Nordson problue 4 инструкция на русском языке

Related Manuals for Nordson PURBlue 4

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Table of Contents

Part 1024496_06

Installation

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Quick‐Start

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Installing 400/480 Volt Melters

Overview

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Additional Information

Installation Tasks

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Experience of Installation Personnel

Installation Requirements

Clearances

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Ventilation

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Electrical Power

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Compressed Air

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Other Considerations

Unpacking the Melter

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Contents of the Installation Kit

Customer‐Supplied Materials

Mounting the Melter

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Configuring the Electrical Service

Connecting a Compressed Air Supply

Connecting Hoses and Guns

Setting Up the Melter

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Quick Setup

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Operating Parameters

Selecting Operating Parameters

Reading or Editing Operating Parameters

Set‐point Temperature of the Tank, Hoses, and Guns

Save and Restore Melter Settings

Review Parameter and Set‐point Temperature Changes

Installing Melter Inputs

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Installing Melter Outputs

Installing Optional Equipment

Connecting a Gun Driver, Pattern Controller, or Timer

Flushing the Melter

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Setting Up Melter Communications

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E 2014 Nordson Corporation

• Page 1
  User’s Guide Customer Product Manual Part 1129255_01 Issued 06/20 This document contains important safety information. Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION  DULUTH, GEORGIA  USA www.nordson.com…
• Page 2
  This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2020. 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 4800 INTEGRA, Allegro, Apogee, Artiste, Asymtek, Automove, Avex, BaitGun, BKG, Blue Box, BM-32, BM-58, BM-63, Bowtie, Build‐A‐Part, CF, Century, CleanSleeve, CleanSpray, Color‐on‐Demand, ColorMax, Conexis, Connections to Life, Contour, Control Coat,…

• Page 3: Table Of Contents

  ProBlue Flex OEM User’s Guide Table of Contents Overview ………..

• Page 4
  ProBlue Flex OEM User’s Guide Basic Melter Operation ……..
• Page 5
  ProBlue Flex OEM User’s Guide Defining System Settings ……..
• Page 6
  ProBlue Flex OEM User’s Guide Tool Settings ……….

• Page 7: Overview

  OEM interface is selected when the primary control of the melter is through communication with a Programmable Logic Controller (PLC). ProBlue Flex melters with an OEM interface are set up using the PLC mapping capability of BBconn Cloud, a web application that runs in a browser on any desktop computer or handheld device.

• Page 8: Safety

  ProBlue Flex OEM User’s Guide Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as “use”) of the product described in this document (hereafter referred to as “equipment”). Additional safety information in the form of task‐specific safety alert messages, appears as…

• Page 9: Responsibilities Of The Equipment Owner

  ProBlue Flex OEM User’s Guide Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment 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,…

• Page 10: User Qualifications

  Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non‐standard auxiliary devices. E 2020 Nordson Corporation…

• Page 11: Instructions And Safety Messages

  Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices.

• Page 12: Operating Practices

  Read and comply with the manufacturer’s instructions and the SDS supplied with equipment cleaning compounds. NOTE: SDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation.

• Page 13: Equipment Safety Information

  ProBlue Flex OEM User’s Guide Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all…

• Page 14: Disabling The Applicators

  General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual.

• Page 15
  WARNING! Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent‐based material through a compatible Nordson melter, read and comply with the material’s SDS. Ensure that the material’s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met.
• Page 16
  WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment should not be used with solvent‐based adhesives that can create an…
• Page 17
  CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment.

• Page 18: Other Safety Precautions

  5. Seek expert medical attention immediately. Give the SDS for the hot melt to the medical personnel providing treatment. Safety Labels and Tags Refer to the ProBlue Flex Core Customer Product Manual, P/N 1128350. E 2020 Nordson Corporation Part 1129255_01…

• Page 19: Where To Find Information

  ProBlue Flex OEM User’s Guide Where to Find Information Getting your melter into operation is a 2-step process: Step Refer to… Description Install and connect power to the melter. Connect your melter to a PLC. Runtime, system settings, and troubleshooting…

• Page 20: Theory Of Operation

  ProBlue Flex OEM User’s Guide Theory of Operation Since the ProBlue Flex OEM melter does not have a user interface, you must use the BBconn Cloud web-based application to do the following: Generate, maintain, and manage .NOR files which contain the daily operational and system settings required for melter operation and production, as well as for PLC setup and connectivity.

• Page 21: Creating A Bbconn Cloud Account

  ProBlue Flex OEM User’s Guide Creating a BBconn Cloud Account BBconn Cloud is a web application that you can use from most any browser- enabled device. Supported browsers include: Browser Macintosh Windows Version Iphone Droid Devices Version Apple Safari 10.12 Sierra and Not available 10.12 Sierra and…

• Page 22
  The Configuration Code field auto-populates after you enter the Serial and UID Numbers. You must Agree to Nordson Terms of Service and Privacy Policy to create your account. Click on the links to view details. 4. To complete the registration, select Accept and Sign UP. An email will be sent to you.

• Page 23: Melter Operation

  PLC, only limited operations are possible. Before proceeding, make sure the melter is fully installed and connected as described in the Installation Guide (P/N 1128353) and in the ProBlue Flex Core Customer Product Manual (P/N 1128350).

• Page 24: About The Control Panel

  ProBlue Flex OEM User’s Guide About the Control Panel The OEM control panel is located on the E-Box door. Master Controls The Master Controls provide On/Off control and status LEDs for the pump, heaters, wireless operation, and remote control operation.

• Page 25: System Status Led Indicators

  ProBlue Flex OEM User’s Guide System Status LED Indicators The system status LEDs provide information about the melter’s operational status. Figure 3 System status and LED indicators Table 3 System Status and LED Indicators Component Function Indicates at a glance the system status. Refer to Table 4 for the System Status LED LED color indications.

• Page 26: System Status Led Colors

  ProBlue Flex OEM User’s Guide System Status LED Colors The system status LED shows at a glance the status of the system. Table 4 System Status LED Color Indications System Color Description State System status LED No Alert or Fault condition exists.

• Page 27: Melter Front Panel Led Behavior

  ProBlue Flex OEM User’s Guide System Status LED Colors (contd) Table 4 System Status LED Color Indications (contd) System Color Description State An issue exists with one or more of the subsystems, causing production to temporarily stop. When a stop occurs:…

• Page 28: Basic Melter Operation

  ProBlue Flex OEM User’s Guide Basic Melter Operation Starting the Melter Before starting the melter for the first time, confirm that the melter is fully installed, including any required inputs and outputs, hoses, and applicators. By default, all connected hoses and applicators are disabled, and the Master Heater control is OFF.

• Page 29: Switching The Master Heater And Pump Controls On/Off

  ProBlue Flex OEM User’s Guide Switching the Master Heater and Pump Controls On/Off When you power-up the melter, by default, the Master Heaters and Pump controls are switched Off. You must manually switch them On. 1. Master Pump control 2. Master Heat control…

• Page 30: Monitoring The Tank Adhesive Level

  ProBlue Flex OEM User’s Guide Monitoring the Tank Adhesive Level The melter has a built-in sensor in the tank. You can purchase the optional Light Tower Kit (part number 1129090) to get a visual and/or audible horn notification using an available output.

• Page 31: Manually Filling The Melter Tank

  ProBlue Flex OEM User’s Guide Manually Filling the Melter Tank Before filling the tank, confirm that the hot melt material is compatible with the melter. NOTE: You should never have to manually fill a Melt-on-Demand system, but if you must manually fill the tank, never go above the sensor.

• Page 32: Manually Adjusting The System Air Pressure

  ProBlue Flex OEM User’s Guide Manually Adjusting the System Air Pressure The following table describes the default and optional pressure monitoring and adjustment options. Pressure Type What you can do… Manually adjust the system pressure using a 5mm hex wrench. Use the gauge Manual pressure to help define the system air pressure you want.

• Page 33: Setting Up The Melter

  FAT or FAT32. No other format, such as NTFS and exFAT are supported. You have the option to use BBconn Cloud or you can use the Nordson touch screen Touch Screen developed user interface to setup and monitor your melter.

• Page 34: Defining Runtime Settings

  ProBlue Flex OEM User’s Guide Defining Runtime Settings The following sections detail the common operator tasks: Temperature settings Pressure settings Defining Temperature Runtime Setting There are two types of heated zones: Internal Zones: Tank and Manifold External Zones: Connected hoses and applicators…

• Page 35: Manually Adjusting System Air Pressure

  ProBlue Flex OEM User’s Guide Manually Adjusting System Air Pressure You can manually adjust the system pressure using a 6mm Hex wrench. Use the gauge to help define the system air pressure you want. Using a 6mm Hex wrench, turn clockwise to increase pressure and counterclockwise to decrease pressure to best suit your production requirements.

• Page 36: Defining Electronic/Runup Pressure Runtime Settings

  ProBlue Flex OEM User’s Guide Defining Electronic/Runup Pressure Runtime Settings You can purchase the following optional pressure kits by contacting your local Nordson representative: For manual pressure monitoring, you will need part number 1128344. For electronic pressure monitor and control, you will need part number 1128345.

• Page 37: Defining Electronic Pressure Settings And Monitoring Alert Settings

  ProBlue Flex OEM User’s Guide Defining Electronic Pressure Settings and Monitoring Alert Settings Use Electronic Pressure Adjust to remotely change and monitor system melter pressure. You can optionally decide if you want to receive pressure alerts when the system pressure-hydraulic or pneumatic-exceeds the defined thresholds.

• Page 38
  ProBlue Flex OEM User’s Guide 6. Select Low Pressure Alert Threshold, then enter the amount of pressure offset below the set point before the melter enters into an Alert condition. Pressure Default Minimum Maximum (-)10 from (-)5 from (-)70 from…

• Page 39: Defining Pressure Runup Settings And Monitoring Alert Settings

  ProBlue Flex OEM User’s Guide Defining Pressure Runup Settings and Monitoring Alert Settings Use Pressure Runup to allow the system pressure to automatically adjust to maintain the same adhesive output when the line speed changes. You can optionally decide if you want to receive pressure alerts when the system pressure, hydraulic or pneumatic exceeds the defined thresholds.

• Page 40: Pressure Runup Output Settings

  ProBlue Flex OEM User’s Guide Press the to toggle (enable or disable) the Zero Line Speed Pressure option. Setting Description Enabled Allows the system pressure to remain at the user-defined Minimum Pressure setting Allows the system pressure to Disabled drop to 0 (zero) 4.

• Page 41: Pressure Runup Alert Threshold Settings

  ProBlue Flex OEM User’s Guide High Line Speed Pressure Default Minimum Maximum Meter/ 30.5 300.2 Minute Feet/ Minute 3. Select SAVE. Select Alert Threshold Settings to continue. Pressure Runup Alert Threshold Settings the maximum/minimum pressure thresholds you want the system to…

• Page 42: Pressure Runup Pressure Limits

  ProBlue Flex OEM User’s Guide Pressure Runup Pressure Limits Enter the maximum/minimum pressure you want the system to use for production. 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file.

• Page 43: Defining System Settings

  ProBlue Flex OEM User’s Guide Defining System Settings WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

• Page 44: Defining System Temperature Settings

  ProBlue Flex OEM User’s Guide Defining System Temperature Settings This section of the manual details the following Temperature System Settings: SmartMelt (Melt-on-Demand only) Global (Temperature) Settings Setback Ready Delay Defining SmartMelt Settings SmartMelt is for Melt-on-Demand systems and allows the system to automatically reduce the tank temperature by 17 C (31 F) if the fill system is inactive for a user‐specified amount of time, thereby preventing adhesive…

• Page 45: Defining Global Temperature Settings

  ProBlue Flex OEM User’s Guide Defining Global Temperature Settings You can define the following global temperature settings: Enable/Disable Heaters On Upon Startup Define Over/Under Temperature Thresholds before receiving alarms Define the Temperature Setback for all Setback options The following sections detail each global temperature setting in more detail.

• Page 46: Defining The Over/Under Temperature Thresholds

  ProBlue Flex OEM User’s Guide Defining the Over/Under Temperature Thresholds Use this setting to define the maximum/minimum temperature offsets from any heated zone set point before the system goes into an Alert condition. If the condition is not resolved within 2 minutes, the system goes into a Fault condition.

• Page 47: Defining Temperature Setback

  ProBlue Flex OEM User’s Guide Defining Temperature Setback Use this setting to define the number of degrees by which all heated components will be decreased (offset from current set point) when the controller is placed into Heat Schedule and Manual/Automatic Setback.

• Page 48: Defining Setback Settings

  ProBlue Flex OEM User’s Guide Defining Setback Settings Setback, also known as Standby, reduces the temperature by a user-defined temperature offset from all enabled external zones. There are three types of Setback options, including: Manual Enter/Exit Setback Automatic System Setback…

• Page 49: Defining Automatic System Setback

  ProBlue Flex OEM User’s Guide Defining Automatic System Setback Use Automatic Setback to allow the melter to enter into Setback mode based on the user-defined time of inactivity based on one of the following: A hose/applicator # is assigned to an input. The melter will enter into Setback if that assigned applicator is not dispensing adhesive for the amount of time you define.

• Page 50: Defining Manual Setback — Auto Exit Time

  ProBlue Flex OEM User’s Guide Defining Manual Setback — Auto Exit Time Use Manual Setback — Auto Exit time to define the amount of time to elapse before the melter exists Setback mode after you manually place it into Setback.

• Page 51: Defining Ready Delay

  ProBlue Flex OEM User’s Guide Defining Ready Delay Use Ready Delay to prevent the melter from immediately exiting out of Heating when the tank reaches its set point temperature, thereby allowing enough time for adhesive to melt that is sufficient for production.

• Page 52: Defining Level Sensing Settings

  ProBlue Flex OEM User’s Guide Defining Level Sensing Settings This section of the manual details the following: Enable/Disable Low Level Alert and Settings Empty Stop Enable/Disable Lid Open Alert and Settings Enabling/Disabling Low Level Alerts and Settings Use the Level Sensing settings to fine-tune the low/empty adhesive messaging.

• Page 53: Enabling/Disabling Empty Stop

  ProBlue Flex OEM User’s Guide Enabling/Disabling Empty Stop Use the Empty Stop option to prevent air from getting into the system, thereby causing the pump to cavitate or pump erratically and potentially damaging the pump. This option also temporarily stops production just before the adhesive output goes out of production specifications, preventing defective product production.

• Page 54: Enabling/Disabling Lid Open Alerts And Settings

  NOTE: A lid switch is standard for (MOD) Melt-on-Demand systems. However, you can purchase the optional lid switch kit, part number 1128173. Contact your Nordson field or sales representative. 1. Log into your BBconn Cloud account, then do the following:: Select SETUP TOOL — create or load a .NOR file…

• Page 55: Defining Fill Settings

  ProBlue Flex OEM User’s Guide Defining Fill Settings Melt-on-Demand systems include the Fill System, but it is optional on tank-based systems. The following section details Fill and Level settings. Melt-on-Demand (MOD) and Tank Systems with Optional Fill Settings Melt-on-Demand and tank systems with the optional Fill System include the…

• Page 56: Enabling And Disabling Auto Pump

  ProBlue Flex OEM User’s Guide Enabling and Disabling Auto Pump To toggle the Master Pump control On, press . The Pump LED flashes. If AutoPump is enabled, then the pump button will flash, indicating that the Master Pump control will be toggled On as soon as system temperature ready is achieved.

• Page 57: About Adhesive Tracking System (Ats)

  ProBlue Flex OEM User’s Guide About Adhesive Tracking System (ATS) Adhesive Tracking System (ATS) monitors adhesive consumption and add‐on weights, including the total amount of adhesive dispensed and the average adhesive dispensed per product, referred to as add-on weight, or just add-on.

• Page 58: Theory Of Operation

  ProBlue Flex OEM User’s Guide Theory of Operation A geared flow meter is installed on top of the hose manifold. A product trigger senses products from leading edge to leading edge as it moves along the production line. Adhesive is measured over the product…

• Page 59: Enabling Flow Monitoring

  ProBlue Flex OEM User’s Guide Enabling Flow Monitoring You must have the Adhesive Tracking System option enabled before you can define and make use of the flow feature. 1. Log into your BBconn Cloud account, then do the following: SETUP TOOL Select SETUP TOOL — create or load a .NOR file.

• Page 60: Calibrating The Flow Meter

  ProBlue Flex OEM User’s Guide Calibrating the Flow Meter Although the default settings were determined by using typical adhesive specific gravity values, if you want the most accurate adhesive output readings, it is strongly recommended that you calibrate the flow meter. You…

• Page 61: Defining Product And Trigger Settings

  ProBlue Flex OEM User’s Guide Defining Product and Trigger Settings You can make use of a PLC or the optional touch screen to use the Teach option, or you can enter the following Product Settings instead and by trial get the same adhesive output you want.

• Page 62
  ProBlue Flex OEM User’s Guide Setting Description Default Minimum Maximum Product Skip Number of products to ignore before teaching or Count monitoring products for out-of-tolerance adhesive output Products to The number of products the system averages to 1000 Average calculate the Target Add-on value…

• Page 63: Trigger Settings

  ProBlue Flex OEM User’s Guide Trigger Settings 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. SETUP TOOL Select SYSTEM SETTINGS | FLOW. 2. From the Trigger Settings section, enter the following information.

• Page 64: Defining Adhesive Tracking System Alarms

  ProBlue Flex OEM User’s Guide Defining Adhesive Tracking System Alarms Use the Teach mode to automatically calculate the Target Add-On and Products to Average values. SETUP TOOL 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file.

• Page 65
  ProBlue Flex OEM User’s Guide Setting Description Default Low Stop Threshold How much lower the add-on weight .3 * Target .05 * .5 * Target (mg) can be from the Target Add-On Add on Target Add on value before a Stop alarm is Add on generated.

