fill secondary filter should be checked periodically and drained/cleaned, as necessary.

Air Blows From Wand

The compressed air should flow upward in the metal pickup wand, not out the opening. There are only two reasons for air to blow out the end of the pickup wand - something is blocking the air flow through the 3D unit, causing air to blow outward or the compressed air lines are connected to the solenoid in reverse. You should check for blockage of the venture holes in the wand, clogged product in the vacuum delivery hose, clogged air filter, or product overfill in the delivery throat, as well as for correct connection of the compressed air lines (use air flow direction arrow stamped on solenoid as your guide). Any of these will cause compressed air blow-back. Clean or clear any clogs, correct air line connections, or adjust level sensor if overfill problem.