fillmaster adhesive feed systememanuals.nordson.com/adhesives/english_manuals/1030629.pdf · 2014....

NORDSON CORPORATION • DULUTH, GEORGIA • USAwww.nordson.com

FillMaster� Adhesive Feed System

Customer Product ManualPart 1030629C

Issued 7/04

Part 1030629C � 2004 Nordson CorporationAll rights reserved

Manual 62-FILLMSTR-MA-02

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999.No part of this document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray,ColorMax, Control Coat, Coolwave, Cross Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Durasystem, Easy Coat, Easymove Plus,

Econo-Coat, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon,Hot Shot, iControl, Isocoil, Isocore, Iso-Flo, JR, KB30, Kinetix, Little Squirt, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium,

Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam,Porous Coat, PowderGrid, Powderware, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, SC5, S. design stylized,Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt,

Super Squirt, SureBead, Sure Coat, Sure-Max, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Veritec, VersaBlue,Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, Apogee, AquaCure, ATS, Auto-Flo, AutoScan, BetterBook, Celero, Chameleon, Check Mate,Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraCoat, DuraPail, Dura-Screen, Easy Clean, Eclipse, EcoDry, e.DOT, E-Nordson,

Equi=Bead, ESP, e Stylized, Exchange Plus, Fill Sentry, Gluie, HDLV, iFlow, iON, Iso-Flex, iTrend, iTRAX, KVLP, Lacquer Cure, Lean Cell, Maxima,MicroFin, MicroMax, Minimeter, Multifil, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process Sentry,Pulse Spray, PurTech, QuadCure, Ready Coat, Royal Blue, Scoreguard, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic,

Speedking, Spray Works, Summit, Sure Brand, Sure Clean, SureWrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart,Universal, Vantage, Viper, Vista, Web Cure, and 2 Rings (Design) are trademarks 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

Part 1030629C� 2004 Nordson Corporation Manual 62-FILLMSTR-MA-02

Table of Contents

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

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

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

Equipment Safety Information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Shutdown 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Warnings and Cautions 6 . . . . . . . . . . . . . . . . . . . . . . . . . . Other Safety Precautions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Label 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Description 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FillMaster Components 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Unit 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Hose 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cone 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level Sensor and Sensor Control 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking and Positioning FillMaster 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioning the Melter 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Melter Lid Kit and the Sensor Kit 19 . . . . . . . . . . . . . . . . . . . . . . Equipment Mounting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching the Cone 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching the Transfer Hose to the Cone 20 . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Compressed Air Supply Hose to the Cone 22 . . . . . . . . . . . .

Table of Contentsii

Part 1030629C � 2004 Nordson CorporationManual 62-FILLMSTR-MA-02

Setup 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Pressure Switch 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Air Throttle to Maintain Cone Temperature 25 . . . . . . . . . . . . . Adjusting Level Sensor Settings 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open Sensor Adjustment 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Point Adjustment 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Timer 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Settings Table 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Param (Parameter) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings Record 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieve System Pressure 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Cleaning 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Record 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Parts List 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Parts 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Parts 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Parts 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Kits 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematics 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Section 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Section 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Cabinet Layout 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FillMaster� Adhesive Feed System 1


FillMaster� Adhesive Feed System

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 productdescribed in this document (hereafter referred to as “equipment”).Additional safety information, in the form of task-specific safety alertmessages, appears as appropriate 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 equipmentor property.

FillMaster� Adhesive Feed System2


Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information,ensuring that all instructions and regulatory requirements for use of theequipment are met, 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 accordancewith governing 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.



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.

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 andTags at 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 and that the processing characteristics of the material will notcreate a hazardous environment. Refer to the Material Safety DataSheet (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 apotential malfunction.



Maintenance and Repair Practices � Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

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

� Use only new factory-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 Nordsonrepresentative.

� 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 ordamaged labels.

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

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 variesby the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of theprocedure. 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, guns, 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 tothe appropriate regulation or standard.

Disabling the Guns

All electrical or mechanical devices that provide an activation signal to theguns, gun solenoid valve(s), or the melter pump must be disabled beforework can be performed on or around a gun that is connected to apressurized system.

