adhesive melters purblue ec - nordsonemanuals.nordson.com/adhesives/english_manuals/7135268.pdf ·...

Adhesive MeltersPURBlue EC�

for Reactive Materials

Manual P/N 7135268_04- English -

Issued 06/12

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

P/N 7135268_04 � 2012 Nordson CorporationPURBlue EC

Note

This document is for products with the following P/Ns:7157567

Melters with configuration code

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2007.

No part of this document may be photocopied, reproduced, or translated to another language without the priorwritten consent of Nordson Corporation. The information contained in this publication is subject to change

without notice.

� 2012 All rights reserved.- Translation of the original document -

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve,CleanSpray, Color‐on‐Demand, ColorMax, Control Coat, Coolwave, Cross‐Cut, cScan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,DuraPail, Dura‐Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized, Excel2000, Fibrijet, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Helix,Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March,Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, MicroSet, Millenium, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, Nordson,Optimum, Package of Values, PatternView, PermaFlo, PicoDot, PluraFoam, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus,Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, SealSentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, Spraymelt, Spray Squirt,Super Squirt, SureBead, Sure Clean, Sure Coat, Sure‐Max, Sure Wrap, Tela‐Therm, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra,UniScan, UpTime, u‐TAH, Vantage, Veritec, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, Walcom, Watermark, Whenyou expect more.. are registered trademarks - ® - of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, Artiste, ATS, Auto‐Flo, AutoScan,Axiom, Best Choice, BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, ContourCoat, Controlled Fiberization, Control Weave, CPX, cSelect, Cyclo‐Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid,DuraCoat, e.dot+, E‐Nordson, Easy Clean, EasyOn, EasyPW, Eclipse, Equalizer, Equi=Bead, Exchange Plus, FillEasy, Fill Sentry, Flow Coat, Fluxplus,G‐Net, G‐Site, Get Green With Blue, Gluie, Ink‐Dot, IntelliJet, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros,MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke, Origin, Partnership+Plus,PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet,PurTech, Quad Cure, Ready Coat, RediCoat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, Trade Plus,Trlogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Viper, Vista, WebCure, YESTECH, 2 Rings (Design) aretrademarks - � - of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights.

Table of Contents I

P/N 7135268_04� 2012 Nordson Corporation PURBlue EC

Table of Contents

Nordson International O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Europe O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributors in Eastern & Southern Europe O‐1. . . . . . . . . . . . . . . . .Outside Europe / Hors d'Europe / Fuera de Europa O‐2. . . . . . . . . . .

Africa / Middle East O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asia / Australia / Latin America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . .Japan O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .North America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1‐2. . . . . . . . . . . . . . . . . . . .

Safety Information 1‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 1‐2. . . . . . . . . . . . . . . .User Qualifications 1‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 1‐3. . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 1‐3. . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 1‐4. . . . . . . . . . . . . . . . . . . . . . .Installation Practices 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 1‐5. . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 1‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 1‐6. . . . . . . . . . . . . . . . . .De‐energizing the System 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Applicators 1‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 1‐7. . . . . . . . . . . . . . . . . . .Other Safety Precautions 1‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 1‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 1‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Introduction 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Area of Use (EMC) 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Restrictions 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use - Examples - 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . .Residual Risks 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Manuals for Previous Models 2‐2. . . . . . . . . . . . . . . . . . . . . . .Definition of Terms 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definition of "Front" 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inert Gas 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key‐to‐line 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Application Head = Applicator 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Description 2‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illustration - Exterior 2‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Illustration - Interior Components 2‐5. . . . . . . . . . . . . . . . . . . . . . . . .Tank Isolation Valve 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Plate 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Valve 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Lid 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Assignment 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet 2‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ID Plate 2‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Installation 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked Melter) 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Requirements 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Space 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melters with Transformer 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhausting Material Vapors 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Personnel's Experience 3‐3. . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Notes 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe when Using Residual Current Circuit Breakers 3‐4. . . . .Laying Cable 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating voltage 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Customer's Power Cable 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface Assignment 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Key‐to‐line (XS5 or XS5.1, XS5.2) 3‐6. . . . . . . . . . . . . . .

Separate Line Speed Signal Inputs (XS5.1, XS5.2) 3‐6. . . . . . .Standard I/O Interface (XS2) 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Notes 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information on I/O Expansion Board 3‐8. . . . . . . . . . . . . . . . . . . . . . . .

Standard Inputs 3‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Outputs 3‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Spare Parts 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Hose 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Electrically 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second Open‐end Wrench 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving pressure 3‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Timer Relay (Inert Gas Interval) 3‐12. . . . . . . . . . . . . . . . . . . . .Pneumatic Connections 3‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inert gas 3‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inert Gas Control Switch 3‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condensate Disposal when Dry Air is Used as Inert Gas 3‐14. .

Manual Pneumatic Pressure Control / Bypass Control (Options) 3‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Air Quality 3‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Pressures 3‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Assignment XS4: Bypass Control 3‐16. . . . . . . . . . . . .

Installing Gun 3‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Conditioning Compressed Air for Gun Control Modules 3‐17. . . . . .

Removing Melter 3‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposing of Melter 3‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Operation 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modes 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Startup 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purging Melter 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functional Diagram: Enabling and Switching On 4‐5. . . . . . . . . . .

Fill tank 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Open/Close the Tank Lid 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum Level 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Pump Speed 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up the Melter 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panels - Overview - 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Names of Function Keys 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Component Key LED 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . .Names of Keyboard Keys 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Operating Parameters 4‐10. . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Information 4‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Saving and Restoring Settings 4‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saving All Current Settings 4‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Restoring Saved Settings 4‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saving Multiple Variations of Melter Settings 4‐12. . . . . . . . . . . . . . .

Daily Startup 4‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Switchoff 4‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Off in an Emergency 4‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring Aids 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED Ready 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LED Fault 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LED Service Required (Wrench Symbol) 4‐15. . . . . . . . . . . . . . . . . .

Resetting LED Service Required 4‐15. . . . . . . . . . . . . . . . . . . . . .LED Reservoir is Empty 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LED Pump / LED Motor 4‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change History Log 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calling Up Change History Log 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . .Structure of Change History Log 4‐18. . . . . . . . . . . . . . . . . . . . . . . . .

Example 1 - Parameter Changed 4‐18. . . . . . . . . . . . . . . . . . . . . .Example 2 - Setpoint Temperature Changed 4‐18. . . . . . . . . . . .Example 3 - Empty Log Entry 4‐18. . . . . . . . . . . . . . . . . . . . . . . . .

Enter password 4‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated Components 4‐20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Meaning of LED Colors of Component Keys 4‐20. . . . . . . . . . . . . . .Setpoint Temperatures (Original State) 4‐20. . . . . . . . . . . . . . . . . . .

Adjusting Setpoint Temperatures 4‐21. . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Temperatures Using the Global Method 4‐21. . . . . . . . . .

Switching Off All Components 4‐21. . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Temperatures Using the Global‐by‐component Group Method 4‐22. . . . . . . . . . . . . . . . . . . . .Adjusting Temperature of an Individual Component 4‐23. . . . . . . . .

Switching Off Component 4‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick Adjustment - Tips - 4‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Information 4‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Temperatures 4‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Actual Temperature in Normal Mode 4‐25. . . . . . . . . . . . .Checking Setpoint Temperature in Normal Mode 4‐25. . . . . . . . . . .Checking Actual Temperature Manually 4‐26. . . . . . . . . . . . . . . . . . .Helpful Information 4‐26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents V


Functions and Function Keys 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Entry/Exit with the Key 4‐27. . . . . . . . . . . . . . . . . . . . . . . .Automatic Exit via Parameter 26 4‐27. . . . . . . . . . . . . . . . . . . . . . .Automatic Entry/Exit via the Seven‐day Clock 4‐27. . . . . . . . . . .Automatic Entry via External Input 1 4‐28. . . . . . . . . . . . . . . . . . . .Entry/Exit via External Input 1 - 4 4‐28. . . . . . . . . . . . . . . . . . . . . .Helpful Information 4‐28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump 4‐29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Key (Control Panel) 4‐29. . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Key (Motor Control Panel) 4‐29. . . . . . . . . . . . . . . . . . . . . .

Heater 4‐29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven‐day Clock 4‐30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overriding the Seven‐day Clock 4‐30. . . . . . . . . . . . . . . . . . . . . . .Setup 4‐30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important when Changing Material 4‐31. . . . . . . . . . . . . . . . . . . . . . . . .Communication via Serial Interface 4‐31. . . . . . . . . . . . . . . . . . . . . . . . .Settings Record 4‐32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving pressure 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important when Using Cleaning Agents 5‐2. . . . . . . . . . . . . . . . . . . . .Processing Materials 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External cleaning 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect for external damage 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Type of Material 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching Protective Panels 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan and air filter 5‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Plate 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Releasing Safety Valve Plate 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Plate: Replacing O‐ring 5‐9. . . . . . . . . . . . . . . . . . .

Securing Safety Valve Plate 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for Leakage 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Pump Shaft Seal 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Retightening Fixing Screws 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor / gear box 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Change lubricant 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricant Selection 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Valve 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing O‐rings 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important for Mechanical Pressure Control Valve 5‐12. . . . . . . . . . .

Measuring Insertion Depth 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Pressure Control Valve 5‐13. . . . . . . . . . . . . . . . . . . . . .

Tank 5‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Tank by Hand 5‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilting Tank 5‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Isolation Valve 5‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing O‐rings 5‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve 5‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve for Pneumatics 5‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance check 5‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record Form 5‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVI


Troubleshooting 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Tips 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Numbers 6‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1, F2 and F3 Faults 6‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F4 Fault 6‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Information 6‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Melter 6‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Log 6‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling Up Fault Log 6‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Structure of Fault Log 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example 1 - Undertemperature 6‐6. . . . . . . . . . . . . . . . . . . . . . . .Example 2 - Unused Log Entry 6‐6. . . . . . . . . . . . . . . . . . . . . . . .

Helpful Information 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Board Overview 6‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indication Lamps (LEDs) and Fuses on Main Board 6‐8. . . . . . . . .Indication Lamps (LEDs) on I/O Expansion Board 6‐8. . . . . . . . . .

Motor Controller Faults 6‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibrating Pump Speed Display 6‐10. . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Motor Control Parameters 6‐11. . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter not Functioning 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A Heated Component does not Heat 6‐12. . . . . . . . . . . . . . . . . . . . .No Line Speed Signal 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel does not Function 6‐13. . . . . . . . . . . . . . . . . . . . . . . . .Main contactor opened 6‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overtemperature shutdown by (tank) thermostat 6‐13. . . . . . . . .Shutdown by transformer thermostat 6‐13. . . . . . . . . . . . . . . . . . .

No Inert Gas 6‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor does not Rotate) 6‐14. . . . . . . . . . . . . . . . . . . . . .No Material (Motor Rotating) 6‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . .Too Little Material 6‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure too High 6‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure too Low 6‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Residue or Hardened Material in Tank 6‐16. . . . . . . . . . . .Others 6‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs of Motor Controller 6‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents VII


Repair 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe Before Performing Repairs 7‐1. . . . . . . . . . . . . . . . . . . . . . . .Relieving pressure 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Notes on Cardan Joint 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Label 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Notes on Safety Valve Plate 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace pump 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detaching Pump 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attaching Pump 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Variseal 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly Tool 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Motor 7‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Safety Valve 7‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Service Kit 7‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Motor Controller 7‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Standard I/O Board of Motor Controller 7‐9. . . . . . . . . .When Performing Work behind Electrical Equipment Covers 7‐10. . .Tank 7‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Thermostat 7‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Heater Cartridges 7‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety valve plate for pump 1 7‐11. . . . . . . . . . . . . . . . . . . . . . . . .Safety valve plate for pump 2 7‐11. . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Temperature Sensor 7‐11. . . . . . . . . . . . . . . . . . . . . . . . . .Grid 7‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reservoir 7‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Band Heater 7‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Thermostat and Temperature Sensor 7‐13. . . . . . . . . . .

Replacing Level Evaluator 7‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important Notes 7‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe when Replacing Level Sensor 7‐14. . . . . . . . . . . . . . . . . . .Empty Calibration 7‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prerequisites 7‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Control Panel (Service Kit) 7‐15. . . . . . . . . . . . . . . . . . . . . . .If the Main Board is to be Replaced 7‐16. . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sensors Ni120 7‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVIII


Parts 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product Configuration 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Use Illustrated Parts List 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Designation 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly Overview 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Parts, Service Kits and Accessories 8‐7. . . . . . . . . . . . . . . . . .

Safety Valve 8‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Pump 8‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Kits (O‐Ring) for all Pumps 8‐8. . . . . . . . . . . . . . . . . . . .Pump Sealing Kits & Assembly Tools for Variseal Pumps 8‐9.

Pressure Control Valve 8‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Safety Valve (Option) 8‐10. . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Control, 1‐fold (Option) 8‐11. . . . . . . . . . . . . . . . . . . . . . .Pneumatic Control, 2‐fold (Option) 8‐11. . . . . . . . . . . . . . . . . . . . . . .Inert Gas Equipment 8‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold 8‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold Accessories 8‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Plate (Bypass Plate) 8‐16. . . . . . . . . . . . . . . . . . . . . . . .

Ship‐With‐Kit 8‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Signs and Tags 8‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter P/N Information (Electrical Components) 8‐17. . . . . . . . . . . . . .Electrical Components 8‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Additional Service Kits 8‐21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses Main Board 8‐21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Board 8‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Expansion Board 8‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Module 8‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Panel 8‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CPU Board 8‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTD Sensor 8‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Switches (Thermostats) 8‐23. . . . . . . . . . . . . . . . . . . .Panel Latch 8‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pack Frequency Converter 8‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Accessory Kits 8‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Casters 8‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories for Pneumatic Connection by the Customer 8‐25. . . . . . .

Technical Data 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Data 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Instructions Regarding Working with Application Materials A‐1. . . . . . . . . . .Definition of Terms A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manufacturer Information A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liability A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vapors and Gases A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Substrate A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Processing Temperature A‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important for Polyurethane Application Materials (PUR) A‐2. . . . . . .

Table of Contents IX


Operating Parameter B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parameter Groups ‐ Overview ‐ B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Restore Melter Default Settings B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Original state B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard B‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input Setup B‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Inputs B‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Inputs B‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Setup B‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Outputs B‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Outputs B‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seven‐day Clock B‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Internal Clock (Realtime Clock) B‐16. . . . . . . . . . . . . . . . . . .Creating Schedule B‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example 1 B‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Example 2 B‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Example 3 B‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic fill timer B‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output (Control Option 3): Reversal of fault logic B‐23. . . . . . . . . . . . . .PID selection B‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Communication C‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Availability C‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Requirements C‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing the Software C‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Software from your PC C‐3. . . . . . . . . . . . . . . . . . . . .Linking PC and Melter C‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Nordson Configuration Manager C‐4. . . . . . . . . . . . . . . . . . . . . .

Saving Melter Settings C‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Restoring Melter Settings C‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Upgrading or Restoring Melter Firmware C‐6. . . . . . . . . . . . . . . . . .

Troubleshooting C‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsX


O‐1Introduction

��2011 Nordson CorporationAll rights reserved

NI_EN_O‐0211‐MX

Nordson International

http://www.nordson.com/Directory

Country Phone Fax

EuropeAustria 43‐1‐707 5521 43‐1‐707 5517

Belgium 31‐13‐511 8700 31‐13‐511 3995

Czech Republic 4205‐4159 2411 4205‐4124 4971

Denmark Hot Melt 45‐43‐66 0123 45‐43‐64 1101

Finishing 45‐43‐200 300 45‐43‐430 359

Finland 358‐9‐530 8080 358‐9‐530 80850

France 33‐1‐6412 1400 33‐1‐6412 1401

Germany Erkrath 49‐211‐92050 49‐211‐254 658

Lüneburg 49‐4131‐8940 49‐4131‐894 149

Nordson UV 49‐211‐9205528 49‐211‐9252148

EFD 49‐6238 920972 49‐6238 920973

Italy 39‐02‐216684‐400 39‐02‐26926699

Netherlands 31‐13‐511 8700 31‐13‐511 3995

Norway Hot Melt 47‐23 03 6160 47‐23 68 3636

Poland 48‐22‐836 4495 48‐22‐836 7042

Portugal 351‐22‐961 9400 351‐22‐961 9409

Russia 7‐812‐718 62 63 7‐812‐718 62 63

Slovak Republic 4205‐4159 2411 4205‐4124 4971

Spain 34‐96‐313 2090 34‐96‐313 2244

Sweden 46‐40-680 1700 46‐40‐932 882

Switzerland 41‐61‐411 3838 41‐61‐411 3818

UnitedKingdom

Hot Melt 44‐1844‐26 4500 44‐1844‐21 5358

IndustrialCoatingSystems

44‐161‐498 1500 44‐161‐498 1501

Distributors in Eastern & Southern Europe

DED, Germany 49‐211‐92050 49‐211‐254 658

O‐2 Introduction

��2011Nordson CorporationAll rights reserved

NI_EN_O‐0211‐MX

Outside Europe / Hors d'Europe / Fuera de Europa

� For your nearest Nordson office outside Europe, contact the Nordsonoffices below for detailed information.

� Pour toutes informations sur représentations de Nordson dans votrepays, veuillez contacter l'un de bureaux ci‐dessous.

� Para obtener la dirección de la oficina correspondiente, por favordiríjase a unas de las oficinas principales que siguen abajo.

Contact Nordson Phone Fax

Africa / Middle East

DED, Germany 49‐211‐92050 49‐211‐254 658

Asia / Australia / Latin America

Pacific South Division,USA

1‐440‐685‐4797 -

Japan

Japan 81‐3‐5762 2700 81‐3‐5762 2701

North America

Canada 1‐905‐475 6730 1‐905‐475 8821

USA Hot Melt 1‐770‐497 3400 1‐770‐497 3500

Finishing 1‐880‐433 9319 1‐888‐229 4580

Nordson UV 1‐440‐985 4592 1‐440‐985 4593

Safety 1‐1

� 2011 Nordson Corporation Safe_PPA1011LUE_EN

Section 1

Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided,can result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Safety1‐2

� 2011 Nordson CorporationSafe_PPA1011LUE_EN

Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuringthat all instructions and regulatory requirements for use of the equipment aremet, and for qualifying all potential users.

Safety Information� Research and evaluate safety information from all applicable sources,

including the owner‐specific safety policy, best industry practices,governing regulations, material manufacturer's product information, andthis document.

� Make safety information available to equipment users in accordance withgoverning regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to theequipment, in readable condition.

Instructions, Requirements, and Standards� Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility's engineering or safetydepartment, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

� Re‐evaluate safety practices and procedures whenever changes aremade to the process or equipment.

Safety 1‐3


User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed bygoverning regulations and best industry practices

� are familiar with the equipment owner's safety and accidentprevention policies and procedures

� receive equipment‐ and task‐specific training from another qualifiedindividual

NOTE: Nordson can provide equipment‐specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry‐ and trade‐specific skills and a level of experienceappropriate to their job function

� are physically capable of performing their job function and are notunder the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment� Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non‐standard auxiliary devices.

Safety1‐4


Instructions and Safety Messages� Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warninglabels and tags affixed to the equipment. Refer to Safety Labels and Tagsat the end of this section.

� If you are unsure of how to use the equipment, contact your Nordsonrepresentative for assistance.

Installation Practices� Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create ahazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installationinstructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements forclearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and allindependently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building codeenforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fusedequipment.

� Contact the authority having jurisdiction to determine the requirement forinstallation permits or inspections.

Operating Practices� Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of a potentialmalfunction.

Safety 1‐5


Maintenance and Repair Practices� Allow only personnel with appropriate training and experience to operate

or service the equipment.

� Perform scheduled maintenance activities at the intervals described inthis document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

� De‐energize the equipment and all auxiliary devices before servicing theequipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the MSDSsupplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing theequipment back into operation.

� Dispose of waste cleaning compounds and residual process materialsaccording to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damagedlabels.

Equipment Safety Information

This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all relatedaccessories

� pattern controllers, timers, detection and verification systems, and allother optional process control devices

Safety1‐6


Equipment Shutdown

To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required varies bythe type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure.The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter‐specific product manual forinstructions on relieving system hydraulic pressure.

De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from allpower sources before accessing any unprotected high‐voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer to theappropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in someprevious publications.

All electrical or mechanical devices that provide an activation signal to theapplicators, applicator solenoid valve(s), or the melter pump must bedisabled before work can be performed on or around an applicator that isconnected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller,timer, PLC, etc.).

2. Disconnect the input signal wiring to the applicator solenoid valve(s).

3. Reduce the air pressure to the applicator solenoid valve(s) to zero; thenrelieve the residual air pressure between the regulator and the applicator.

Safety 1‐7


General Safety Warnings and Cautions

Table 1‐1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1‐1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andapplicators)

Table 1‐1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING! Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent‐based material through a compatibleNordson melter, read and comply with the material's MSDS. Ensurethat the material's processing temperature and flashpoints will not beexceeded and that all requirements for safe handling, ventilation, firstaid, and personal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, including death.

HM

WARNING! Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and applicators contain aluminum components thatmay react violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relieve thesystem hydraulic pressure can result in the uncontrolled release of hotmelt or cold adhesive, causing personal injury.

Continued...

Safety1‐8


General Safety Warnings and Cautions (contd.)