• Page 66: Troubleshooting Adhesive Tracking System

  This section covers only the most common problems you may encounter. If you cannot solve a problem with the information given here, contact your local Nordson representative for help. Understanding the ATS PCA Board LEDs WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment.

• Page 67
  ProBlue Flex OEM User’s Guide Figure 3: ATS PCA Board Part 1129255_01 E 2020 Nordson Corporation…
• Page 68
  ProBlue Flex OEM User’s Guide Description Color 24V Enable for external devices Green: Enabled Amber: enabled with overload condition Red: Disabled with no load connected Off: Disabled CPU Reset Off: Normal operation Red: CPU reset in progress 3.3V Supply Status Green: Normal operation Amber or Red: Fault in 3.3V regulator…

• Page 69: General And Flow Control Alarms

  ProBlue Flex OEM User’s Guide General and Flow Control Alarms Alarm Possible Cause Corrective Action Detector Error Adhesive flowing but product detector Check the production line. Check the not sensing products product detector installation/position. Replace the product detector if failed.

• Page 70
  ProBlue Flex OEM User’s Guide General and Flow Control Alarms (contd) Problem Possible Cause Corrective Action Under limit alarm (Alarm Failed solenoid, module, or nozzle Refer to the applicator manual to Lower Limit) troubleshoot applicator problems. Repair or replace failed components as needed.

• Page 71: About System I/O

  ProBlue Flex OEM User’s Guide About System I/O The melter is equipped with one user‐configurable input and one user‐configurable output. Wire the inputs/outputs to the melter then configure the inputs and outputs through using the user interface. NOTE: You can expand the total number of inputs to a total of 5 and the total number of outputs to 4 by ordering the Legacy I/O kit, part number 1127717.

• Page 72: Assigning Remote Recipe Inputs

  ProBlue Flex OEM User’s Guide Assigning Remote Recipe Inputs Using a PLC, you can toggle input bits high or low to “remotely” load a recipe. 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file.

• Page 73
  ProBlue Flex OEM User’s Guide The following table details the input bits and their sequence required to remotely load a recipe. 4-bit 3-bit 2-bit 1-bit Selected Recipe No Recipe High Recipe 1 High Recipe 2 High High Recipe 3 High…

• Page 74: Assigning Outputs

  ProBlue Flex OEM User’s Guide Assigning Outputs 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. Select SYSTEM SETTINGS | SYSTEM IO. SETUP TOOL 2. Select Output. 3. Standard is the default output selection and has only one output that you can define.

• Page 75: Assigning Light Tower Outputs

  ProBlue Flex OEM User’s Guide Assigning Light Tower Outputs 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. Select SYSTEM SETTINGS | SYSTEM IO. SETUP TOOL 2. Select Output, then select Light Tower.

• Page 76: Modifying External Zone Names

  ProBlue Flex OEM User’s Guide Modifying External Zone Names You can only rename external zone names. Internal zones, Tank and Manifold cannot be renamed. External zone names can be up to 15 characters long and English only. 1. Log into your BBconn Cloud account, then do the following: SETUP TOOL Select SETUP TOOL — create or load a .NOR file.

• Page 77: Modifying User Management Access Rights

  ProBlue Flex OEM User’s Guide Modifying User Management Access Rights Refer to the manual that came with your control system. Not all Nordson products or platforms support User Management. 1. Log into your BBconn Cloud account, then do the following: SETUP TOOL Select SETUP TOOL — create or load a .NOR file.

• Page 78: Defining And Modifying Shift Schedules

  ProBlue Flex OEM User’s Guide NOTES: Click on the Green (heat Schedule) or Blue (Setback) area to modify the event time. Maximum number of event pairs is 6. You must enter an on/off time for each Heat or Setback Event.

• Page 79: Defining Network Access

  ProBlue Flex OEM User’s Guide Defining Network Access The following section details how to connect this melter to your network, so you can remotely monitor and change melter settings. 1. Log into your BBconn Cloud account, then do the following: SETUP TOOL Select SETUP TOOL — create or load a .NOR file.

• Page 80: Defining Wifi Access

  (enable or disable) the WiFi option. The default is Disabled. NETWORKING Note: If you have more than one ProBlue Flex melter in the same location, make sure each melter has a unique SSID name and that they are using different WiFi channel numbers.

• Page 81
  ProBlue Flex OEM User’s Guide 4. Enter or select the WiFi settings you want to use: Option Description Default Minimum Maximum Number of Number of WiFi Clients users you want to grant access to the melter at any one time…

• Page 82: Defining Plc Access

  ProBlue Flex OEM User’s Guide Defining PLC Access 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. SETUP TOOL Select SYSTEM SETTINGS | NETWORKING. 2. Select PLC. Please select how to load a configuration file 3.

• Page 83: Defining Plc Communications

  ProBlue Flex OEM User’s Guide Defining PLC Communications Profinet, Ethernet/IP and Modbus TCP are natively supported and do not require you to install a communication card. SETUP TOOL Refer to Connecting Profinet, Ethernet IP and Mod BUS/TCP for more information.

• Page 84
  ProBlue Flex OEM User’s Guide Notes: Refer to the OEM and Field Bus Communications manual, part number 1128352 for more information about creating a Flexible map using BBconn Cloud application. If you change, for example from melter1 the OEM door to an…

• Page 85: Connecting Profinet, Ethernet/Ip And Modbus Tcp

  ProBlue Flex OEM User’s Guide Connecting Profinet, Ethernet/IP and Modbus TCP Profinet, Ethernet/IP and Modbus TCP requires a direct connection between your PLC and the melter. Only the Profinet requires the Station Name, which you can enter using BBconn Cloud or a touch screen. Refer to Defining PLC Communications on the previous page for more information.

• Page 86
  ProBlue Flex OEM User’s Guide 4. (Refer to Figure 3) Connect one end of the Ethernet cable to either (d) External 1 (X14) or (e) External 2 (X15) on the low voltage controller and the other to your PLC. When connected, the melter determines which protocol to use based on the packet information.

• Page 87: Defining Web Access

  ProBlue Flex OEM User’s Guide Defining Web Access 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. SETUP TOOL Select SYSTEM SETTINGS | NETWORKING. 2. Select WEB SERVER.

• Page 88: About System Preferences

  ProBlue Flex OEM User’s Guide About System Preferences You can change any preference at any time. 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. SETUP TOOL Select SYSTEM SETTINGS | USER MANAGEMENT.

• Page 89: Uploading A .Plc File From Bbconn Cloud File To A Melter

  The ProBlue Flex melter is designed for maximum backward compatibility with older Blue Series melters. For many melters using Ethernet/IP, it is possible to connect the ProBlue Flex melter where a Blue Series melter was connected and it will run automatically with no PLC programming required:…

• Page 90: Editing A .Plc File From Bbconn Cloud

  ProBlue Flex OEM User’s Guide Editing a .PLC File from BBconn Cloud 1. Log into your BBconn Cloud account, then do the following: Select SETUP TOOL — create or load a .NOR file. SETUP TOOL Select SYSTEM SETTINGS | PLC COMMUNICATIONS.

• Page 91: Tool Settings

  ProBlue Flex OEM User’s Guide Tool Settings WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

• Page 92: Managing Melter Data Files

  (upgrading), .NOR files (system configuration) and .PLC (flex map). .DAT files contain the melter firmware and are used for upgrading the firmware on the melter. The ProBlue Flex melter internally retains knowledge of its current software version. .NOR files contain the data shown in Table 6. The .NOR file is used to transfer system settings, recipes, PLC maps, and event log data to/from a melter and BBconn Cloud.

• Page 93: How The Melter Processes Data Files

  ProBlue Flex OEM User’s Guide How the Melter Processes Data Files When you insert a USB drive into a melter’s USB port, or start the melter with a USB drive already inserted, the melter automatically does the following in sequential order: 1.

• Page 94: Setting Up Maintenance Reminders

  ProBlue Flex OEM User’s Guide Setting Up Maintenance Reminders Use the Maintenance system to monitor and remind you when to inspect, perform maintenance or replace the following components. Component What you need Based on Default/hrs Minimum / hrs Maximum / hrs…

• Page 95: Managing The Maintenance System

  ProBlue Flex OEM User’s Guide Managing the Maintenance System 1. From BBconn Cloud, do the following: SETUP TOOL — create or load a .NOR file. TOOLS, then select MAINTENANCE SCHEDULE. SETUP TOOL 2. Press the to toggle (enable or disable) the Maintenance System option.

• Page 96: Setting Up And Viewing Component Maintenance Status

  ProBlue Flex OEM User’s Guide Setting Up and Viewing Component Maintenance Status 1. From BBconn Cloud, do the following: SETUP TOOL — create or load a .NOR file. TOOLS, then select MAINTENANCE SCHEDULE. SETUP TOOL 2. Select View Maintenance Status.

• Page 97: Defining A Custom Maintenance Component Item

  ProBlue Flex OEM User’s Guide Defining a Custom Maintenance Component Item 1. From BBconn Cloud, do the following: SETUP TOOL — create or load a .NOR file. TOOLS, then select MAINTENANCE SCHEDULE | View Maintenance Status. SETUP TOOL 2. Select ADD ITEM, then do the following:…

• Page 98: Changing The Melter Software Version

  1. Log into your BBconn Cloud account and select MEDIA CENTER. 2. Under Software Updates, select the link for your ProBlue Flex. The default location is to your /Downloads folder. Copy the .DAT file to the root of a USB drive.

• Page 99: Backing Up Melter Settings

  ProBlue Flex OEM User’s Guide Backing Up Melter Settings When you insert a USB drive into the melter while it is powered on, a backup is automatically performed and is saved to the root of the USB iF no other .NOR file is detected.

• Page 100: Restoring Saved Melter Settings

  ProBlue Flex OEM User’s Guide Restoring Saved Melter Settings You can restore melter settings that were previously saved as a .NOR file and uploaded to BBconn Cloud. 1. Place on a USB drive the .NOR file that includes the settings you want to restore.

• Page 101: Restoring A Melter To The Factory Default Settings

  ProBlue Flex OEM User’s Guide Restoring a Melter to the Factory Default Settings You can restore a melter’s factory default settings by creating a new .NOR file on BBconn Cloud and then transferring the new file to a melter. 1. Log into your BBconn Cloud account.

• Page 102: Managing The System Configuration

  ProBlue Flex OEM User’s Guide Managing the System Configuration The Tools menu includes the System Configuration menu and the Event Log: The System Configuration menu provides access to the screens you need to view your system information, accessories, and configuration code.

• Page 103: Viewing System And Configuration Information

  ProBlue Flex OEM User’s Guide Viewing System and Configuration Information The System Information screen provides the application and boot version numbers and the hardware revision numbers for the following: 1. Log into your BBconn Cloud account. SETUP TOOL Select SETUP TOOL — create or load a .NOR file.

• Page 104: Viewing Installed Accessories

  ProBlue Flex OEM User’s Guide Viewing Installed Accessories You can customize the melter with additional software and hardware features and options. Most accessories are automatically detected, but some are not. Typically, the instruction sheet that accompanies the accessory will indicate whether or not you need to manually update the melter accessories list.

• Page 105: Viewing The Configuration Code

  ProBlue Flex OEM User’s Guide Viewing the Configuration Code You can view the configuration of each melter registered on BBconn Cloud. 1. Log into your BBconn Cloud account. Open the .NOR file of the applicable melter. SETUP TOOL 2. Select TOOLS | SYSTEM CONFIGURATION | CONFIGURATION CODE 3.

• Page 106: Managing Licenses

  ProBlue Flex OEM User’s Guide Managing Licenses Contact your Nordson sales representative or call Nordosn directly to purchase additional licenses. 1. Log into your BBconn Cloud account. Open the .NOR file of the applicable melter. 2. Select TOOLS | SYSTEM CONFIGURATION | LICENSES.

• Page 107: Managing Recipes

  ProBlue Flex OEM User’s Guide Managing Recipes 1. Log into your BBconn Cloud account, then do the following: SETUP TOOL Select SETUP TOOL — create or load a .NOR file. 2. Select RECIPE to do the following: Option Description Please select how to load a configuration file…

• Page 108: Performing Basic Melter Maintenance

  ProBlue Flex OEM User’s Guide Performing Basic Melter Maintenance This section details the common maintenance procedures that you can do on the melter, such as: Drain adhesive from the melter View the Event Log AutoTune the heated zones Calibrate Full/Empty Tank CAUTION! Wear eye protection and long-sleeve shirt when draining the melter.

• Page 109: Draining Or Purging The Melter

  ProBlue Flex OEM User’s Guide Draining or Purging the Melter Use the Drain feature to remove adhesive from the tank. The melter must be in a Ready State. 1. Using a 4mm Hex driver, remove the front panel (a). 2. Extend the drain pathway (b), and use a large enough pan to collect the adhesive from the tank.

• Page 110: Autotuning Heated Zones

  ProBlue Flex OEM User’s Guide AutoTuning Heated Zones Use AutoTune to improve the regulation and control of the external heated zones. You must use a PLC or the touch screen version to perform this task. NOTES: The external zones that you want to tune must be enabled and at set point temperature for at least 15 minutes.

• Page 111: Troubleshooting

  ProBlue Flex OEM User’s Guide Troubleshooting WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

• Page 112: Viewing The Event Log

  ProBlue Flex OEM User’s Guide Viewing the Event Log The melter software includes a detailed Event Log for troubleshooting purposes. The Event Log keeps track of all melter events, including the time, day, and type of an event, such as an Alert, Fault, or Stop condition, as well as parameter changes.

• Page 113: Viewing An Event Log On Bbconn Cloud

  ProBlue Flex OEM User’s Guide Viewing an Event Log on BBconn Cloud Event log files are contained in .NOR files. To view a melter’s event log on BBconn Cloud, you must download the .NOR file from the melter and upload the file to BBconn Cloud.

• Page 114: Heater Sub System Alarms

  ProBlue Flex OEM User’s Guide Heater Sub System Alarms The following table details the troubleshooting tips to resolve Alert and Fault conditions. Alarm Details Short Description Troubleshooting Tips Type The zone exceeds the Check heater connections programmed upper for intermittent wiring,  open Zone Over Temperature temperature limit.

• Page 115
  ProBlue Flex OEM User’s Guide Heater Sub System Alarms (contd) Alarm Details Short Description Troubleshooting Tips Type RTD resistance is below the Check for intermittent or short circuit threshold. If Alert broken RTD connections. condition continues for 2 Verify the resistance. It minutes, a fault will occur.

• Page 116: Fill System Alarms

  ProBlue Flex OEM User’s Guide Fill System Alarms The following table details the troubleshooting tips to resolve Alert and Fault conditions. Alarm Details Short Description Troubleshooting Tips Type Calibration was never done. A new control board has been connected. Level sensor cable is…

• Page 117
  ProBlue Flex OEM User’s Guide Fill System Alarms (contd) Alarm Details Short Description Troubleshooting Tips Type Adhesive level in melter is Check the following; abnormally low. The system Check for loose or should have filled before disconnected level reaching this point.

• Page 118: Electronic Pressure Adjust Alarms

  ProBlue Flex OEM User’s Guide Electronic Pressure Adjust Alarms The following table details the troubleshooting tips to resolve Alert and Fault conditions. Alarm Details Short Description Troubleshooting Tips Type Pressure exceeds the High Check or do the following: Pressure Threshold.

ProBlue Adhesive Melters

M odels P4, P7, and P10

Customer Product Manual

Part 1024496_06

Issued 3/14

This document contains important safety information

Be sure to read and follow all safety information in this document and any other related documentation.

NORDSON CORPORATION



DULUTH, GEORGIA



USA www.nordson.com

For CE Declaration, refer to equipment documentation.

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

Address all correspondence to:

Nordson Corporation

Attn: Customer Service

11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2002.

Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice.

Trademarks

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Color‐on‐Demand, ControlCoat, Coolwave, Cross‐Cut, cScan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura‐Screen,

Durasystem, EasyCoat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI ‐ stylized, Excel 2000, Fillmaster,

FlexiCoat, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil,

Isocore, Iso‐Flo, iTRAX, Kinetix, LEANCELL, LittleSquirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet,

Millennium, Mini Squirt, Mountaingate, Nordson, Optimum, Package of Values, Pattern View, PermaFlo, PicoDot, PorousCoat, PowderGrid, Powderware,

Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard,

Seal Sentry, SelectCharge, SelectCoat, Select Cure, Signature, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, SureBead, Sure Coat,

Sure‐Max, Sure Wrap, TrackingPlus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UpTime, u‐TAH, Vantage, VersaBlue, Versa‐Coat, VersaDrum,

VersaPail, Versa‐Screen, Versa‐Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice,

Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, Controlled Fiberization, ControlWeave, ContourCoat,

CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E‐Nordson, Equalizer,

Equi



Bead, FillEasy, FillSentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend, Lacquer Cure, Maxima, Mesa,

MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke, Partnership+Plus,

PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PowderPilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, Ready Coat,

RediCoat, Royal Blue, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, Summit, SureFoam,

SureMix, SureSeal, SwirlCoat, TAH, ThruWave, TradePlus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista,

Web Cure, and 2Rings (Design) aretrademarks of NordsonCorporation.

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.

DeviceNet is a trademark of Open DeviceNet Vendors Association, Inc.

EtherNet/IP is a trademark used under license by ODVA.

Loctite is a registered trademark of

Loctite Corporation.

Never Seez is a registered trademark of

Bostik Inc.

Parker Lubricant is a registered trademark of

Parker Seal.

PROFIBUS is a registered trademark of PROFIBUS International.