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

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

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

General Safety Warnings and Cautions Table 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 as follows:

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

PC = Process control

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



Table 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 acompatible Nordson melter, read and comply with the material’sMSDS. Ensure that the material’s processing temperature andflashpoints will not be exceeded and that all requirements for safehandling, ventilation, first aid, and personal protective equipment aremet. Failure to comply with MSDS requirements can cause personalinjury, including death.

HM

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

HM, CA

WARNING: System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relievethe system hydraulic pressure can result in the uncontrolled release ofhot melt or cold adhesive, causing personal injury.

HM

WARNING: Molten material! Wear eye or face protection, clothingthat protects exposed skin, and heat-protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hotmelt can still cause burns. Failure to wear appropriate personalprotective equipment can result in personal injury.

Continued...



General Safety Warnings and Cautions (contd)

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


HM, PC

WARNING: Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt guns. Before workingon or near an operating gun, disable the gun’s triggering device andremove the air supply to the gun’s solenoid valve(s). Failure todisable the gun’s triggering device and remove the supply of air to thesolenoid 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.

CA

WARNING: Risk of fire or explosion! Nordson cold adhesiveequipment is not rated for use in explosive environments and shouldnot 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.

HM, CA, PC

WARNING: 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.

Continued...




HM

CAUTION: Hot surfaces! Avoid contact with the hot metal surfacesof guns, hoses, and certain components of the melter. If contact cannot 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.If you are unsure of the equipment’s ability to process PUR, contactyour Nordson 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 withNordson Type R fluid that contains polyester adipate plasticizer.Certain hot melt materials can react with Type R fluid and form a solidgum that can clog the equipment. Before using the equipment,confirm that the hot melt is compatible with Type R fluid.

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,or leaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.



First AidIf molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove it from your skin.

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

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

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

Safety Label Figure 1 illustrates the location of the product safety labels affixed to theequipment. Table 2 provides an illustration of the hazard identificationsymbols that appear on each safety label, the meaning of the symbol, or theexact wording of any safety message.

6202001A

Figure 1 Safety Label

Table 2 Safety Label Description

Item Part Description

1. N/A WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.



System Overview The FillMaster� Adhesive Feed System is an automated adhesive supplysystem that works with most Series 3000 Vista� or Multiscan, ProBlue

and DuraBlue melters.

There are two types of FillMaster units:

� FillMaster I — supplies adhesive to one melter

� FillMaster II — supplies adhesive to two melters

6202002A

Figure 2 FillMaster Connected to a Melter (Series 3000 melter shown)

Intended Use The FillMaster cannot be used in any other way other than specified in thismanual. Observe all instructions in the Safety section carefully.



Features � Automatically supplies adhesive to the melter at a preset level

� Ensures uninterrupted production and saves operator time

� Simple design reduces maintenance requirements

� A closed adhesive reservoir provides clean adhesive

� Can be fitted to most hot melt systems

� Easily installed

� Unique design features deliver consistent transfer of adhesive

- Venturi pump design minimizes bridging in the adhesive container byproviding air bursts into the adhesive reservoir to promote adhesivefree flow

- Cone shape allows an even dispersion of adhesive in the tank

� Eliminates missed beads and poor bonding caused by empty tanks

System Description The FillMaster supplies granulated adhesive in response to a low levelsignal provided by the melter’s sensor control. Adhesive is supplied throughthe transfer hose, assisted by compressed air, in sufficient quantity into themelter tank. The FillMaster replenishes adhesive only when the melter is atoperating temperature, when there is sufficient air pressure, and if no alarmcondition is detected. An adjustable shot duration determines the quantity ofadhesive delivered with each cycle, ensuring that only sufficient quantities ofadhesive refresh the tank on a regular basis.

See Figure 3, FillMaster Components.



1

2 35 7

12

813

11

19

20

14

15

16

17

18

4

6

9

10

13

14

17

11

Figure 3 FillMaster Components (Series 3000 melter shown)

1. FillMaster I or II2. Compressed air hose3. Transfer hose4. Tank lid5. Pump cover6. Communication cable7. Sensor control

8. Melter power line9. Compressed air supply

10. Cone11. Melter (3000 melter shown)12. Timer (inside)13. Air throttle (inside)14. Venturi pump (inside)

15. Solenoid valve (inside)16. Accumulator (inside)17. On/Off Switch18. LED indicators19. Electrical cabinet and pneumatic

controls (inside)20. Adhesive reservoir

Note: Pressure regulator is located on the back of the FillMaster.