Table 1‐1 General Safety Warnings and Cautions (contd)


HMWARNING! Molten material! Wear eye or face protection, clothing thatprotects exposed skin, and heat‐protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

WARNING! Equipment starts automatically! Remote triggering devicesare used to control automatic hot melt applicators. Before working onor near an operating applicator, disable the applicator's triggeringdevice and remove the air supply to the applicator's solenoid valve(s).Failure to disable the applicator's triggering device and remove thesupply of air to the solenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De‐energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and has not been cerfifiedfor the ATEX directive or as nonincendive. In addition, this equipmentshould not be used with solvent‐based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent‐based adhesives or the improperprocessing of solvent‐based adhesives can result in personal injury,including death.

Continued...

Safety 1‐9


Table 1‐1 General Safety Warnings and Cautions (contd)


HM, CA, PCWARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.

HMCAUTION! Hot surfaces! Avoid contact with the hot metal surfaces ofapplicators, hoses, and certain components of the melter. If contactcan not be avoided, wear heat‐protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt. Ifyou are unsure of the equipment's ability to process PUR, contact yourNordson representative for assistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer's instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION! Nordson hot melt equipment is factory tested with NordsonType R fluid that contains polyester adipate plasticizer. Certain hot meltmaterials can react with Type R fluid and form a solid gum that canclog the equipment. Before using the equipment, confirm that the hotmelt is compatible with Type R fluid.

Safety1‐10


Other Safety Precautions� Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, orleaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

First Aid

If molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melthas cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hotmelt to the medical personnel providing treatment.

Safety Instructions 1‐11


Safety Labels and Tags

Figure 1‐1 shows the location of the safety labels and tags that are affixed tothe melter. Table 1‐2 provides the text of any safety instruction that appearson the labels as well as the meaning of the symbols that appear without anysafety message.

The text on a label may be covered with a new sticker to comply with localregulations.

5

4

3

2

1

67

8

9

Fig. 1‐1 Location of safety labels and tags

Continued ...

Safety Instructions1‐12


Table 1‐2 Safety Labels and Tags

Position P/N Description

1+2+4 1059866 1 set of labels, multi‐lingual

1 1024720replaced by

1100252

ATTENTION: Hot adhesive. Relieve pressure.

System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

2 1025326replaced by

1100254

CAUTION: Hot surface. Failure to observe can cause burns.

3

(bandheater)

290083 ATTENTION: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

4 1025795 ATTENTION: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

5 455754 CAUTION: Risk of squash! Failure to observe can cause handburns.

6

7

7126025

417709

Symbol Inert gas.

Maximum inlet pressure (in this case: inert gas)

8 7150020 Self‐adhesive label for switch Inert gas control

9 729077 Maximum inlet pressure (in this case: compressed air)

Introduction 2‐1


Section 2

Introduction

Intended Use

PURBlue EC� melters may be used only to melt and convey hot meltadhesives such as polyurethane (PUR), ethylene vinyl acetate copolymers(EVA) and polyolefines (PO).

Any other use is considered to be unintended. Nordson will not be liable forpersonal injury or property damage resulting from unintended use.

Intended use includes the observance of Nordson safety instructions.Nordson recommends obtaining detailed information on the materials to beused.

Area of Use (EMC)

In regard to electromagnetic compatibility (EMC), the melter is intended foruse in industrial applications.

Operating Restrictions

When operated in residential or commercial areas, the melter may causeinterference in other electrical units, e.g. radios.

Unintended Use - Examples -

The melter may not be used under the following conditions:

� In defective condition

� Without protective panels

� With electrical cabinet door open

� With tank lid open

� In a potentially explosive atmosphere

� When the values stated under Technical Data are not complied with.

The melter may not be used to process the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction2‐2


Residual Risks

In the design of the unit, every measure was taken to protect personnel frompotential danger. However, some residual risks can not be avoided:

� Risk of burns from hot material

� Risk of burns when filling the tank and from the tank lid

� Risk of burns when conducting maintenance and repair work for whichthe melter must be heated up

� Risk of burns when attaching and removing heated hoses

� Material fumes can be hazardous. Avoid inhalation

� Risk of damage to cables/lines belonging to the customer, if they wereinstalled such that they come into contact with hot or rotating parts

� The safety valve and parts of the inert gas equipment may malfunctiondue to hardened or charred material.

Note on Manuals for Previous Models

7126267 7140890

Revision C applies to the melters with these P/Ns.

These melters are no longer manufactured.

7126990 7140891

7126991

7140887

7140888

7140889

Operating side (= front)

Introduction 2‐3


Definition of Terms

Definition of "Front"

Inert Gas

The inert gas prevents the material in the tank from reacting to humidity. Itdisplaces the air in the tank and protects the material from an unintendedreaction, which could cause the material to harden prematurely.

Inert gases are e.g. nitrogen (N) and carbon dioxide (CO2).

An air dryer can condition compressed air such that it can be used as inertgas. Refer to section Installation, Condensate Disposal when Dry Air is Usedas Inert Gas.

CAUTION: Use only suitable inert gas. Information can be obtained from theMaterial Safety Data Sheet or the manufacturer of the material in the tank.

Key‐to‐line

Referred to in Nordson literature as either Key‐to‐line (KTL) or Automaticmode.

In key‐to‐line the motor/pump speed is proportional to the speed of theparent machine.

Application Head = Applicator

In newer Nordson literature, an application head is referred to as applicator.

Introduction2‐4


Melter Description

Illustration - Exterior

4

2

5

67

8

9

1

13

10

11

1514

12

3

16

Fig. 2‐1

1 Electrical Cabinet

2 Fan

3 Motor control panel

4 Control Panel

5 Main Switch

6 Tank Lid

7 Hinged cover plate

8 Protective panel, removable

9 Casters (option)

10 Manifold

11 Protective bar

12 Tower with inert gas /compressed air connection

13 ID plate

14 Cable Glands

15 Hose Receptacles

16 Switch Inert gas control

Introduction 2‐5


Illustration - Interior Components

ÂÂÂÂ

76

5

9

8

4

2

1

10

12

3

11

Fig. 2‐2

1 Motor 1

2 Cardan joint 1

3 Pump 1

4 Safety valve plate 1 (example withpneum. pressure control valve)

5 Safety valve plate 2

6 Manifold 2

7 Tank isolation valve Pump 2

8 Tank with band heater

9 Insulating sleeve

10 Inert gas inlet

11 Electrical equipment cover

12 Fastener (4x)

1

0

1

2

2

1

Introduction2‐6


Tank Isolation Valve

The tank isolation valve (1) enables replacement of the pump without firstemptying the tank.

NOTE: Operate the tank isolation valve only when the melter is heated tooperating temperature.

Pin in position 0: Closed

Pin in position 1: Open

Fig. 2‐3

Safety Valve Plate

For control purposes, the heated manifold belongs to the reservoir.

The safety valve plate can be slid in the groove to perform maintenance andrepair work. Refer to section Maintenance, Releasing Safety Valve Plate andSecuring Safety Valve Plate.

Safety Valve

The standard safety valve (1) is fixed at

85 bar 8�500 kPa 1�235 psi.

When the pressure is exceeded, the safety valve opens, allowing thematerial to circulate within the safety valve plate.

Pressure Control Valve

The mechanical pressure control valve (2) can be manually adjusted up to

75 bar 7�500 kPa 1�100 psi.

The pneumatic pressure control valve replaces the mechanical pressurecontrol valve on some options.

Fig. 2‐4

1

2

3

4

Introduction 2‐7


Tank

The tank is divided into hopper (tank extension) with band heater, grid(melting plate) and reservoir (high melt) sections. The different heating zonesallow the material in the hopper (1) to be gently melted at a low temperature.The material is then heated to processing temperature in the grid (2) andreservoir (3).

The tank can be tilted and dismantled for cleaning purposes (Refer to sectionMaintenance, Tank).

An optional 2-point sensor (4) monitors the level. It is responsible for thesignals Filling and Reservoir empty. Reservoir empty switches off the motors.

Fig. 2‐5

Tank Lid

The tank lid is pressure-tight. A pneumatic safety valve limits the pressure inthe tank to 0.4 bar (40 kPa / 5.8 psi).

Interface Assignment

3

21 2

Fig. 2‐6 Back wall of electrical cabinet

1 Cable gland Power supply 2 Interface(s) Key‐to‐line

3 Interface Standard I/O

Standard I/O (XS2): Transmits the digital input/output signals between theparent machine and the Nordson melter.

Key‐to‐line mode: Component designation XS5.1 and XS5.2 with twopumps.

Introduction2‐8


Electrical Cabinet

3

5

6

8

9

10

11

18

16

17

14

12

2021

22

2

1

19

4

7

13

24

Left door Right door

15

23

Fig. 2‐7 Example: 230 V model

1 I/O expansion board

2 Main board

3 Mains terminals

4 Circuit breaker Main fuse

5 Relay connector

6 Main contactor

7 Circuit breaker

8 Solid State Relay

9 Power supply (internal)

10 Circuit breakers

11 Power supply (external)

12 Adapter Hopper (band heater)

13 Timer relay Inert gas.

14 Motor controller Motor 2

15 Power board

16 Motor controller Motor 1

17 Interference filter

18 Control panel board (CPU)

19 Fan with Filter

20 Motor control panel Pump 1

21 Motor control panel Pump 2

22 Coupler components KTL

23 Terminal block XL9‐11/12

24 Level evaluator (back panel)

Introduction 2‐9


ID Plate

The system has two ID plates. One is located on the outside of the melter,and the other is in the electrical cabinet.

ADHESIVE MELTER

Nordson Engineering GmbHLilienthalstr. 6D 21337 Lüneburg - Germany

www.nordson.comSerial No:

3

4

5

1 2

Year

LISTEDUSC

UL

Fig. 2‐8 Example

1 Melter designation

2 Order number

3 Configuration code

4 Electrical connection, operating voltage, line voltage frequency, melter fuse protection

5 Serial number

...

G July

H August

J September

K October

...LU10J01234

MonthYear

NOTE: The year and month of production are indicated within the serial number.

6 Year of construction

Introduction2‐10


1

2

3

4

Installation 3‐1


Section 3

Installation

ATTENTION: Allow only qualified personnel to perform the following tasks.Follow the safety instructions here and in the entire documentation.

Transport

� Refer to section Technical Data for weight. Use only suitable transportdevices.

� If possible, use the pallet (3) that came with the melter and use anglebrackets (2) to fasten the melter.

� Use a sturdy box (1) or the folding box (4) to protect from damage.

� Protect from humidity and dust.

� Avoid jolts and vibrations.Fig. 3‐1 Principle drawing

StorageCAUTION: Do not store melter outside! Protect from humidity, dust andextreme temperature fluctuations (formation of condensation).

UnpackingUnpack carefully and check for damage caused during transport. Save pallet,angle brackets and box for later use, or dispose of it properly according tolocal regulations.

Fig. 3‐2

Installation3‐2


Lifting (Unpacked Melter)

Refer to the section Technical Data for weight. Lift melter only at the chassisusing suitable lifting equipment or a forklift.

Installation Requirements

Set up only in an environment that corresponds to the stated Degree ofProtection (Refer to section Technical Data). Do not set up in a potentiallyexplosive atmosphere! Protect from vibration.

Required Space

NOTE: *) For minimum bending radius refer to the hose manual

1385

400

1270

36683

5

245

210 *)

Fig. 3‐3

Melters with Transformer

The transformer is located under the melter.

� Keep cables and hoses out of the space under the melter.

� Position the unit such that air can circulate sufficiently under the melter.

Installation 3‐3


Exhausting Material Vapors

Ensure that material vapors do not exceed the prescribed limits. Alwaysobserve the safety data sheet (MSDS) for the material to be processed. Ifnecessary, exhaust material vapors and provide sufficient ventilation of thelocation of the system.

Fig. 3‐4 Principle drawing

Installation Personnel's Experience

The instructions contained in this section are intended for personnel withexperience/authorization in the following fields:

� Application methods with hot melt adhesive or similar materials

� Industrial electrical wiring of power and control lines

� Industrial mechanical installation

� General knowledge of process control.

CAUTION: Illuminated seals may not be installed in the application system.

Installation3‐4


Electrical ConnectionsATTENTION: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

General Notes

� To conform with a European standard regarding electro‐magneticcompatibility (EMC), only shielded cable may be connected. The shieldmust be connected to ground in compliance with the standard regardingelectromagnetic compatibility.

� Inductive loads (e.g. solenoid valves) connected to the melter must beequipped with a protective device (e.g. recovery diode) that disables theinductive voltage generated when an inductive load is switched off.

� The permitted voltage deviation is �10%.

Observe when Using Residual Current Circuit Breakers

Local regulations in some industrial branches require residual current circuitbreakers.

Then observe the following points:

� Residual current circuit breakers are to be installed only between thepower supply and the melter.

� Use only residual current circuit breakers sensitive to pulsating current oruniversal current (> 30 mA).

Laying Cable

ATTENTION: Use only temperature resistant cable in warm areas of theequipment. Ensure that cables do not touch rotating and/or hot meltercomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

Operating voltage

ATTENTION: Operate only at the operating voltage shown on the ID plate.

NOTE: Permitted deviation from the rated line voltage is �10%.

NOTE: The power cable cross‐section must comply with the maximumpower consumption (refer to section Technical Data).

XS2

XS5

XS5.1XS5.2Powersupply

Installation 3‐5


Power Supply

NOTE: The melter must be installed securely (permanent power supplyconnection).

Line voltage Terminals Mains terminals in electrical cabinet

L1 L2 L3 N PE

230 VAC 3‐phase without neutral(Delta)

� � � �

400 VAC 3‐phase with neutral (star -WYE)

� � � � �

Customer's Power Cable

1. Connect the power cable / adapter cable to XS2 (Fig. 3‐5) on the back ofthe electrical cabinet.

2. Line speed signal input XS5 / XS5.1 for motor 1

Line speed signal input XS5.2 for motor 2

Fig. 3‐5 Back of electrical cabinet

Out

put

s

Inp

uts

Installation3‐6


Interface Assignment

Interface Key‐to‐line (XS5 or XS5.1, XS5.2)

The voltage of the line speed signal must be between 0 and 10 VDC.

Separate Line Speed Signal Inputs (XS5.1, XS5.2)

XS5.n (3‐pin)

Pin Input Function

1 - (Ground) Analog input

2 0 to 10 VDC

Pin 3 not assigned

Standard I/O Interface (XS2)

General Notes

� To conform with a European standard regarding electro‐magneticcompatibility (EMC), only shielded cable may be connected. The shieldmust be connected to ground in compliance with the standard regardingelectromagnetic compatibility.

� Inductive loads (e.g. solenoid valves) connected to the melter must beequipped with a protective device (e.g. recovery diode) that disables theinductive voltage generated when an inductive load is switched off.

� The permitted voltage deviation is �10%.

Continued ...

Installation 3‐7


Digital inputs

Pin Input Function

1* 24 VDC Internal (melter)

2* 0 VDC External (customer's)NOTE: Customer connects his reference potential here, if 24 VDC is provided bycustomer.

30 V

24 V Rising edge: Heaters ON (main contactor closes)

0 V

24 V Falling edge: Heaters OFF (main contactor opens)

4 24 V: Enable Motor 1 or collective enable with two motors0 V: No enable

50 V

24 V Rising edge: Motor 1 ON

6 24 V: Motor 1:´OFF

70 V

24 V Rising edge: Motor 2 ON

8 24 V: Motor 2:´OFF

90 V

24 V Rising edge: Enter Standby

0 V

24 V Falling edge: Exit Standby

* optional Pin 10 - 16 not assigned

NOTE: Contact rating max. 24 VDC/2 A

Digital outputs

Pin Contact Function

17 Make contact Contact closed: Motor 1 runningContact open: Motor 1 not running18

19 Make contact Contact closed: Motor 2 runningContact open: Motor 2 not running20

23 0 V External power supply -71T2

24 24 VDC/100 W

25 24 VDC External (customer's; to be connected by customer)

26 Make contact 24 V: Unit ready0 V: System not ready

28 Break contact 24 V: No general alarm -fault-0 V: General alarm -fault-

29 Make contact 24 V: Fill0 V: Do not fill

30 Break contact 24 V: Reservoir is empty0 V: Reservoir is not emptyNOTE: Reservoir empty is also indicated by the yellow lamp on the light tower.

Pin 21, 22, 27, 31, 32 not assigned

Installation3‐8


Information on I/O Expansion Board

Standard Inputs

The inputs are activated by a constant signal of 10 to 30 VDC. The polarity isnot important for the inputs.

The operator can override the melter inputs via the function keys on thecontrol panel.

ATTENTION: Ensure that the control logic of external devices that transmitan input signal to the melter is programmed such that unsafe conditions cannot occur if the operator overrides an external input to the melter.

Input

(standard)

Operating Parameter Control option

Original state - Do not change -

Plug connector and

terminal

130

3: Collective motor enable P/N 277909

8 and 9

231

1: Standby on/off P/N 277909

10 and 11

332

2: Heaters on/off P/N 277909

12 and 13

Standard Outputs

All of the output contacts are intended for 240 VAC 2 A or 30 VDC 2 A. Allcontacts are open when the melter is switched off.

Output

(standard)

Operating Parameter Control option

Original state - Do not change -

Plug connector and

terminal

140

1: Ready P/N 277908

1 and 2

241

3: Fault P/N 277908

3 and 4

Installation 3‐9


Note on Spare Parts

� Connector P/N 277908 is physically keyed to prevent it from being usedin place of connector P/N 277909, which has terminals numbered 8through 14.

� Connector P/N 277909 is physically keyed to prevent it from being usedin place of connector P/N 277908, which has terminals numbered 1through 7.

P/N 277909

P/N 277908

1234567

XT7

Fig. 3‐6 I/O expansion board

Installation3‐10


Connecting Hose

Also refer to the hose manual.

Connecting Electrically

1. First connect the hose (1) electrically to the unit.

Use hose receptacles XS10 to XS13 (2b) for the plugs (2a) of the hoses. Theconnections are protected with a clamp.

NOTE: For more than one hose: Every hose connection is allocated to acorresponding receptacle. Do not mistakenly exchange!

Refer to wiring diagram for connecting arrangement.

2a

1

2b

2a

Fig. 3‐7 Connecting electrically (example Ni120)

Connecting

Second Open‐end Wrench

Use a second open‐end wrench when connecting and disconnecting thehose. This prevents the melter's hose connection from turning.

Fig. 3‐8

3 14

Installation 3‐11


Connecting Hose (contd.)

NOTE: For units with recirculation hoses: do not mistake recirculation hosesfor feed hoses.

If cold material can be found in the hose connection, the components (3, 4)must be heated until the material softens (approx. 70 °C/158 ° , depending onmaterial).

ATTENTION: Hot! Risk of burns. Wear heat‐protective gloves.

2. Heat the melter and hose to approx. 70 ° C (158 °F).

3. Connect the hoses in the order of the numbers on the manifold. Thisprevents the creation of dead space that would otherwise result fromunused connections.

Close unused hose connections with Nordson port plugs.

Fig. 3‐9

Disconnecting

ATTENTION: System and material pressurized. Relieve system pressurebefore disconnecting hoses. Failure to observe can result in serious burns.

Relieving pressure

1. Switch off the motor(s) (Refer to section Operation).

2. Place a container under the nozzle(s) of the gun / assembly handgun.

3. Activate the solenoid valve(s) electrically or manually, or pull the trigger ofthe assembly handgun. Repeat this procedure until no more materialflows out.

4. Properly dispose of material according to local regulations.

E

Installation3‐12


Setting Timer Relay (Inert Gas Interval)

The timer relay is located in the electrical cabinet. The relay is used to set theintervals at which the tank is pressurized with inert gas.

The mode may not be changed.

CAUTION: Change settings only when the melter is switched off.

1. Set the time T1 for the filling duration. Default: 5 s

2. Set the time T2 for the break time. Default: 30 min

Fig. 3‐10 Mode E

Range Scale Time

1 S 0 - 1 0.1 s - 1 s

10 S 0.3 s - 10 s

10 M 15 s - 10 min

1 S 0 - 6 0.1 s - 6 s

10 S 1 s - 60 s

1 M 6 s - 6 min

10 M 1 min - 60 min

1 H 6 min - 6 h

NOTE: When the limit is crossed from 10 M to 1 S, the scale automaticallychanges.

Fig. 3‐11 Extract from manufacturer's instructions

1

3

2

Installation 3‐13


Pneumatic Connections

Inert gas

ATTENTION: Observe safety instructions regarding handling technical gasin cylinders. Use an adjustable pressure reducer. The inert gas inlet pressuremay not exceed 2 bar (200 kPa / 29 psi).

CAUTION: Use only suitable inert gas. Information can be obtained from theMaterial Safety Data Sheet or the manufacturer of the material in the tank.

The arrow points to the handwheel of the pressure controller.

Recommended setting: 0.3 bar / 30 kPa / 4.35 psi

1: Pressure display Inert gas2: Pneumatic safety valve3: Connection Inert gas

The pneumatic safety valve (2, Fig. 3‐12) limits the inert gas inlet pressure to2 bar (200 kPa / 29 psi).

A second pneumatic safety valve limits the pressure in the tank to 0.4 bar(40 kPa / 5.8 psi).

1

Fig. 3‐12 Tower and inert gas labels

Installation3‐14


Inert Gas Control Switch

The switch (slide) is located on the front of the melter, below the main switch.Set the switch (1, Fig. 3‐13) to "0" (closed) during installation.

0.4 bar2.0 bar

1

3

4

2max.2 bar

1

Tank

1

3

2

3

Fig. 3‐13

Condensate Disposal when Dry Air is Used as Inert Gas

Condensate consists primarily of precipitation created by compression.However, it is extremely polluted and harmful to the environment, so it mustbe disposed of properly. Some examples of hazardous substances:

� Mineral oil aerosols from the intake air of the compressor

� Dust and dirt particles from the intake air of the compressor

� Cooling oil and lubricant from the compressor

� Rust and abraded particles from the tube network.