Viton is a registered trademark of

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Part 1024496_06

2014 Nordson Corporation

All rights reserved

2014 Nordson Corporation

Table of Contents

i

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Responsibilities of the Equipment Owner . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions, Requirements, and Standards . . . . . . . . . . . . . . . . . . .

User Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions and Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Practices

Operating Practices

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Repair Practices

Equipment Safety Information

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . .

De‐energizing the System

Disabling the Applicators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions

Other Safety Precautions

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1‐4

1‐4

1‐5

1‐5

1‐6

1‐6

1‐6

1‐6

1-1

1‐1

1‐2

1‐2

1‐2

1‐3

1‐3

1‐3

1‐4

1‐7

1‐10

1‐10

1‐11

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Sources of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Guide

User’s Guide

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Online Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Resource CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Description

Intended Use

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Identification

Key Components

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2‐2

2‐2

2‐2

2‐2

2‐2

2‐3

2‐4

2‐4

2‐4

2‐5

2‐6

2‐8

Part 1024496_06

ii

Table of Contents

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing 400/480 Volt Melters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information

Installation Tasks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Experience of Installation Personnel

Installation Requirements

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3‐1

3‐2

3‐3

3‐3

3‐4

Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents of the Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer‐Supplied Materials

Mounting the Melter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting a Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Hoses and Guns

Setting Up the Melter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading or Editing Operating Parameters . . . . . . . . . . . . . . . . . .

Set‐point Temperature of the Tank, Hoses, and Guns

Save and Restore Melter Settings

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Review Parameter and Set‐point Temperature Changes

Installing Melter Inputs

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Melter Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting a Gun Driver, Pattern Controller, or Timer

Flushing the Melter

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Up Melter Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3‐13

3‐18

3‐20

3‐24

3‐24

3‐26

3‐26

3‐26

3‐5

3‐6

3‐6

3‐8

3‐8

3‐8

3‐10

3‐32

3‐34

3‐36

3‐40

3‐44

3‐47

3‐47

3‐47

3‐47

Part 1024496_06

2014 Nordson Corporation

2014 Nordson Corporation

Table of Contents

iii

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

More About Heated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Confirm that the Melter is Operating Correctly . . . . . . . . . . . . . . . . .

Monitor Component Temperatures

Monitor Melter Faults

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How F1, F2, and F3 Faults are Handled

How F4 Faults are Handled

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor the Level of Hot Melt in the Tank . . . . . . . . . . . . . . . . . . . . .

Monitor and Adjust the Operating Air Pressure . . . . . . . . . . . . . . . .

Monitor the Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering the Melter Password

Using the Melter Function Keys

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Key

Pump Key

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seven‐day Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standby Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4‐6

4‐7

4‐8

4‐10

4‐14

4‐15

4‐17

4‐17

4-1

4‐1

4‐2

4‐3

4‐4

4‐18

4‐19

4‐24

4‐25

4‐25

4‐26

4‐26

4‐27

4‐28

4‐29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking Out External Communications

Cleaning the Melter

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring the Life of the Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Melter from the Sub‐base . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5‐2

5‐2

5‐4

5‐6

5‐6

5‐8

5‐10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400/480 Volt Melters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Troubleshooting Flowchart

Troubleshooting Quick‐checks

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning the Melter Setup to Factory Settings

Identifying Electrical Components

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DP.1 Isolate a Failed Control Component . . . . . . . . . . . . . . . . . . . .

DP.2 Check the Tank or Manifold RTD . . . . . . . . . . . . . . . . . . . . . . .

Reheating the Melter During an F1 Fault . . . . . . . . . . . . . . . . . . .

Remove the Tank RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Manifold RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DP.3 Check the Operation of the Power Relay or Thermostats

DP.4 Check the Operation of the Tank or Manifold TRIAC

. .

. . . . . .

DP.5 Check the Resistance of the Tank and Manifold Heaters

ProBlue Troubleshooting Flowcharts

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6‐12

6‐13

6‐13

6‐14

6‐15

6‐16

6‐17

6‐21

6-1

6‐1

6‐1

6‐2

6‐4

6‐4

6‐5

6‐5

6‐11

6‐11

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Table of Contents

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank, Pump, and Manifold Parts List

Manifold Assembly Parts List

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15:1 Pump Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15:1 Low‐Viscosity Pump Assembly Parts

6:1 Pump Assembly Parts

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Shifter Assembly Parts

Pump Piston Assembly Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Components Parts List

Electrical Enclosure Parts List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior Panels Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis Components Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Cable Parts List

Service Kits

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15:1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15:1 Low‐Viscosity Pump Replacement . . . . . . . . . . . . . . . . . . . . . .

6:1 Pump Replacement

Pump General Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Discharge Valve

Manifold Service Kit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7‐1

7‐26

7‐28

7‐30

7‐31

7‐31

7‐31

7‐31

7‐32

7‐2

7‐4

7‐7

7‐7

7‐10

7‐14

7‐18

7‐20

7‐22

7‐24

7‐32

7‐33

7‐33

Main Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Central Processor Unit (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose/Gun Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Circuit Board Fuses

Hose/Gun Module Fuses

Basic Spare Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expanded Spare Parts

Level Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Guard (P4)

Manifold Guard (P10)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Guard (P10)

Replacement Tank

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Lid Hinge Pin

Heater Block 230V

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold 4‐ or 6‐Hose/230V or 480V . . . . . . . . . . . . . . . . . . . . . . . . .

Option Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6‐Hose Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input/Output Expansion Card

Fill Master

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ethernet Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DeviceNet Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Profibus Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P10 8 H/G Expansion Base

Schedule of Fasteners

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7‐35

7‐35

7‐36

7‐36

7‐36

7‐36

7‐36

7‐37

7‐37

7‐38

7‐38

7‐38

7‐38

7‐34

7‐34

7‐34

7‐34

7‐34

7‐35

7‐35

7‐38

7‐39

7‐39

7‐39

7‐40

Part 1024496_06

2014 Nordson Corporation

2014 Nordson Corporation

Table of Contents

v

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P4 Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P7 Melter

P10 Melter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams—200/240 VAC Melter . . . . . . . . . . . . . . . . . . . . . . . .

Calculating Melter Power Requirements . . . . . . . . . . . . . . . . . . . . .

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seven‐day Clock

Example 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example 2

Example 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1

B‐6

B‐9

B‐12

B‐14

B‐15

B‐15

B‐15

Melter Communications

Software Availability

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Software from Your PC . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the PC and the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Nordson Configuration Manager . . . . . . . . . . . . . . . . . . . . . . . . .

Saving and Restoring Melter Settings . . . . . . . . . . . . . . . . . . . . . . . .

Upgrading or Restoring Melter Firmware . . . . . . . . . . . . . . . . . . . . .

Using Nordson Configuration Manager . . . . . . . . . . . . . . . . . . . . . .

C-1

C‐1

C‐1

C‐2

C‐4

C‐5

C‐6

C‐6

C‐8

C‐11

8‐3

8‐4

8‐5

8‐7

8-1

8‐1

8‐2

8‐2

8‐2

A-1

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Table of Contents

SP Pump Diagnostics and Repair

Pump Function

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Discharge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D‐7

Remove the Pump from the Melter

Special Reassembly Instructions

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

D‐8

D‐8

Remove the Actuator and Air Manifold and the Cylinder Assembly D‐10

Special Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Magnetic Actuator Assembly . . . . . . . . . . . . . . . . . . . .

D‐10

D‐12

Remove the Valve Spool and Sleeve

Special Reassembly Instructions

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Shifter Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Piston Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the Pump Frame and the Insulator

Special Reassembly Instructions

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

D‐15

D‐16

D‐18

D‐18

D‐20

D‐20

D‐22

D‐22

D‐26

D‐26

Remove the Lower Ball Seat Assembly and the Piston

Special Reassembly Instructions

. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

Disassemble the Lower Ball Seat and the Pressure Ball

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Remove the O‐ring and the Pump Seal . . . . . . . . . . . . . . . . . . . . . .

Special Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly Parts List

Pump Service Kit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Pump Maintenance Kits

Schedule of Fasteners

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D‐28

D‐30

D‐30

D‐32

D‐34

D‐34

D‐34

D-1

D‐1

D‐2

D‐2

D‐4

D‐6

D‐6

D‐6

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Table of Contents

vii

400/480 Volt ProBlue Adhesive Melters . . . . . . . . . . . . . . . . . . . . . . .

E-1

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformer Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transformer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E‐2

E‐2

E‐3

E‐5

Installation Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Transformer for Installation . . . . . . . . . . . . . . . . . . . . . .

Mount the Transformer to the Parent Machine . . . . . . . . . . . . . . . .

Connect the Electrical Service to the Transformer . . . . . . . . . . . . . .

Mount the Melter to the Transformer . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Transformer to the Melter . . . . . . . . . . . . . . . . . . . . . . .

E‐7

E‐8

E‐10

E‐12

E‐14

E‐16

Transformer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400/480‐Volt Melter‐Specific Components . . . . . . . . . . . . . . . . . . .

Service Kits

Wiring Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E‐20

E‐23

E‐23

E‐23

2014 Nordson Corporation

Part 1024496_06

viii

Table of Contents

Part 1024496_06

2014 Nordson Corporation

Safety

1-1

Section

1

Safety

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

WARNING!

Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all 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 potentially hazardous situation that, if not avoided, can result in damage to equipment or property.

2014 Nordson Corporation

Issued 10-11

1-2

Safety

Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment 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, and this document.

Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information.

Maintain safety information, including the safety labels affixed to the equipment, 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 best industry practices.

If applicable, receive approval from your facility’s engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time.

Provide appropriate emergency and first aid equipment.

Conduct safety inspections to ensure required practices are being followed.

Re‐evaluate safety practices and procedures whenever changes are made to the process or equipment.

Issued 10 − 11

2014 Nordson Corporation

Safety

1-3

User Qualifications

Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner’s safety and accident prevention policies and procedures receive equipment‐ and task‐specific training from another qualified individual

NOTE:

Nordson can provide equipment‐specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry‐ and trade‐specific skills and a level of experience appropriate to their job function are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices 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 on material compatibility or the use of non‐standard auxiliary devices.

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Safety

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 warning labels and tags affixed to the equipment. Refer to

Safety Labels and Tags

at the end of this section.

If you are unsure of how to use the equipment, contact your Nordson representative 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 be used. This equipment has not been certified for compliance with the

ATEX directive nor as nonincendive and should not be installed in potentially explosive environments.

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

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

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

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

Properly ground all equipment. Contact your local building code enforcement agency for specific requirements.

Ensure that fuses of the correct type and rating are installed in fused equipment.

Contact the authority having jurisdiction to determine the requirement for installation 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 required environmental conditions exist.

Use the personal protective equipment (PPE) specified for each task.

Refer to

Equipment Safety Information

or the material manufacturer’s instructions and MSDS for PPE requirements.

Do not use equipment that is malfunctioning or shows signs of a potential malfunction.

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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 in this document.

Relieve system hydraulic and pneumatic pressure before servicing the equipment.

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

Use only new Nordson‐authorized refurbished or replacement parts.

Read and comply with the manufacturer’s instructions and the MSDS supplied with equipment cleaning compounds.

NOTE:

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

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

Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information.

Keep equipment safety warning labels clean. Replace worn or damaged labels.

Equipment Safety Information

This equipment safety information is applicable to the following types of

Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices

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Safety

Equipment Shutdown

To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the 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 hydraulic connection or seal. Refer to the melter‐specific product manual for instructions on relieving system hydraulic pressure.

De‐energizing the System

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

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

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

NOTE:

Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard.

Disabling the Applicators

NOTE:

Adhesive dispensing applicators are referred to as “guns” in some previous publications.

All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected 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; then relieve the residual air pressure between the regulator and the applicator.

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General Safety Warnings and Cautions

Table 1‐1 contains the general safety warnings and cautions that apply to

Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment 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, and applicators)

Equipment

Type

Table

1‐1 General Safety Warnings and Cautions

Warning or Caution

HM

WARNING!

Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent‐based material through a compatible

Nordson melter, read and comply with the material’s MSDS. Ensure that the material’s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with

MSDS requirements can cause personal injury, including death.

HM

HM, CA

WARNING!

Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids.

Nordson melters and applicators contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death.

WARNING!

System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury.

Continued…

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Safety

General Safety Warnings and Cautions

(contd)

Equipment

Type

Table

1‐1 General Safety Warnings and Cautions

(contd)

Warning or Caution

HM

WARNING!

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

HM, PC

HM, CA, PC

HM, CA, PC

WARNING!

Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator’s triggering device and remove the air supply to the applicator’s solenoid valve(s).

Failure to disable the applicator’s triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury.

WARNING!

Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices.

De‐energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death.

WARNING!

Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been cerfified for the ATEX directive or as nonincendive. In addition, this equipment should not be used with solvent‐based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations.

The use of incompatible solvent‐based adhesives or the improper processing of solvent‐based adhesives can result in personal injury, including death.

Continued…

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Equipment

Type

HM, CA, PC

Safety

1-9

Table

1‐1 General Safety Warnings and Cautions

(contd)

Warning or Caution

WARNING!

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage to the equipment.

HM

HM

HM, CA

HM

CAUTION!

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

CAUTION!

Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process

PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment’s ability to process PUR, contact your

Nordson representative for assistance.

CAUTION!

Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer’s instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment.

CAUTION!

Nordson hot melt equipment is factory tested with Nordson

Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid.

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Safety

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 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 melt has 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 hot melt to the medical personnel providing treatment.

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Safety Labels and Tags

Figure 1‐1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 1‐2 provides an illustration of the hazard

identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message.

The installation kit provided with the melter may contain label overlays that are printed in a variety of languages. If required by governing safety regulations, apply the appropriate overlay to the text portion of the labels

shown in Figure 1‐1.

2

3

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1

Figure 1‐1

Location of safety labels and tags

Item

1

Table

1‐2 General Safety Warnings and Cautions

Description

WARNING

Burn hazard.

Hot adhesive.

Release pressure before servicing.

2

3

4

5

CAUTION

Burn Hazard. Hot Surfaces.

WARNING

Burn hazard.

Hot adhesive.

Release pressure before servicing.

WARNING

Hazardous voltage.

Disconnect all power supply connections before servicing.

Symbol means: Hot Surface! Do not touch.

4

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Safety

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Description

2-1

Section 2

Description

This manual describes the installation and use of the ProBlue 4 (P4),

ProBlue 7 (P7), and ProBlue 10 (P10) adhesive melter. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties.

With the exception of tank capacity, hose/gun capacity, and exterior appearance, all ProBlue melters are functionally identical. To simplify the presentation of information in this manual, depictions of the model P4 are used generically throughout this manual to represent all ProBlue melters.

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Description

Other Sources of Information

Refer to the following additional resources for quick‐reference information, technical support, and information about getting the most out of your ProBlue melter.

Installation Guide

The installation guide shipped with the melter provides a visual quick‐reference for installing the melter.

User’s Guide

The user’s guide shipped with the melter provides a visual quick‐reference to the most common operator‐level tasks. The guide is appropriately sized and laminated so that it can be kept with the melter on the production floor.

Online Support

Visit www.enordson/support to download melter firmware updates and software utilities.

Visit www.emanuals.nordson.com to download product manuals and instruction sheets.

Product Resource CD

The resource CD, which is stored in the back of this manual, contains an electronic version of this manual, parts information, and other useful resources that are designed to assist you with using and servicing your melter.

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Description

2-3

Product Description

See Figure 2‐1. Nordson ProBlue adhesive melters are used in conjunction

with Nordson hot melt hoses and guns to create a hot melt application system.

The melter liquifies solid‐form hot melt and maintains the hot melt at the desired temperature. When the guns are activated, the melter pumps the liquified hot melt through the hoses and out the gun nozzles, where it is commonly applied to the surface of a product or package.

Figure

2-1

System components

2. Hot melt gun

3. Hot melt hose

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2-4

Description

Intended Use

ProBlue melters are specifically designed to:

Melt and pump solid‐form hot melt materials that are engineered to be liquified and extruded at temperatures below 230 C (450 F)

Be used with compatible hot melt hoses and guns that are manufactured by Nordson Corporation

Be used in non‐explosive environments

Limitations of Use

Use ProBlue melters only for the purpose for which they are designed.

ProBlue melters should not be used to melt or pump polyurethane reactive or polyamid hot melt materials or any other material that creates a health or safety hazard when heated in environments that will require the melter to be cleaned using a water wash or spray

Modes of Operation

ProBlue melters operate in the following modes:

Automatic scan

—The melter automatically checks and displays the current temperature of the tank, hoses, and guns to confirm that they are within their pre‐defined temperature range. By default, the melter is always in the automatic scan mode unless it is placed into another operating mode.

Standby

—The temperatures of the tank, hoses, and guns are reduced down from their operating temperature (hereafter referred to as set‐point temperature) by a pre‐set number of degrees.

Setup

—The setup mode is used to configure melter control options and features and to review stored operating data. To prevent unauthorized changes to the melter’s configuration, the melter can be password‐protected

Fault

—The melter alerts the operator when an abnormal event occurs.

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Description

2-5

Melter Identification

See Figure 2‐2. You will need the model and part number of your melter

when requesting service or ordering spare parts and optional equipment. The model and part number are indicated on the equipment identification plate that is located on the front of the melter.

1/3O AC 200 − 240

1/3ON/PEAC 400/230

..

R

Figure

2-2

Equipment identification plate

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Description

Key Components

Figure 2‐3 provides the name and the location of key melter

components.