FillMaster ID plate



ID Plate

The FillMaster ID plate is affixed on the back of the unit. The ID plateprovides the part number information and the type of FillMaster being used.

Specifications

Electrical Item Specification

Operating voltage 120/230/1∅ VAC ±10%, w/ neutral

Operating voltage frequency 50/60 Hz

Fuse rating (P) 1A

Dimensions Item Specification

length x width x height mm (in.) 420 X 420 X 975(16.53 x 16.53 x 38.26)



General Item Specification

Melters used (standard installationkits available)

3400 Vista or Multiscan3500 Vista or Multiscan3700 Vista or MultiscanProBlueDuraBlue D10 and D16

Adhesive Pellets, pastilles, mini slats

Adhesive transfer rate:

Maximum rate

Maximum conveying distance

100 kg (220 lb)/hr

10 m (32.8 ft), horizontal (novertical rise);2.5 m (8.2 ft) vertical

Transfer hose:

Length

ID

10 m (32.8 ft) maximum

40 mm (1.6 in.)

Cone height 320 mm (12.6 in.)

Screen mesh size 0.5 x 0.5 mm (0.02 x 0.02 in.)

Adhesive reservoir 69 l (44 kg/97 lb)

Design Stainless steel with casters andlockable cabinet

Operating air:

Minimum pressure

Maximum pressure

Air consumption

Air hose rating

Dry, non-lubricated supply:

6 bar (0.6 MPa, 87 psi)

10 bar (1.0 MPa, 145 psi)

0.4 m3 (14.1 SCFM) @ 5 shotduration (1.5 seconds each) and10 second interval/minute

At least 10 bar (1 MPa/145 psi)

Connection 13 mm (1/2 in.)

Weight (empty) 43.0 kg (95 lb.)

Pump type Venturi (patented design)

Noise emission 80 dBA (3 seconds)



FillMaster Components See Figure 3.

Main Unit The main unit is a stainless steel cabinet which is divided into two sections:

� upper portion which contains the adhesive reservoir.

� lower portion which contain the front panel, electrical cabinet, andpneumatic controls.

Front Panel

The FillMaster front panel contains LED indicators and an On/Off switch.FillMaster I has one row of LEDs and FillMaster II has two rows of identicalLEDs.

!

1

2 3

4

5

Figure 4 FillMaster I Front Panel

1. OK (green)2. Shot duration (blue)3. Alarm (red)

4. Power (white)5. ON/Off switch



The front panel LEDs indicate the following conditions:

� OK (system ready) LED: the melter is at the correct operatingtemperature, air pressure is set, and there is no alarm condition.When the melter sends a low level signal, the FillMaster transfersadhesive from the reservoir to the melter tank through the transferhose.

� Shot duration LED: adhesive delivery cycle.

The length of time that the venturi pump cycles is called shotduration. Shot duration is dependent on adhesive characteristics(size and shape) and transfer height and length. Shot duration mustbe long enough to move the adhesive over the highest point of thetransferring hose route. The recommended highest point of thetransferring hose is 2.5 m (8.20 ft).

� Alarm or fault condition.

� Power status on or off.

Electrical Cabinet

The electrical cabinet contains:

� A timer that controls shot duration, interval, and alarm. The timer ispreset at the factory but can be adjusted for different applicationsituations.

� A power supply that converts input power to DC voltage.

Pneumatic Controls

The pneumatic controls include:

� A Venturi pump that cycles air bursts (preset time duration) to transportadhesive from the reservoir through the transfer hose to the melter tank.

� An accumulator that supplies specific volume of compressed airrequired for each cycle of the venturi pump.

When a low level is detected from the level sensor in the melter, asolenoid valve opens, sending compressed air from the accumulator tothe venturi nozzle. Adhesive discharges from the adhesive reservoir intothe air passages, propelled by air bursts from the venturi pump. Thedesign of the venturi pump also deflects compressed air upward into theair passages from the reservoir, loosening adhesive particles andpreventing bridging or clogging.

� An air throttle that provides volume adjustment of air to cool the cone.

� A pressure regulator that is located at the back of the FillMaster. Thereis a pressure switch inside the pressure regulator that can be set toadjust and verify air pressure supply.