1

2

5

4

3

Installation 3‐15


Manual Pneumatic Pressure Control / Bypass Control (Options)

The pneumatic pressure control valve replaces the installed mechanicalpressure control valve.

Required Air Quality

The compressed air must be dry and non‐lubricated. Dirt particles in the airmay not exceed 30 �m in size.

Setting Pressures

The operator sets the required compressed air with the pressure controllerhandwheel.

The safety valve for pneumatics limits the inlet pressure to 6 bar (600 kPa /87 psi).

The pneumatic pressure control valve has a transmission ratio operating airpressure / material pressure of 1:15.

1: Pressure display Pump 12: Pressure display Pump 23: Pneumatic safety valve4: Interface XS4 (with option Bypass control)5: Connection Compressed air

The arrows point to the handwheels of the individual pressure controllers.

1

21

Fig. 3‐14 Tower and labels with one pump / two pumps

Installation3‐16


Interface Assignment XS4: Bypass Control

PIN Input Function

1 24 VDC/4 W

Pneumatic pressure control valve 1

2

3 24 VDC/4 W

Pneumatic pressure control valve 2

4

In normal production mode, the pressure control valve is supplied withmaximum air pressure (approx. 6 bar) and closed. The material is conveyedto the melter outlet.

When the gun closes, the solenoid valve receives an electrical signal. Thepressure control valve is supplied with regulated compressed air and beginsto open. The material is returned to the tank (bypass).

M

Solenoid Valve

Electrical signal input

Gun open

Gun closed

Pressure controller

Nozzle

Hose

MotorPump

Filter

Tank

Gun

Compressed air

PneumaticPressure ControlValve

Pressure Display

Fig. 3‐15 Option Bypass control (1 pump)

Installation 3‐17


Installing Gun

Refer to the gun manual.

CAUTION: The maximum operating temperature of the installed gun and theother heated components should be considered when setting temperatureson the melter control panel.

Conditioning Compressed Air for Gun Control Modules

The quality of the compressed air must be at least class 2 in compliance withISO 8573-1. This means:

� Max. particle size 1 �m

� Max. particle density 1 mg/m3

� Max. pressure dew point - 40 ° C

� Max. oil concentration 0.1 mg/m3.

Removing Melter

Run the melter until empty, separate all connections from the melter, andallow the melter to cool down.

Disposing of Melter

When your Nordson product has exhausted its purpose, dispose of itproperly according to local regulations.

Installation3‐18


Operation 4‐1


Section 4

Operation


Modes

� Normal mode

Recognizable by scan cycle.

� Key‐to‐line

� Manual mode

� Standby

� Setup mode

Auto‐scan

The actual temperatures of the heated components are displayed if theirsetpoint temperatures are greater than zero degrees. The sequence of theautomatic scan is:

Left display Component Note

� Empty Reservoir *)

� 1 Hose 1

� 1 Gun 1

� 2 Hose 2 If present

� 2 Gun 2 If present

� 5 Band heater (hopper)

� Empty Reservoir

� 1 Hose 1

� ... ...

*) The actual temperature of the grid must be checked manually; refer toCheck Actual Temperature Manually - Helpful Information.

Operation4‐2


Initial Startup

After the melter has been properly installed, initial startup can take place.

Purging Melter

The melter was subjected to extensive testing prior to shipment. In doing so,the tank was filled with a special test material. Material residue may still bepresent in the melter. To remove the residue, melt and feed severalkilograms of material before starting production.

1. Ensure that inert gas is connected.

CAUTION: Do not operate Nordson gear pumps without material. Beforeswitching on the motor, ensure that the tank is filled.

2. Fill the tank (Refer to Filling the Tank).

3. Set the main switch to I/ON.

Position I/ON = Melter switched on.

Position 0/OFF = Melter switched off.

Padlocks can be used to protect the main switch from being turned on byunauthorized personnel.

The melter tests the LEDs of the component and function keys on the controlpanel and begins heatup (LED on Heater key turns green).

NOTE: The LED test allows the operator to check that the LEDs are workingproperly. There is no error indication in the event of a faulty LED. Refer tosection Repair, Replacing Control Panel (Service Kit).

Operation 4‐3


4. Set the inert gas control switch to Apply gas.

The tank is pressurized with inert gas according to the time set on thetimer relay.

“0”(closed)

Apply gas Deaerate

Fig. 4‐1 Position of the Inert gas control switch

5. Set the setpoint temperatures (Refer to Adjusting SetpointTemperatures).

Comply with the processing temperature prescribed by the materialmanufacturer.

6. Set the operating parameters (Refer to Setting Up the Melter).

Observe for Edge‐controlled Signals (Example)

If standby is switched on via an input (rising edge), it can be switched off withthe seven‐day clock or by the operator on the control panel.

If standby is then to be switched on again via the input, it must first beswitched off (falling edge) then on again via the interface.

7. Wait until the system is ready for operation.

The Ready LED lights up (green) when all of the heated components arewithin 3 �C (5 �F) of their assigned setpoint temperature.

Ready Delay Time (Original State: 30 min)

The remaining ready delay time (in minutes) appears in the right display atthe end of every scan cycle. When less than one minute remains in the readydelay time, the right display counts down in seconds.

CAUTION: Always allow at least a 30 minute ready delay to prevent thepump from being damaged when it is switched on.

Continued ...

Pump key

1

Pump mode key

Motor key

Operation4‐4


8. Switch on the motor/pump:

a. Press the Pump key.

Set Manual mode for the duration of initial startup. To do this

b. Press the Pump mode key to select manual mode (LED on) orautomatic mode (LED off).

Manual mode - If the system is ready (LED in the Pump key is green)when the Motor key is pressed, the motor starts.

If the system is not ready (LED in the Pump key is yellow) when the Motorkey is pressed, wait until the LED is green and press the Motor key again.

Automatic mode - If the system is ready (LED in the Pump key is green)when the Motor key is pressed, the motor starts.

If the system is not ready (LED in the Pump key is yellow) when the Motorkey is pressed, the motor starts automatically as soon as the system isready.

c. Press the button Motor on the motor control panel to start the motor.

d. Use the arrow keys to set the pump speed. Also refer to Setting thePump Speed in this section.

CAUTION: Heating and cooling that occur during daily operation can causescrewed parts to loosen, resulting in leakage.

9. After the first day, while the material is still soft (approx. 70 ° C/158 ° F,depending on the material), retighten the following:

� Safety Valve

� Pressure control valve

� Plug

� Hose connections.

Then check at regular intervals and repeat as required. Refer to sectionMaintenance.

Purging

1. Ensure that the gun control modules are open.

2. Set manual mode.

3. Enable the motor(s) and allow the pump to turn at a maximum speed of50 min‐1.

Operation 4‐5


Functional Diagram: Enabling and Switching On

1

1

XS2:5Motor 1 ON

Operatingparameter 31:30V/24VDC

Srt:0

Srt:1

24V

0V

XS2:7Motor 2 ON

24V

0V

NOTE: 24 V to XS2:6 or XS2:8 (not shown): The motor stops or cannot be started.

Fig. 4‐2 Conditions for motor/pump running (function diagram)

2

1

25 m

m

max

Operation4‐6


Fill tankCAUTION: Cease operation before the tank is completely empty. If there istoo little material in the tank, the material can overheat. Overheated materialcan char, collect on surfaces and cause malfunctioning.

Ensure that no material is blocking the inert gas inlet.

ATTENTION: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Tank and tank lid are hot. When filling, hot material maysplash out of the tank. Use caution when filling tank with material.

CAUTION: Before filling the tank, ensure that the tank and material areclean and free of foreign material. Foreign substances can hinder functioningor even cause damage to the melter or accessories.

Open/Close the Tank Lid

1. Set the inert gas control switch to Deaerate; otherwise the pressure willprevent the lid from being opened.

2. Release the star grip (1) and open the lid until the locking pin (2) locksinto place.

Observe the maximum level when filling (Refer to Maximum Level).

3. To close the tank lid, lift the locking pin, pivot the lid in as far as possibleand fasten with the star grip.


Maximum Level

The level should not exceed 25 mm (1 inch) under the inert gas inlet (max).

Adapt the maximum level to the material dispensing speed. Feed materialssensitive to temperature quickly to prevent loss of quality.

Fig. 4‐3 Hopper

Arrow keys Pump speed

Example 1

Example 2

Operation 4‐7


Setting the Pump Speed

The pump speed is set with the arrow keys in manual mode. Display in min‐1.

Setting the Pump Speed in Manual Mode

CAUTION: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min‐1 (rpm) or continuously exceed 80 min1 (rpm).

1. Apply the following formula to determine the optimum pump speed:

Pump�speed�[1�min] �desired�adhesive�quantity�[g�min]

adhesive�density�[g�ccm]� output�quantity�of�pump�[ccm�rev.]

2. Press the Pump speed arrow keys to set the pump speed to the desiredvalue [min‐1].

The current pump speed is shown in the display.

Setting the Pump Speed in Automatic Mode

Pressing the arrows in automatic mode causes the proportion of thereference line speed signal to change. This allows calibration with theincoming signal and fine adjustment of the adhesive quantity fed.

Values from 0.01 to 5.00 are possible.

The bulk melter accepts a line speed signal from 0 to 10 V. A reference linespeed signal of 10 V corresponds to a pump speed of 100 min‐1.

The parent machine runs at maximum speed and sends an input signal of8 V. If the pump should run at maximum speed when the parent machine is atmaximum speed, set the value to 1.25. This results in a reference line speedsignal of 10 V (8 x 1.25 = 10).

The parent machine runs at maximum speed and sends an input signal of10 V. If the pump should run at 80 min‐1 when the parent machine is atmaximum speed, set the value to 0.8. This results in a reference line speedsignal of 8 V (10 x 0.8 = 8).

Operation4‐8


Setting Up the Melter

Control Panels - Overview -

1 2

00

4 5

7 8

3

6

91

8

1

610

2 3

4

579

12

13

11

14

2

One motor control panelper motor/pump

Fig. 4‐4 Control panel and motor control panel

1 LED Fault

2 LED Ready

3 Component keys / LEDs

4 Keypad

5 Serial interface

6 Right display and scroll keys

7 LED Reservoir is empty

8 Left display and scroll key

9 LED Service required

10 Function keys

11 Arrow keys Pump speed

12 Display Pump speed [min‐1]

13 Key Pump mode/LED

14 Key Motor/LED

NOTE: The function key Pump 2 has no function on melters with one pump or motor control panel.

1

Operation 4‐9


Names of Function Keys

Key Standby

Key Pump 1(The key Pump 2 has no function on melters with one pump or motor control panel.

Key Heater

Key Seven‐day clock

Key Setup

Tank Component Key LED

LED Reservoir is empty

Names of Keyboard Keys

Key Clear/reset

Key Input

Operation4‐10


Setting Operating Parameters

Operating parameters are stored in the melter's firmware as a sequentiallynumbered list. Refer to Appendix B.

In addition to the ability to read and edit parameter values, you can also saveand restore the current value of every operating parameter and call up a logof the last ten changes that were made.

1. Press the Setup key.

Parameter 1 flashes in the left display.

2. Use the keypad to enter the desired parameter.

NOTE: If you incorrectly enter the parameter number, press theClear/Reset key to return to parameter 1, then re‐enter the correctparameter number.

When you have finished entering the one‐ or two‐digit parameter number,the right display indicates the parameter's current value.

3. Press the Enter key.

The right display flashes.

4. Use the keypad to enter the value in the right display.

NOTE: If the keypad has no affect on the right display, the melter ispassword protected. You must enter a valid password before parametervalues can be edited. Refer to Entering Password.

You can also use the right display scroll keys to change a parameter'svalue. After entering the parameter number in the left display, press eitherof the right display scroll keys to change the value.


The melter checks the validity of the new value.

� If the parameter value is accepted, the left and right displays show thenext parameter number and value.

� If the parameter value is not accepted, the right display shows dashes(‐‐‐‐) for three seconds and then changes back to the original value.

6. Press the Setup key to exit Setup mode.

Operation 4‐11


Helpful Information

� You can exit Setup mode at any time by pressing the Setup key.

� If no key is pressed for two minutes while in Setup mode, the melter willreturn to Normal mode.

If password protection is enabled, the system will return to the passwordprotected mode.

� Parameter numbers that are reserved (not applicable) are skipped whenscrolling through the operating parameter list in the left display.

� When the right display is flashing, you can quickly set the value of thecurrent parameter to its lowest possible value by simultaneously pressingboth of the right display scroll keys.

� For information on the serial interface (5, Fig. 2‐4), refer to Appendix C.

+

+

Operation4‐12


Saving and Restoring Settings

The current value of all editable operating parameters and the setpointtemperature of each component can be saved and restored at a later time.

NOTE: If the restore feature is used before the save feature is used for thefirst time, the original state will be restored. Hoses and guns will then stopheating; their setpoint temperature is 0 degrees (= switched off).

Saving All Current Settings

With the system in normal mode, simultaneously press the number key 1 andthe Setup key.

S‐1 appears briefly in the right display.

Fig. 4‐5

Restoring Saved Settings

CAUTION: The settings currently in use are overwritten! Before restoringsaved settings, ensure that use of the restored settings will not disrupt thecurrent process or create unsafe operating conditions.

With the system in normal mode, simultaneously press the number key 2 andthe Setup key.

S‐2 appears briefly in the right display.

Fig. 4‐6

Saving Multiple Variations of Melter Settings

A PC and the Nordson Configuration Manager are needed. Refer toAppendix C, Melter Communication for detailed information.

Pump key

1

Operation 4‐13


Daily Startup

CAUTION: Do not operate Nordson gear pumps without material. Beforeswitching on the motor, ensure that the tank is filled.

When the material is changed, keep in mind that the setpoint temperaturesmay need to be adjusted.

1. Ensure that there is enough inert gas available and that the inert gas inletis clean.

2. Set the main switch to I/ON. The melter begins to heat up.

EXCEPTION: If the seven‐day clock is enabled and the melter is thenswitched on, heatup does not begin automatically. The melter starts inthe mode specified by the program for startup.


The tank is pressurized with inert gas according to the time set.

4. Press the Pump key.

5. Wait until the system is ready for operation (Ready LED lights up green).

ATTENTION: Depending on the set parameters, the motor can startautomatically when the melter is ready.

Refer to Functional Diagram: Enabling and Switching On for moreinformation.

Operation4‐14


Daily Switch Off1. Switch off the motor(s).

2. Switch off the heaters.

or

1. Switch off the motor(s).

2. Set the main switch to 0/OFF.

CAUTION: The inert gas is switched off when the main switch is set to0/OFF.

3. Set the inert gas control switch to "0" (closed). The pressure‐tight tank lidensures that the inert gas remains in the tank for several hours.

The switch position can be secured with a padlock.

Fig. 4‐7 Position "0"

4. If necessary, secure the main switch with padlocks against unauthorizedaccess.

Switching Off in an Emergency

ATTENTION: Switch off the melter immediately in any emergency situation.


2. After standstill and before switching the melter on again, have theemergency situation remedied by qualified personnel.

Operation 4‐15


Monitoring Aids

LED Ready

The Ready LED lights up (green) when all of the heated components arewithin 3 �C (5 �F) of their setpoint temperature.

The Ready LED will not turn on, or will turn off, if any of the following eventsoccur:

� Ready delay time has not yet elapsed

� The operator or a remote input places the melter in standby mode

� The seven‐day clock places the melter in standby mode

� There is a fault (the Fault LED is illuminated).

LED Fault

For detailed information on melter faults, refer to the section Troubleshooting.

LED Service Required (Wrench Symbol)

The melter can be set such that, when a time specified by the customer haselapsed, the Service LED lights up. The customer can decide what the LEDshould indicate, e.g. a filter change or some other maintenance task.

When maintenance is completed, the service LED must be reset.

Resetting LED Service Required

In normal mode, press the Clear/reset key to turn off the Service LED andreset the service interval.

LED Reservoir is Empty

In addition to the illuminated LED, the yellow lamp on the light tower alsolights up.

1

Pump key

Motor key

Operation4‐16


LED Pump / LED Motor

Meaning of the LED on the Pump key:

LED off . . . . . . Key was not pressed

LED yellow . . . . . . Motor/pump enabled; system not ready

LED green . . . . . . . Motor/pump enabled; system readyMotor/pump running when the LED on the Motor key is alsogreen

LED flashing green No signal from standard input

Meaning of the LED on the Motor key:

LED off . . . . . . Key was not pressed, or pressing was ignored

LED green . . . . . . . Motor/pump running

+

Operation 4‐17


Change History Log

Calling Up Change History Log

The melter stores in a change history log a record of the last ten changes thatwere made to either operating parameters or setpoint temperatures.


Parameter 1 flashes in the left display.

2. Press the left display scroll key to change the display to parameter 3 (tochange history log).

� If the last change was to an operating parameter, all of the componentkey LEDs remain off.

� If the last change was to a setpoint temperature, the LED on theassociated component key(s) turns on.

The right display shows the four‐digit log entry associated with the lastchange that was made.

Refer to Structure of Change History Log.

3. Press the right display scroll key to review each of the remaining nine logentries. Each time a scroll key is pressed, a progressively older log entryis displayed.

4. To see how many hours the heater has been operating since a certain(displayed) change, press both right display scroll keys simultaneously.

5. Press the Setup key to return to normal mode.

Operation4‐18


Structure of Change History Log

First digitSecond

digitThird and fourth digit

P(Parameter)

-

Indicates the number of the parameter that was changed

S(Setpoint)

Used in conjunction with the LEDs on the component keys to indicate thelocation and method of a setpoint temperature change.

When this LEDis on..

And the fourthdigit indicates..

The changewas to..

And themethod ofchange was..

Tank key 1 Tank Individual

Hose key 1– 6 Hose Individual

Gun key 1– 6 Gun Individual

All keys 0 All components Global

Hose key 0 All hosesGlobal‐by‐component

Gun key 0 All gunsGlobal‐by‐component

Example 1 - Parameter Changed

Parameter 4 (ready delay) was changed.

Example 2 - Setpoint Temperature Changed

If the LED on the gun key is illuminated, it indicates that the"Global‐by‐component" method was used to change the temperature of theguns.

Example 3 - Empty Log Entry

Operation 4‐19


Enter password

If a melter is password protected, a valid password must be entered beforeany setpoint temperature or parameter value can be changed.


Parameter 0 flashes in the left display, and the right display shows 4000.


The right display begins to flash.

3. Enter the melter password with the keypad.


� If the password is correct, the left display indicates parameter 1.

� If the password is incorrect, the left display remains at 0, while theright display briefly indicates dashes (‐‐‐‐) then returns to 4000.

Enter the password again and then press the Enter key.

The melter returns to password‐protected mode two minutes after the lastkey is pressed.

Or press the Setup key twice to immediately return to password‐protectedmode.

Operation4‐20


Heated Components

The melter has three groups of heated components: These are the tankgroup (grid and reservoir), the hose group that contains the hopper, and thegun group. Component groups are shown on the control panel as componentkeys (Fig. 4‐8).

Fig. 4‐8

Heated components within each group are identified by their positionnumber.

Hose and gun position numbers are automatically assigned based on thehose/gun receptacle they are connected to. For example, the positionnumbers of a hose/gun pair that is connected to the second receptacle wouldbe hose position 2 and gun position 2.

The position of the hopper is fixed with hose number 5.

NOTE: If individual components are disconnected from the melter, theirsetpoint temperatures should be set to 0 (Off) to prevent an F1 fault.

Observe for Auxiliary Devices

In some installations, auxiliary devices (e.g. a heated air manifold) may beconnected to a hose/gun receptacle. The control panel will identify suchauxiliary devices as a hose or gun, regardless of what the device actually is.

Meaning of LED Colors of Component Keys

The LEDs on each component key will change from green to yellow if anycomponent in the group drops more than 3 �C (5 �F) below its assignedsetpoint temperature.

Setpoint Temperatures (Original State)

Component Original state Max. temperature Min. temperature Overtemperaturethermostat

Example, whenBox12:L

Grid 150 ° C 300 ° F 230 ° C 450 ° F 40 ° C 100 ° F 180 ° C 356 ° F

Reservoir 180 ° C 356 ° F

Hopper 150 ° C 300 ° F 180 ° C 356 ° F

Hose 0 (off) 230 ° C 450 ° F 40 ° C 100 ° F - -

Gun 0 (off) - -

Operation 4‐21


Adjusting Setpoint Temperatures

Setpoint temperatures are assigned with any of the following methods:

� Global — The tank (grid and reservoir), hopper and all hoses andguns are set to the same setpoint temperature.

� Global‐by‐component group — All of the hoses or all of the gunsare set to the same setpoint temperature.

� Individual component — The setpoint temperature of eachcomponent is set separately.

Adjusting Temperatures Using the Global Method

1. Press and hold the Tank key for three seconds.

The left display flashes 1.

2. Scroll the left display to 0 (flashing).

The right display shows dashes (‐‐‐‐) and the LEDs on all componentsturn green.



4. Use the keypad to enter the setpoint temperature recommended by thematerial manufacturer.

NOTE: If the keypad or the right display scroll keys have no effect on theright display, the melter is protected by a password. Enter a validpassword before changing the setpoint temperatures. Refer to EnteringPassword in this section.

5. Press the Tank key.

All of the components begin to heat or cool to the new global setpointtemperature. When all of the components have reached their setpointtemperatures, the Ready LED lights up (green).