Figure

2-3

Key components

1. Tank

2. Air filter

3. Hose/gun modules

4. Chassis

5. Manifold

6. Sub‐base

7. Pressure adjustment screw

8. Pressure gauge

9. Pump enclosure door

10. Control switch

11. Keypad door

12. Electrical enclosure door

13. Control panel (see Figure 2‐4)

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Description

2-7

Figure

2-4

Control panel

1. Fault LED

2. Ready LED

3. Component keys/LEDs

4. Right display and scroll keys

5. Function keys

6. Serial port

7. Keypad

8. Left display and scroll key

9. Service LED

10. Tank low‐level LED

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Description

Optional Equipment

The following equipment may be ordered to expand the functionality and capacity of ProBlue adhesive melters.

Input/output (I/O) expansion cards

that allow you to expand the number of available control inputs.

Communications cards

that allow the melter to communicate with other process equipment or a controller that uses standard network protocols.

Hose/Gun modules

that allow you to increase the number of hoses/guns that can be connected to the melter.

Automatic Fill Systems

that provide automated transfer of dry adhesive materials to your melter. Choose either the FillEasy



or

FillMaster



product.

8‐Hose/Gun Expansion Base

that expands the capacity of a P10 adhesive melter from 6‐hoses/guns to 8‐hoses/guns.

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Installation

3-1

Section 3

Installation

WARNING!

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

Quick‐Start

If you have already installed the melter using the installation guide

(P/N 1024498) that is provided inside the shipping container, and you have no questions concerning the installation, go to

Setting Up the Melter

later in this section for information about how to prepare the melter to operate with your manufacturing process.

Installing 400/480 Volt Melters

Refer to Appendix E for information about installing 400/480 volt ProBlue adhesive melters. After completing the procedures described in Appendix E, you will be referred back to this section to set up the melter.

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Installation

Overview

ProBlue melters are factory‐configured for each order and require only the assembly and set up tasks described in this section. If your melter was ordered as a complete system, the shipping container will also contain one or more hot melt hoses and guns. ProBlue 400/480 volt melters include a transformer assembly that is shipped separately from the melter.

The melter is shipped from the factory with an installation kit that contains components that must be assembled onto the melter by the customer. Some additional materials must also be supplied by the customer to complete the installation.

If optional equipment was ordered with the melter, refer to the documentation provided with the optional equipment for installation and operating instructions.

The illustrations accompanying the procedures in this section depict the P4 melter. Unless otherwise noted, the instructions also apply to the P7 and P10 melter.

Additional Information

This section presents installation procedures in their most commonly used form. Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross‐reference information. Additional information tables are indicated by the symbol shown to the left.

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Installation

3-3

Installation Tasks

The installation sequence is as follows:

1. Verify that the required environmental conditions and utilities exist.

2. Unpack and inspect the melter.

3. Mount the transformer/melter onto the parent machine or support structure.

4. Configure the electrical service.

5. Connect a compressed air supply.

6. Connect hot melt hoses and guns.

7. Set up the melter to work with the manufacturing process.

8. (Optional) Install inputs and outputs.

9. Install optional equipment.

10. Connect a gun driver, pattern controller, or timer.

11. Flush the melter.

12. (Optional) Set up communications between the melter and a PC.

Experience of Installation Personnel

The instructions provided in this section are intended to be used by personnel who have experience in the following subjects:

Hot melt application processes

Industrial power and control wiring

Industrial mechanical installation practices

Basic process control and instrumentation

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Installation

Installation Requirements

Before installing the melter, ensure that the desired installation location provides the required clearances, environmental conditions, and utilities.

Clearances

Figure 3‐1 illustrates the

minimum

clearances that are required between the

melter and surrounding objects. Table 3‐1 describes each clearance.

NOTE:

400/480 volt melter clearances are provided in Appendix E.

A

C

B

Figure 3‐1

Minimum installation clearances (Top and side views shown)

D

A

B

C

D

Item

Table 3‐1 Installation Clearances

Description

The distance from the outside edge of a

5

/

16

‐inch Nordson hose to the front face of the melter when a short 90‐degree hose fitting is used to connect the hose to the melter

The clearance required to open the pump enclosure door

The distance from the melter sub‐base to the front edge of the tank lid when the lid is at its highest point.

The clearance required on the left side of the melter to open the electrical enclosure door or remove a hose/gun module.

Required Clearance

P4 = 370 mm (14.5 in.)

P7 = 370 mm (14.5 in.)

P10 = 391 mm (15.4 in.)

P4 = 243 mm (9.6 in.)

P7 = 243 mm (9.6 in.)

P10 = 268 mm (10.55 in.)

P4 = 502 mm (20.0 in.)

P7 = 564 mm (22.2 in.)

P10 = 656 mm (26.0 in.)

P4 = 648 mm (25.5 in.)

P7 = 711 mm (28.0 in.)

P10 = 714 mm (28.1 in.)

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Ventilation

Installation

3-5

See Figure 3‐2. ProBlue melters are cooled by convection. Air is drawn in

through openings in the chassis of the melter and is exhausted out of the ventilation slots at the top of the melter.

CAUTION!

Do not block the air intake openings and ventilation slots.

Figure 3‐2

Melter cooling

Electrical Power

Before installing the melter, ensure that the melter will not be overloaded and that the plant’s electrical service is rated to handle the power required by the melter and the hoses and guns that you plan to use.

Refer to Appendix A,

Calculating Melter Power Requirements

, for information about how to calculate the maximum allowable hose lengths and gun wattages that can be used in your manufacturing application.

WARNING!

Risk of electrocution! Install a lockable power disconnect switch between the electrical service and the melter. Failure to install or properly use the disconnect switch when servicing the melter can result in personal injury, including death.

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Installation

Compressed Air

To achieve maximum hot melt output, the melter must be connected to an air supply that is capable of providing a maximum of 6.2 Bar (90 psi) of dry, nonlubricated air. The actual pressure required for the melter to support your manufacturing process will depend on such factors as the type of hot melt and gun you are using and the required dimensions of the hot melt bead.

NOTE:

The minimum operating air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically.

Nordson recommends that an isolation valve be installed in the plant air supply line just before the melter.

Other Considerations

Consider the following additional factors when evaluating where to install the melter.

The maximum distance between the melter and each gun is dictated by the power requirement of each hose. Refer to Appendix A,

Calculating

Melter Power Requirements

, for information about how to determine the maximum allowable length.

The operator must be able to safely reach the control panel and accurately monitor the control panel indicators.

The operator must be able to safely observe the level of hot melt inside the tank.

The melter must be installed so that it can be safely removed from its sub‐base.

The melter must be installed away from areas with strong drafts or where sudden temperature changes occur.

The melter must be installed where it will be in conformance with the ventilation requirements specified in the Material Safety Data Sheet for the hot melt being used.

The melter should not be exposed to excessive vibration.

P4 and P7 melters provide an auxiliary hose port at the bottom of the manifold. If the auxiliary hose port will be used, the parent machine or other support structure must provide clearance under the melter to connect the hose to the auxiliary hose port.

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Installation

3-7

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Installation

Unpacking the Melter

Before starting the installation, remove the melter from the pallet, locate the installation kit, and inspect the melter for damaged and missing parts. Report any problems to your Nordson representative.

Contents of the Installation Kit

The installation kit provided with the melter contains the components shown

in Figure 3‐3. The quantity and type of hose fittings provided in the kit

depends upon the melter’s model number and configuration.

NOTE:

400/480 volt transformers are shipped with a separate installation kit.

Refer to Appendix E for information about the contents of the transformer installation kit.

The installation kit also contains a package of safety label overlays that are printed in a variety of languages. If required by local regulations, the appropriate language overlay should be applied over the English version of the same label. Refer to Section 1,

Safety Labels and Tags

, for the location of each safety label.

NOTE:

P10 melters also include a manifold guard kit P/N 1031871.

Customer‐Supplied Materials

The following additional materials are also required to install the melter.

A power cable. If the cable clamp that is provided in the installation kit is not used, rigid or flexible electrical conduit will be required.

Four 8 mm (

5

/

16

in.) machine bolts with locking hardware

A plant air supply with an in‐line isolation valve

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Installation

3-9

Figure 3‐3

Installation kit components

1.

Voltage plug (2)

2.

Voltage plug with neutral (2)

3. I nput and Output connector (2)

4.

Cable clamp

5.

Electrical connector

6.

NPTF-to-BSPP adapter

7.

Air filter

8.

45-degree hose fitting

9.

90-degree hose fitting

10.

6-hose manifold guard (P10 only)

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Installation

Mounting the Melter

ProBlue melters use a unique mounting sub‐base that allows the melter to be easily mounted onto and removed from the parent machine or support structure, without the need to unbolt the melter.

Melter sub‐base

Before mounting the melter, ensure that the parent machine or support structure is level with respect to the floor, provides an even mounting surface, is free of excessive vibration, and that it is capable of supporting the combined weight of the melter, a full tank of hot melt, and the hoses and guns.

Refer to Section 8,

Technical Data

, for the dimensions of the sub‐base and the weight of the melter. Refer to the technical data provided by the hot melt manufacturer for information about the volumetric weight of the hot melt.

To mount the melter

See Figure 3‐4.

1. Remove the PG‐21 conduit knockout from the sub‐base. See Figure 8‐4 for the location of the conduit knockout.

2. Lay out the sub‐base bolt pattern on the parent machine or support structure and then drill/tap holes for four 8 mm (

5

/

16 in.) mounting bolts

(customer‐supplied).

NOTE:

The mounting sub‐base has the same bolt‐mounting pattern as

Nordson’s 3100V and 3400V melters.

3. Bolt the sub‐base to the parent machine using four 8‐mm (

5

/

16

in.) machine bolts with locking hardware.

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Installation

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WARNING!

Risk of electrical shock or short circuit. Use the cable clamp that is provided or use electrical conduit to protect the power cable from the sharp edge of the conduit knockout.

4. Install the cable clamp in the PG‐21 conduit knockout.

5. Route the power cable between the power disconnect switch and the melter and through the cable clamp. Tighten the cable clamp.

CAUTION!

Before setting the melter down onto the sub‐base, ensure that both locking srews on the front chassis of the melter are turned fully counterclockwise until they stop.

6. Carefully lower the melter onto the sub‐base so that the back of the melter is approximately

1

/

2 inch in front of the rear locking tabs.

7. Slide the melter to the rear of the sub‐base until the rear locking tabs enter the slots in the back of the melter.

8. Lock the melter to the sub‐base by turning each of the locking screws, which are located in the front of the melter, clockwise until they stop.

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Installation

Mounting the Melter

(contd)

Figure 3‐4

Mounting the sub‐base and the melter

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Installation

3-13

Configuring the Electrical Service

ProBlue melters are shipped from the factory without an attached power cable and without an electrical service type specified. To configure the melter to function in your facility, you must connect a power cable and a

Nordson‐supplied voltage plug to the melter.

To connect a power cable to the melter

1. Select a power cable rated for the maximum amperage required by the melter. Ensure that the power cable meets applicable electrical codes and standards.

The maximum power draw for each ProBlue shipping configuration, operating at 230 volt, in both 1‐phase and 3‐phase are listed in

Table 3‐2. The values presented in Table 3‐2 assume that each hose gun

module is being used at its maximum capacity of 2000 watts.

NOTE:

Contact your Nordson representative for assistance in calculating the melter’s power draw for operating voltages other than 230 volts or for assistance in calculating the exact power draw for specific hoses and guns that are manufactured by Nordson Corporation.

Melter

P4

P7

P10

Number of

Hose/Guns

2

4

6

2

4

2

4

Table 3‐2 Melter Power Requirement

1‐Phase Power

Draw (Amps)

18

27

36

17

26

18

27

3‐Phase Power

Without Neutral

15

23

16

24

16

24

31

With Neutral

9

17

10

17

10

17

18

2014 Nordson Corporation

Part 1024496_06

3-14

Installation

Configuring the Electrical Service

(contd)

Opening the electrical enclosure door

Electrical connector

(P/N 1022993)

WARNING!

Risk of electrocution! Install a lockable power disconnect switch between the electrical service and the melter. Failure to install or properly use the disconnect switch when servicing the melter can result in personal injury, including death.

2. Open the electrical enclosure door.

3. Route the power cable into the wire tray in the base of the electrical enclosure.

NOTE:

If the power cable cannot be routed through the conduit knockout provided in the sub‐base (Refer to

Mounting the Melter

earlier in this section), route the cable through the optional knockout provided on the left side of the chassis.

See Figure 3‐5.

4. Connect each power cable lead to the appropriate terminal on the

electrical connector (P/N 1022993). Table 3‐3 describes the terminal

connections for each type of electrical service.

5. Plug the electrical connector into receptacle TB1 on the main board.

6. Connect the ground lead from the power cable to the ground lug that is located on the chassis. The lug is marked PE/G.

7. Connect the ground jumper that is connected to the ground lug, to the ground post that is located on the sub‐base.

Part 1024496_06 2014 Nordson Corporation

Installation

3-15

TB1

PE / G

EXAMPLE ONLY

(3/N/PE AC wiring shown)

Figure 3‐5

Connecting the power cable, ground lead, and ground jumper

2014 Nordson Corporation

Part 1024496_06

3-16

Installation

To connect a power cable to the melter

(contd)

Table 3‐3 Electrical Service Information

Use Electrical Connector

Terminals..

Use Voltage Plug..

If the Electrical Service Type is..

400/230 VAC 3‐phase

(4‐wire service, including a neutral) See note.

230 VAC 1‐phase

(2‐wire service, including a neutral) See note.

3/N/PE AC

400/230V

1/N/PE AC

200–240V

200 to 240 VAC 3‐phase

(3‐wire service without a neutral)

200 to 240 VAC 1‐phase

(2‐wire service without a neutral)

3/PE AC

200–240V

1/PE AC

200–240V

L1 L2 L3 N

   



  

 



227569

Red/Yellow

232617

Blue/Yellow

227568

Red/Green

227567

Blue/Green

NOTE:

The 400/230 VAC 3‐phase service (4‐wire service including neutral) includes the 415/240 VAC

3‐phase (4‐wire service, including neutral) voltage. The 230 VAC 1‐phase service (2‐wire service, including a neutral) includes the 240 VAC 1‐phase (2‐wire service, including a neutral) voltage.

Voltage plugs with and without the neutral lead

To connect a voltage plug to the melter

1. Refer to Table 3‐3 to determine the part number of the voltage plug that

matches the required electrical service.

NOTE:

Each voltage plug is color‐coded and is labeled with its part number and service type.

See Figure 3‐6.

2. Insert the correct voltage plug into receptacle J1 on the main board.

Ensure that the plug snaps into place. If the plug contains a neutral lead, connect the neutral lead to receptacle J2 on the main board.

3. When the electrical service is completely installed and inspected in accordance with local electrical codes and standards, close the electrical enclosure door and switch the local power disconnect switch on.

If the electrical service was configured correctly, the melter control panel will display dashes.

2014 Nordson Corporation Part 1024496_06

Installation

3-17

Figure 3‐6

Connecting a voltage plug

2014 Nordson Corporation

Part 1024496_06

3-18

Installation

Connecting a Compressed Air Supply

CAUTION!

Do not force the air pressure adjustment screw beyond its normal range of adjustment. Forcing the adjustment screw beyond its normal range of adjustment will damage the pneumatic assembly.

To connect an air supply

1. Use a 5 mm hex wrench to turn the pressure adjustment screw counterclockwise until it stops (off).

See Figure 3‐7.

2. Insert the male fitting located on the outlet side of the air filter

(P/N 1023267) into the air inlet port on the back of the melter.

Pressure regulator and adjustment screw

CAUTION!

Rigidly support the plant air supply before connecting it to the air filter.

3. Connect a regulated plant air supply to the inlet of the air filter. If required, use the

1

/

4

NPTF‐to‐G

1

/

4

BSPP male adapter fitting

(P/N 1034145) that is provided in the installation kit.

NOTE:

The air filter inlet is threaded to receive a male G1/4 BSPP fitting.

4. Open the plant air supply to the melter.

5. Turn the pressure regulator adjustment clockwise to set the melter’s operating air pressure (pressure supplied to the pump) to

1.4 Bar (20 psi). The operating air pressure should be adjusted later to meet the requirements of the manufacturing process.

NOTE:

The minimum operating air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically.

2014 Nordson Corporation Part 1024496_06

P/N 1034145

1

/

4

NPTF G

1

/

4

BSPP

Installation

3-19

Figure 3‐7

Connecting the air filter and the plant air supply line

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Installation

Connecting Hoses and Guns

ProBlue melters use standard Nordson hoses and guns. The P4 and P7 melters support the connection of up to four hose/gun pairs. The P10 melter supports the connection of up to six hose/gun pairs.

b a

The hose/gun capacity of each melter is determined by the number of hose/gun modules installed on the melter. Each hose/gun module supports the connection of two hose/gun pairs. The hose/gun capacity of melters that were ordered with less than their full hose/gun capacity can be increased by adding additional hose/gun modules. Unused hose/gun module positions are covered by blank modules.

Hose/gun module 1

a

) Receptacle 1

b

) Receptacle 2

WARNING!

Risk of fire or equipment damage. Before connecting hoses and guns to the melter, confirm that the power required by each hose/gun pair and each hose/gun module, does not exceed the maximum wattages specified in Appendix A, Table A‐2,

Maximum Allowable Wattages

.

1

Hose port 1

(P4/P7 melter manifold shown)

To connect hoses

See Figure 3‐8.

Observe the following guidelines:

For information about choosing the correct Nordson hot melt hose for your manufacturing process, refer to the latest edition of Nordson’s hot melt dispensing equipment

Replacement Parts Catalog

or contact your

Nordson representative.

Refer to the user’s guide provided with each Nordson hose. The guide contains important information about routing and installing the hose.

Always use hose port 1 first. The position of port 1 is stamped on the face of the manifold. The P4 and P7 melters provide four hose ports on the face of the manifold and a fifth hose port at the bottom of the manifold.

The P10 melter provides nine ports, six of which can be used at any one time.