Transfer Hose The transfer hose transports adhesive from the adhesive reservoir of theFillMaster to the melter tank. The transfer hose grounding strap must beconnected at both ends to avoid static charges.

Cone The cone attaches the transfer hose to a modified melter tank lid(purchased separately) precut to the dimensions of the cone. The new tanklid must be retrofitted to the melter before the cone is attached. The conecontains a screen that prevents fine particles and powder in the adhesive topermeate the ambient air. Air supplied to the cone prevents adhesivebridging by cooling the point at which the transfer hose connects to thecone.

NOTE: Bridging occurs when adhesive (usually pellets) heats up rapidly,and the layer directly above the heated adhesive heats partially to form abridge in the melter tank grid. This prevents the rest of the adhesive frommelting and being transferred from the adhesive reservoir to the melter tank.To prevent this, change to a lower-viscosity adhesive or to an adhesive formthat is less likely to bridge, or raise the tank operating temperature setpointto reduce viscosity.

Level Sensor and Sensor Control The level sensor (purchased separately) detects the level of adhesive in thethe melter tank. When adhesive falls below setpoint, the level sensortransmits a signal to the FillMaster, which transfers adhesive from thereservoir to the melter. FillMaster will not transport adhesive until it gets aready signal from the melter.



Installation This section provides information to position and connect the FillMaster.

WARNING: Allow only personnel with appropriate training and experienceto operate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Unpacking and Positioning FillMaster

CAUTION: Do not store the FillMaster outside! Protect from humidity anddust.

1. Exercise normal care to prevent equipment damage during unpacking.

2. Inspect for any damage that may have occurred during shipping. Reportany damage to the Nordson representative.

3. Position FillMaster close to the production line and make sure that theseguidelines are followed:

� Provide sufficient space for cleaning and maintenance above and onall sides of FillMaster.

� Provide sufficient access to transfer hose for cleaning andmaintenance purposes.

� Ensure that the cables, air hoses, and the transfer hose do not getbent, pinched, torn off, or damaged.

Positioning the Melter Firmly anchor the melter in the correct position on the floor or a workingsurface by using the holes on its base. Refer to the appropriate meltermanual for more information.

Installing the Melter Lid Kit and the Sensor Kit A lid kit and a sensor kit, both purchased separately, must be installed inorder to connect a FillMaster to the melter. Refer to Mounting Kits inRecommended Parts List. Follow the installation instructions provided withthe melter lid kit and the sensor kit before continuing.

1

2

Clamp location



Equipment Mounting Once the melter lid and sensor kits are installed, attach the cone, transferhose and FillMaster controller to the melter.

Attaching the Cone

CAUTION: Use a screen with a mesh size of 0.5 x 0.5 mm (0.02 x 0.02 in.).A finer mesh screen can cause heat and air retention in the cone, andcause the adhesive to clog.

1. Insert the screen mesh into the cone.

2. Place the cone on the modified tank lid and secure with the two bracketsprovided.

Attaching the Transfer Hose to the Cone

WARNING: Equipment must be properly grounded and fused according toits rated current consumption (see ID plate). Failure to follow the safetyprocedures can result in serious injury.

1. Attach the transfer hose to the cone.

2. Secure the grounding strap firmly between the cone and the clamp (seedrawing on left). The grounding strap is molded inside the walls of the transfer hose andmust be secured to the cone to prevent static charges.

3. Secure the cone to the lid using the clamp (see drawing on left).

See Figure 5.

1. Clamp2. Cone



4. Position the transfer hose vertically (2.5 m maximum [8.20 ft]), and thenhorizontally. Make sure that there are no sharp vertical deviations.

Figure 5 Transfer Hose Position



Connecting Compressed Air Supply Hose to the Cone The compressed air hose is connected to the FillMaster at the factory. TheFillMaster must be connected to regulated, dry air.

1. Connect the 13 mm (1/2 in.) air hose to the pressure regulator located onthe back of the FillMaster.

3

6202008A

12

Figure 6 Compressed Air Hose Connected to the Cone (3000 Melter Shown)

1. Compressed air hose2. Air inlet

3. Cone

2. Connect the 8 mm (0.31 in.) air inlet onto the cone.

NOTE: The air throttle located inside the pneumatic section is used tocontrol the constant flow of air volume to the cone.