Switching Off All Components

A global setpoint temperature of zero degrees (Celsius or Fahrenheit) turnsall components off.

Operation4‐22


Adjusting Temperatures Using the Global‐by‐component Group Method

1. Press and hold the Hose or Gun key for three seconds.

Reminder: The band heater is assigned to the hose group and will bechanged with the hose key.

The left display indicates the number of the first sequential hose or gun.The right display indicates the current setpoint temperature of the hose orgun.

2. Scroll the left display to 0.

The right display shows dashes (‐‐‐‐).






6. Press the Hose or Gun key to return to normal mode.

The hoses or guns begin to heat or cool to the new global setpointtemperature.

Operation 4‐23


Adjusting Temperature of an Individual Component

1. Press and hold the Tank, Hose or Gun key for three seconds.

If the tank key has been pressed, the left display flashes 1. The rightdisplay then indicates the current setpoint temperature of the reservoir.

NOTE: The setpoint temperatures for grid and reservoir can not be setseparately. However, it is possible in software versions 2.023 and higherwith a temperature offset (operating parameter 29):

Setpoint Reservoir + Temperature offset = Setpoint GridExample: 150 �C + (-15 �C) = 135 �C

If a hose or gun key has been pressed, the left display flashes thenumber of the first sequential hose or gun. The right display thenindicates the current setpoint temperature of the component shown in theleft display.

2. Scroll the left display to the number of the desired component.

The right display then indicates the current setpoint temperature of thecomponent selected in the left display.





5. If additional setpoint temperatures are to be changed, press Enter toconfirm and then select the next component.

6. Press any component key (tank, hose or gun) to return to normal mode.

The selected component begins to heat or cool to the new setpointtemperature.

Switching Off Component

A setpoint temperature of zero degrees (Celsius or Fahrenheit) turns thecomponent off.

Operation4‐24


Quick Adjustment - Tips -

� When the right display is flashing, the setpoint temperature can quicklybe set to 0 degrees (Off) by simultaneously pressing both of the rightdisplay scroll keys.

� When a setpoint temperature is set with the right scroll keys, the rightdisplay automatically jumps from 0 to 175 or 230 �C or from 0 to 350 or450 �F.

Helpful Information

� If you make a mistake while changing a setpoint temperature but have notyet pressed the Enter key, press the Clear/Reset key to reset the rightdisplay to the original temperature.

� If you enter a valid setpoint temperature for a hose/gun that is notconnected to the melter, the right display will indicate dashes (‐‐‐‐) forthree seconds and then change back to the original setpoint temperature.

� If you enter a setpoint temperature for a hose/gun that is out of range, theright display will indicate dashes (‐‐‐‐) for three seconds and then changeback to the original setpoint temperature.

� When scrolling through component numbers in the left display,component numbers assigned to unused hose/gun receptacles areskipped.

� The setpoint temperature of a component can be checked at any time bypressing the right scroll key UP. The setpoint of every scannedcomponent is displayed when the scroll key is held down in normal mode.

NOTE: Only the setpoint temperature of the reservoir is displayed andnot that of the grid, even if a temperature offset � 0 was set.

Operation 4‐25


Checking Temperatures

The actual temperature of every heated component can be checked via thescan cycle in normal mode or by manually selecting the components.

By default, the melter remains in normal mode except when:

� The melter is in Setup mode

� A fault occurs.

Checking Actual Temperature in Normal Mode

1. When the Ready LED is illuminated, observe the LEDs on the componentkeys.

2. When the LED on the key that represents the desired component group(Fig. 4‐9) lights up, observe the left display (8, Fig, 4‐4) until it shows theposition number of the component to be checked.

Fig. 4‐9

3. When the position number of the desired component appears in the leftdisplay, the right display (6, Fig. 4‐4) shows the component's actualtemperature.

NOTE: Components with a setpoint temperature of zero degrees areskipped.

Checking Setpoint Temperature in Normal Mode

The setpoint temperature of a component can be checked at any time bypressing the right scroll key UP. The setpoint of every scanned component isdisplayed when the scroll key is held down in normal mode.

NOTE: Only the setpoint temperature of the reservoir is displayed and notthat of the grid, even if a temperature offset � 0 was set.

Operation4‐26


Checking Actual Temperature Manually

1. Press the key that represents the component group to be checked. Theautomatic scan cycle stops.

� When the tank key is pressed, the left display does not show acomponent number (blank display). The right display shows thereservoir's actual temperature.

Reminder: If the tank key is held down for three seconds, the leftdisplay flashes 1. The right display shows the reservoir's setpointtemperature.

� If the key for a different component group is pressed, the left displayindicates the number of the first component in the selectedcomponent group. The right display shows the component's actualtemperature.

Fig. 4‐102. If the first sequential component is not the component to be checked, use

the left display scroll key to move to the correct component number.

When you scroll past the number of the last sequential component in acomponent group, the number of the first component in the next groupappears.

3. The melter returns to normal mode two minutes after the last key ispressed.

Or press Setup twice to immediately return to normal mode.

Helpful Information

� Briefly press the tank key to check the actual temperature of thereservoir.

� To check the actual temperature of the grid, simultaneously press theTank key and the left display scroll key.

� Call up Hose 5 to check the actual temperature of the hopper.

Operation 4‐27


Functions and Function Keys

Standby

Standby serves to protect the hot melt material and to save energy duringbreaks in production.

The melter can be set up to automatically enter standby using a series ofparameters (Refer to Appendix B, Parameters 25, 26, 30–33, 57, 62 and 67)or standby can be entered manually with the key Standby.

When the melter enters standby, the temperatures of all components arereduced from their setpoint temperatures by a preset standby delta.

Manual Entry/Exit with the Key

The melter enters or exits standby mode when the key Standby is pressed.

Automatic Exit via Parameter 26

Parameter 26 is the amount of time that the melter remains in standby modeafter the Standby key is pressed. When the parameter is enabled, the LED inthe Standby key flashes,

After the time has expired, the melter once again begins heating all of thecomponents to their assigned setpoint temperatures.

Automatic Entry/Exit via the Seven‐day Clock

Refer to Appendix B for detailed information on setting up the seven‐dayclock.

Operation4‐28


Standby (contd.)

Automatic Entry via External Input 1(Parameter 30, value: 10)

If there is no 24 VDC signal at input 1 for the duration of parameter 24, themelter enters standby.

Entry/Exit via External Input 1 - 4(Parameter 30 - 33, value: 1)

Helpful Information

Using the Standby key overrides the control of the melter by the seven‐dayclock or a remote input.

1

Pump key

Motor key

Operation 4‐29


Pump

Switching the pump on and off does not affect heater control.

Pump Key (Control Panel)

Motor Key (Motor Control Panel)

Enabling is requested with the Pump key. If the bulk melter is ready, themotor key is enabled and the motor can be started with the Motor key.

Refer to Functional Diagram: Enabling and Switching On in this section.

� Meaning of the LED on the Pump key:

LED off . . . . . . Key was not pressed

LED yellow . . . . . . Motor/pump enabled; system not ready

LED green . . . . . . . Motor/pump enabled; system readyMotor/pump running when the LED on the Motor key is alsogreen

LED flashing green No signal from standard input

� Meaning of the LED on the Motor key:

LED off . . . . . . Key was not pressed, or pressing was ignored

LED green . . . . . . . Motor/pump running

Heater

Use the heater key to manually turn the component heaters on and off.Pressing the heater key overrides the heater control by the seven‐day clockfeature or a remote input. The LED on the heater key is illuminated when theheaters are on.

When a fault occurs the heaters automatically turn off. The heater key is usedto turn the heaters back on after correcting the fault condition.

Operation4‐30


Seven‐day Clock

Use the Seven‐day clock key to turn the clock feature on and off. When theclock is on, the temperature of each heated component is automaticallyregulated by user‐defined schedules.

Three schedules are available to accommodate daily shift work. They areused to specify when the heaters should turn on and off or when the meltershould enter and exit the standby mode. Refer to AppendixB, Seven‐dayClock for information on creating programs.

Control option 0 of the operating parameters 71 to 77 is used to keep themelter in the last state specified by the clock (e.g. Heaters off on non‐workingdays).

When the heaters switch on as dictated by the schedule, they are regulatedto their assigned setpoint temperatures. When the clock activates thestandby mode, the setpoint temperatures are all temporarily reduced by apreset standby delta.

If the heaters are manually turned off during the time that a clock schedulecalls for the heaters to be on, the heaters will not turn back on until the nextclock schedule calls for them to be on.

If the melter is switched off while the seven‐day clock is on, the clock willautomatically turn back on the next time the melter is switched on.

If F4 appears in the right display when the Seven‐day clock key is pressed,the internal clock (realtime clock) has failed. Refer to sectionTroubleshooting.

Overriding the Seven‐day Clock

You can override the seven‐day clock at any time. If the clock has turned theheaters off, pressing the Heater key will turn the heaters back on.

If the clock has placed the melter in standby mode, pressing the Standby keywill return the heated components to their assigned setpoint temperatures.

Setup

The melter enters or exits Setup mode when the Setup key is pressed. Theautomatic scan cycle stops in Setup mode. The left and right displays areused to select, read or edit operating parameters.

11 22

00

44 55

33

66

99

Operation 4‐31


Important when Changing MaterialThe temperature setting is determined by the processing temperatureprescribed by the material supplier. The maximum operating temperature forthe product described here and heated components may not be exceeded.

Nordson will grant no warranty and assume no liability for damage resultingfrom incorrect temperature settings.

NOTE: The overtemperature thermostats must be adjusted (replaced) toaccommodate the maximum temperature of the material used. The shutdownvalue of the thermostat may not exceed the maximum operating temperatureof the melter!

Also refer to Changing Type of Material and Purging with Cleaning Agent inthe section Maintenance.

Communication via Serial InterfaceIf a computer with the Nordson Configuration Manager software is connectedto the serial interface, the following is possible:

� Installation of melter firmware

� Transmission of operating parameters and setpoint temperaturesbetween melters

� Saving multiple variations of melter settings.

Refer to Appendix C for information on hardware and software requirementsas well as on operation.

Fig. 4‐11

Operation4‐32


Settings Record

Production information:

Material: Manufacturer

Processing Temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Inert gas: Inlet pressure (set on pressure controller)

Timer relay, times T1 / T2

Processing temperatures (Setpoint temperatures):

� Grid and reservoir

Hopper

Hose 1

Gun 1

�Hose 2

� Gun 2

�

Pump speeds:

Pump 1

Pump 2

Air pressures at gun (accessories):

Control air

Spray air

Notes:

Name Date

Maintenance 5‐1


Section 5

Maintenance


NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the service life of the unit. It should not beneglected under any circumstances.

Risk of BurnsATTENTION: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

Some maintenance work can only be done when the melter is heated up.

Relieving pressureATTENTION: System and material pressurized. Relieve system of pressurebefore disconnecting hoses, plugs, guns and hot melt handguns. Failure toobserve can result in serious burns.



3. Activate the solenoid valve(s) electrically or manually; or, pull the triggerof the assembly handgun. Repeat this procedure until no more materialflows out.


Maintenance5‐2


Important when Using Cleaning Agents

� Never used halogenated hydrocarbon solutions to clean componentsmade of aluminum or to purge Nordson equipment. The strong chemicalreaction can cause injury or death. Also refer to the section Safety.

� Use only a cleaning agent recommended by the hot melt materialmanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

� Properly dispose of cleaning agent according to local regulations.

Processing Materials

Designation Order number Use

High temperature grease To be applied to O‐rings, threadsand sealing surfaces

NOTE: The grease may not bemixed with other lubricants.Oily/greasy parts must be cleanedbefore application.

� Can 10 g P/N 394769

� Tube 250 g P/N 783959

� Cartridge 400 g P/N 402238

Temperature‐resistantadhesive Loctite 640

Secures screw connections

� 50 ml P/N 230359

Heat transfer compoundNTE303

To improve heat conducting oftemperature sensors

� 1 g P/N 1023441

Maintenance 5‐3


Preventive MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the operating environment, production conditions and melterhours of operation, other scheduled maintenance tasks may provenecessary.

Melter part Activity Interval

Complete melter External cleaning Daily

Inspect for external damage Daily

Purging with Cleaning Agent When material is changed

Power cable Inspect for damage Every time the melter is serviced

Air hoses Inspect for damage Every time the melter is serviced

Fan and air filter Check filter, clean or replace ifnecessary

Clean fan screen

Depending on dust accumulation;daily if necessary

Safety valve plate Replace O‐ring(s) At the latest when leakage occurs

Pump Checking for Leakage Depending on hours of operation,pump speed and pump temperature

Recommendation: Monthly

Retightening Fixing Screws Every 500 hours of operation

Motor / gear box Clean fan cover Depending on dust accumulation;daily if necessary

Change lubricant Every 15 000 hours of operation orat least every 4 years

Pressure control valve Replace O‐rings At the latest when leakage occurs

Tank Cleaning Tank by Hand

Keep inert gas inlet clean

When there is material residue intank

Tank Isolation Valve Replace O‐rings At the latest when leakage occurs

Safety Valve Activating the Piston Monthly

Replace outer O‐rings At the latest when leakage occurs

Pneumatic safety valve Performance check; replace ifnecessary

Every six months

NOTE: Motor controllers are maintenance‐free.

Maintenance5‐4


External cleaningExternal cleaning prevents impurities created during production from causingthe melter to malfunction.

CAUTION: Observe the unit's Degree of Protection when cleaning (Refer tosection Technical Data).

CAUTION: Do not damage or remove safety labels. Damaged or removedsafety labels must be replaced by new ones.

Remove material residue only with a cleaning agent recommended by thematerial supplier. Heat with an air heater if necessary.

Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.

Nordson recommends the orange cleaning agent P/N 771192 (12 spraybottles, 0.5 l each).

Inspect for external damageATTENTION: When damaged parts pose a risk to the operational safety ofthe melter and/or safety of personnel, switch off the melter and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

Changing Type of MaterialNOTE: The overtemperature thermostats must be adjusted (replaced) toaccommodate the maximum temperature of the material used. The shutdownvalue of the thermostat may not exceed the maximum operating temperatureof the melter!

1. Run the melter until empty.

2. Determine whether the new material may be mixed with the old material.

� May be mixed: Remaining old material can be flushed out using the newmaterial.

� May not be mixed: Thoroughly purge the unit with a cleaning agentrecommended by the material supplier.

NOTE: Properly dispose of the old material according to local regulations.

3. Adjust setpoint temperatures if necessary.

Maintenance 5‐5


Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the hot melt materialmanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

Cleaning agent residue can be flushed out of the melter with new materialbefore production begins again.

NOTE: Properly dispose of cleaning agent according to local regulations.

Detaching Protective Panels

Open the protective panels with a 4 mm Allan key.

On the inside

Fig. 5‐1

Maintenance5‐6


Fan and air filterThe air filters must be cleaned (knocked out) or replaced, depending on dustaccumulation.

1

2

Fig. 5‐2 Previous model

1 Fan with filter 2 Air filter, air outlet

Maintenance 5‐7


Safety Valve PlateCAUTION: If the safety valve plate is pulled out to enable maintenance to orrepair of other components, ensure that the O‐ring (6, Fig. 5‐5) is positionedproperly in the groove when the safety valve plate is slid back into place.Otherwise leakage can occur.

Releasing Safety Valve Plate

ATTENTION: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

1. Heat the melter until the adhesive softens (approx. 770 °C/158 °F,depending on the material).

2. Relieve the tank of inert gas pressure. Set the inert gas control switch toDeaerate and work quickly.

3. Close the tank isolation valve in the corresponding safety valve plate /pump.

4. Turn the cardan joint such that it can swivel out in the direction in whichthe safety valve plate is pulled (Fig.6‐4, bottom).

5. Release the hexagonal screw (1 or 2, Fig. 5‐3). This releases the safetyvalve plate (4 or 5, Fig. 5‐3).

6. Pull the safety valve plate in the groove in the direction of the arrow.

1

2

3

4

5

Fig. 5‐3 Tank from below

Maintenance5‐8


Fig. 5‐4 Photos show the previous model

6

Maintenance 5‐9


Safety Valve Plate: Replacing O‐ring

1. Remove the old O‐ring (6, Fig. 5‐5).

2. Clean sealing surfaces on tank, safety valve plate and pump.

3. Apply high temperature grease to the O‐ring and sealing surfaces. AttachO‐ring.

Ensure that the O‐ring (6) sits properly in the groove. Otherwise theO‐ring may be damaged when the safety valve plate is slid back intoplace.

Fig. 5‐5 Example

Securing Safety Valve Plate

1. Slide the safety valve plate all the way back (Screw head: 3, Fig. 5‐3) andsecure with a hexagonal screw (1 or 2, Fig. 5‐3).

2. Fill the tank.


4. Open the tank isolation valve again at operating temperature.

Maintenance5‐10


Pump

Checking for Leakage

The gear pump is equipped with a shaft seal. Material may seep out alongthe shaft at irregular intervals. Then replace the pump shaft seal.

Replacing Pump Shaft Seal

When the pump shaft seal needs to be replaced, Nordson recommendsreplacing the pump and sending the old one in to be repaired. Only trainedpersonnel using special assembly tools can replace the pump shaft seal.Refer to section Repair and to the separate parts list.

Retightening Fixing Screws

Normal heat cycling (heating and cooling) can cause the fixing screws tobecome loose.

NOTE: Retighten fixing screws only using a torque wrench (25 Nm / 220Ibin) and when the melter is cold.

Maintenance 5‐11


Motor / gear boxThe only motor maintenance required is cleaning the fan cap.

Change lubricant

NOTE: Use only the stated lubricant or one that has proven to be equivalent(Refer to Lubricant Selection). Using any other lubricant can result inpremature wear and/or damage to the gear box.

NOTE: Drain lubricant when warm.

Remove gear box from the motor to change lubricant. Wash out casing withsuitable cleaning agent and remove lubricant residue.

NOTE: Properly dispose of the old lubricant according to local regulations.

Lubricant Changing Interval

When lubricant temperature is below 100° C / 212° F:Every 15000 hours of operation or at least every 4 years.

Capacity

The lubricant quantity is indicated on the ID plate. Ensure that the uppergears and rolling bearings are properly lubricated.

NOTE: Never mix different types of lubricants.

Lubricant Selection

Lubricant manufacturer Mineral oil CLP 220

AGIP Blasia 220

ARAL Degol BMB 220 or Degol BG 220

BP Energol GR‐XP 220

DEA Falcon CLP 220

ESSO Spartan EP 220 or GP 90

KLÜBER Klüberoil GEM 1‐220

OPTIMOL Optigear 220

SHELL Omala Oil 220

TEXACO Geartex EP‐A SAE 85 W‐90

optional

X

1 2

Maintenance5‐12



Replacing O‐rings


1. Heat the melter to operating temperature.

2. Relieve melter pressure.

3. Close the tank isolation valve.

4. Optional: Close the compressed air supply.

5. Refer to Measuring Insertion Depth or optional: Unscrew the air hose.

6. Use an open‐end wrench to screw out the pressure control valve, thenextract with a pliers.

7. Remove old O‐rings and clean pressure control valve.

8. Install new O‐rings. Apply high temperature grease to all threads andO‐rings.

9. Guide the pressure control valve into the hole when the melter is warmand tighten with torque wrench. Torque: 15 Nm (133 lbin).

10. Refer to Adjusting Pressure Control Valve or optional: Unscrew the airhose.

11. Open tank isolation valve.

12. Optional: Open the compressed air supply again.

Important for Mechanical Pressure Control Valve

Measuring Insertion Depth

Measure and make a note of the insertion depth of the setting screw(dimension X). This way the insertion depth can be replicated afterreassembly.

Maintenance 5‐13


Adjusting Pressure Control Valve

The setting screw (2) is secured with the locknut (1, Fig. 5‐6).

1. Loosen the locknut.

2. Adjust the setting screw to the recorded dimension X.

� Turning to the right increases material pressure.

� Turning to the left decreases material pressure (Fig. 5‐6).

3. Tighten the locknut.

Fig. 5‐6 Reduce pressure

TankNOTE: The inside of the tank is release coated. Do not use metallic tools toclean. Do not use wire brushes! This could damage the release coating.

CAUTION: Relieve the tank of inert gas pressure. Set the inert gas controlswitch to Deaerate.

Cleaning Tank by Hand

CAUTION: Do not feed charred material through the gun. Particles canblock the gun. Instead unscrew the hose (Refer to the section Installation).

1. Pump the material out of the melter or drain it through the material drainbore if there is one.

Cold material can usually be peeled off of the sides of the tank. If necessary,first heat tank to material softening temperature (approx. 70 °C / 158 °F,depending on the material).

Continued ...

3 4

2 1

Maintenance5‐14


Tilting Tank

Check the O‐rings between hopper/grid and grid/reservoir every time theequipment is cleaned. Replace any damaged O‐rings.

1. Detach protective panels.

2. Pivot the tank lid out and check if tank is empty.

3. Release the fitting (1, Fig. 5‐7) and remove the bottom three elements (2,Fig. 5‐7) together.

The band heater need not be removed.

4. Release the four fasteners (3, Fig. 5‐7).

5. Hold the hopper by the handle and tilt it. The indexing bolt (4, Fig. 5‐7)engages.

6. Disconnect the grid plug XS1 (arrow).

7. Extract the temperature sensor from the grid (bayonet fastener).

8. Detach the grid from the reservoir.

9. Clean the tank and reassemble.

10. Reconnect the temperature sensor and the grid plug.

11. Pull and release the indexing bolt (4, Fig. 5‐7) to tilt the hopper back intoplace.

Fig. 5‐7

12. Close the fasteners (3, Fig. 5‐7) again.

13. Attach the protective panels again and close the tank lid.

Size 13

Maintenance 5‐15



Replacing O‐rings

1. Heat melter to operating temperature.

1

00: Closed1: Open

Fig. 5‐8


2. Empty tank.

3. Release four Allan screws M5 and lift off plate. Use a pliers to extract thetank isolation valve.

4. Remove the old O‐rings and clean the tank isolation valve.

5. Apply high temperature grease to the O‐rings, then install again with thetank isolation valve.

NOTE: Operate the tank isolation valve only when the melter has reachedoperating temperature.