If you install an additional hose/gun module, you must restart the melter and enter a set‐point temperature for each hose/gun that you connect to the new module in order for the new hoses/guns to be recognized.

2014 Nordson Corporation Part 1024496_06

P10 6‐hose manifold guard

Installation

3-21

CAUTION!

Failure to connect a hose to port 1 may create spaces within the manifold where hot melt will not circulate. The presence of these spaces can result in the build‐up of hot melt char, which can lead to an increase in the frequency of melter maintenance.

Use the 6‐hose manifold guard that is shipped with all P10 melters.

Instructions for installing the guard are provided with the guard.

Coordinate the connection of each hose with the receptacles on each hose/gun module. For example, connect the cordset from the hose that is connected to port 1 (marked) to receptacle 1.

Save all of the port plugs removed from the manifold. A port plug will need to be reinstalled into the manifold if a hose is later removed.

Use the 45‐ or 90‐degree hose fittings provided in the installation kit.

NOTE:

Only 90‐degree fittings are shipped with the P4 and P7 melters.

Figure 3‐8

Connecting a hose

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Installation

Connecting Hoses and Guns

(contd)

P10 Hose Routing Options

The unique angled design of the manifold on the P10 melter allows each hose (six hoses maximum) to be routed in the same or different directions without interfering with each other. Use the 45‐ or 90‐degree hose fitting supplied with the melter. Additional 45‐degree, 90‐degree, and straight fittings may be ordered to customize your hose configuration.

P10 hose routing options

To connect guns

Observe the following guidelines:

ProBlue melters support all T‐style handguns.

For information about choosing the most appropriate Nordson hot melt gun for your manufacturing process, refer to the latest edition of

Nordson’s hot melt dispensing equipment

Replacement Parts Catalog

or contact your Nordson representative. Refer to Appendix A,

Calculating

Melter Power Requirements

, for information about how to calculate the power required by Nordson hot melt guns.

Refer to the user’s guide that is shipped with each gun for information about installing the gun and connecting a hose to the gun.

NOTE:

ProBlue melters are shipped with a 100‐mesh (.15 mm) hot melt filter installed in the pump. Order the appropriate gun nozzle based on this filter mesh size.

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Installation

3-23

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3-24

Installation

Setting Up the Melter

After physically installing the melter, it must be set up to support your manufacturing process. Melter setup consists of enabling or making changes to factory‐set operating parameters that affect the use and function of the melter. The operating temperature (set‐point) of the tank and each hose and gun is also established during melter setup.

The melter is shipped from the factory with the most commonly used operating parameters already set up. The factory setup can be modified at any time to suit your manufacturing process.

Quick Setup

Table 3‐4 describes the most commonly used operating parameters and their

factory settings. Review the table to determine if the factory settings for each parameter will support your manufacturing process. If the default values for each of these operating parameters are appropriate for your manufacturing process, then no melter setup is required. Go directly to

Set‐point

Temperature of the Tank, Hoses, and Guns

later in this section to complete the installation process.

If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section,

Operating

Parameters

.

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Installation

3-25

Table 3‐4 Common Operating Parameters

Parameter Parameter Name Purpose

4

5

8

11

20

21

22

23

Default Value

Ready Delay Time

A timer that delays the activation of the ready

LED for a pre‐defined time period after the tank, hoses, and guns are at the desired set‐point temperature. The ready delay timer will only activate if the temperature of the tank, at the time the melter is turned on, is below its assigned set‐point temperature by

27



C (50



F) or more.

Service Interval Time

A timer that turns on a service LED when the value set for the timer equals the number of hours that the heaters have been on. The service LED is used to signal the need for maintenance.

0 minutes

500 hours

Automatic Pump On

Create Password

Temperature Units

Determines whether the pump will turn on automatically when the all components are at their desired set‐point temperature (enabled) or whether the pump must be turned on manually

(disabled).

Sets a password that must be entered before any melter operating parameter or set‐point temperature can be changed.

Sets the units of the temperature display to degrees Celsius (C) or to degrees Fahrenheit

(F).

Enabled

5000

C

Over Temperature

Delta

Under Temperature

Delta

Standby Delta

Sets the number of degrees that any heated component can exceed its assigned set‐point temperature before an over temperature fault occurs.

Sets the number of degrees that any heated component can drop below its assigned set‐point temperature before an under temperature fault occurs.

Sets the number of degrees that the temperature of all heated components will be decreased when the melter is placed into the standby mode.

15

25

50







C (25

C (50

C (100







F)

F)

F)

26

50 to 77

Manual Standby

Time

Seven‐day Clock

Sets the amount of time the melter will remain in the standby mode after the standby key is pressed.

Disabled

A group of parameters that control the melter’s clock. The clock is used to automatically turn the heaters on and off and to place the melter into the standby mode.

Disabled

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Installation

Operating Parameters

The melter uses operating parameters to store noneditable and editable values. Noneditable values are those that provide information about the historical performance of the melter. Editable values are either a numeric set‐point or a control option setting. Control options settings affect the display of information or the function of the melter.

Operating parameters are stored in the melter’s firmware in the form of a sequentially numbered list. The list is organized into the logical groups

described in Table 3‐5.

Group

Standard

Temperature Control

Input Setup

Output Setup

Seven-day Clock

Table 3‐5 Parameter Groups

Parameter

Numbers

Group Description

0 to 11 and 14

20 to 26

30 to 39

40 to 46

50 to 77

Noneditable and other frequently used parameters

Control heaters

Configure the standard and optional inputs

Configure the standard and optional outputs

Configure the clock feature

In addition to the ability to read and edit parameter values, you can also save and restore the current value of every operating parameter and review a log of the last ten changes that were made to editable parameters.

Selecting Operating Parameters

Table 3‐6 provides a complete list of the operating parameters.

Review the list to determine which operating parameters would best support your manufacturing process. Refer to Appendix B,

Operating Parameters

, for detailed information about each parameter. Appendix B contains a complete description of each parameter, including its affect on the melter, default value, and format.

NOTE:

Parameters that are used to configure optional equipment or that are otherwise reserved in the firmware are excluded from Table 3‐6 and

Appendix B.

Reading or Editing Operating Parameters

Regardless of whether a parameter’s value is editable or not, the procedure for accessing each parameter in order to read or edit its current value is the same.

Part 1024496_06 2014 Nordson Corporation

Melter control switch (On/Off)

Setup key

Clear/Reset key

Enter key

Installation

3-27

To read or edit a parameter

1. Switch the melter on.

The melter performs a start‐up check.

2. Press the

Setup

key.

The left display flashes parameter 1.

3. Use the numeric keypad to enter the number of the desired parameter.

Refer to Table 3‐6 for a complete list of parameters.

NOTE:

If you incorrectly enter the parameter number, press the

Clear/Reset

key to return to parameter 1 and then re‐enter the correct parameter number.

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

4. Do

one

of the following:

If the value is noneditable, refer to Section 4,

Monitoring the Melter

.

If the value is editable go to step 5.

5. Press the

Enter

key.

The right display flashes.

6. Use the keypad to enter the desired numeric set‐point or control option into the right display. Refer to Appendix B for information about the numeric value or control option choices for each parameter.

NOTE:

If the keypad has no affect on the right display, the melter is password protected. You must enter a valid password before you can edit parameters. Refer to Section 4,

Entering the Melter Password

.

7. Press the

Enter

key.

The melter checks that the new value or control option is acceptable.

If the numeric set‐point or control option is accepted, the left and right displays index to the next sequential parameter number and value.

If the numeric set‐point or control option is not accepted, the right display will indicate dashes (‐‐‐‐) for three seconds and then it will change back to the original value.

8. Repeat step 5 through step 7 to read or change the next sequential parameter number or press the

Setup

key to exit the setup mode.

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Installation

Operating Parameters

(contd)

Parameter Name

Table 3‐6 Operating Parameters

Range of Values

Standard

0

1

9

10

11

14

4

5

6

8

2

3

Enter Password

Total Hours with Heaters On

(noneditable)

Fault Log (noneditable)

Change History Log (noneditable)

Ready Delay Time

Service Interval Time

Service LED Heater Hours

Automatic Pump On

Automatic Pump On Temperature

Enable or Disable Password

Create Password

External Communications Lock‐out

Temperature Control

20

Temperature Units (degrees C or F)

21

22

23

24

25

26

Over Temperature Delta

Under Temperature Delta

Standby Delta

Automatic Standby Timeout

Automatic Heaters Off Time

Manual Standby Time

0 to 9999

0-999,999

—

—

0 to 60 minutes

0 to 8736 hours

0 to 9999hours

0 (disabled) or 1(enabled)

0 (disabled) or (1 to 230 C)

0 (disabled) or 1(enabled)

0 to 9999

0 or 1

Default Value

4000

0

_‐F0 (empty)

P‐_ (empty)

0 minutes

500 hours

0

1 (enabled)

0 (disabled)

0 (disabled)

5000

0 (disabled)

C (degrees Celsius) or F

(degrees Fahrenheit)

5

5

C (10

C (10

F) to 60

F) to 60

C(110

C(110

F)

F)

C (degrees Celsius)

15 C (25 F)

25 C (50 F)

25 C (50 F) to 190 C (350 F) 50 C (100 F)

0 to 1440minutes 0 (disabled)

0 to 1440minutes

0 to 180 minutes

0 (disabled)

0 (disabled)

Input Setup

30

Standard Input 1

34

35

36

37

38

39

31

32

33

Standard Input 2

Standard Input 3

Standard Input 4

Optional Input 5

Optional Input 6

Optional Input 7

Optional Input 8

Optional Input 9

Optional Input 10

0-10, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

0-9, 15-16

10 (Automatic

Standby)

1 (Standby on/off)

2 (Heaters on/off)

4 (Hose/gun 1 enable/disable)

0 (disabled)

0 (disabled)

0 (disabled)

0 (disabled)

0 (disabled)

0 (disabled)

Continued…

Part 1024496_06 2014 Nordson Corporation

Parameter Name

Output Setup

44

45

46

40

41

42

43

Standard Output 1

Standard Output 2

Standard Output 3

Optional Output 4

Optional Output 5

Optional Output 6

Optional Output 7

Seven‐day Clock

57

58

60

61

50

51

55

56

62

63

65

66

67

68

71

72

73

74

75

76

77

Current Day

Current hour

Schedule 1 Heaters On

Schedule 1 Heaters Off

Schedule 1 Enter Standby

Schedule 1 Exit Standby

Schedule 2 Heaters On

Schedule 2 Heaters Off

Schedule 2 Enter Standby

Schedule 2 Exit Standby

Schedule 3 Heaters On

Schedule 3 Heaters Off

Schedule 3 Enter Standby

Schedule 3 Exit Standby

Schedule for Monday

Schedule for Tuesday

Schedule for Wednesday

Schedule for Thursday

Schedule for Friday

Schedule for Saturday

Schedule for Sunday

Range of Values

0–6

0–6

0–6

0–6

0–6

0–6

0–6

1 to 7 (1 = Monday)

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0-7

0-7

0-7

0-7

0-7

0-7

0-7

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

0000 to 2359

Installation

3-29

Default Value

0

0

0

0

0

0

0

—:—

—:—

—:—

—:—

—:—

—:—

—

—

06:00

17:00

—:—

—:—

—:—

—:—

1 (Ready)

3 (Fault)

4

0 (disabled)

0 (disabled)

0 (disabled)

0 (disabled)

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Installation

Operating Parameters

(contd)

You can exit the setup mode at any time by pressing the

Setup

key.

Parameter numbers that are not applicable are skipped when you scroll through the operating parameter list in the left display.

When the right display is flashing, you can quickly set the value of the current parameter to it’s lowest possible value by simultaneously pressing both of the right‐display scroll keys.

While in the setup mode, if no key is pressed for two minutes, the melter will return to the automatic scan mode.

You can also use the right‐display scroll keys to enter or change a parameter’s value or control option. After entering the parameter’s number in the left display, press either of the right‐display scroll keys to change the value or control option.

If password protection is enabled, the melter will return to the password protected mode whenever you exit the setup mode.

Appendix B,

Parameter 10

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Installation

3-31

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Installation

Set‐point Temperature of the Tank, Hoses, and Guns

The melter is shipped from the factory with the tank set‐point temperature at

175



C (350



F) and the hose and gun set‐point temperatures at 0 degrees

(turned off).

Before the melter can be used, a set‐point temperature must be assigned to the tank, hoses, and guns. Assign set‐point temperatures using any of the following methods:

Global

—The tank and all hoses and guns are set to the same set‐point temperature.

Global‐by‐component group

—All of the hoses or all of the guns are set to the same set‐point temperature.

Individual Component

—The set‐point temperature of the tank and each hose and gun is set individually.

Since most manufacturing processes will require the tank, hoses, and guns to be set to the same temperature, only the global method of assigning set‐point temperatures is described in this section. For information about the other two methods of assigning set‐point temperatures, refer to Section 4,

Adjusting Component Temperatures

.

As with operating parameters, you can also save and restore set‐point temperatures and review past changes that were made to set‐point temperatures.

Part 1024496_06 2014 Nordson Corporation

Tank key

Left display and scroll key

Enter key

Ready LED

Installation

3-33

To assign a global set‐point temperature

1. Press and hold the

Tank

key for three seconds.

The left display flashes 1.

2. Scroll the left display to 0.

The right display indicates all dashes (‐‐‐‐) and the LEDs on the tank, hose, and gun keys turn green.

3. Press the

Enter

key.

The right display flashes.

4. Use the numeric keypad to enter the set‐point temperature recommended by the manufacturer of the hot melt.

Refer to the technical data sheet provided by the manufacturer of the hot melt to determine the optimal set‐point temperature.

5. Press the

Tank

key.

Each component begins to heat or cool to the new global set‐point temperature and the melter returns to the automatic scan mode.

When all of the components reach the global set‐point temperature, the ready LED turns on (green).

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Installation

Save and Restore Melter Settings

The current value of all editable operating parameters and the set‐point temperature of each component can be saved and, if necessary, restored at a later time. When saved settings are restored, they overwrite the settings that are presently in use.

This save‐restore feature is useful in instances where the settings that are in use are deliberately or accidentally changed and you need to return the melter to its pre‐change setup.

+

Saving current settings

+

Restoring saved settings

To save current settings

With the melter in the automatic scan mode, simultaneously press the number

1

key and the

Setup

key.

S‐1 appears momentarily in the right display.

To restore saved settings

CAUTION!

All melter settings will be deleted! Before restoring saved settings, ensure that use of the restored settings will not disrupt the current process or create an unsafe operating condition.

With the melter in the automatic scan mode, simultaneously press the number

2

key and the

Setup

key.

S‐2 appears momentarily in the right display.

If you use the restore feature before the save feature is used for the very first time, the factory default set‐point temperatures will be restored. This will cause the hoses and guns to stop heating.

You can transfer melter settings from one melter to another using the

Nordson Configuration Manager software utility.

Refer to Appendix C,

Melter Communications

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Installation

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3-36

Installation

Review Parameter and Set‐point Temperature Changes

The melter stores in a change history log, a record of the last ten changes that were made to either operating parameters or set‐point temperatures.

Since the log only stores ten changes, old log entries are overwritten beginning with the first log entry, by the eleventh and following log entries.

Setup key

Left display and scroll key

Component key LEDs

To review the change history log

1. Press the

Setup

key.

Operating parameter 1 flashes in the left display.

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

The following occurs:

If the last change was to an editable parameter, all of the component key LEDs remain off.

or

If the last change was to a set‐point temperature, the LED on the associated component key(s) turns on.

and

The right display indicates the four‐digit log entry associated with the

last

change that was made.

Table 3‐7 provides the meaning, from left to right, of each digit in the

log entry. Following the table are two example log entries.

3. Press the right‐display scroll key to review each of the remaining nine log entries. Each press of the scroll key displays a progressively older log entry.

4. Press the

Setup

key to return to the automatic scan mode.

Scrolling through the log

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Installation

3-37

First Digit

P

(Parameter)

Second Digit

Table 3‐7 Change History Log

Third and Fourth Digits

Indicates the number of the parameter that was changed

S

(Set‐point)

—

Are used in conjunction with the LEDs on the component keys to indicate the location and method of a set‐point temperature change

.

When this LED is on..

Tank Key

Hose Key

Gun Key

All Keys

Hose Key

Gun Key

And the Fourth

Digit

Indicates..

1

The change was to..

The tank

A single hose 1– 6

1– 6

0

A single gun

All components

0

0

All hoses

All guns

And the

Method of

Change was..

Individual

Individual

Individual

Global

Global‐by‐ component

Global‐by‐ component

Change History Log Examples

Example 1:

Example 2:

Parameter 4 (ready delay) was changed.

If the LED on the gun key is on, then this display would indicate that the global‐by‐component method was used to change the temperature of the guns.

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Installation

Review Parameter and Set‐point Temperature Changes

(contd)

Unused log entries in the change history log are indicated by “P‐_” in the right display.

To view how many heater hours have elapsed since a specific change

(displayed) was made, simultaneously press both of the right‐display scroll keys.

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Installation

Installing Melter Inputs

ProBlue melters are equipped with four standard inputs. Each input is customer‐wired to the melter and then set up to provide one of the following control options:

Place the melter into the standby mode

Turn the heaters on and off

Enable or disable a specific hose or gun

Turn the pump on and off

Inputs are activated using a constant 10 to 30 VDC signal voltage, which is supplied by the customer’s control equipment. The inputs are not polarity sensitive.

WARNING!

The operator can override the melter inputs by using the control panel function keys. Ensure that the control logic for any external device that sends an input signal to the melter is programmed to prevent the creation of an unsafe condition in the event that the operator overrides an external input to the melter.