To set air pressure, refer to Adjusting Pressure Switch in Setup.



Setup This section provides information on adjusting the pressure switch that islocated inside the pressure regulator, air throttle, level sensor, and timer.

Adjusting the Pressure SwitchThe pressure switch is located inside the pressure regulator. It adjusts andverifies air pressure supply. The pressure switch signals the OK LED(system ready). If the air supply falls below the pressure switch setpoint,the OK LED turns off. The factory setting for the pressure switch is 5 bar (72psi).

The pressure gauge on the pressure regulator has two indicators:

� Green indicator indicates the actual set point

� Black indicator indicates the actual air pressure

1

2

3

4

5

Figure 7 Pressure Regulator Components

1. Pressure switch (inside)2. Pressure gauge3. Set screw

4. Black indicator (air pressure)5. Green indicator (pressure

switch setpoint)



Adjusting the Pressure Switch (contd)

NOTE: The air pressure on the air regulator must always be higher thanthe set pressure of the air switch. A minimum of 6 bar (87 psi) is requiredfor the air regulator. Refer to Specifications for additional information.

1. Remove the pressure gauge cover.

2. Using a flat head screwdriver:

a. Turn the set screw clockwise (−) until the setpoint (green indicator) isat zero (0).

While the FillMaster is supplying adhesive to the melter, the airpressure (black indicator) will drop.

b. Turn the set screw counterclockwise (+) to adjust the setpoint of thepressure switch (green indicator) to a pressure value of 0.1−0.2 bar(1.45−2.9 psi) below the lowest pressure reading from the airregulator (black indicator).

Below this setting the pressure value (black indicator) will drop whilethe FillMaster is supplying adhesive to the melter.

3. Check settings on the next feeding shot.

The OK LED (green) on the front panel should stay ON while supplyingadhesive. If the OK LED turns OFF while feeding turn the set screwclockwise (−) to decrease setpoint by measures of 0.1 bar (1.45 psi)until the OK LED remains on.

4. Replace the pressure gauge cover.

Maintain a record of the settings in the Settings Record form given afterOperation.

1

2

Cone temperature check

6202014A

1

2

Air Throttle



Adjusting the Air Throttle to Maintain Cone Temperature See Figure 3, FillMaster Components.

The air throttle is located in the pneumatic section of the FillMaster. Theaccumulator provides continuous air supply to the air throttle, which can beadjusted to regulate the volume of air to the cone. This enables the cone toremain cool and prevents adhesive from sticking or coagulating.

1. Using a temperature measuring device, check the temperature of thecone above the collar. Cone temperature should not exceed 40 �C(104 �F).

1. Collar2. Cone

2. Open the electrical cabinet door and access the air throttle located in thepneumatic section.

CAUTION: Do not turn the adjustment screw more than 11/2 turns. If turnedmore than 11/2 turns, the temperature of the lower portion of the cone canrise above 85.5 �C (186 �F).

3. Turn the adjustment screw (see illustration on the left) clockwise to closethe air throttle and stop air flow.

4. Turn the adjustment screw ± 1/4 turn counterclockwise to open the airthrottle.

1. Adjustment screw2. Locknut

5. Tighten the locknut (see illustration on the left) to secure the setting.

6. Repeat steps 2 and 3 if the cone exceeds the recommendedtemperature setting.

6202016A

12

3

Sensor Control LEDs



Adjusting Level Sensor Settings Adjustment of the level sensor settings is necessary when replacing thelevel sensor or the sensor controller. However, the adjustments must bemade after the level sensor is mounted in the melter and when the meltertank is empty. Refer to the Level Sensor Installation instruction sheet foradditional information.

There are two methods of adjusting the level sensor:

� Open sensor, and

� Switch point

1. Power (green)2. Full (on constantly) or

open sensor (blinking green)3. Low level (red)

Open Sensor Adjustment The adjustment should be made when the melter tank is empty so that thelevel sensor works at the highest sensitivity level.

1. Turn the melter on.

2. Turn the potentiometer 1 (or P1) twenty turns counterclockwise. In thissetting the sensor control receives minimum input and cannot detectadhesive levels. A reading lower than the minimum input will generate afault condition resulting in an open sensor condition (blinking LED).