Fig. 5‐9

X

1 2

Maintenance5‐16


Safety Valve

Activate the safety valve piston. This prevents the material from blocking thesafety valve.

Procedure:

1. Relieve pressure as described in section Installation.

2. Disconnect all hoses.

3. Close the hose connections with Nordson port plugs (Fig. 5‐10).

Fig. 5‐10

4. Mechanical pressure control valves: Measure the insertion depth (Fig.5‐11): of setting screw (2) (dimension X) and make a note. This ensuresthat the insertion depth can be reproduced. Close the pressure controlvalve by turning it all the way clockwise.

Pneumatic pressure control valves:Set the compressed air supply to6 bar.

5. Operate the melter at full motor speed and with hose connections closed.Switch the motor on and off several times.

Fig. 5‐11

CAUTION: For safety reasons, the safety valve may not be disassembled.The complete valve must be replaced every time. Refer to section Repair.

Nordson recommends keeping a supply of replacement safety valves. Thereis a spare parts kit available for the outer O‐rings.

ÂÂÂÂ

Maintenance 5‐17


Safety Valve for Pneumatics

The safety valves, preset at the factory and lead sealed, prevent higherpressurization than permitted of the subsequent pneumatic components.When the factory settings are exceeded, compressed air audibly escapes.

NOTE: One safety valve is in the melter tower and - depending on the theoption - the second would be in the tank.

Performance check

The performance of the safety valve should be checked approx. every sixmonths. Do this by turning the knurled screw until the compressed air isaudibly released. If the safety valve does not function properly, it should bereplaced.

NOTE: A defective safety valve may be replaced only with an original sparepart. Only the manufacturer may perform repairs to the safety valve!

Maintenance5‐18


Maintenance Record Form

Melter part Date / Name Date / Name Date / Name

Safety valve plate

Safety Valve

Pump

Motor / gear box

Air filter

Tank


Pressure control valve

Pneumatic safety valve

Troubleshooting 6‐1


Section 6

Troubleshooting


ATTENTION: Troubleshooting activities may sometimes have to be carriedout when the unit is energized. Observe all safety instructions andregulations concerning energized unit components (active parts). Failure toobserve may result in an electric shock.

Helpful Tips

Before starting systematic troubleshooting, check the following:

� Is the seven‐day clock set correctly?

� Are all parameters set correctly?

Refer to Appendix B for possible operating parameters and values.

� Is the interface wired correctly?

� In key‐to‐line mode: Is there a line speed signal provided?

� Do all plug connections have sufficient contact?

� Have circuit breakers been activated?

� Could the fault have been caused by an external PLC?

� Are external, inductive loads (e.g. solenoid valves) equipped withrecovery diodes?

� Were operating parameters misadjusted? Refer to Appendix B for propersettings.

Troubleshooting6‐2


Fault Numbers

DisplayCode/subcode

Name Effect Cause Corrective Action

F1 / NoneRTD (resistance temperature detector)

Heaters turn off

The RTD for the componentindicated has failed or thecomponent was disconnected fromthe melter.

Replace RTD

Check hose/gun connections

F2 / NoneUndertemperature

The actual temperature of thecomponent indicated has droppedbelow the undertemperature delta,which was set using parameter 22.

Check whether external factorshave caused the ambienttemperature to fall

Replace RTD

F3 / NoneOvertemperature

The actual temperature of thecomponent indicated has increasedbeyond the overtemperature delta,which was set using parameter 21.

Replace RTD

F4/1

RAM (randomaccessmemory)

Test

Melter stopsfunctioning

Internal RAM failure Replace CPU

F4/2Realtimeclock

Time

Heaters remainon, but faultconditionpersists

Internal clock failure Replace CPU

F4/4

Realtimeclock

Battery‐backedRAM

Battery‐backed RAM failure Replace CPU

F4/5Realtimeclock

Battery

Battery dead Replace CPU

F4/6 Analog‐digital

Melter stopsfunctioning

RTD analog‐digital converter failed Replace main board or CPU

F4/7Analog‐digitalcalibration

RTD analog‐digital converter couldnot be calibrated

Replace main board, ribbon cableor CPU

F4/8Main boardfeedback

Communication failure betweenmain board and processor

Replace main board, ribbon cableor CPU

F4/A Thermostat Open reservoir or grid thermostat Replace thermostat, cable harnessor main board

F4/dOptional I/Oexpansionboard

Heaters remainon, but faultconditionpersists

Communication failure betweenprocessor and optional I/Oexpansion board

Replace I/O expansion board orCPU

F4/EField buscommunicationfailure

Alarm output (ifoutput option 6is selected)

The meltercontinues tofunction normally

Field bus board failure Replace field bus board



F1, F2 and F3 Faults

When the melter detects an F1, F2 or F3 fault:

1. The automatic scan stops and the melter begins to monitor the potentialfault for up to two minutes. The ready and heater LEDs remain on duringthe two minute period. If during the two minutes the melter determinesthat the fault condition no longer exists, the melter reverts to normalmode.

2. The LED on the affected component key (tank, hose or gun) lights up toindicate the type of component that has, or is, failing.

3. The type of fault (F1, F2 or F3) appears in the right display.

4. The component that is or was failing appears in the left display as follows:

� If the LED on the tank key is on, the left display shows either 1 for thegrid or 2 for the reservoir.

� If the LED on the hose or gun key is on, the left display shows thenumber of the affected hose or gun.

5. If after the two‐minute monitoring period the fault still exists, the ReadyLED goes off, the red Fault LED turns on, the heaters turn off and themelter records the fault in the fault log. Refer to Fault Log in this section.

To be able to put the melter back into operation, the fault must be remediedand the melter reset. Refer to Resetting Melter.



F4 Fault

When the melter detects an F4 fault:

1. The Ready LED turns off and the red Fault LED lights up.

2. All of the component key LEDs (tank, hose and gun) turn off.

3. The right display indicates F4.

4. The left display indicates a subcode. The subcode classifies the fault asbeing fatal or nonfatal. These two classes of F4 faults affect the melterlike this:

Fatal — The Fault LED turns on and stays on; the melter stopsfunctioning completely.

Nonfatal — The Fault LED turns on for five seconds, but the heaters andpumps continue to operate normally.

5. The melter records the fault in the fault log. Refer to Fault Log in thissection.

Helpful Information

An F1 fault (RTD) can be temporarily dismissed and the bulk melter returnedto normal mode by pressing the Clear/Reset key. The heaters will remain off.If the fault condition still exists two minutes after pressing the Clear/reset key,the Fault LED will turn back on.

If, for any reason, a component reaches 235�C (458 �F), an immediate F3fault will occur (no two‐minute monitoring period).

When an F1 fault occurs, you can determine whether the fault was caused byan open or shorted RTD by simultaneously pressing both of the right displayscroll keys. If the right display indicates OP, the RTD is open; if it indicatesSH, the RTD has shorted.

To view the temperature of a heated component when an F2 or F3 faultexists, simultaneously press and hold down both of the right display scrollkeys.

If F4 appears in the right display when the Seven‐day clock key is pressed,the internal clock (realtime clock) has failed.



Resetting Melter

1. Determine cause of fault and then remedy it.

2. Return the melter to normal mode by pressing the Setup key twice.

3. Press the Clear/reset key.

4. Press the Heater key to switch on the heaters.

Fault Log

Calling Up Fault Log

The fault log indicates the type, sequence and respective time of the last tenfaults.

1. Hold down the Setup key.

The automatic scan stops, and parameter 1 appears in the left display.

2. Scroll the left display to parameter 2 (fault log).

The right display indicates the last fault as follows:

� If the last fault was an F1, F2 or F3 fault, then the LED on the affectedcomponent key turns yellow.

� If the last fault was an F4 fault, all of the component key LEDs turn off.

� The right display indicates the log entry for the most recent fault.Refer to Structure of Fault Log.

3. Press a right display scroll key to review each of the remaining nine logentries. Each time a scroll key is pressed, a progressively older log entryis displayed.

NOTE: The fault log only stores the last ten faults.

4. Press the Setup key to return to normal mode.



Structure of Fault Log

First digit Second and third digit Fourth digit

Component:

‐F

Type of fault:

1 = Grid or hose/gun 1 0 = Unused log entry

2 = Reservoir or hose/gun 2 1 = RTD (open or short)

3 = Hose 3 or gun 3 2= Undertemperature

4 = Hose 4 or gun 4 3 = Overtemperature

5 = Hopper 4 = Processor or electrical failure

Example 1 - Undertemperature

If the LED on the tank key is on, the log entry indicates gridundertemperature. If the LED on the hose key is on the log entry indicateshose 1 undertemperature.

Example 2 - Unused Log Entry

Helpful Information

To view the number of heater hours that have elapsed since a fault log entry,press both right display scroll keys simultaneously. The hours appear in theright display.

The melter will return to normal mode if the fault log is left open for a period oftwo minutes without any key being pressed.

When an F1 fault is the result of a hose/gun pair being disconnected from themelter, two fault log entries are created. The first entry is for the gun, thesecond for the hose.



Board Overview

X5

XT

5X

T6

CP

UG

rid R

TD

Res

ervo

ir R

TD

DS

3D

S5

MA

IN B

OA

RD

EX

PA

NS

ION

Ma

in b

oa

rd

to P

OW

ER

MO

DU

LE (

HO

SE

/GU

N 3

+4)

to A

DA

PT

ER

(H

eizb

and

)

Ex

pa

ns

ion

bo

ard

X4

Fig. 6‐1



Indication Lamps (LEDs) and Fuses on Main Board

Designation Description

LED

DS2 ... DS7 Fuse monitoring (illuminated when fuses are OK)

DS2 Reservoir heaters

DS3 Grid heaters

DS4 Voltage supply 5 VDC and 24 VDC

DS5 Hose/ gun 1 heaters

DS6 Hose/ gun 2 heaters

DS7 Motor

DS8 ... DS14 Control voltage (illuminated when voltage is present)

DS8 Hose 1 heater

DS9 Gun 1 heater

DS10 Grid heaters

DS11 Motor

DS12 Gun 2 heater

DS13 Hose 2 heater


DS15 +5 VDC control voltage

DS17 Trigger signal from a handgun to XP3 or XP4

Fuses (Refer to parts list for fuse types)

F1/F2 Grid heaters

F3/F4 Voltage supply 5 VDC and 24 VDC

F5/F6 Reservoir heaters

F7/F8 Hose/ gun 1 heaters

F9/F10 Hose/ gun 2 heaters

F11/F12 Motor

Refer to wiring diagram for connections

Indication Lamps (LEDs) on I/O Expansion Board

Designation Description

LED

DS1 24 VDC at X3 (24V SUPPLY)

DS3 Grid heaters


Refer to wiring diagram for connections

Display Pump speed



Motor Controller Faults

Table 6‐1 shows the motor controller faults and fault codes that may appearin the pump speed display.

Tab. 6‐1 Motor controller faults

Fault code / problem Possible fault Corrective Action

no EnAFlashes when the Motor key is pressed

No enable Press the Pump key on thecontrol panel until the LED lightsup

hOt Motor thermostat open Wait until the motor has cooledoff; check that the pump speed isnot set too low, then start thepump again. If the fault code hOtcontinues to be displayed, go tothe troubleshooting table NoMaterial (Motor does not Rotate)/ Motor Overheated

The displayed speed is not theactual speed

The pump speed display is notcalibrated

Refer to Calibrating Pump SpeedDisplay in this section

The motor controller does notfunction as expected

Motor control parameters are notset properly

Check the motor controlparameters. Refer to ChangingMotor Control Parameters in thissection

Arrow keys

Pump mode key



Calibrating Pump Speed Display

The pump speed display is calibrated before the bulk melter is delivered tothe customer. If calibration is required again, perform the following steps.

1. Operate the motor at maximum speed.

2. Measure the pump speed with strobe.

3. Press both arrow keys and hold them down.

4. Release the keys when CAL appears in the display.

5. Use the arrow keys to set the value to the pump speed measured.

6. Press the Pump mode key to save the setting and exit calibration mode.

Arrow keys

Pump mode key



Changing Motor Control Parameters

The motor control parameters have been set at the factory (Refer to table6‐2) and can be changed via the motor control panel:

1. Switch off motor.


3. Hold down both arrow keys and turn on the main switch again. As soonas SEt appears, release the keys.

4. Use the arrow keys to set a value for the parameter indicated by thepump speed display. Refer to Table 6‐2 for the list of parameters.

5. Press the Pump mode key to save the value and move to the nextparameter.

6. Repeat steps 4.+ 5. for each of the parameters to be changed.

7. To exit setup mode, press the Pump mode key again after the lastparameter has been displayed.

Tab. 6‐2 Motor control parameters (defaults)

Parameters Default value Designation Explanation

SEt 100 Maximum pumpspeed

In manual mode, this parameter determinesthe size of the step by which the speed ischanged when one of the Pump speed arrowkeys is pressed.

To change the pump speed in steps of 1, setthis parameter to the maximum pump speed.

Srt 0 Type of motor start 0: Motor key is active. The enabled pump isswitched on with the Motor key and switchedoff with the Motor key or the Pump key.

1: Motor key is not active.

LoS 0 Minimum speed inautomatic mode

If the bulk melter is operated in manual mode,enter 0.

If the bulk melter is operated in automaticmode, a minimum speed can be entered. Thenthe speed does not fall below this value, evenif the line speed signal falls to 0 V.



Troubleshooting Tables

When a fault occurs the heaters automatically turn off. The heater key is usedto turn the heaters back on after correcting a fault condition.

Melter not Functioning

Problem Possible Cause Corrective Action

1. No line voltage - Connect line voltage

2. Main switch notswitched on

- Switch on main switch

3. Main switch defective - Replace main switch

4. Main circuit breakeractivated

- Switch on main circuit breaker

5. Main circuit breakeractivated again

Check for short circuit in melter oraccessories

-

6. 24 VDC power supplydefective

- Replace

A Heated Component does not Heat


1. Component isdisabled / turned off

- Enable / switch on

Zero degrees = switched off

2. Component does notheat

- Check LEDs on main board; replacefuses if necessary

Replace heater cartridge

No Line Speed Signal


1. Parent machine notoperating

- Start up parent machine

2. Polarity of line speedvoltage input isreversed

- Reverse polarity

3. Encoder defective - Replace



Control Panel does not Function


1. Display is blank PLC ribbon cable not connected Connect

2. One or more roundLEDs do not light upduring the test whenthe system is startedup

Replace the control panel (Refer tosection Repair).

Main contactor opened

Overtemperature shutdown by (tank) thermostat

The shutdown value depends on the thermostats installed on the grid /reservoir / band heater (Also refer to Technical Data for possiblethermostats).

Shutdown by transformer thermostat

The shutdown temperature for the transformer is 155�5 ° C / 311�9 ° F.

No Inert Gas

“0”(closed)

Apply gas Deaerate

Fig. 6‐2 Position of the Inert gas control switch


1. Tank was not suppliedwith inert gas

Inert gas bottle empty Replace

Solenoid valve of inert gasequipment defective

Replace

(The solenoid valve is in the meltertower on the pressure display)

Inert gas inlet blocked Clean

Inert gas control switch is set to "0"(closed) or to Deaerate

Check the switch setting according toFig. 6‐2 and move to Apply gas ifnecessary.NOTE: The main switch of the meltermust be switched on.



No Material (Motor does not Rotate)


1. Melter not yet readyfor operation (heatupphase)

- Wait until the melter has heated upand the Ready LED is illuminated.

2. Motor not switchedon

- Refer to the section Operation /Functional Diagram: Enabling andSwitching On

3. Speed (rpm) not set - Refer to the section Operation /Setting the Pump Speed

4. Standby entered - Exit or wait until standby period hasexpired

5. Motor Overheated Ambient temperature too high Decrease ambient temperature bycooling or airing out

Fan cap dirty Clean

Pump blocked by foreign material Replace pump

Pump operates too sluggish Replace pump

Material too cold Set temperature accordingly

6. Motor defective - Replace

7. Motor not suppliedwith voltage

- Technical inspection

8. Motor controller fault - Switch melter off and on again withmain switch

Motor Overheated See above.

Motor controller overheated Decrease ambient temperature bycooling or airing out

Clean cooling section of motorcontroller

Short circuit Check motor cable

Overload (pump blocked by foreignmaterial, pump too sluggish,material too cold)

Refer to 5.

9. Motor controllerdefective

- Replace

10. Ready delay too short Check whether a value under 30min. has been set

Set value to � 30 min



No Material (Motor Rotating)


1. Tank empty - Fill tank

2. Material supply holeto pump or pumpsuction hole clogged

- Detach pump and clean supply holeor suction hole

Too Little Material


1. Material supply holeto pump or pumpsuction hole partiallyclogged

- Detach pump and clean supply holeor suction hole

2. Pressure controlvalve defective

- Clean or replace

3. Processingtemperature set toolow

- Correct temperature setting

4. Ready delay too short Check whether a value under 30min. has been set

Set value to � 30 min

5. Pump block is worn - Replace pump



Material Pressure too High


1. Safety valve orpressure controlvalve dirty and thusblocked

- Safety valve: Replace

Pressure control valve: Disassembleand clean or replace

2. Safety valve orpressure controlvalve defective

- Replace

3. Pressure controlvalve set incorrectly

- Set to default

Material Pressure too Low


1. Pump is worn - Replace pump

2. Safety valve does notclose any more

- Replace

3. Pressure controlvalve dirty and thusclogged

- Disassemble and clean or replace

4. Pressure controlvalve defective

- Replace

5. Pressure controlvalve set incorrectly

- Set to default

Material Residue or Hardened Material in Tank


1. Tank setpointtemperature set toohigh

- Correct temperature setting

Material of low quality or notappropriate for application(temperature resistance poor)

Consult material supplier

2. No Inert Gas - Refer to No Inert Gas

3. Inert gas interval setincorrectly

- Check settings on timer relay

4. Unsuitable inert gas Consult material supplier



Others


1. Leakage at pumpshaft seal

Pump shaft seal is worn Replace pump shaft seal

- Replace pump

2. Material pressure toolow, output quantitytoo low

Pump is worn Replace pump

3. Pump blocked Processed material too cold Correct temperature setting (observedata sheet of material manufacturer)

Foreign material in pump Replace pump

4. Leakage at gunduring heatup phase

Safety valve does not open(expansion pressure)

Replacing Safety Valve

LEDs of Motor ControllerDuring operation the operating mode of the motor controller is displayed bytwo LED's on the front of the unit.

Fig. 6‐3 LEDs

LED display Operating mode

Green Red

On Off Motor controller enabled

On On Mains switching and automatic start blocked

Flashing Off Motor controller blocked

Off Flashing (every 1 s) Fault message or motor controller is being parameterized

Off Flashing (every 0.4s)

Overvoltage or undervoltage shutdown

Off Off Missing voltage supply

Repair 7‐1


Section 7

Repair


Risk of BurnsATTENTION: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

Some melter components can only be detached when the melter is heatedup.

Observe Before Performing RepairsATTENTION: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

ATTENTION: Disconnect equipment from line voltage before any repairs.

Relieving pressureATTENTION: System and material pressurized. Relieve system of pressurebefore disconnecting hoses, plugs, guns and hot melt handguns. Failure toobserve can result in serious burns.



3. Activate the solenoid valve(s) electrically or manually; or, pull the triggerof the assembly handgun. Repeat this procedure until no more materialflows out.


Repair7‐2


Notes on Cardan Joint

Fig. 7‐1

Label

When installing the cardan joint, ensure that the label (arrows or points) ispositioned properly. Refer to Fig. 7‐1.

Notes on Safety Valve PlateThe procedure for releasing and extracting the safety valve plate is describedin the section Maintenance. Refer to Safety Valve Plate / Releasing SafetyValve Plate and Securing Safety Valve Plate.

CAUTION: If the safety valve plate is pulled out, ensure that the O‐ring ispositioned properly in the groove when the safety valve plate is slid back intoplace. Otherwise leakage can occur.

Repair 7‐3


Replace pump

Nordson recommends replacing the pump and sending the old one in to berepaired.


1

3

2

4

5 (1x)

5 (2x)

6

7

8

9

Fig. 7‐2

1 Pump

2 O‐ring

3 Hex bolt M8x70

4 Cardan joint

5 Setscrew

6 Hex bolt M8x20

7 Washer

8 Bracket

9 Motor

Repair7‐4


Detaching Pump

NOTE: Detach the pump only when the material is soft (approx. 70 ° C/158° F, depending on material).

1. Close the tank isolation valve.

2. Turn the Cardan joint until the two setscrews (5) on the pump side areaccessible.

3. Loosen the setscrews on the pump side.

4. Pump 1: Release the motor bracket screws and slide back the motorbracket with the motor and cardan joint in the slot.

5. Extract the safety valve plate.

6. Place a container under the pump to collect any material left.

7. Detach pump.

8. Clean sealing surface on the plate. If necessary, heat material residuewith a hot air fan, then remove.

9. Allow melter to cool to room temperature.

Attaching Pump

NOTE: The pump may only be attached when the melter is cold.

The sealing surfaces on the plate and the pump must be clean. Alwaysreplace the O‐ring(s).