Opening the electrical enclosure door

To wire inputs to the melter

1. Route a 2‐, 4, 6, or 8‐conductor signal cable from the control equipment to the melter, and through the PG‐16 penetration in the sub‐base. Use rigid or flexible conduit or a suitable strain relief to protect the cable from the sharp edge of the conduit penetration.

NOTE:

Use a signal cable suitable for NEC class1 remote control and signaling circuits. To reduce the possibility of electrical shorting, route the cable so that it does not touch nearby circuit boards.

Part 1024496_06 2014 Nordson Corporation

Connector P/N 277909

Installation

3-41

See Figure 3‐9.

2. Connect each pair of input wires to the appropriate terminals (8 through

14) on connector P/N 277909. If input number four is used, terminal 7 on connector P/N 277908 must also be used. Both connectors are provided

in the installation kit. Table 3‐8 lists the terminal numbers that correspond

to each input.

NOTE:

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

3. Plug the connector (P/N 277909) into the bottom receptacle of terminal

TB2, which is located on the right side of the main board. If input number four is used, plug connector P/N 277908 into the top receptacle on terminal TB2.

TB2

Figure 3‐9

Wiring inputs

8 9 10 11 12 13 14

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Part 1024496_06

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Installation

Installing Melter Inputs

(contd)

To set up an input

Set up the parameter control option for each input that you connected to the melter. Table 3‐8 list the available control options. Refer to

Setting Up the

Melter

earlier in this section for information about how to select operating parameters and edit parameter control options.

With the exception of the pump enable/disable control option

(Table3‐8), All inputs are transition‐based.

The input capacity of the melter may be increased from four inputs to a total of ten inputs by adding an optional I/O card that is available from Nordson

Corporation.

Appendix B,

Input Setup

Section 7,

Parts

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Installation

3-43

Table 3‐8 Input Data

Input Terminals Operating Parameter Control Option

Standard Inputs

Note

1

2

8 and 9

10 and 11

30

31

0 ‐ Input Disabled

1 ‐ Standby On/Off

2 ‐ Heaters On/Off

3 ‐ Pump Enable/Disable

4 ‐ Hose/Gun 1 Enable/Disable

5 ‐ Hose/Gun 2 Enable/Disable

6 ‐ Hose/Gun 3 Enable/Disable

7 ‐ Hose/Gun 4 Enable/Disable

8 ‐ Hose/Gun 5 Enable/Disable

9 ‐ Hose/Gun 6 Enable/Disable

10 – Automatic standby (Default)

0 ‐ Input Disabled

1 ‐ Standby On/Off (Default)

2 ‐ Heaters On/Off

3 ‐ Pump Enable/Disable

4 ‐ Hose/Gun 1 Enable/Disable

5 ‐ Hose/Gun 2 Enable/Disable

6 ‐ Hose/Gun 3 Enable/Disable

7 ‐ Hose/Gun 4 Enable/Disable

8 ‐ Hose/Gun 5 Enable/Disable

9 ‐ Hose/Gun 6 Enable/Disable

Same as parameter 31 (Default=2)

Same as parameter 31 (Default=4)

A, B

C

F

D

F

7

8

5

6

3

4

12 and 13

7 and 14

Optional Inputs

9

10

NOTE

11 and 12

13 and 14

15 and 16

17 and 18

32

33

34

35

36

37

0 (Disabled)

0 (Disabled)

0 (Disabled)

0 (Disabled)

E

E

E

E

19 and 20

9 and 10

38

39

0 (Disabled)

0 (Disabled)

E

E

A:

Parameter 30 has 10 control options. parameters 31, 32, and 33 each have only 9 control options.

B:

Parameters 34 through 39 are reserved for the six inputs created when the optional I/O expansion card is installed.

The six optional inputs have the same control options as parameter 31.

C:

If control option 3 is selected, the pump will not turn on—even if you press the pump key—if voltage is not present on the input’s contacts.

D:

If control option 10 is selected for input 1, a time must be set in parameter 24.

E:

Refer to the instruction sheet provided with the optional I/O expansion card for wiring information.

F: When the 8-Hose/Gun Expansion option is installed, the option for Hose/Gun 7 or 8 Enable/Disable appear as options 15 and 16 respectively.

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Installation

Installing Melter Outputs

The melter is equipped with three user‐configurable outputs. Outputs are used to communicate with user‐supplied production equipment or control hardware, such as a programmable logic controller.

Each output is customer‐wired and then set up in the melter’s firmware to provide one of the following outputs:

The melter is ready

The melter is ready

and

the pump is on

A fault has occurred

The hot melt level is low

The service LED is on

A potential fault is detected

All outputs contacts are rated at 240 VAC 2 A or 30 VDC 2 A. All contacts are normally open when the melter is turned off.

Opening the electrical enclosure door

To connect an output to the melter

See Figure 3‐10.

1. Route a 2‐, 4, or 6‐conductor signal cable from the control equipment to the melter, through the PG‐16 penetration on the floor of the electrical compartment. Use rigid or flexible conduit or a suitable strain relief to protect the cable from the sharp edge of the conduit penetration.

NOTE:

Use a signal cable suitable for NEC class1 remote control and signaling circuits. To reduce the possibility of electrical shorting, route the cable so that it does not touch nearby circuit boards.

2. Connect each pair of output wires to the appropriate terminals

(1 through 7) on connector P/N 277908. The connector is provided in the

installation kit. Table 3‐9 lists the terminal numbers that correspond to

each output.

NOTE:

Terminal number 7 on connector P/N 277908 is reserved for input number four.Connector P/N 277908 is physically keyed to prevent it from being used as connector P/N 277909, which has terminals numbered 8 through 14.

3. Plug connector P/N 277908 into the top receptacle on terminal TB2, which is located on the main board.

Connector P/N 277908

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Installation

3-45

TB2

1 2 3 4 5 6 7

Figure 3‐10

Wiring outputs

To set up an output

Set up the parameter control option for each output that you connected to the

melter. Table 3‐9 lists the available control options. Refer to

Setting Up the

Melter

earlier in this section for information about how to select operating parameters and edit parameter control options.

The output capacity of the melter may be increased from three outputs to seven outputs by adding an optional

I/O expansion card that is available from Nordson Corporation.

Section 7,

Parts

Part 1024496_06

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Installation

Installing Melter Outputs

(contd)

2

3

Output Terminals

Standard Outputs

1 1 and 2 40

Operating

Parameter

Table 3‐9 Output Data

Control Options

0 ‐ Output Disabled

1 ‐ Ready (Default)

2 ‐ Ready

and

the pump is on

3 ‐ Fault

4 ‐ Tank Low Level

5 ‐ Service LED is On

6 ‐ Alert

3 and 4

5 and 6

41

42

Same as parameter 40 (Default=3)

Same as parameter 40 (Default=4)

Optional Outputs

4 1 and 2

5

6

7

NOTE

3 and 4

43

44

0 (Disabled)

0 (Disabled)

D

5 and 6 45 0 (Disabled)

7 and 8 46 0 (Disabled)

A:

When control option condition occurs, contacts close. Contacts are normally open when power is off.

B:

When control option condition occurs, contacts open. Contacts are normally open when power is off.

C:

Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used, then both a fault output and an alert output signal will be present when the fault LED turns on.

D:

For wiring information, refer to the instruction sheet that is provided with the optional I/O expansion card

Note

A

B

A

A

A

C

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Installation

3-47

Installing Optional Equipment

Each item of optional equipment is shipped with instructions for installing and operating the equipment. Refer to Section 7,

Parts

, for equipment part numbers.

Connecting a Gun Driver, Pattern Controller, or

Timer

If applicable, complete the melter installation by connecting the guns to the desired gun driver, pattern control, or timer. Refer to the product manual provided with the device for information about installing and operating the equipment.

Flushing the Melter

Before using the melter for production, it should be flushed to remove any residue left over from factory‐testing. Flushing the melter is accomplished by processing a minimum of one tank volume of hot melt through the melter, hoses, and guns.

Refer to Section 4,

Operation

, for information about filling the tank and operating the melter.

Setting Up Melter Communications

You can transfer melter settings between melters, and upgrade or downgrade the melters operating firmware by using a personal computer that is connected to your melter’s serial port.

Refer to Appendix C,

Melter Communications

, for information about downloading, installing, and using the software that is required to connect a personal computer to your melter.

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Installation

Part 1024496_06 2014 Nordson Corporation

Operation

4-1

Section 4

Operation

WARNING!

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

This section provides information about the following operator‐level tasks:

Filling the melter tank

Starting the melter

Monitoring melter operation

Adjusting the operating temperature of heated components

Using the melter function keys

Shutting the melter down

Most of the controls described in this section are located on the control panel behind the keypad door. Refer to Section 2,

Key Components

, for the location of the control panel.

Additional Information

This section presents operating procedures in their most commonly used form. Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross‐reference information. Additional information tables are indicated by the symbol shown to the left.

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Part 1024496_06

4-2

Operation

More About Heated Components

The melter contains three groups of heated components. These are the tank group, which contains the tank and the manifold, the hose group, and the gun group. Component groups are represented on the control panel by the component keys shown to the left.

Component keys

(tank, hose, and gun)

Heated components within each group are identified by their position number. The position of the tank and pump is fixed at 1. Hose and gun position numbers are automatically assigned based on the hose/gun receptacle they are connected to. For example, the position numbers of a hose/gun pair that is connected to the second receptacle would be hose position 2 and gun position 2.

The number of hose/gun receptacles available on each melter depends on the configuration in which the melter was ordered. ProBlue adhesive melters may have either two, four, or six hose/gun receptacles. An optional expansion base may be ordered that adds receptacles for two additional hoses/guns.

Part 1024496_06 2014 Nordson Corporation

Operation

4-3

Filling the Tank

Before filling the tank, confirm that the hot melt material is compatible with the melter. Refer to Section 2,

Intended Use

, for information about hot melt materials that should not be used in ProBlue melters.

The tank is equipped with a low‐level float switch. When the volume of adhesive in the tank reaches approximately one‐half of the tank’s rated capacity, the float switch turns on the low‐level LED located on the control panel.

Low‐level LED (yellow)

To fill the tank

WARNING!

Hot! Risk of burns! Use a scoop to fill the tank with hot melt

Never use your bare hands. Using your bare hands to fill the tank may result in personal injury.

1. Open the tank lid.

See Figure 4‐1

2. Use a scoop to fill the tank with hot melt up to the tank fill line. The line is

marked on the screen that protects the tank float switch. Table 4‐1 lists

the tank capacity of each ProBlue melter.

3. Close the tank lid when you are finished filling the tank.

2014 Nordson Corporation

Figure

4-1

Tank fill line

Model

P4

P7

P10

Liters

Table 4‐1 Tank Capacity

Capacity

Kilograms

4

7

10

4

7

10

*Assumes a hot melt with a specific gravity of 1

Pounds

9

15

22

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4-4

Operation

Starting the Melter

Before starting the melter for the first time, confirm that the melter is fully installed including any required inputs and outputs, gun drivers, pattern controllers, and timers melter’s operating parameters are set up to support the current manufacturing process

Refer to Section 3,

Installation

, if any of the items listed above are not complete.

Melter control switch (on/off)

Heaters LED

Automatic scan sequence

To start the melter

1. Switch the melter on.

The melter:

Tests the control panel LEDs

Turns on the heaters (the heaters LED turns green)

Begins to automatically scan through and display the actual temperature of the tank and each hose and gun that has a set‐point temperature that is greater than zero degrees. The sequence of the automatic scan is: tank, each hose and gun pair, and then back to the tank.

Turns on the ready LED (green) when the tank and all of the hoses and guns are within 3 C (5 F) of their assigned set‐point temperature.

NOTE:

Appendix D contains a functional description of the pump.

2. Check the air pressure gauge on the front of the melter to confirm that the operating air pressure is set correctly.

NOTE:

The minimum operating air pressure is 0.7 bar (10 psi).

Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically.

Ready LED

Air pressure gauge

Part 1024496_06 2014 Nordson Corporation

2014 Nordson Corporation

Operation

4-5

If the melter is switched on when the temperature of the tank is 27 C (50

F) or greater below its assigned set‐point temperature (cold start condition), the ready LED will not turn on until the ready delay (defined when the melter was set up) has elapsed.

The time remaining on the ready delay

(in minutes) appears in right display at the end of every scan cycle. When only one minute remains in the ready delay time, the right display counts down in seconds.

You can by‐pass the ready delay time by pressing the

Heaters

key twice.

The appearance of F4 in the right display immediately after the melter is switched on indicates a problem with the melter’s processor or main board.

The appearance of F1 in the right display immediately after starting the melter indicates that a hose or gun cordset may be loose or disconnected.

If the melter is set up for manual pump activation, the pump LED will not turn on when the melter is ready.

The condition of one or more inputs, may prevent the heaters from turning on.

If the seven‐day clock feature was set up and turned on when the melter was last switched off, the clock will automatically turn on the next time the melter is switched on.

It is normal for the pump to slowly cycle when no hot melt is being dispensed from the guns.

If a power failure occurs, the melter will restart in its normal heat‐up cycle, even if the heaters were off or the melter was in standby prior to the power failure. If the seven‐day clock was on prior to the power failure, the melter will restart in the mode dictated by the clock schedule at the time the melter restarts.

Appendix B,

Parameter 4

Appendix B,

Parameter 4

Section 4,

Monitor Melter Faults

Section 6,

Troubleshooting

Appendix B,

Parameter 8

Section 3,

Installing Inputs

Section 4,

Using Melter

Function Keys

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4-6

Operation

Monitoring the Melter

The melter provides indicators that allow you to:

Quickly confirm that the melter is operating correctly

Monitor the actual temperature of the manifold and each hose and gun

Identify melter faults

Identify when the level of hot melt in the tank is low

Check the operating air pressure

Determine when service is required

The melter automatically determines the number and location of all hoses and guns that are connected to it. Refer to

More About

Heated Components

earlier in this section for information about hose/gun capacity and the identification of heated components.

You can also use a personal computer to monitor the melter. Refer to

Appendix C,

Melter Communications

, for information about connecting a personal computer to the melter and installing the required software.

Part 1024496_06 2014 Nordson Corporation

Operation

4-7

Confirm that the Melter is Operating Correctly

The ready LED turns on (green) when all of the heated components are within 3 C (5 F) of their set‐point temperature.

Ready LED

The ready LED will not turn on, or will turn off, if any of the following events occur:

The ready delay is still counting down.

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

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

There is a fault (the fault LED will turn on).

Refer to

Monitoring Melter Faults

and

Using Melter Function Keys

later in this section for information about melter faults and using the seven‐day clock and standby functions. Refer to Appendix B,

Parameter 4

, for information about the ready delay.

Heated components with a set‐point temperature of zero degrees are skipped during the automatic scan cycle.

The set‐point temperature of the tank and the manifold cannot be set independently.

The time remaining on the ready delay appears in the right display at the end of each scan cycle.

You can override the seven‐day clock at any time. If the clock has turned the heaters off, pressing the heaters key will turn the heaters back on. If the clock has placed the melter into the standby mode, pressing the standby key will return the heated components to their assigned set‐point temperature.

Appendix B,

Parameter 4

Section 4,

Using Melter

Function Keys

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Part 1024496_06

4-8

Operation

Monitor Component Temperatures

You can check the actual temperature of each heated component—the tank and each hose and gun—using the automatic scan mode or by manually selecting and checking each component.

By default, the melter remains in the automatic scan mode except when:

The melter is placed into the setup mode

The set‐point temperature of all hoses and guns is set to zero degrees

A fault occurs

LEDs on component keys

To check component temperatures using the automatic scan mode

1. When the ready LED is on, observe the LEDs on the component keys.

2. When the LED on the key that represents the desired component group (tank, hose, or gun) turns on, observe the left display until it indicates the position number of the specific component you want to check.

3. When the position number of the desired component appears in the left display, observe the right display to determine the component’s actual temperature.

Left display and scroll key

Component temperature display

To manually check a component’s temperature

1. Press the key (tank, hose, or gun) that represents the component group you want to check.

The automatic scan stops and the left display indicates the number of the first sequential component in the selected component group. The right display indicates the component’s actual temperature.

NOTE:

When the tank key is pressed, the left display does not indicate a component number (blank display).

2. If the first sequential component is not the component you want to check, use the left‐display scroll key to change to the correct component number.

The right display indicates the actual temperature of the selected component.

3. Press the

Setup

key twice to return to the automatic scan mode.

Part 1024496_06 2014 Nordson Corporation

Operation

4-9

Monitor Component Temperatures

(contd)

When you scroll the left display past the number of the last sequential component in a component group, the number of the first sequential component in the next component group appears in the left display.

The melter will return to the automatic scan mode two minutes after the last key is pressed.

When you press the

Tank

key, it is the manifold temperature that is actually indicated in the right display. To check the actual temperature of the tank, simultaneously press the

Tank

key and the left‐display scroll key.

The default unit for temperature display is degrees Celsius (C). This may be changed to degrees

Fahrenheit using operating parameter 20.

The LEDs on each component key will change from green to yellow if any component in the component group drops more than 3 C (5 F) below its assigned set‐point temperature.

You can check the set‐point temperature of a component at any time, by pressing the right‐display

UP scroll key. Holding down the scroll key while the melter is in the automatic scan mode reveals the set‐point of each component that is scanned.

Appendix B, Parameter 20

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4-10

Operation

Monitor Melter Faults

The melter alerts the operator to the faults listed in Table 4‐3. Faults affect

the melter in one of three ways: the heaters turn off; the heaters remain on, but the fault condition persists; or the melter stops functioning.

When a fault occurs, you must diagnose and correct the fault condition and then place the melter back into operation. You can use the fault log to determine the type, order, and relative time of the last ten faults.

Setup Key

Left display and scroll key

To review the fault log

1. Press and hold the

Setup

key.