3. Turn P3 clockwise until the red LED turns off and the green LED startsblinking.

4. Turn P3 counterclockwise until the green LED turns off and the red LEDturns on.

5. Turn P3 1−2 turns counterclockwise.

Switch Point Adjustment Make sure that the melter tank is empty so that the level sensor works atthe highest sensitivity level.

1. Turn the melter on.

2. Turn P1 clockwise until the red LED (low) turns off and the green LEDturns on.

3. Turn P1 from the switching point between the LEDs 1/2 turncounterclockwise, and leave it in its present position.



Adjusting the Timer The factory default timer settings are adequate for most applications.Nordson Corporation recommends that the timer parameter may beadjusted as application conditions require. If the timer settings need to bechanged, make small adjustments, and then operate the system todetermine if the changes were sufficient.

6202017A

2

1

3

4

Figure 8 Timer

1. Display screen2. Arrow buttons

3. OK button4. ESC button

NOTE: Longer shot durations reduce the advantage of using maximum airfrom the accumulator, the remaining air will then have to be provided bynormal plant air. This offers little benefit to adhesive transfer whileconsuming greater volume of air. The interval between two shots, a factorysetting of 10 seconds, should be sufficient to refill the accumulator.



Parameter Settings Table Use the factory default settings in Tables 3 and 4 when setting the timerparameters.

Table 3 FillMaster I and II for Melter Number 1

Parameter Function Factory Default Setting

B 17 Filling alarm 2 minutes

B 30 Time between two shots 10 seconds

B 29 Shot duration 1.5 seconds

Table 4 FillMaster II for Melter Number 2

Parameter Function Factory Default Setting

B 22 Filling alarm 2 minutes

B 26 Time between two shots 10 seconds

B 25 Shot duration 1.5 seconds



Set Param (Parameter) Use the arrow buttons to modify the timer parameters. The arrow buttonallows the cursor to move from one parameter to another.

1. Turn the FillMaster power on.

See Figure 8.

2. Press ESC on the timer, and the following screen will appear.

> StopSet ParamSet ClockPrg Name

Figure 9 Display Screen

3. Press the � arrow to select Set Param, to modify or review theparameters.

>StopSet ParamSet ClockPrg Name

Figure 10 Display Screen



4. Press OK. The Set Param parameters appear on the display panel.

B17 = Filling alarm or preset time delaybefore an alarm condition is detected

T= 02.00 m (2 minutes) is the defaultvalue

Ta= 00.00 m indicates the timer’scountdown if activated during operation

B17 : T

T =

Ta 00.00 m

02.00 m

=

Figure 11 Display Screen and Text Explanation

5. Press the � or � arrow to select the timer that needs to be modified.

B30 : T

T = 20.00 s

Ta = 00.00 s

B30: timer name (in this case, the waittime between two shots)

T= 20.00 s (20 seconds) is the programmed time value

Ta= 00.00 m indicates the timer’s count-down if activated during operation


6. Press OK to modify the timer value. The cursor will move to theparameter value.

B30: wait time between two shots

T= 10.00 s (10 seconds) is the programmed time value changed that waschanged from 20 seconds in step 4.

Ta= 00.00 m indicates the timer’s count-down if activated during operation.

B30 : T

T = 10.00 s

Ta = 00.00 s


7. Press OK when the timer is set to the required value.

8. Press ESC two times to return to the first display screen.



Operation This section provides information for starting the FillMaster system.

1. Turn on the melter.

2. Fill the adhesive reservoir with adhesive.

3. Turn on the FillMaster. The Power LED (white) will turn on.

4. The system is ready to operate when the OK LED (green) turns on.

5. Maintain a record of the settings in the Settings Record form forreference.

NOTE: Check the wiring and/or air supply connection, if the Ready light inthe melter is on but the OK LED in the FillMaster is not on.

NOTE: Check the timer and level sensor settings, if the OK LED in theFillMaster is on but the adhesive is not being delivered. If the problem is notsolved refer to Troubleshooting.



Settings Record

Production Information

Adhesive

Manufacturer / type

Softening temperature

Max. processingtemperature

Viscosity

FillMaster I Basic Settings FillMaster II Basic Settings

Shot Duration (in s)

Interval (in s)

Air pressure

Filling alarm timer

Pressure switch

Notes

Form filled out by:

Name Date:



Maintenance Maintenance is an important preventive measure for maintaining operatingsafety and extending the operational lifetime of the unit. It should not beneglected under any circumstances.