1. Apply high temperature grease (Refer to section Maintenance,Processing Materials) to the new pump.

2. Apply high‐temperature grease to the fixing screws and O‐rings.

3. Tighten the fixing screws crosswise using a torque wrench; tighten onlywhen the tank is cold. Torque: 25 Nm / 220 lbin

4. Slide back the safety valve plate.

5. Slide the motor bracket with the motor and cardan joint all the way in theslot, then tighten the motor bracket screws.

6. Fasten the pump shaft to the Cardan joint using the two setscrews.

7. Heat melter to operating temperature and open tank isolation valve again.

Repair 7‐5


Replacing VarisealNOTE: When the pump shaft seal needs to be replaced, Nordsonrecommends replacing the pump and sending the old one in to be repaired.Only trained personnel using special assembly tools can replace the pumpshaft seal.

NOTE: Nordson cannot provide a guarantee for Variseals that have beenreplaced by anyone besides a Nordson employee.

1. Remove the gear pump from the melter but do not disassemble it!

Refer to Replacing Pump in this section.

2. Have a new seal and a suitable assembly tool ready.

Assembly Tool

The assembly tool is used to slide new seals over the shaft journal and thepump shaft pulley key groove without damaging the seals.

CAUTION: The seal must be put into place using the tool; otherwise the sealwill be destroyed.

1. Follow the instructions Assembly Tools for Sealing Kits with VarisealSeals (P/N 7146229) to proceed.

2. Put the gear pump back into place.

Repair7‐6


Replacing Motor

NOTE: Perform work only when the material is soft (approx. 70 ° C/158 ° F,depending on material); otherwise the Cardan joint can not be turned.

1

3

2

4

5 (1x)

5 (2x)

6

7

8

9

Fig. 7‐3

1 Pump

2 O‐ring

3 Hex bolt M8x70

4 Cardan joint

5 Setscrew

6 Hex bolt M8x20

7 Washer

8 Bracket

9 Motor

Repair 7‐7


Replacing Motor (contd.)

1. Disconnect motor power cable in the electrical cabinet.

2. Detach plug connector from motor controller.

3. Turn the Cardan joint (4, Fig. 7‐3) until the setscrew (5) on the motor sideis accessible.

4. Loosen the setscrew.

5. Remove the hex bolts (6) and detach the old motor (9).

6. Remove any protective varnish from the shaft of the new motor.

Guide the shaft into the Cardan joint without using force (no jolts orpounding). If necessary, sand pulley keys and shaft with emery cloth.Lubricate pulley keys and shaft if needed.

7. Install new motor in the bracket. Tighten the fixing screws crosswiseusing a torque wrench. Torque: 20 Nm / 177 lbin.

8. Fasten the motor shaft to the Cardan joint using the setscrew.

Reconnect motor electrically.

9. Secure power cable with strain relief. Ensure that the cable shield and theclamp have contact.

10. Verify that the connection effects the desired direction of rotation (seearrow).

Fig. 7‐4 Direction of pumprotation

Repair7‐8


Replacing Safety ValveATTENTION: For safety reasons, the safety valve may not bedisassembled. The complete valve must be replaced every time.

Refer to Installing Service Kit for procedure. However, points 3 and 4 areomitted.


Installing Service Kit

The kit contains two O‐rings and high‐temperature grease.

NOTE: Screw in/out only when the valve and the pump are warm and thematerial is soft (approx. 70 ° C / 158 ° F, depending on material).

Service kit P/N: 394592

Required tools:

Open‐end wrench, size 19PliersTorque wrench

1. Close tank isolation valve.

2. Use an open‐end wrench to screw out the safety valve, then extract with apliers.

3. Remove outer O‐rings and clean outside of safety valve.

4. Install new O‐rings.

5. Apply grease to all threads and O‐rings.

6. To prevent damage to the O‐rings, carefully guide the valve into the holewhen the melter is warm.

7. Tighten the valve with a torque wrench.

Torque: 15 Nm (133 lbin)

8. Open tank isolation valve.

Repair 7‐9


Replacing Motor ControllerCAUTION: Connect or disconnect the terminals only when the melter isdeenergized. The motor controller is still energized after switching off. Wait atleast three minutes before beginning any work!

Use only original Nordson motor controllers. They are parameterized andguarantee the required function.

Replacing Standard I/O Board of Motor Controller

1. Disconnect motor controller from power supply and wait at least 3minutes.

2. Disconnect standard I/O connections

3. Use a screwdriver to pry away the male connector (1) first and then thestandard I/O board (2).

4. Remove protective cap (3) of the new standard I/O board.

5. Set the DIP‐switch of the standard I/O board as indicated by the wiringdiagram (Refer to Motor Controller).

6. Insert standard I/O board into the serial port of the motor controller.

7. Insert male connector (1) into female connector of the standard I/Oboard.

8. Connect standard I/O board according to cable designation.

3

1

1

2

Fig. 7‐5

Repair7‐10


When Performing Work behind Electrical EquipmentCovers

The seals behind the electrical equipment covers are continuous. A groundconductor is not needed.

Continuous seal

Non-continuous seal

Fig. 7‐6 Example tank

With the previous model and non-continuous seal:

ATTENTION: The electrical covers are linked to ground conductors. Theground conductor must be reconnected after every repair.

Tank

Replacing Thermostat

1

Fig. 7‐7

1. Remove the electrical equipment cover.

2. Release fixing screws and remove the old thermostat.

3. If necessary, clean the fastening point with a lint‐free cloth.

4. Attach connecting wires to the new thermostat.

5. Apply heat transfer compound to the bottom of the thermostat (Refer toProcessing Materials in section Maintenance), then fasten it to the tankagain.

CAUTION: Ensure that the flat receptacles (1, Fig. 7‐7) do not touch the sideof the tank.

6. Attach the electrical equipment cover again.

Repair 7‐11


Replacing Heater Cartridges

CAUTION: A total of 5000 Watt for the grid and 3200 Watt for the reservoirmay not be exceeded.

Slide in the new heater cartridges without heat transfer compound.

400 W 400 W

600 W600 W 600 W

600 W

600 W 600 W1150 W 1150 W750 W 750 W

Fig. 7‐8 Positions of heater cartridges

Safety valve plate for pump 1

Three heater cartridges, 300 Watt each.

Safety valve plate for pump 2

Three heater cartridges, 300 Watt each.

Replacing Temperature Sensor

Grid

The grid temperature sensor has a bayonet fastener. Slide in the new sensorwithout heat transfer compound.

Fig. 7‐9 Grid

Repair7‐12


Replacing Temperature Sensor (contd.)

Reservoir

Fig. 7‐10 Reservoir

Installing Service Kit

The kit contains the temperature sensor for the reservoir and heat transfercompound.

Service kit P/N: 394597 (Ni120)

Required tools:

PliersSide cutting pliers

1. Remove electrical equipment cover.

2. Disconnect connecting wires and extract old temperature sensor by the connecting wires or with theaid of a pliers.

3. Apply heat transfer compound to new sensor.

4. Insert sensor and reconnect electrically.

5. Attach electrical equipment cover again.

Repair 7‐13


Band Heater

Replacing Thermostat and Temperature Sensor

The thermostat and temperature sensor are located behind the electricalequipment cover of the band heater (Arrow, Fig. 7‐11).

Fig. 7‐11

Fig. 7‐12 TemperatureSensor

O‐ring

Repair7‐14


Replacing Level Evaluator

Important Notes

� The length of the sensor cable may not be changed.

� Adjustment by electrostatically charged persons can cause the amplifierto malfunction.

� All adjustments should be made with operating ground (no groundconductor function) connected. The operating ground must be linked tothe metal casing of the melter along the shortest path. Do not connect viaground conductor!

� All potentiometers have 20 revolutions and no mechanical limit stop,meaning no fixed end position. They can not be damaged by turning toofar.

Observe when Replacing Level Sensor

� Insert O‐ring

� Screw in the level sensor until the sensor hexagon nut no longerprotrudes

CAUTION: Plastic casing. Tighten the hexagon nut only by hand.

� Switching point marking: The level sensor has two switching points(reservoir full / reservoir empty). The lower switching point is assigned topotentiometer A and the upper switching point to potentiometer B of theevaluator. The yellow LED indicates the switching state.

Empty Calibration

Prerequisites

� Level sensor is installed, fastened mechanically and connectedelectrically

� For empty calibration (most sensitive setting, material irrelevant): Levelsensor clean + tank empty

� Operating voltage is applied (green LED illuminated)

1. With the potentiometer, find the switching point of the yellow LED (LEDjust lights up).

� Turn clockwise: LED on� Turn counterclockwise: LED off

2. From the switching point, turn half of a revolution counterclockwise.

Repair 7‐15


Replacing Control Panel (Service Kit)NOTE: The software need not be installed again.

M4

Contents of kit

Fig. 7‐13

ATTENTION: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.


ATTENTION: Disconnect the unit from the line voltage.

2. Open the electrical cabinet door.

3. Unplug the ribbon cable from the old control panel.

4. Release the M4 hexagon nuts and remove with the tooth lock washers.

5. Press the old control panel and old seal forwards and out of the electricalcabinet door.

6. Insert new control panel with new seal.

7. Screw on new control panel. Use tooth lock washers.

8. Plug the ribbon cable into the new control panel.

9. Close the electrical cabinet door.

Repair7‐16


If the Main Board is to be Replaced

Temperature Sensors Ni120

JP1

Fig. 7‐14 Ni120: No jumper installed

CAUTION: PURBlue EC melters are supplied exclusively as Ni120 units. Ifthere is a jumper, remove it!

Temperature Sensors PT100

There is a jumper between connections 1 and 2.

There is a second jumper between connections 5 and 6.

JP1

Fig. 7‐15 PT100: Jumper installed

Parts 8‐1


Section 8

Parts

Product Configuration

The configuration code and the table indicate the components and parts of this product that are configurable.The codes are also used to identify the spare parts.

PB‐EC-T4AX4L/XXXXXXXXXXXXXX

CodeBox

ADHESIVE MELTERPURBlue EC

Nordson Engineering GmbHLilienthalstr. 6D 21337 Lüneburg - Germany

www.nordson.comSerial No: Year

1 2 3 4 5 6 7 8 9 1011 ...P B ‐ E C - T 4 A X 4 ...

CAUTION: The maximum operating temperature of the installed gun and the other heated componentsshould be considered when setting temperatures on the melter control panel.

Parts8‐2


Box Code Components / parts

1‐5 PB‐EC PURBlue EC Melter

6 - Standard Configurable Melter

E Engineered Melter

7 T Tank

8 3 230 V 3 Phase Delta

4 400 V 3 Phase WYE

9‐10 A Gear Pump SN0030 (PR2m1)

C Gear Pump SN0062 (PR4m1)

D Gear Pump SN0093 (PR6m1)

E Gear Pump SN0186 (PR12m1)

F Gear Pump SN0371 (PR12m2)

G Gear Pump SN0773 (PR25m2)

X None

11 2 2 Hose/Gun Pairs

4 4 Hose/Gun Pairs

12 L 150 ° C 300 ° F

Max. Operating TemperatureM 180 ° C 350 ° F

H 230 ° C 450 ° F

13 / Options

14 M Manual Pneumatic Pressure Control

F Flow Control Bypass

X Standard: Manual Pressure Control

15 X None

16 F Level Control, fixed

17 W Light Tower

18 X Standard: Main Switch Red - 3 Pole

19 X None

20 K Key‐To‐Line Per Drive

21 C Casters

X Feet

22 X Reserved

23 X Reserved

24 X Reserved

Parts 8‐3


How to Use Illustrated Parts List

The parts lists in this section are divided into the following columns:

Item— Identifies parts that can be obtained from Nordson.

Part— Nordson part number for each spare part shown in the illustration.A row of hyphens in the column Part (‐ ‐ ‐ ‐ ‐) indicates that this part cannot be ordered separately.

Description— This column contains the name of the part and, whenappropriate, its dimensions and other properties. The points in thecolumn Description show the relationship between assemblies,subassemblies and single parts.

Quantity— The quantity needed per unit, assembly or subassembly.The abbreviation AR (as required) is used when this item is a bulk item orwhen the quantity per assembly depends on the product version ormodel.

Melter — This column indicates the melter P/N or features in which thispart is installed. It is not contained in all of the melters shown on the backof the cover page.ORBox:Code for configured melters.

NOTE: The texts are available only in English.

Component Designation

The electrical components are labeled according to DIN 40719, part 2.

Parts8‐4


Assembly Overview

7

8b

8a

9

13

3

4

1

5a

16

11

1418

20

6

ÂÂÂÂ

1710

5b

19

2

12

15

Fig. 8‐1

Parts 8‐5


Item Part Description Page Quantity MelterBox:Code

- ------- Inert gas equipment 12 1

1 7150005 Hopper D290 1

7114541 O-Ring 307x4 Hopper-Grid 1

2 7126344 Heating band NI120 w/cable+temp.sensor 1

‐8E2 ------ � Heater 3000 W 1

‐8B7 ------ � Temperature sensor 1

‐85S3 ------ Thermostat 23 1

3 7126272 Grid 1

7126282 Seal, electric cover grid 1

‐85S4 ------ Thermostat 23 1

3

‐6E2.1

‐6E4.1

402542 Heater cartridge 1/2”x6” 230V-750W 2

3

‐6E3

‐6E4


3

‐6E2

‐6E4.2


3 142278 ADAPTER,BAYONET,1/8NPT (grid) 1

‐6B7 151011 Temperature sensor NI120 90deg. BAYONET 1

3 7114541 O-Ring 307x4 Grid-Reservoir 1

4 7157569 Reservoir, 2x SN 1

7126373 Seal, electric cover,reservoir

7126617 Insulation tensioning band 4

‐7B7 120167 Temperature sensor. RTD 1/4X1.25, nickel 1

‐85S2 ------ Thermostat 23 1

4

‐7E2

‐7E4.1


4

‐7E2.2

‐7E3

‐7E3.1

‐7E4


Continued...

Parts8‐6


Item MelterBox:Code

QuantityPageDescriptionPart

5 ------

7157362

7157677

Bypass plate

Seal, electric cover (bypass plate)

Heater cartridge 3/8"x2,5" 230V-300W

16 1,2

1

3

6

‐61M1

207398 Motor 0,25kW 1

7

‐63M1

207398 Motor 0,25kW 1

8a 7126342 Shaft joint, extractable type:2GA D12,7 1

8b 7157574 Shaft joint, type:2GD D12,7 1

9 ------

7126686

Pump

Insulation pump PR2-PR25 complete

8 1,2

10 7157575 Hose manifold, 1x2 NW13 compl 14 1,2

------ Hose connect.ftg.a9/16UNF-a3/4UNF 15 1

7109634 PLUG,O RING 16x2FPM,STR THD,3/4-16 15 3

11 1031503 PANEL DISPLAY ASSY,W/CPU,DURA BLUE 1

12 ------- Fan 20 1

13 203208 Filter mat back top 1

14 ------ Main switch 20 1

15 ------- Casters 25 1

16 ------- Refer to Signs and Tags 17 -

17 250266

250267

O‐Ring 30x2 Viton Rotary valve

O‐Ring 32x2 Viton Rotary valve

1

1

18 7157622

7150019

7150021

7150014

455754

432200

Cover top, complete

� Insulation plate, cover top D330

� Insulation plate, cover top D270

� O-ring 275x6 Viton500

� Sign, risk of hand injury

� Star grip

1

1

1

1

1

1

7157627 Insulation cover top black 6

19 7140202 Insulation sleeve hopper 1

20 ------ Transformer -

21 7157563 Level sensor, 2pt 1 16:F

- 253145 Two‐way key no.5 (control cabinet) 1

Parts 8‐7


Spare Parts, Service Kits and Accessories

Safety Valve

1

2

Fig. 8‐2

Item Part Description Quantity Note MelterBox:Code

- 207932 Safety valve, 85 bar 1 all

- 394592 SERVICE KIT 1

1 ‐ ‐ ‐ ‐ ‐ � O‐ring 11x2 1

2 ‐ ‐ ‐ ‐ ‐ � O‐ring 9x2 1

- ‐ ‐ ‐ ‐ ‐ � High‐temp. grease, GLS 595/N2, 10g 1

Parts8‐8


Gear Pump


- 7109715 Gear pump SN0030 1 9‐10:A

- 7116270 Gear pump SN0062 1 9‐10:C

- 7104514 Gear pump SN0093 1 9‐10:D

- 203708 Gear pump SN0186 1 9‐10:E

- 729106 Gear pump SN0371 1 9‐10:F

- 729107 Gear pump SN0773 1 71575679‐10:G

Service Kits (O‐Ring) for all Pumps


- 394589 SERVICE KIT for pump sizes SN0030 to SN0773

1

- ‐ ‐ ‐ ‐ ‐ � O‐ring 10x1,5 1

- ‐ ‐ ‐ ‐ ‐ � High‐temp. grease, GLS 595/N2, 10g 1 A

NOTE A: Apply only high temperature grease on sealing surfaces for melters that process reactive materials. Do notuse Stucarit!

Parts 8‐9


Pump Sealing Kits & Assembly Tools for Variseal Pumps

NOTE: Nordson recommends the entire pump to be replaced instead of replacing the seal by the customer.


- 7136920 Sealing Kit

Gear pump SN0030 to SH0773

1 9‐10:A to G

- 7136915 Assembly Tool & Instructions

Gear pump SN0030 to SH0773

1

Parts8‐10



1

2

Fig. 8‐3


1 1120098 Pressure control valve 1100 PSI 1 14:X

2 1034042 Pressure control valve 1100 PSI, pneum. 1 14:M, F

Pneumatic Safety Valve (Option)

1

2


1 279615 Pneumatic Safety valve, 6 bar, G1/4 SW20 1 14:M, F

2 255166 Sealing ring, R1/4 type: PDR‐14 1

Parts 8‐11


Pneumatic Control, 1‐fold (Option)

2

1


- 394265 Pneumatic control, 1‐fold, Man Pr. Control, cpl. 1 14:M

- 394542 Pneumatic control, 1‐fold, Flow Control, compl. 1 14:F

1 394814 Solenoid valve (see Electrical Components) 1 14:F

2 394813 Pressure gauge 1 14:M, F

Pneumatic Control, 2‐fold (Option)

2

1


- 394266 Pneumatic control, 2‐fold, Man Pr. Control, cpl. 1 14:M

- 394543 Pneumatic control, 2‐fold, Flow Control, compl. 1 14:F

1 394814 Solenoid valve (see Electrical Components) 2 14:F

2 394813 Pressure gauge 2 14:M, F

Parts8‐12


Inert Gas Equipment

F54

2

3

4

5

7

8, 9, 10, 11, 12

11

1413

15

16

18F54

17

6

F36

F13

F36

19

20

21

Fig. 8‐4

Parts 8‐13



- 7140886 Cable inert gas control 1 all

1 ‐ ‐ ‐ ‐ ‐ Plug, FK‐MCP1,5/2‐ST‐3,81 1

2 394812 Pressure gauge 1

3

‐230Y3

394814 Solenoid valve 1

4 ‐ ‐ ‐ ‐ ‐ Reducer aR1/4-iRp1/8 L11 1

5 ‐ ‐ ‐ ‐ ‐ Quick thread-in fitting -W-d03-G1/8-TURN 1

6 ‐ ‐ ‐ ‐ ‐ Tower Back, mounting plate, pneumatic 1

7 ‐ ‐ ‐ ‐ ‐ Hose, D4,0 d2,5, PTFE 1000 mm

8 ‐ ‐ ‐ ‐ ‐ Coupling, male air, aG1/8 NW5 L26 1 A

9 255167 Sealing ring, R1/8 type:PDR‐18 1

10 ‐ ‐ ‐ ‐ ‐ Reducer, aR1/4‐iRp1/8 L11 1

11 255166 Sealing ring, R1/4 type:PDR‐14 1

12 ‐ ‐ ‐ ‐ ‐ Connection, bulkhead, iG1/4 1

13 ‐ ‐ ‐ ‐ ‐ Nipple, double, aR1/4‐aR1/4 1

14 ‐ ‐ ‐ ‐ ‐ T‐piece, 3xiRp1/4 1

15 269261 Pneumatic safety valve, 2 bar, 1/4 1 (Tower)

16 ‐ ‐ ‐ ‐ ‐ Hose, D6,0 d4,0, PUR silver 500 mm

17 ‐ ‐ ‐ ‐ ‐ Plug-type thread-in ftg.-W-D06-R1/4-TURN 1

18 417709 Sign Max. 2 bar, self adhesive 1

19 7126025 Sign ”symbol inert gas” self adhesive 1

20 7126026 Sign ”symbol inert gas” 24x 9 2

- ‐ ‐ ‐ ‐ ‐ Cable tie TYP-23 M 2,5x100mm 2

-

-

21

402372

785088

7150022

Safety valve 0,4bar G1/4 DN8

Check valve D06-D06 NW5

Control slide G1/8

1

1

1

(Tank)

NOTE A: See Accessories for Pneumatic Connection by the Customer for female air coupling and hoses