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

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

The right display indicates the last fault that occurred as follows:

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

If the last fault to occur was an F4 fault, then the LEDs on all of the component keys turn off.

The right display indicates the log entry for the last fault to

occur. Table 4‐2 provides the meaning of each digit in the log

entry. Following the table are two example fault log entries.

3. Press the right‐display scroll key to review each of the remaining nine log entries. Each press of the scroll key displays a progressively older log entry.

NOTE:

The fault log only stores the last ten faults. After ten faults occur, the existing log entries are overwritten, beginning with the oldest entry, by the eleventh and following log entries.

4. Press the

Setup

key to return to the automatic scan mode.

Scrolling through the fault log

Part 1024496_06 2014 Nordson Corporation

Component:

First Digit

1 = Tank or hose/gun 1

2 = Manifold or hose/gun 2

3 = Hose 3 or gun 3

4 = Hose 4 or gun 4

5 = Hose 5 or gun 5

6 = Hose 6 or gun 6

Operation

4-11

Table 4‐2 Fault Log

Second and Third Digits

‐ F

Fourth Digit

Type of fault:

0 = Unused log entry

1 = RTD (open or short)

2 = Component under temperature

3 = Component over temperature

4 = Processor or electrical failure

Fault Log Examples

Example 1:

Example 2:

An unused log entry.

If the LED on the tank key were on, this log entry would indicate that the tank is under temperature. If the LED on the hose key were on, this log entry would indicate that hose 1 is under temperature.

To view the number of heater hours that have elapsed since a log entry was created, simultaneously press both of the right‐display scroll keys. The hours are indicated in the right display.

The melter will return to the automatic scan mode if the fault log is left open for a period of two minutes without any key being pressed.

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

Part 1024496_06

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4-12

Operation

Monitor Melter Faults

(contd)

Display

Code/Sub‐code

F1/None

F2/None

F3/None

F4/1

F4/2

F4/4

F4/5

F4/6

F4/7

F4/8

F4/A

F4/d

F4/E

RTD

Name

Under temperature

Over temperature

RAM test

Internal Clock time

Internal clock battery backed RAM

Internal clock battery

Analog‐to‐digital

Table 4‐3 Melter Faults

Affect on Melter

Heaters turn off

Heaters turn off

Heaters turn off

Cause

The RTD for the component indicated has failed or the component was disconnected from the melter.

The actual temperature of the component indicated has dropped below the under temperature delta, which was set using parameter22.

The actual temperature of the component indicated has increased beyond the over temperature delta, which was set using parameter21.

Internal RAM failure Melter stops functioning

Heaters remain on, but fault condition persists

Heaters remain on, but fault condition persists

Heaters remain on, but fault condition persists

Melter stops functioning

Internal clock failure

Battery‐backed RAM failure

Battery‐backed RAM battery dead

RTD analog‐to‐digital converter failed

Analog‐to‐digital calibration

Melter stops functioning

RTD analog‐to‐digital converter could not be calibrated

Faulty hose or gun.

Communication failure between main board and CPU

Tank or manifold thermostat is open

Main board feedback

Thermostat

Communications with optional I/O card

Fieldbus communications failure

Melter stops functioning

Melter stops functioning

Heaters remain on, but fault condition persists

Alert output (if output option 6 is selected)

Melter continues to operate normally.

Communication failure between CPU and the optional I/O card

Fieldbus card failure.

Part 1024496_06 2014 Nordson Corporation

Clear/Reset key

Heater key

Operation

4-13

To put the melter back into operation

1. Diagnose and correct the fault condition. Refer to Section 6,

Troubleshooting

, for information about diagnosing and correcting fault conditions.

NOTE:

When a fatal F4 fault exists, the control switch will not function.

Remove power to the melter at the local disconnect switch.

2. Return the melter to the automatic scan mode by pressing the

Setup

key twice.

3. Press the

Clear/Reset

key.

4. Press the

Heater

key to turn on the heaters.

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Part 1024496_06

4-14

Operation

Fault LED (red)

How F1, F2, and F3 Faults are Handled

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

1. The automatic scan stops and the melter begins to monitor the potential fault for up to two minutes. The ready and heater LEDs remain on during the two‐minute time period. If, at any time during the two‐minute period, the melter detects that the fault condition no longer exists, the melter will return to the automatic scan mode.

2. The LED on the affected component key (tank, hose, or gun) turns on to indicate the type of component that has, or is, failing.

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

4. The left display indicates, as follows, the component that has, or is, failing.

If the LED on the tank key is on, the left display will indicate either 1 for the tank or 2 for the manifold.

If the LED on the hose or gun key is on, the left display will indicate the number of the affected hose or gun.

5. If the fault condition still exists at the end of the two‐minute monitoring period, the ready LED will turn off, the red fault LED will turn on, the heaters turn off, and the melter records the fault in the fault log. Refer to

To review the fault log

earlier in this section.

Part 1024496_06 2014 Nordson Corporation

Operation

4-15

How F4 Faults are Handled

When the melter detects an F4 fault:

1. The ready LED turns off and the red fault LED turns on.

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 sub‐code. Sub‐codes classify the fault as being fatal or nonfatal. The affect on the melter of each of these two classes of F4 faults is:

Fatal

—The fault LED turns on and stays on and the melter stops functioning completely.

Nonfatal

—The fault LED turns on for five seconds, but the heaters and pump continue to operate normally. Nonfatal faults affect the internal clock and the optional I/Os.

Refer to Section 6,

Troubleshooting

, for information about diagnosing F4 faults.

5. The melter records the fault in the fault log. Refer to

To review the fault log

earlier in this section.

2014 Nordson Corporation

Part 1024496_06

4-16

Operation

How F4 Faults are Handled

(contd)

To view the temperature of a heated component when an F2 or F3 fault exists, simultaneously press and hold both of the right‐display scroll keys.

You can temporarily dismiss an

F1fault (RTD) and return to the automatic scan mode by pressing the

Clear/Reset

key. The heaters will, however, remain off. If the fault condition still exists two minutes after pressing the clear/reset key, the fault

LED will turn back on.

When an F1 fault code appears, you can determine whether the fault was caused by an open or a shorted RTD by simultaneously pressing both of the right‐display scroll keys. If the right display indicates OP, the RTD is open, if it indicates SH, the RTD has shorted.

If, for any reason, a component reaches

235 C (458 F), an immediate F3 fault will occur (no two‐minute monitoring period).

If F4 appears in the right display when you press the clock key, the internal clock function has failed.

Part 1024496_06 2014 Nordson Corporation

Operation

4-17

Monitor the Level of Hot Melt in the Tank

The tank contains a low‐level float switch. When the volume of hot melt in the tank drops below one‐half of the tank’s rated capacity, the float switch turns on the low‐level LED located inside the tank key.

Low‐level LED (yellow)

Nordson recommends that the tank be kept at least one‐half full while the melter is operating.

NOTE:

The melter is also equipped with a low‐level output that can be connected to a customer‐supplied signaling device or process control system. Refer to Section 3,

Installing Melter Outputs

, for information about using the low‐level output.

Monitor and Adjust the Operating Air Pressure

The air pressure gauge located on the front of the melter indicates the air pressure that is supplied to the melter’s pump. The air pressure must be adjusted to meet the requirements of your manufacturing process.

Pressure regulator and adjustment screw

NOTE:

The minimum operating air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically.

Use the adjustment screw located to the right of the pressure gauge to adjust the operating air pressure.

Typically, adjustments to the operating air pressure are made in order to change the volume of hot melt dispensed by the guns. Other factors such as the temperature of the hot melt, the speed of the manufacturing line, and the type and size of the nozzles used on the guns also impact the volume of hot melt that is dispensed.

CAUTION!

Do not force the air pressure adjustment screw beyond its normal range of adjustment. Forcing the adjustment screw beyond its normal range of adjustment will damage the pneumatic assembly.

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Operation

Monitor the Service Interval

The melter can be set up so that the service LED located on the left side of the control panel turns on after a customer‐defined time period elapses.

The service LED may be used to signal the need to change the hot melt filter or to complete any other customer‐specified maintenance activity. Once the specified maintenance is performed, the service LED must be reset.

To reset the service LED

With the melter in the scan mode, press the

Clear/Reset

key to turn off the service LED and reset the service interval time.

Service LED (yellow)

Clear/Reset key

The default setting for the service interval time is 500 hours.

Appendix B,

Parameter 5

Part 1024496_06 2014 Nordson Corporation

Operation

4-19

Adjusting Component Temperatures

You can adjust the the set‐point temperature of heated components using the following methods:

Global

—The tank and all hoses and guns are set to the same set‐point temperature.

Global‐by‐component group

—All of the hoses or all of the guns are set to the same set‐point temperature.

Individual Component

—The set‐point temperature of the tank and each hose and gun is adjusted independently.

Before adjusting set‐point temperatures, confirm that each hose/gun pair is connected to the correct hose/gun module. For example, hose/gun pair 1 should be connected to the first receptacle (lowest) on hose/gun module 1

(lowest module). Refer to

More About Heated Components

earlier in this section for information about hose/gun modules.

Tank key

Left display and scroll key

Enter key

To adjust set‐point 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 indicates all dashes (‐ ‐ ‐ ‐) and the LEDs on all of the component keys turn green.

3. Press the

Enter

key.

The right display flashes.

4. Use the keypad to enter the set‐point temperature recommended by the manufacturer of the hot melt. Refer to the technical data sheet provided by the manufacturer of the hot melt to determine the optimal set‐point temperature.

NOTE:

If the keypad or the right‐display scroll keys have no affect on the right display, the melter is password protected. You must enter a valid password before you can change set‐point temperatures. Refer to

Entering the Melter Password

later in this section.

5. Press the

Tank

key.

All components begin to heat or cool to the new global set‐point temperature. When all of the components reach their set‐point temperature, the ready LED turns on (green).

Ready LED

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Operation

Tank, hose, and gun keys

To adjust the set‐point temperature using the global‐by‐component method

1. Press and hold the

Hose

or

Gun

key for three seconds.

The left display indicates the number of the first sequential hose or gun. The right display indicates the current set‐point temperature of the hose or the gun.

2. Scroll the left display to 0.

The right display indicates all dashes (‐ ‐ ‐ ‐).

3. Press the

Enter

key.

The right display flashes.

4. Use the keypad to enter the set‐point temperature recommended by the manufacturer of the hot melt. Refer to the technical data sheet provided by the manufacturer of the hot melt to determine the optimal set‐point temperature.

NOTE:

If the keypad or the right‐display scroll keys have no affect on the right display, the melter is password protected. You must enter a valid password before you can change set‐point temperatures. Refer to

Entering the Melter Password

later in this section.

5. Press the

Enter

key.

The hoses or the guns begin to heat or cool to their new set‐point temperature.

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Operation

4-21

To adjust the set‐point temperature of an individual component

1. Press and hold the

Tank

,

Hose

, or

Gun

key for three seconds.

If the tank key was pressed, the left display indicates 1 (Flashing). If a hose or gun key was pressed, the left display indicates the number of the first sequential hose or gun (Flashing). The right display indicates the current set‐point temperature of the component indicated in the left display.

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

The right display indicates the current set‐point temperature of the component that you selected in the left display.

3. Press the

Enter

key.

The right display flashes.

4. Use the keypad to enter the set‐point temperature recommended by the manufacturer of the hot melt. Refer to the technical data sheet provided by the manufacturer of the hot melt to determine the optimal set‐point temperature.

NOTE:

If the keypad or the right‐display scroll keys have no affect on the right display, the melter is password protected. You must enter a valid password before you can change set‐point temperatures. Refer to

Entering the Melter Password

later in this section.

5. Do

one

of the following:

To register the new set‐point temperature and then move on to change the set‐point temperature of the next sequential component, press the

Enter

key and then repeat steps 4 and 5.

To register the new set‐point temperature and return to the automatic scan mode, go to step 6.

6. Press any component key (tank, hose, or gun).

The selected component begins to heat or cool to its new set‐point temperature.

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Operation

To adjust the set‐point temperature of an individual component

(contd)

If you enter a valid set‐point temperature for a hose/gun that is not connected to the melter or if you enter a set‐point temperature that is out of range, the right display will indicate dashes (‐‐‐‐) for three seconds and then change back to the original set‐point temperature.

When the right display is flashing, you can quickly change the current set‐point temperature to 0 degrees (off) by simultaneously pressing both of right‐display scroll keys.

After removing a hose or a gun, use the individual component method of set‐point temperature adjustment to set the component’s temperature to zero degrees (off). This will avoid causing an

F1 fault when a hose or gun is added.

The factory set‐point temperature of the tank is

175 C (350 F). The factory set‐point temperature of all others components is zero degrees (off).

When the units of temperature is set to degrees Celsius, the minimum and maximum set‐point temperatures are 40

C and 230 C. When the units of temperature are set to degrees

Fahrenheit, the minimum and maximum set‐point temperatures are 100 F and

450 F.

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Operation

4-23

When using the right‐display scroll keys to adjust a set‐point temperature, the right display automatically increments between 0, 175, and 230 C or between 0, 350, and 450

F.

If you make a mistake while you are changing a set‐point temperature, but you have not yet pressed the enter key, press the

Clear/Reset

key to reset the right display to the original temperature.

The melter will exit the setup mode and return to the automatic scan mode two minutes after the last key is pressed.

A global set‐point temperature of zero degrees (Celsius or Fahrenheit) turns all components off.

When scrolling through component numbers in the left display, component numbers that are associated with unused hose/gun receptacles are skipped.

The melter stores a record of the last ten changes made to the set‐point temperatures (and operating parameters) in the change history log.

You can save set‐point temperature changes by simultaneously pressing the

1

key and the

Setup

key.

Section 3,

Installation

,

Review Parameter and Set‐point Temperature

Changes

Section 3,

Operation

,

Save and Restore Melter Setting

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Operation

Entering the Melter Password

If the melter is password protected, a valid password must be entered before any set‐point temperature or melter parameter can be changed.

To enter a melter password

1. Press the

Setup

key.

The left display indicates parameter 0 (flashing) and the right display indicates 4000.

2. Press the

Enter

key.

The right display begins flashing.

3. Use the keypad to enter the melter password.

4. Press the

Enter

key.

One of the following occurs:

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

If the password is incorrect, the left display remains at 0 and the right display momentarily indicates dashes (‐‐‐‐) and then returns to

4000.

If the password is incorrect, re‐enter it and then press the

Enter

key.

The melter will automatically revert back to the password‐protected mode two minutes after the last key press

(any key). To force the melter back into the password protected mode before two minutes has elapsed, press the

Setup

key twice.

The melter password is created and enabled/disabled during system setup.

Section 3,

Setting Up the Melter

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Operation

4-25

Using the Melter Function Keys

The control panel provides the following standard and special function keys.

Standard function keys

Heater

Pump

Setup

Special function keys

Seven‐day clock

Standby

CAUTION:

Unintentionally activating function keys can, under the correct circumstances, have undesirable effects on the melter or the manufacturing process. Only personnel who are familiar with the melter’s setup and its connection with the manufacturing process should use the function keys. Improper use of the function keys can result in erratic process behavior or personal injury.

Heater Key

Use the heater key to manually turn the component heaters on and off. Pressing the heater key overrides the control (on or off) of the heaters by either the seven‐day clock feature or a remote input. The LED on the heater key turns on when the heaters are on.

When a fault occurs (Refer to

Monitor Melter Faults

earlier in this section) the heaters automatically turn off. The heater key is used to turn the heaters back on after correcting a fault condition.

Heater key

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Operation

Pump Key

Pump key

Setup Key

Use the pump key to start or stop the pump. The LED on the pump key turns on (green) when the pump is running.

If the automatic pump on feature (parameter is disabled, then the pump key must be used to start the pump when the melter is ready.

If any of the inputs are set up to use the pump enable/disable control option

(option 3), the pump will not start until the pump key is pressed (LED on)

and

the correct voltage is applied to the input contacts. If the pump is enabled, but the input voltage is not present, the pump LED will flash green.

Use the setup key to place the melter into and take the melter out of the setup mode. When the melter is placed into the setup mode, the automatic scan stops and the left and right displays are used to select and read or edit operating parameters.

Setup key

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Operation

4-27

Seven‐day Clock Key

Use the seven‐day clock key to turn the melter’s clock feature on and off.

When the clock is on, the temperature of each heated component is automatically regulated based on a set of user‐defined schedules.

Seven‐day clock key

To accommodate daily shift work and non‐working days, four clock schedules are available. Schedules 1, 2, and 3 are used to specify when the heaters should turn on and off or when the melter should enter and exit the standby mode. Schedule 0 is used to keep the melter in the last condition dictated by the clock (heaters on or off, or standby).

When a clock schedule calls for the heaters to be on, the heaters are regulated at their pre‐assigned set‐point temperatures. When the clock activates the standby mode, the set‐point temperature of each component is temporarily reduced by a pre‐set standby delta.

Refer to Appendix B,

Operating Parameters

,

Seven‐day Clock

, for information about setting up the seven‐day clock and the standby delta.

If the melter is switched off while the clock is on, the clock will automatically turn back on the next time the melter is switched back on.

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

The clock will still operate when the melter is faulting or is in the setup mode.

If F4 appears in the right display when you press the clock key, the internal clock function has failed.

Section 7,

Troubleshooting

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Operation

Standby Key

Standby key

Use the standby key to manually place the melter into, and take it out of, the standby mode. Using the standby mode during periods of time when the melter is inactive helps to conserve energy and allows heated components to quickly return to their set‐point temperatures when the melter is once again needed.

When the melter is placed into the standby mode, the temperatures of all components are reduced down from their set‐point temperature by a pre‐set standby delta. The melter will remain in the standby mode until the standby key is pressed or the function of one of the operating parameters takes the melter out of the standby mode.