Use the Maintenance Record form given after this section to keep a recordof the maintenance.

WARNING: Allow only personnel with appropriate training and experienceto operate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

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

Relieve System Pressure Always begin the maintenance procedure by relieving system pressure asdirected in the Safety section of this manual.

External Cleaning External cleaning prevents impurities from causing the unit to malfunction.Remove dust, fluffs, etc. with a vacuum cleaner or a soft cloth.

Maintenance Schedule The table below shows maintenance tasks and how often they should beperformed. Unit location, enviroment, and operating time may affect thefrequency of necessary maintenance intervals. Use the MaintenanceRecord form to keep a record of unit maintenance.

Unit Activity Frequency

FillMaster Inspect for damage Daily

External cleaning Daily

Inspect compressed air setting Daily

Inspect transfer hose for damage, replace if necessary Daily

Cone Clean Weekly

Screen mesh Clean, replace if necessary Daily

Compressed air filter Inspect and clean Weekly



Maintenance Record

Unit Activity Date Name Date Name

FillMaster

Melter

Cone

Screen mesh

Compressed air filter



Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

This section contains troubleshooting procedures. These procedures coveronly the most common problems that may be encountered. If the problemscannot be solved with the information given here, contact the local Nordsonrepresentative.

Problem Possible Cause Corrective Action

1. No adhesive beingtransported

Air pressure is too low Check air pressure (6−8 bar). Adjustif necessary.

System ready contact on melteropen

Wait until melter has reachedsetpoint temperature and the systemready LED lights up.

Transfer hose is blocked or bent Search for blockage and remove it.Unbend the transfer hose.

Sensor has no power supply Check the electrical connection to themelter.

Sensor or tank grounding is open Check the level sensor and inspectthe wiring.

Filling alarm has occurred Check if the FillMaster is empty, orthe transfer hose is clogged.

Reset the filling alarm.

2. Melter tank isover-filled

Level sensor is dirty Clean the level sensor. Replace ifnecessary.

Level sensor is set incorrectly Set the level sensor correctly.

3. Melter is not refilled Level sensor is dirty Clean the level sensor. Replace ifnecessary.

Melter is not ready Check melter.

Sensor has no power supply Check the electrical connection to themelter.

Sensor or tank grounding is open Check the level sensor, and inspectthe wiring

Filling alarm has occurred Check if FillMaster is empty or thetransfer hose is clogged.

Reset the filling alarm.

No sufficient air supply Check the air supply pressure.

4. Adhesive dirty Oil or water in Venturi pump withthe adhesive

Check the compressed air supply.

Check that the air used is dry,non-lubricated, and compressed.

Insert new screen mesh.



Recommended Parts List Use this recommended parts list to order the required parts. Call theNordson Customer Service Center or the local Nordson representative toorder the required parts.

Electrical Parts Part Description

771409 Power supply, 24 VDC, 1.3 A

771408 Timer (PLC) logo, 24 VDC, 8E/AS

771410 Terminal relay pitch, 6.2 mm, 24 VDC, 1 contact RT

771411 Electrical breaker, 10 A (includes handle)

771412 Fuse 10 x 38, 1 A

771396 Communication cable 1 m, melter to FillMaster

Mechanical Parts Part Description

771413 Screen mesh

771402 Filling cone, outer

Pump Parts Part Description

771404 Venturi kit (includes seals)

771414 Reinforced tube, 50 external/40 internal, 11 m length(FillMaster I uses one tube and FillMaster II uses twotubes)

771406 Pressure switch

771407 Filter, regulator

771403 Servo valve kit

771405 Air throttle



Mounting Kits A lid kit and a sensor kit must be ordered in able to connect a FillMaster to amelter. The parts list below provides the correct ordering information.