Schedule of Fasteners

Item Part Description

F13 255264 Washer, D5,3, DIN125 type A

F36 250142 Hexagon nut, M5, DIN934‐5.8, steel

F54 457444 Allan head cap screw M5x10 DIN7984 niro

Parts8‐14


Manifold

42

3

1

Fig. 8‐5


- 7157575 Manifold, 1x2, NW13, complete, 1 all

1 ------ � Manifold, 1x2, NW13 1

2 252242 � O‐ring, 18x1.5, viton 1

3 446987 � Screw plug G3/8 with O‐ring 1

4 7142747 � M8x30/12.9 DIN912 4

Parts 8‐15


Manifold Accessories

1

2

4

4

Fig. 8‐6

Item Part Description Quantity Note

1 446617 Hose fitting a9/16UNF‐a3/4UNF (NW8) with O‐ring 1,2

1 203786 Hose fitting a1 1/16‐12‐a3/4UNF (NW16) withO‐ring

1,2

2 7109634 PLUG,O RING 16x2FPM,STR THD,3/4-16 1,2

1 7104944 Accessory kit, check valve NW08

� Check valve 9/16UNF-3/4UNF NW8

� � O‐ring 16x2, High Temperature

� Paded bag 170x225mm outside C13

1 Replaces hose fitting NW8

1 7116158 Accessory kit, check valve NW16

� Check valve 1 1/16UNF-3/4UNF NW16

� � O‐ring 16x2, High Temperature

� Paded bag 170x225mm outside C13

1 Replaces hose fitting NW16

4 1056531 Drain Valve Kit 1 Air bleed

Parts8‐16


Safety Valve Plate (Bypass Plate)

3

2

22

33

4

1

33

2

2

1

4

22

22

Fig. 8‐7


- 7157570 Bypass plate PURBlue SN back cpl. 1 10:X

1 ------ � Body 1

2 413261 � SCREW PLUG G1/4 DIN908 4

3 401878 � Screw plug G1/8 with o-ring 4

4 256800 � O-Ring 26x2 Viton 1

- 7157572 Bypass plate PURBlue SN front cpl. 1 10:�X

1 ------ � Body 1

2 413261 � SCREW PLUG G1/4 DIN908 4

3 401878 � Screw plug G1/8 with o-ring 1

4 256800 � O-Ring 26x2 Viton 1

Parts 8‐17


Ship‐With‐Kit


- 422464 Hexagon socket screw key SW4 1

- 203786 Hose connect.ftg.a1 1/16-12-a3/4UNF 2

- 446617 Hose connect.ftg.a9/16UNF-a3/4UNF 2

- 251539 Fine-wire fuse 5,0x20 2,00A T 1

- 251562 Fine-wire fuse 5,0x20 6,30A FF 2

Signs and Tags


- 1100254 TAG,CAUTION,HOT SURFACE 1

- 1100252 TAG,WARNING,HOT ADHESIVE 1

- 1025795 TAG,WARNING,HAZARDOUS VOLTAGE 1

- 1059866 TAGS,SHEET OF,VERSA/DURABLUELG,CE LANG

1

- 290083

267420

Sign, dangerous voltage

Notched taper pin 2,5x5

1

2

- 455754 Sign, risk of hand injury 1

Melter P/N Information (Electrical Components)

Melter P/N Wiring diagram Description Note

7157567 7157640 PURBlue EC 3x230 VAC Delta SN0773 Prototyp

Config. 7157668 3x230 VAC DELTA

Config. 7157667 3x400 VAC Y

Parts8‐18


Electrical Components

3

5

6

8

9

10

11

19

17

18

14

12

2021

22

2

1

25

4

7

13

24

left door right door

15

23

16

Fig. 8‐8 230 V


2

‐85A1

1077997 BOARD, MAIN W/HT SINK ASSY 1 B, C

1

‐81A1

1025597 PCA,EXPANSION 1 A

19

‐85A6

1031503

1031805

1013727

Panel display, assembly, w/CPU

� MEMBRANE PANEL,2PUMP

� PCA,DISPLAY/CPU,ALPHA

1

1

1

E

D

NOTE A: Order service kit 1031201 for replacement

B: Order service kit 1078624 for replacement

C: Order service kit 1031203 for fuse replacement

D: Order service kit 1028325 when only board 1013727 has to be replaced

E: Order service kit 394734 for replacement

Continued...

Parts 8‐19



3 7109929

7109931

Terminal block XL0 3x230V

Terminal block XL0 3x400V

1 8:3

8:4

4

‐1F6

254244

256144

Circuit breaker 50A 3-pole FAZ-B50/3


1

1

8:3

8:4

5

161K3

7104924 Relay coupler 24VDC 1

6

161K5

7116739

7116738

Contactor DILM40(230V50/60HZ)

Contactor DILM17-10(230V50/60HZ)

1 8:3

8:4

7

161F7

254251 Circuit breaker 10A 2-pole FAZ-C10/2 1

8

‐6N2

‐7N2

‐8N2

207397 Solid-state relay G3PB 100-260V MAX. 25A 3

9

‐70T2

207678 Switching power supply 230V/N/24V 90W 1

10

‐6F2

‐7F2

‐8F2

‐61F2

------

255593

255593

255592

408303

Circuit breakers




Circuit breaker 16A 2-pole FAZ-S16/2

1

1

1

1

Grid

Reservoir

Hopper

Motor

8:3

10

‐6F2

‐7F2

‐8F2

‐61F2

------

7174552

7174552

251364

456986

Circuit breakers




Circuit breaker 16A 1-pole FAZ-S16/1

1

1

1

1

Grid

Reservoir

Hopper

Motor

8:4

11

‐71T2

207678 Switching power supply 230V/N/24V 90W 1

12

‐81X4

285169 Adapter 1

13

161K4

262896 Double timer relay 200-240VAC 1

14

‐63N1

7109749 Motor Controller, prog. 550W E82EV 1

15

‐81A2

(1087150)

1087152

PCA, Power Module, 4CH, 240V

Service Kit for replacement

1

16

‐63N1

7109749 Motor Controller, prog. 550W E82EV 1

17

‐61N5

‐63N5

783277 Standard-I/O f.freq.conv E82EVxxxKx

1

1

18

‐61Z1

7140101 Interference filter 230VAC/2x6A 1

Continued...

Parts8‐20



20

‐62A2

7157448 Motor controller assy, compl.

1

21

‐64A2

7157448 Motor controller assy, compl.

1

22

190U1

190U4

-

729931

729931

Coupler component 0-10/0-10VDC

1

1

Motor 1

Motor 2

221K5 285332 Relay MY4N-D2 24VDC 1 left door 16:F

221K4 285332 Relay MY4N-D2 24VDC 1 16:F

132K3 285332 Relay MY4N-D2 24VDC 1

132K8 285332 Relay MY4N-D2 24VDC 1

131V2 7109723 Terminal block ZDK 2,5/1,5D1 1

23 7109934 Terminal block XL9..11 + PE 1

24

221A1

7157582 Level Control 1 back wall 16:F

25

161E5

207400 Fan type:4184NGX V=160 3,5W 1

785745 Exhaust filter PFA2000 RAL9011 1

280869 Safety guard type: LZ30-4 f.fan 1

161V3 7109723 Terminal block ZDK 2,5/1,5D1 1

‐1Q1 252794

253639

Main switch 3x63A / red/yellow

Main switch 3x32A / red/yellow

1 8:3

8:4

XL8 7109926 Terminal block XL8 1 8:4

Parts 8‐21


Additional Service Kits

Fuses Main Board

F11F12

Fig. 8‐9


- 1031203 Service kit, fuses, main board -

1 ‐ ‐ ‐ ‐ ‐ ‐ � Fuse, fast, 10 A, 250 VAC, 1/4 x 11/4 in. 2 F1-F2

2 ‐ ‐ ‐ ‐ ‐ ‐ � Fuse, slow, 2 A, 250 VAC, 5 x 20 mm 2 F3-F4

3 ‐ ‐ ‐ ‐ ‐ ‐ � Fuse, fast, 5 A, 250 VAC, 5 x 20 mm 2 F5-F6

4 ‐ ‐ ‐ ‐ ‐ ‐ � Fuse, 6.3 A, 250 VAC, 5 x 20 mm 6 F7-F12

- ‐ ‐ ‐ ‐ ‐ ‐ � Instruction sheet 1

Parts8‐22


Main Board


- 1078624 Service Kit Main Board 1

- ‐ ‐ ‐ ‐ ‐ ‐ � Board, with heat‐sink 1


Expansion Board

X5

XT5 XT6

Fig. 8‐10


- 1031201 Service Kit Expansion Board 1


Power Module


- 1087152 Service Kit for replacement of PCA,POWER MOD,4CH,240V,MS/US/AS

1,2 11:4

Parts 8‐23


Front Panel


- 394734 Service Kit Front Panel 1

- ------ � PANEL DISPLAY ASSY,W/CPU 1 1031503

- ------ � Seal controller DuraBlue operating panel 1

- ------ � Hexagon nut M4 DIN934 6

- ------ � Washer D4,3 DIN125 type A 6

- ------ � Sliding box f.control panel 315x205x65 1

- ------ � Instruction sheet 1

CPU Board


- 1028325 Service Kit CPU Board(display/central processing unit)

1

- ‐ ‐ ‐ ‐ ‐ ‐ � PCA, display/CPU 1

- ‐ ‐ ‐ ‐ ‐ ‐ � Stand‐off, hex, M3 x 8 mm 6

- ‐ ‐ ‐ ‐ ‐ ‐ � Washer, lock, M3 6


RTD Sensor


- 394597 RTD Sensor Ni120 Kit 1

1 ‐ ‐ ‐ ‐ ‐ � Temperature sensor. RTD 1/4X1.25, nickel 1

2 ‐ ‐ ‐ ‐ ‐ � Paded bag 170x225mm outside C13 1

- ‐ ‐ ‐ ‐ ‐ � Compound, thermal, NTE303 ,1 gram 1

Temperature Switches (Thermostats)


- 7140223

7140224

7174617

THERMOSTAT 260°C,24V,1A,FASTON



1

1

1

12:H

12:L

12:M

Parts8‐24


Panel Latch

Panel


- 394482 Turnbuckle w/spr.latch, hex.socket head 1

Pack Frequency Converter


- 7140702 Pack frequency converter 1

Parts 8‐25


Additional Accessory Kits

Casters


- 394793 Casters Kit

1 ‐ ‐ ‐ ‐ ‐ � Casters complete 203446

2 ‐ ‐ ‐ ‐ ‐ � Hexagon socket screw key DIN6911 SW5

3 ‐ ‐ ‐ ‐ ‐ � Packing, cardboard 410x310x335mm

Accessories for Pneumatic Connection by theCustomer

Part Description

419872 Female air coupling d6 NW5 L44 Inert Gas

252998 Air Operated Hose, D8.0 d6.0 PTFE

Parts8‐26


Technical Data 9‐1


Section 9

Technical Data

General Data

Storage temperature - 45° C to + 75 ° C - 49 ° F to + 167 ° F

Min. ambient temperature - 5 °C 23 °F

Max. ambient temperature 40 ° C 104 °F

Humidity 10 to 95 %, not condensing

Max. operating height abovesea level

3,000 m 9840 ft

Type of heating Heater cartridges (grid and reservoir / safety valve plate)

Band heater (hopper)

Temperature Sensor Ni120

- Measuring precision � 1 ° C

Material pressure(standard)

The pressure control valve is preset at the factory. Default:

35 bar 3500 kPa 508 psi

Degree of protection IP 54

Noise Emissionat a distance of 1 m

1 motor: 62 dB(A)

2 motors: 65 dB(A)

Motor type 3 ph AC motor

Gear box type Helical gear

Motor/pump speed settingrange

1.0 to 100 min-1

To prevent excessive wear, the motor/pump speed should not continuouslyfall below 5 min-1 (rpm) or continuously exceed 80 min-1 (rpm).

Heatup time <45 min

Melting capacity 20 kg per hour

Technical Data9‐2


TemperaturesCAUTION: The maximum operating temperature of the installed gun and theother heated components should be considered when setting temperatureson the melter control panel.

Min. operating temperature(setpoint)

40 ° C 100 °F

Max. operating temperature 230 ° C 450 °F

Overtemperature shutdownby (tank) thermostat

180 ° C 356 °F Box12:L

210 ° C 410 °F Box12:M

260 ° C 500 °F Box12:H

Shutdown by transformerthermostat

155 ° C

(�5 ° C)

311 °F

(�9 °F)

Not present with Box 8:3,4

Electrical DataATTENTION: The unit is designed for only one operating voltage. Operateonly at the operating voltage shown on the ID plate.

Operating voltage 230 VAC 3‐phase delta

400 VAC 3‐phase with neutral (star - WYE)

Permissible voltagedeviations

Power supply:

Standard I/O:

� 10%

� 10%

Operating voltagefrequency

50/60 Hz

Melter fuse protection 230 V 2 hose/gun pairs

41 A

4 hose/gun pairs

49 A

Melter fuse protection 400 V 2 hose/gun pairs

26 A

4 hose/gun pairs

31 A

Key‐to‐line

Max. input

0 to 10 VDC

Max. power consumption

(without hose/gun)13�800 W

Mechanical Data

Weight [kg]

Transformer [kg]

170

approx. 43 (additional)

Dimensions [mm]

Length x width x height

885 x 585 x 1385

Tank opening [mm] � 290

Tank volume [kg] 30,5

General Instructions Regarding Working with Application Materials A‐1


Appendix A

General Instructions Regarding Working withApplication Materials

(with instructions on PUR application materials)

Definition of TermsApplication materials can be e.g. thermoplastic hot melt adhesives, hot meltadhesives, sealants, cold glues and similar application materials, hereafterreferred to as materials.

NOTE: The materials that may be processed with your Nordson product canbe found in the manual under Intended Use and Unintended Use Pleasecontact your Nordson representative when in doubt.

Manufacturer InformationMaterials may be processed only in compliance with the product descriptionsand the safety data sheets issued by the manufacturer.

They offer information on proper processing of the product, transport,storage, disposal and other topics. They also contain information onreactivity and potentially hazardous decomposition products, toxicproperties, flash points, etc.

LiabilityNordson will not be liable for hazards or damage caused by the material.

Risk of BurnsHeated materials pose a risk of fire and burning. Work carefully and wearappropriate protective clothing/equipment.

General Instructions Regarding Working with Application MaterialsA‐2


Vapors and GasesEnsure that vapors and gases do not exceed the prescribed limits. Ifnecessary, exhaust vapors and gases and/or provide sufficient ventilation ofthe working area.

SubstrateThe substrate should be free of dust, grease and humidity. Determine thesuitable material, the optimum working conditions and any pretreatmentrequired for the substrate by experimentation.

Processing TemperatureWhen tempered materials are used, the quality of the application depends oncompliance with the prescribed processing temperature. It may not beexceeded! Overheating can cause the material to char and crack, which willresult in malfunction or equipment failure.

Material should always be melted gently. Avoid extended, unnecessaryheating. Lower the temperature during breaks in production. Thetemperature in the melter tank should correspond to the materialconsumption. When a large quantity of material is used, set the temperaturenear the processing temperature; when less material is used, set thetemperature accordingly lower.

Consider the effect of shear heat and the ambient temperature when coldprocessing of materials is performed; cool if necessary.

Important for Polyurethane Application Materials (PUR)When processing polyurethane application materials (PUR), it is imperativeto comply with these instructions:

� Use respiratory protection when the maximum pollutant concentrationpermitted is exceeded.

� During interruptions or breaks in production, lower the temperature andclose the application slot of the applicators as far as possible. Seal theremaining opening with high-temperature grease or high-temperaturetape.

� Purge the application system with a suitable cleaning agent beforeextended standstill. Use only a cleaning agent recommended by the hotmelt material manufacturer.

� Seal open material connections airtight.

Operating Parameter B‐1


Appendix B

Operating Parameter

Parameter Groups ‐ Overview ‐NOTE: Reserved parameters do not appear in this appendix.

Group Parameters Description

Standard

Pressure

Temperature

0 to 26

15 to 17

20 to 26

Frequently used parameters

Input Setup 30 to 39 Select function for input 1 to 4 and optional inputs

Output Setup 40 to 46 Select function for output 1 to 3 and optional outputs

Seven‐day clock 50 to 77 Seven‐day clock setup

Automatic filling 78 Set timer for automatic filling

Reversal of fault logic 79 Select contact opens or closes when fault occurs

PID selection 80 to 91 Change control parameters

Restore Melter Default Settings1. Press and hold Setup and the scroll key Page down at the same time.

2. Keep the keys pressed and, at the same time, switch the main switch ofthe melter off and then on again.

3. Release the keys when the melter restarts.

CAUTION: Defaults are dependent on the software. The Original statedepends on the melter. Some parameters may differ from the Default.

Original stateThe operating parameters and setpoint temperatures have been adapted forPUR processing. The original state was saved.

Refer to Save and Restore Settings in the section Operation.

Operating ParameterB‐2


Standard

0 Enter password

Description: A user‐defined password that prevents unauthorized changes to setpointtemperatures and operating parameters.

Value: 0 to 9999

Resolution: 1

Default: 4000

Format: —

Use: This parameter only appears if a password is created using parameter 11 andthen activated using parameter 10.

NOTE: The melter remains in password‐protected mode for two minutes afterthe last key was pressed. If the user exits Setup mode and then tries to enterSetup mode again, he must enter the password again, even if two minutes havenot yet elapsed.

1 Total Hours with Heater On (Non‐editable)

Description: Shows the total number of hours that the heaters were on.

Value: 9999 (control panel) and 999.999 on web browser

Resolution: 1 hour

Default: 0

Format: —

Use: The display registers up to 9999 hours and then rolls over to 0000.

2 Fault Log (Non‐editable)

Description: Stores a record of the last ten faults.

Value: —

Resolution: —

Default: -F0 (unused log entry)

Format: F1, F2, F3 and F4

Use: Press the right display scroll keys to review the last ten faults in the log. Emptylog entries are indicated by "_ -F0".



3 Change History Log (Non‐editable)

Description: Records the last ten changes made to either the setpoint temperatures or theoperating parameters.

Value: —

Resolution: —

Default: P‐_ (unused log entry)

Format: Refer to section Operation, Structure of Change History Log.

Use: Use the right display scroll key to review the last ten changes made to either thesetpoint temperatures or the operating parameters. Empty log entries areindicated by "P‐_"

4 Ready Delay Time

Description: The amount of time that will elapse after all of the components have reachedtheir setpoint temperatures before the Ready LED turns on. The ready delaytime only functions when the temperature of the tank, at the time the melter isturned on, is more than 27 °C (50 °F) or more below its setpoint temperature.The ready delay time begins when all components are within 3 °C (5 °F) of theirrespective setpoint temperature.

Value: 0 to 60 minutes

Resolution: 1 minute

Default: 0 minutes

Format: —

Use: The ready delay allows the tank additional time to heat up before the pumpstarts up.

NOTE: The time remaining on the ready delay is indicated in minutes in the rightdisplay at the end of every automatic scan cycle. Below one minute, the timeremaining appears in seconds.

Pressing the Heater key twice overrides the ready delay time. BUT

CAUTION: Always allow at least a 30 minute ready delay to prevent the pumpfrom being damaged when it is switched on.

Original state: 30 min

5 Service Interval

Description: The number of hours of heater operation that must elapse before the Servicerequired LED lights up.

Value: 0 hours (deactivated) to 8736 hours (one year)

Resolution: 1 hour

Default: 500 hours

Format: —

Use: Set the service interval time to signal a user‐defined maintenance event, such aschanging the filter. The Service required LED lights up after the preset time haselapsed.

Press the Clear/Reset key to turn off the service LED and reset the time whenthe melter is in Normal mode.

Note: Heater hours of operation are counted whenever the heater LED is on.



Standard (contd.)

6Time until Service(Non‐editable)

Description: Indicates how many more hours the heaters need to remain on before theService required LED lights up.

Value: 0 (deactivated) to 9999 hours

Resolution: 1 hour

Default: 499

Format: —

Use: Enable the service interval (parameter 5) for this parameter to work.

7 Motor OFF Delay - Not Shown -

Description: Determines the amount of time that the motor will remain on after the switchingdevice (e.g. foot switch, assembly handgun trigger) turns off.

Value: 0 to 360 seconds

OR

‐ ‐ ‐ ‐ (infinite)

Resolution: 1 second

Default: 0

Format: —

Use: E.g. with assembly handguns. Pulling the trigger causes a microswitch inside thegun to switch. This electric signal is transmitted through a special receptacle tothe melter and is evaluated there.

8 Automatic Pump On

Description: Determines whether the pump can be enabled before the melter is ready

Only in conjunction with Srt:1, when the melter has a motor control panel.

Value: 0 (deactivated)

1 (activated)

Resolution: —

Default: 1 (activated)

Format: —

Use: If the function is deactivated, the pump must be started by pressing the motorkey when the melter is ready.

NOTE: If Automatic pump on is deactivated (0) while one of the pumps isrunning, the pump will remain on until the key for this pump is pressed.



10 Enable or Disable Password

Description: Enables or disables the melter password. When password protection isactivated, component setpoint temperatures or melter operating parameters cannot be changed until a valid password is entered using parameter 0.


1 (activated)

Resolution: —

Default: 0

Format: —

Use: A password must first be created using parameter 11 before it can be activatedor deactivated with parameter 10.

11 Create Password

Description: A user‐defined password that prevents unauthorized changes to setpointtemperatures and operating parameters.

Value: 0 to 9999

Resolution: 1

Default: 5000

Format: —

Use: Refer to section Operation, Enter Password.

NOTE: When the password is created and activated, parameter 10 will notappear again in the right display until the password is entered.

12 Change Hose 1 Output to Electric Gun Activation

Description: Changes the proportioned 240 VAC current that is provided to the hose 1 heaterto a switched 240 VAC current that is used to activate an electric gun.


1 (activated)

Resolution: —

Default: 0 (deactivated)

Format: —

Use: For Nordson electric guns that use a switching device to evaluate an electricalsignal sent by the melter through a special receptacle.

The operating parameter is not suitable for these melters.



Standard (contd.)