Part Description

735142 Lid kit assembly, 3100 melter




771416 Lid kit assembly, P4 melter

771417 Lid kit assembly, P7 and P10 melter

735162 Lid kit assembly, D10/D16 melter

1030061 Sensor mounting kit, 3400 melter

1030062 Sensor mounting kit, 3400 melter, 480V



771399 Sensor kit, Series 3000

735141 Sensor kit, 3100 melter

771415 Sensor kit, ProBlue

735161 Sensor kit, D10/D16



Schematics

Pneumatic Section

6202024A

To feeding cone

To Venturi pump

Pressure gauge with pressure switch

Pressure regulator

Throttle

Solenoid valve 24V DCCompressed air supply

dry, nonlubricatedmin. 6 bar / max.10 bar hose I.D. 1/2”

FillMaster I

Solenoid valve 24V DCdry, nonlubricated

hose I.D. 1/2”min. 6 bar / max.10 bar

Compressed air supply

Pressure gauge with pressure switch

Pressure regulator

To Venturi pump 1

To feeding cone 1

Throttle

To Venturi pump 2

Solenoid valve 24V DC

To feeding cone 2

Throttle

FillMaster II

Accumulator 7.5 liters

Accumulator 7.5 liters

Figure 14 Pneumatic Schematic



Electrical Section

6202027B-1

4

56

N

12

0Q2

Power Supply

Power Supply115 VAC

230 VAC

230 VAC230 VAC

System 1Ready

System 2Ready

Power Supply

For the 100 VAC supply, replace this LED with

the spare (100V) available in the electrical box

03.06

03.07

03.08

03.09

03.10

03.11

03.01

03.05

03.11

03.0

1

03.01

03.05

Earth Terminal

24 VDC

03.01

6EP13311SH01

AL.1

H1X1

X21.3AQ1

Or

Supply OK

P2

P1 S1

S2

1 2

3

Folio:04

Folio:04

B 14 B B B15 16 17

Brown

03.0

5

03.0

5

03.02

P2.1

P2.4

Black

Melter 2

Filling Alarm 2

03.1

2

B

4

KA4

03.13Folio:04

N0

Folio:83

NF

03.13 KA2

Folio:03Folio:04

11

12 14

03.05 03.05

GreenKA224V

H3

X2

X1

Sys

tem

2 R

eady

for

Cus

tom

er U

se

Sys

tem

1 R

eady

for

Cus

tom

er U

se

11

14

Brown

Blue

White

Air Pressure

Black

Brown

Filling Alarm 1

Melter 1

BlackP1.4

03.0

3

P1.1

P3.4

S1

P3.1

P

B

B

B

1

2

3

Folio:04

KA3

11

14

Folio:83

N0 NF

03.04

Folio:03

KA111

12 14

03.0503.05

GreenH3

X2

X1

03.04

Folio:04

KA124V

Figure 15 Electrical Schematic 1 of 2



6202027B-2

1

04.05

03.0

5

− −

P2.5

− −

LE

VE

L S

EN

SO

R

LE

VE

L S

EN

SO

R

Mel

ter

Rea

dy 1

Fill

Mas

ter

Rea

dy O

ut 1

No

Fill

ing

Ala

rm 1

Air

Sup

ply

OK

Mel

ter

Rea

dy 2

Fill

Mas

ter

Rea

dy O

ut 2

No

Fill

ing

Ala

rm 2

Air

Sup

ply

OK

Folio:03

Folio:03

03.01

03.05

03.01 03.01 03.01 03.01

03.05 03.05 03.05 03.05 03.05

03.05

Blue Red

1

2V

NO NF EV.1 NF

B 6

Blue RedNF NF EV2NO NO NO

B 10

1

2

Folio:03

B 5 B 9

04.01

24V V 24VKA3 KA4H4 H5.2 H6 H7.2

Folio:03

Figure 16 Electrical Schematic 2 of 2



Electrical Cabinet Layout

6202026A

A2 A2 A2 A2

A1 A1 A1 A1

14 14 14 14

11 11 11 11

12 12 12 12

KA

1

KA

3K

A2

KA

4

API 1

AL.1 Q2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17

Inside the electrical cabinet

FuseTimer

Customer use: System Ready 1

Customer use: System Ready 2

Siemens

Siemens

Input

Output

LOGO

LOGO Power

Power Supply

Ferraz

Terminal Relay Pitch

MSC 10

Relays KA2 and KA4 only used for FillMaster 2

Terminal blocks 1 to 8 used for FillMaster 1

Terminal blocks 1 to 12 used for FillMaster 2

Figure 17 Electrical Cabinet

fillmaster adhesive feed systememanuals.nordson.com/adhesives/english_manuals/1030629.pdf · 2014....

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