13 Change Hose 2 Output to Electric Gun Activation

Description: Not in use


1 (activated)

Resolution: —


Format: —

Use: For Nordson electric guns that use a switching device to evaluate an electricalsignal sent by the melter through a special receptacle.


14 Melter Inputs/Outputs InterlockDescription: Serves as a safety lock during melter maintenance work. Prevents the melter

from being controlled externally via standard or optional inputs/outputs


1 (activated)

Resolution: —


Format: —

Use: Before beginning maintenance work to the melter, set the parameter to 1(interlock enabled). External control of the melter is completely disabled until theparameter is set to 0 (disabled) again.

15 Pressure Setpoint - Not Shown -

Description: Used to set a percentage value of the maximum output pressure (from 0 - 100%).

Value: 0 to 100 (percent)

Resolution: —


Format: —

Use: This parameter is available only if the analog I/O board is installed in the melter.The pressure is displayed after the last gun temperature. The left displayindicates P (pressure), and the right display shows the pressure value.



16 Overpressure Setpoint - Not Shown -Description: If the pressure in the system exceeds this setting, an overpressure alarm is

triggered.

Value: 0 to 50 (percent) above the pressure setpoint (parameter 15)

Resolution: —


Format: —

Use: This parameter is available only if the analog I/O board is installed in the melter.

17 Underpressure Setpoint - Not Shown -Description: If the pressure in the system falls below this setting, an underpressure alarm is

triggered.

Value: 0 to 50 (percent) below the pressure setpoint (parameter 15)

Resolution: —

Default: 0

Format: —

Use: This parameter is available only if the analog I/O board is installed in the melter.

20 Temperature units

Description: Sets the units for temperature display.

Value: C (degrees Celsius)

F (degrees Fahrenheit)

Resolution: —

Default: C

Format: —

Use: —

21 Overtemperature Delta

Description: The number of degrees that the temperature of any component can exceed itsassigned setpoint temperature before an overtemperature fault (F3) occurs.

Value: 5 �C (10 �F) to 60 �C (110 �F)

Resolution: 1�C

1�F

Default: 15 �C (25�F)

Format: —

Use: —



Standard (contd.)

22 Undertemperature Delta

Description: The number of degrees that the temperature of any component can fall below itsassigned setpoint temperature before an undertemperature fault (F2) occurs.

Value: 5 �C (10 �F) to 60 �C (110 �F)

Resolution: 1�C

1�F


Format: —

Use: —

23 Standby Delta (Global)

Description: The number of degrees that the temperature of all heated components will bedecreased when the melter enters standby mode.

Value: 25�C to 190�C (50�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: A Standby delta (= differential value) should be selected that results in a balancebetween melter energy savings during periods of inactivity, the amount of timeand energy required to bring the melter back up to setpoint temperature, and atemperature at which the hot melt can be held in the tank for extended periodswithout charring.

NOTE: The Standby delta does not affect the Undertemperature delta(parameter 22).

24 Automatic Standby

Description: The amount of time that must elapse after the last signal (gun driver) is receivedby input 1 before the melter enters standby mode. The Automatic standby feature saves energy by allowing the melter to enter standby mode as soon as theguns are no longer applying material.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: 1. Change parameter 23 if required.

2. Set parameter 30 (input 1) to control option 10 (automatic standby).

NOTE: Only enable parameter 24 when a 24 VDC signal is connected to input 1.If there is no voltage on the input contacts when the melter is ready, the melterwill enter standby mode when the Automatic standby time has elapsed.



25 Automatic Heaters Off

Description: The amount of time that must elapse after Automatic standby time expires(parameter 24) before the heaters turn off.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: Set parameter 24 (Automatic standby) to the desired value before settingparameter 25.

26 Standby Time

Description: The amount of time that the melter will remain in standby mode after the Standbykey is pressed.

Value: 0 to 180 minutes


Default: 0

Format: —

Use: Set the standby time when the operator is to place the melter in standby for alimited period (production stoppage, lunch, etc.). Whenever standby is enabled(value greater than 0 minutes), the Standby LED flashes, indicating that the timeis elapsing.

Set the Standby delta (parameter 23) to the desired value before settingparameter 26.

27 Standby Delta (All Hoses)

Description: A standby value that applies only to the hoses.

Value: 1�C to 190�C (1�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: If this parameter is deactivated, the standby value of parameter 23 Standby delta(global) applies instead.

NOTE: For control purposes, the hopper belongs to the hoses.



28 Standby Delta (All Guns)

Description: A standby value that applies only to the guns.

Value: 1�C to 190�C (1�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: If this parameter is deactivated, the standby value of parameter 23 Standby delta(global) applies instead.

29 Temperature Offset

Description: The grid and reservoir may be assigned different temperature setpoints.

The setpoint temperature entered on the control panel is that of the reservoir.The grid setpoint temperature is lowered internally by the value set here. Use thearrow keys to set the value.

Value: 0�C to -15�C (0�F to -30�F)

Resolution: 1�C

1�F

Default: 0

Format: —

Use: In case different temperatures for grid and reservoir are needed.

Setpoint Reservoir + Temperature offset = Setpoint GridExample: 150 �C + (-15 �C) = 135 �C

NOTE: For control purposes, the hopper is hose 5. To ensure a steadilyincreasing temperature hopper - grid - reservoir, its setpoint temperature mustbe taken into consideration when setting the temperature offset.



Input Setup

Standard Inputs

30 Input 1

Description: Control options that determine the function of input 1.

Value: 0 – Input deactivated1 - Standby on/off2 - Heaters on/off

3 – Enable/disable motor 1

4 – Enable/disable hose/gun 1






10 – Automatic standby


13 – Timer Automatic filling 1


Resolution: 1

Default: 10

Format:

Use: Only input 1 offers control option 10.

NOTE: Multiple inputs set to the same input value are logical ORed.

With these melters, option 3 grants collective motor enable

Option 11 is not used with these melters, even if they have two motors.

NOTE: To be able to use option 13 or 14, parameter 78 must be set to 1 orhigher. Output option 6 (alarm) can be used to signal that the timer has expired.

Option 13/14 is not suitable for these melters.

Original state: 3

31 Input 2




4 – Enable/disable hose/gun 1...Refer to input 1

Resolution: 1

Default: 1

Format: —

Use: NOTE: Multiple inputs set to the same input value are logical ORed.





Input Setup (contd.)

32 Input 3





Resolution: 1

Default: 2

Format: —




33 Input 4


Value: 0 – Input deactivated1 - Standby on/off

2 – Heaters on/off



Resolution: 1

Default: 4

Format: —






Optional Inputs

34 – 39Optional Inputs 5, 6, 7, 8, 9 and 10- Not Shown -

Description: Control options that determine the function of the six optional inputs, providedthe optional I/O expansion board is installed on the main board.

Value: 0 – Input deactivated1 - Standby on/off

2 – Heaters on/off











Resolution: 1


Format: —

Use: NOTE: When more than one input is set to the same value, the controller actsaccording to the state of the active input.




Output Setup

Standard Outputs

All contacts are open when the melter is switched off.

40 - 42 Outputs 1, 2 and 3

Description: Determines the function of the output.

Value: 0 = Output deactivated1 = Ready2 = Ready and pump running3 = Fault4 = Reservoir is empty5 = Service LED on6 = Alarm

Resolution: 1

Default: Output 1 = 1Output 2 = 3Output 3 = 4

Format: —

Use: Refer to the section Installation for information on setting up outputs.

Control options 1, 2, 4 and 5: When the state occurs, the contact closes.

Control option 3: The contact opens when a fault occurs.

When control options 6, Alarm, is selected, the output is active whenever themelter enters the two minute fault monitoring period. If the potential faultcondition clears before the end of the two minute period, the output signal ends.

If control option 3 and 6 are both used, the illuminated error LED indicates a faultsignal as well as an alarm signal.



Output Setup (contd.)

Optional Outputs

43 - 46 Optional Outputs 4, 5, 6, and 7 - Not Shown -

Description: Control options that determine the function of the four optional outputs, providedthe optional I/O expansion board is installed on the main board.

Value: 0 = Output deactivated1 = Ready2 = Ready and pump running3 = Fault4 = Reservoir is empty5 = Service LED on6 = Alarm

Resolution: 1

Default: 0 (all optional outputs)

Format: —

Use: Refer to the instruction sheet provided with the optional I/O expansion board forinformation about wiring and setting up the optional outputs.



Seven‐day Clock

Refer to Functions and Function Keys in the section Operation.

Setting Internal Clock (Realtime Clock)

1. Enter the current day of the week with parameter 50.

2. Enter the current time of day with parameter 51.

Creating Schedule

NOTE: In order for the clock to operate continuously throughout the week, acontrol option must be assigned to every day of the week (parameters 71 to77).

Up to three schedules can be assigned for each day (to support three workshifts).

To prevent unintentional activation of the seven‐day clock, the default settingfor parameters 71 to 77 is control option 0. If the Seven‐day clock key ispressed unintentionally in this setting, the melter is not affected.

3. Create schedule 1:

a. Set parameters 55 and 56 to the time of day that the heaters shouldturn on and off.

b. Set parameters 57 and 58 to the time of day that the melter shouldenter and exit standby mode.

4. Repeat step 3 to create schedules 2 and 3 with parameters 60 to 68.

5. Determine which control options should apply to each day of the weekwith parameters 71 to 77.

6. Press the Seven‐day clock key to enable the clock.



Seven‐day Clock (contd.)

50 Current Day

Description: Used to set the current day of the week.

Value: 1 to 7 (1 = Monday, 2 = Tuesday, etc.)

Resolution: 1

Default: —

Format: —

Use: —

51 Current Time

Description: Used to set the current time of day.

Value: 0000 to 2359 (European time format)


Default: (Time set at factory)

Format: Hour, Hour: Minute, Minute

Use: This setting only needs to be made once for all daily schedules.

55 Schedule 1 Heaters On

Description: Used to set the time that the clock turns on the heaters during schedule 1.

Value: 0000 to 2359, ‐ ‐ ‐ ‐


Default: 0600


Use: Set the desired time for the heaters to turn on.

To disable this parameter, set the parameter's value to "‐ ‐ ‐ ‐" by simultaneouslypressing both of the right display scroll keys.

56 Schedule 1 Heaters Off

Description: Used to set the time that the clock turns off the heaters during schedule 1.

Value: 0000 to 2359, ‐ ‐ ‐ ‐


Default: 1700


Use: To disable this parameter, set the parameter's value to "‐ ‐ ‐ ‐" by simultaneouslypressing both of the right display scroll keys.



57 Schedule 1 Enter Standby

Description: Used to set the time that the melter enters standby during schedule 1.

Value: 0000 to 2359, ‐ ‐ ‐ ‐


Default: ‐ ‐ ‐ ‐



Note: Do not set an enter standby time that is outside of the time period definedby the schedule's heater on and off time. The melter can not enter standby modewhen the heaters are off.

58 Schedule 1 Exit Standby

Description: Used to set the time that the melter will exit standby mode during schedule 1.

Value: 0000 to 2359, ‐ ‐ ‐ ‐








Value: 0000 to 2359, ‐ ‐ ‐ ‐











Value: 0000 to 2359, ‐ ‐ ‐ ‐







Value: 0000 to 2359, ‐ ‐ ‐ ‐








Value: 0000 to 2359, ‐ ‐ ‐ ‐










Value: 0000 to 2359, ‐ ‐ ‐ ‐








Value: 0000 to 2359, ‐ ‐ ‐ ‐







Value: 0000 to 2359, ‐ ‐ ‐ ‐











Value: 0000 to 2359, ‐ ‐ ‐ ‐






71-77 Control Options for the Days of the Week

Description: Used to select which schedule(s) should be used on a certain day of the week.

Value: 0 – Remain at last clock transition

1 – Use only schedule 1



4 – Use schedules 1 and 2



7 – Use schedules 1, 2 and 3

Resolution: 1

Default: 0

Format: —

Use: Parameter 71 (Monday)

Parameter 72 (Tuesday)

Parameter 73 (Wednesday)

Parameter 74 (Thursday)

Parameter 75 (Friday)

Parameter 76 (Saturday)

Parameter 77 (Sunday)

Note: If control option 0 is used, e.g. the heaters will not turn on again until thenext scheduled Heater on time is reached. Refer to example 2.



Example 1

Turn heaters on at 0600 and off at 0015 every day of the week:

Par 55 = 0600Par 56 = 0015Par 57 = - - - -Par 58 = - - - -Par 71 to 77 = 1

Example 2

Turn heaters on at 0700 and off at 1700 Monday through Friday, and leaveheaters off Saturday and Sunday:

Par 55 = 0700Par 56 = 1700Par 57 = - - - -Par 58 = - - - -Par 71 to 75 = 1Par 76 and 77 = 0

Example 3

Turn heaters on at 0600 each morning, go into standby for lunch at 1130,come out of standby after lunch at 1230, and switch the heaters off at 1600 atthe end of the day, every day of the week:

Par 55 = 0600Par 56 = 1600Par 57 = 1130Par 58 = 1230Par 71 to 77 = 1



Automatic fill timer

78 Timer Automatic FillingDescription: A timer that counts down; it can be connected to a switch at one of the

inputs.

Value: 0 to 90 seconds

Resolution: 1


Format: —

Use: Used in conjunction with input control option 13 or 14. Enable outputcontrol option 6 (alarm) to transmit a signal when the time has elapsed.


Output (Control Option 3): Reversal of fault logic

79 Reversal of Fault Logic - Not Shown -

Description: Reversal of fault output logic from Contact opens when fault occurs toContact closes when fault occurs.

Value: 0 or 1

Resolution: —

Default: 0 (Contact opens when fault occurs)

Format: —

Use: Caution when reversing fault logic: Ensure that the parent machine cannot be endangered when a fault signal is received.

PID selection

80-91 PID Selection for Hose/Gun 1, 2, ..., 6

Description: Changes the default PID settings. Use parameter 80 to select the value for hose1, parameter 81 to select the value for gun 1, and so on.

Value: 0 = Hose1 = Standard gun2 = Large gun3 = Air heater

Resolution: 1

Default: 0 or 1, depending on component (hose or gun)

Format: —

Use: Consult your Nordson representative before changing PID settings.

Original state: Operating parameter 88 (hopper) = 2

Melter Communication C‐1


Appendix C

Melter Communication

This appendix describes the installation and use of the NordsonConfiguration Manager (NCM). The following are possible with this software:

� Installation of melter firmware

� Transmission of operating parameters and setpoint temperaturesbetween melters

� Saving multiple variations of melter settings.

Software Availability

If you do not have the NCM software yet, you can download it from theInternet under www.enordson.com/support ProBlue/DuraBlue.

NOTE: When the Configuration Manager is downloaded and installed for thefirst time, the newest version of the melter firmware is also downloaded.

If you do not have Internet access, your Nordson representative can sendyou the software on a CD.

System Requirements

The following hardware and software requirements must be met to be able toinstall and operate the software:

� Serial cable

� PC with:

� CD‐RW drive

� COM port

� 640 x 480 color monitor

� Windows 95, 98 (second edition), ME, XP or 2000

� Internet Explorer, version 4.0 or newer (IE 5.0 recommended)

� Administrator rights (Windows XP, 2000 and NT)

Melter CommunicationC‐2


Installing the SoftwareNOTE: When the system prompts you to select an installation location,Nordson recommends accepting the suggested location.

Version Use

Single installation file

NCMBlue.exe

You download the software from www.enordson.com, and the PC used fordownloading is or can be linked to the melter.

OR

You download the software from www.enordson.com onto a PC that cannot be linked to the melter but has a CD‐RW drive and the PC linked to themelter has a CD drive.

OR

You have a CD with the software and a PC with a CD drive that can belinked to the melter.

1. Save the file NCMBlue.exe on the PC or insert the CD.

2. Double click on NCMBlue.exe.

The installation assistant NCM_Blue InstallShield� Wizard appears

3. Click on Next and follow the instructions on the screen.

4. When the message appears indicating that installation is completed, clickon Finish.

11 22

00

44 55

33

66

99



Removing the Software from your PC

NOTE: Users of Windows XP, 2000 and NT must have administratorprivileges to remove the software from their PCs.

When the software is removed, the files containing melter settings, savedwith the NCM, are not deleted. Settings files (file extension .ncm) are storedin your Windows folder My Documents (default).

With the NCM_Blue InstallShield� Wizard

1. Double click on the file NCMBlue.exe.

2. Select Remove and follow the instructions on the screen.

With Windows (Example: Windows 2000)

1. Select Start > Preferences > Control Panel

2. Double click on Software.

3. Select NCM_Blue from the list, then click on Change/remove andconfirm.

Linking PC and Melter

Connect a serial cable between the COM port of the PC and the serialinterface (COM port) on the melter control panel.

Fig. C‐1

Desktop symbol NCM



Using Nordson Configuration ManagerThe Configuration Manager is started from the Windows desktop by clickingon the symbol shown at left.

Saving Melter Settings

When the settings are saved, the current setpoint temperatures andoperating parameter values are copied onto your PC.

1. Put the melter in setup mode. Do this by simultaneously pressing theStandby key and the Setup key.

”COnF” appears in the right display.

2. Double click on the NCM icon on the Windows desktop.

The Configuration Manager dialog box appears.

3. Click on Select Device.

The Select Product dialog box appears.

4. Select DuraBlue from the list, then click on OK.

The Select COM Port dialog box appears.

5. Select the COM port used for the connection to the melter, then click onOK.

The PC and the melter establish communication, and an image of theselected melter appears in the melter status area. The right side of thestatus area indicates CONNECTED.

6. Click on Save Settings.

The Save As dialog box appears.

NOTE: The default storage location for the settings files is the Windowsfolder My Documents. To avoid losing saved settings files, Nordsonrecommends not to change the default storage location.



7. Enter a file name for the group of settings to be saved, then click onSave.

The bar indicates the progress of the storage. When saving is completed,the melter automatically reverts to normal mode (Auto‐scan).

NOTE: If you intend to save several variations of melter settings with theNCM, use a name system that clearly allocates each settings file (fileextension .ncm) to the respective process or final application.

8. Click on OK to close the NCM.

Restoring Melter Settings

1. Perform steps 1 to 5 under Saving Melter Settings

2. Click on Restore Settings.

The Open dialog box appears.

3. Select the settings file (file extension ncm) you wish to restore and thenclick on Open.

The Restore Settings bar indicates the progress of restoring. Whenrestoring is completed, the melter automatically reverts to normal mode(Auto‐scan).



Upgrading or Restoring Melter Firmware

Use the NCM to upgrade your melter firmware to a newer version or to reloadthe current firmware version. The currently available firmware version can bedownloaded from www.enordson.com/support.

NOTE: The firmware version installed on your melter appears on the controlpanel when the melter is switched on.

The current melter settings are downloaded and saved on your PC when anupgrade is performed. When the melter firmware has been upgraded orrestored, the pre‐upgrade settings can be restored with the NCM.

CAUTION: The melter settings are returned to the defaults when an upgradeis performed. Only the hours of heater operation are saved. The contents ofthe fault log and the change history log are lost when the firmware isupgraded.

Upgrading or Restoring Melter Firmware

1. Connect the PC to the melter. Refer to Linking PC and Melter earlier inthis section.

2. Put the melter in upgrade mode. To do this, hold down the Setup key andthe left display scroll key, and switch the melter off and then on again.

UPLOAd appears in the right display.

3. Double click on the NCM icon on the Windows desktop.

The Configuration Manager dialog box appears.

4. Click on Select Device.

The Select Product dialog box appears.

5. Select DuraBlue from the list, then click on OK.






7. Click on Upgrade.

The Select Upgrade dialog box appears.

8. From the list of Available Upgrades, select the firmware version that youwish to upload onto the melter, then click on OK.

The warning for upgrades appears.

9. Click on OK.

The Upgrade in Progress dialog box appears. The upgrade can take upto 12 minutes. When the upgrade is completed, the Success dialog boxappears and the melter restarts.

CAUTION: Do not interrupt the upgrade process when the timer is visible.Interrupting the upgrade can destroy the processor.

10. Click on OK.

The communication link between the melter and the PC is terminated.

11. Do one of the following:

� To restore melter settings that were not in use immediately before theupgrade, refer to Restoring Melter Settings earlier in this section.

� Click on Exit to close the NCM.

� To restore melter settings that were in use immediately before theupgrade, proceed with step 12.

12. Put the melter in setup mode. Do this by simultaneously pressing theStandby key and the Setup key.

”COnF” appears in the right display.

13. Click on Connect.




15. Click on Restore Pre‐upgrade Settings.

The settings previous to the upgrade are restored, and the melter revertsto normal mode (Auto‐scan).

16. Click on Exit to close the NCM.



Troubleshooting

Problem Corrective Action

Access Denied appears when a unit or COM porthas been selected.

Communication is already in progress, or a differentapplication is using the COM port.

Close the Internet Explorer and terminate thecommunication connection (when prompted). Closeall other applications.

The melter is in UPLOAd mode, the upgrade hasnot yet begun, and you wish to stop and exit theUPLOAd mode, but you can not get the melter outof UPLOAd mode.

Switch melter off and on again with main switch.

CAUTION: Ensure that the firmware upgradeprogress is not running before switching off.

UPLOAd does not appear in the melter displaywhen the Setup key and the left display scroll keyare pressed at the same time.

Hold down the Setup key and the left display scrollkey simultaneously, and turn the main switch off andthen on again.

Attempted a firmware upgrade, but the melterdisplay still indicates UPLOAd.

OR

Attempted firmware upgrade, but the PC hasstopped responding or was interrupted during theupgrade process.

Switch melter off and on again with main switch,then try the upgrade again.

If the upgrade is not successful or the melter doesnot restart, the processor may be damaged.Replace the CPU.