If the melter was set up to use the manual standby timer

(parameter 26), pressing the standby key will place the melter in the standby mode for the period of time specified by the timer. After the manual standby time has elapsed, the melter will once again begin heating all of the components to their assigned set‐point temperature.

Using the standby key overrides the control of the melter (on or off) by the seven‐day clock or a remote input.

Refer to Section 3,

Operation, Setting Up the Melter

, and to Appendix B,

Operating Parameters

, for information about setting the standby delta and the standby timer.

The melter may also be set up to enter the standby mode using a variety of operating parameters.

Whenever manual standby is enabled, the standby LED blinks.

Appendix B, Parameters 23,

24, 25, 26, 30–33, 57, 62, and

67

Appendix B, Parameter 26

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Operation

4-29

Shutting Down the Melter

Shut down the melter when it will not be used for an extended period of time.

To shut the melter down

1. Switch the melter off.

The automatic pressure discharge (APD) valve relieves the hydraulic pressure in the manifold back to the tank.

2. Disable the guns as follows:

Air‐operated guns: Turn off the air supply to the guns.

Electric guns: Turn off the gun driver, pattern controller, or timer.

Melter control switch (on/off)

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Operation

Part 1024496_06 2014 Nordson Corporation

Maintenance

5-1

Section 5

Maintenance

WARNING!

Allow only qualified personnel to perform the following tasks.

Follow the safety instructions in this document and all other related documentation.

Table 5‐1 describes the preventive maintenance tasks required to keep

ProBlue melters operating within their specified limits and to prevent equipment malfunctions. For information about maintaining optional equipment that was supplied by Nordson, refer to the instructions provided with the equipment.

If the melter stops operating or is operating incorrectly, refer to Section 6,

Troubleshooting

, for information about diagnosing common problems and performing corrective maintenance.

Task

Relieving system pressure

Lockout external communications

Cleaning the exterior of the melter, hoses, and guns

Replacing the filter

Table 5‐1 Preventive Maintenance Tasks

Frequency

Before performing any maintenance task that requires opening a hydraulic connection or port

Reference

Relieving System Pressure

Before performing any maintenance task

Daily

Locking Out External

Communications

Cleaning the Melter

Replacing the Filter

As needed

When changing the type or grade of hot melt

Cleaning the tank

Cleaning the Tank

When changing the type or grade of hot melt

When excessive charring occurs

Removing the melter from the sub‐base

As needed

Removing the Melter from the

Sub‐base

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Part 1024496_06

5-2

Maintenance

Relieving System Pressure

Before disconnecting any hydraulic fitting or opening any pressurized port, always complete the following procedure to safely relieve hydraulic pressure that may be trapped inside the melter, hoses, and guns.

Melter control switch (on/off)

To relieve system pressure

1. Switch the melter off.

See Figure 5‐1.

2. Lower the drain chute and place a suitable waste container under the drain port.

3. Using a flat‐tip screwdriver,

slowly

turn the drain valve counterclockwise three turns.

4. Turn the drain valve clockwise until it stops (valve closed), and then wipe off and raise the drain chute.

5. Trigger the guns until hot melt no longer flows from the guns.

Locking Out External Communications

WARNING!

Disable external inputs and fieldbus communcations (if installed) with the melter before performing maintenance. Failure to disable external inputs or fieldbus communications with the melter can result in personal injury due to unexpected operation of the melter while performing maintenance.

To lockout external communications with the melter

Set the control option for operating parameter 14 to 1 (Enabled).

Refer to Section 3,

Setting Up the Melter

, for information about changing operating parameters.

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Maintenance

5-3

2014 Nordson Corporation

Figure

5-1

Lowering the drain chute and opening the drain valve

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5-4

Maintenance

Cleaning the Melter

To prevent components from overheating due to heat build‐up or loss of air circulation, regularly remove any hot melt that collects on the exterior of the melter, hoses, and guns.

If hot melt inadvertently spills inside the pump compartment or other interior spaces, the exterior panels can be removed in order to clean out the spilled hot melt.

WARNING!

Risk of electricution and fire! Do not clean the melter with a direct stream of water or steam. Use only water or an appropriate, non‐flammable cleaning solution that is applied using a clean cloth. Cleaning the melter using a direct stream of water or steam or a flammable solvent can result in property damage and personal injury, including death.

To clean the exterior of the melter

Use citrus‐based or other cleaning compounds that are compatible with polyester.

Apply cleaning compounds using a soft cloth.

Do not use pointed or sharp tools to clean the exterior surface.

To remove and replace the exterior panels

See Figure 5‐2.

1. De‐energize the melter. Refer to Section 1,

De‐energizing the System

.

2. Turn off the plant air supply to the melter and then disconnect the air filter from the back of the melter.

3. Open the pump enclosure door (The door must be open in order to remove the top panel.).

4. Loosen the screws that secure panels P1, P2, P3, and P4 to the melter.

Panel P4 has three screws.

NOTE:

The location of the screws on the P7 and P10 melter vary slightly

from Figure 5‐2.

5. Remove each panel by sliding or rotating it in the direction shown in

Figure 5‐2.

6. To replace the panels, complete steps 2 through 4 in reverse order and then re‐energize the system.

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Part 1024496_06

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Maintenance

5-5

NOTE:

When re‐installing panel P4, ensure that the metal hooks on P4 engage the hinge pin before rotating the panel back into position.

P1

P2

P3

P4

Figure

5-2

Removing the exterior panels

Part 1024496_06

5-6

Maintenance

Replacing the Filter

ProBlue melters are equipped with a 100‐mesh (.15 mm) disposable hot melt filter. The filter removes debris and char from the hot melt as it flows from the tank. Hot melt flows from the inside to the outside of the filter, trapping contaminants inside the filter. There is no need to back‐flush or clean the filter.

Filter location

When the filter reaches the end of its service life, it should be replaced. The factors that determine the service life of the filter are: the type, grade, and purity of the solid‐form hot melt the set point temperature of the tank the period of time that the hot melt remains in the tank

The filter should also be replaced when making the change to a different type or grade of hot melt.

To determine the optimal service life for the filter, monitor and compare the total number of hours that the heaters are on with observations of: the purity of the dispensed hot melt increases in operating pressure the frequency of gun nozzle replacement or cleaning

Hot melt flow path

Monitoring the Life of the Filter

As an aid to ensuring that the filter is replaced at the end of its service life, the melter is equipped with a service LED that turns on at the end of a customer‐defined time period. You can use this feature to alert you when it is time to change the filter. Refer to Section 3,

Setting Up the Melter

, for information about the service interval time.

When the service LED turns on, replace the filter, and then press the

Clear/Reset

key to reset the timer and turn off the service LED.

NOTE:

The melter must be in the automatic scan mode when you press the

Clear/Reset key.

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Part 1024496_06

Pump key

Maintenance

5-7

To replace the filter

NOTE:

Instructions for replacing the filter are also provided on the inside of the pump enclosure door.

1. Relieve the system pressure. Refer to

Relieving System Pressure

at the beginning of this section.

2. Use a 8 mm hex wrench or an adjustable wrench to loosen

(counterclockwise) and then remove the filter.

3. Properly dispose of the old filter.

4. Confirm that the O‐ring on the new filter is in good condition.

5. Screw the filter into the pump body and then tighten the filter to

4.5 N

 m (40 in.‐lb).

6. Resume normal operation.

Loosening the filter

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Part 1024496_06

5-8

Maintenance

Cleaning the Tank

To avoid the problems that can occur when different hot melt materials are mixed or when hot melt char forms in the tank, clean the tank when: changing to a different type of hot melt excessive char builds up inside the tank

NOTE:

The tank cleaning procedures provided in this section require that an appropriate hot melt cleaning fluid be used to soften or dissolve residual hot melt. Each type of hot melt should be supplied with a technical data sheet that names the appropriate cleaning fluid. If the technical data sheet is not available, contact the hot melt supplier.

Pump key

To clean the tank when changing hot melt

1. Operate the melter normally until the tank is empty.

2. Allow the melter to heat or cool to the temperature recommended by the manufacturer of the hot melt cleaning fluid.

3. Press the

Pump

key to stop the pump.

4. While wearing the appropriate protective equipment, wipe any residual hot melt from the inside of the tank.

5. Add the appropriate type and quantity of hot melt cleaning fluid to the tank.

6. Press the

Pump

key to start the pump.

7. Following the instructions provided with the cleaning fluid, pump all of the cleaning fluid from the tank.

8. Return the melter to normal operation and pump a minimum of one tank volume of the new type of hot melt through the tank, hoses, and guns.

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Part 1024496_06

Pump key

Maintenance

5-9

To clean the tank of excessive char

1. Remove the old hot melt and loose char as follows: a. Operate the melter normally until the tank is empty.

b. Allow the melter to heat or cool to the temperature recommended by the manufacturer of the hot melt cleaning fluid.

c. Press the

Pump

key to stop the pump.

d. While wearing the appropriate protective equipment, wipe any residual hot melt and loose char from the inside of the tank.

e. Add the appropriate type and quantity of cleaning fluid to the tank.

See Figure 5‐1.

2. Lower the drain chute and place a suitable waste container under the drain valve.

3. Press the

Pump

key to start the pump.

4. Using a flat‐tip screwdriver,

slowly

turn the drain valve counterclockwise until cleaning fluid begins to flow from the drain.

5. Continue to slowly open the drain valve to create a controlled flow of cleaning fluid from the drain.

6. Add cleaning fluid to the tank and clean the tank according to the instructions provided with the cleaning fluid.

7. Press the

Pump

key to stop the pump.

8. Turn the drain valve clockwise until it stops (valve closed).

9. Wipe any cleaning fluid or hot melt residue away from the drain chute and then raise the chute.

10. Change the filter. Refer to

Replacing the Filter

earlier in this section.

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5-10

Maintenance

Removing the Melter from the Sub‐base

NOTE:

For 400/480 VAC melters, refer to Appendix E.

1. Switch the melter off.

2. Relieve system pressure. Refer to

Relieving System Pressure

earlier in this section.

3. Disconnect the hoses.

See Figure 3‐5.

4. Disconnect the power cable and ground lead.

See Figure 3‐4.

5. Turn the locking screws counterclockwise approximately 16 turns until they stop.

6. Slide the melter forward, and then lift it clear of the sub‐base (See Figure

3‐4).

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Troubleshooting

6-1

Section 6

Troubleshooting

WARNING!

Allow only qualified personnel to perform the following tasks.

Follow the safety instructions in this document and all other related documentation.

This section provides quick‐reference information for diagnosing melter faults indications as well as comprehensive melter diagnostic information that is provided in flowchart format. When required, the troubleshooting flowchart will refer you to diagnostic procedures provided later in this section.

If you cannot resolve the problem using the troubleshooting flowchart, contact your Nordson representative for technical assistance.

400/480 Volt Melters

Refer to Appendix E for information about troubleshooting the transformer,

400/480 volt heater information, and information about parts that are specific to 400/480 volt melters.

NOTE:

With the exception of power supply and heater failure problems, the information provided in this section applies to all ProBlue adhesive melters.

Safety

Never disconnect cables from, or reconnect cables to, the main board while the melter is energized.

Before breaking any hydraulic connection, always relieve system pressure. Refer to Section 5,

Relieving System Pressure

.

Refer to the safety information provided with optional equipment.

If the melter is removed from its sub‐base for diagnostic checks or service, ensure that the ground lead between the chassis and the sub‐base is re‐attached when the melter is reconnected to the sub‐base.

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6-2

Troubleshooting

Melter Faults

Table 6‐1 lists the four types of melter faults, potential causes, and expected

corrective actions.

Display

Code/Sub‐code

F1/None

F2/None

F3/None

F4/1

F4/2

F4/4

F4/5

F4/6

RTD

Name

Under temperature

RAM test

Table 6‐1 Melter Faults

Affect on Melter

Heaters turn off

Heaters turn off

Over temperature Heaters turn off

Cause

The RTD for the component indicated has failed or the component was disconnected from the melter.

The actual temperature of the component indicated has dropped below the under temperature delta, which was set using parameter22.

The actual temperature of the component indicated has increased beyond the over temperature delta, which was set using parameter21.

Internal RAM failure

Corrective Action

Replace RTD

Check hose/gun connections

See flowchart T.2

Check for conditions that may cause a drop in ambient temperature

Raise the set‐point temperature of the component

Replace RTD

See flowchart T.2

Replace RTD

See flowchart T.2

Replace CPU

Internal Clock time

Internal clock battery backed

RAM

Internal clock battery

Analog‐to‐digital

Melter stops functioning

Heaters remain on, but fault condition persists

Heaters remain on, but fault condition persists

Heaters remain on, but fault condition persists

Melter stops functioning

Internal clock failure

Battery‐backed RAM failure

Battery‐backed RAM battery dead

RTD analog‐to‐digital converter failed

Replace CPU

Replace CPU

Replace CPU

Replace main board or

CPU

Continued…

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Part 1024496_06

Troubleshooting

6-3

Display

Code/Sub‐code

F4/7

F4/8

F4/A

F4/d

F4/E

Name

Analog‐to‐digital calibration

Main board feedback

Thermostat

Communications with optional I/O card

Fieldbus communications failure

Table 6‐1 Melter Faults

(contd)

Affect on Melter Cause

Failed hose or gun

Melter stops functioning

Melter stops functioning

Melter stops functioning

Heaters remain on, but fault condition persists

Alert output (if output option 6 is selected)

Melter continues to operate normally.

RTD analog‐to‐digital converter could not be calibrated

Communication failure between main board and CPU

Tank or manifold thermostat is open

Communication failure between CPU and the optional I/O card

Fieldbus card failure.

Corrective Action

Replace hose or gun.

Note: Set set‐point to zero to avoid F1 fault.

Replace main board or ribbon cable, or CPU

Replace main board, ribbon cable, or CPU

Replace thermostat, J7 harness, or main board

Replace the I/O card or

CPU

Replace the Fieldbus card

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6-4

Troubleshooting

Using the Troubleshooting Flowchart

a

The flowchart, which is provided at the end of this section, is designed to assist you in diagnosing and correcting a complete or partial stop in hot melt output from the guns. The chart is organized in a simple question‐action block format. If your response to a question is yes (Y), continue downward in the chart to the next question or action block. If you response is no (N), continue to the right to the next question or action block. All diagnostic paths within the chart end with an action block that specifies one of the following three courses of action:

b

Troubleshooting question and action blocks

Refer to information provided elsewhere in this manual

Replace a component

Complete a diagnostic procedure (DP.x)

a

) Question

b

) Action

To return your melter to service as quickly as possible, the chart is designed under the assumption that it is preferable to immediately replace a faulty assembly as opposed to conducting detailed diagnostics and repair of the assembly while the melter is out of service.

Use of the chart assumes that the melter is installed correctly and that it is set up to support the current manufacturing process. Refer to Section 3,

Installation

, for information about installing and setting up the melter.

Troubleshooting Quick‐checks

Before using the troubleshooting charts confirm: whether or not service was recently performed on the melter or the melter’s settings were recently adjusted.

the correct voltage plug is installed on terminal J1. Refer to Section 3,

Installation

, for information about selecting the correct voltage plug.

external inputs (if used) are functioning properly.

the standby or clock functions are not turned on (if not required or expected at the current time).

2014 Nordson Corporation

Part 1024496_06

Troubleshooting

6-5

Returning the Melter Setup to Factory Settings

By returning the melter to its factory setting many common melter problems can be isolated to either a problem with the melter settings or the melter hardware.

To return the melter to its factory settings, simultaneously press and hold the

Setup key and the right‐display DOWN arrow key, and then, while holding down these keys, cycle the melter control switch off and on. When the melter restarts, release the two keys.

Identifying Electrical Components

Tables 6‐2 through 6‐5 describe the circuit board indicators, connection

points, and test points that are referred to in the troubleshooting flowchart.

Figure 6‐1 illustrates the location of each of these circuit board components.

J6

J7

J8

J9

J10

Item Number

Indicators

DS1

DS2

DS3

DS4

DS5

Fuses

F1/F2

F3/F4

Connection Points

J1/J2

TB1

TB2

J5

Type

LED (Yellow)

Neon (Orange)

LED (Yellow)

Neon (Orange)

LED (Green)

—

—

Jumper

Input

Input/output

Input/output

Output

Input/Output

Input/Output

Output

Input

Table 6‐2 Main PCA

Description

Control signal for tank heater

Power available for tank and manifold heaters after fuses F1/F2

Control signal for manifold heater

Power available into main board after fuses F3/F4

+5 VDC control voltage present on board

15 A, 250 V, Fast‐acting,

1

/

4

inch

2 A, 250 V, Slow‐blow, 5 x 20 mm

Voltage configuration plug with and without neutral

AC power into board

Output contacts 1–6. Input contacts 7–14

Control signal between main board and 6‐hose expansion board

Power harness for tank and manifold heaters

Control signal harness (RTD, control switch, thermostat, solenoid). See Figure 6‐2 for pin‐out.

Analog/digital signal cable

Control signal to 400/480 VAC transformer

AC power out to 6‐hose expansion board

2014 Nordson Corporation

Part 1024496_06

6-6

Troubleshooting

Identifying Electrical Components

(contd)

Item Number

Indicators

Red LED

Green LED

Connection Points

J1

J5

—

—

Type

Input/Output

Input/Output

Test Points

TP2/TP4 Contacts

Table 6‐3

CPU board

Description

Indicates that CPU board has failed

+ 5 VDC control voltage is present at the CPU board

Control signal between main PCA and CPU

Control signal between I/O expansion card or Anybus card and the CPU

4.75–5.25 V control voltage present at CPU

Item Number

Indicators

DS1

DS2

DS3

DS4

DS5

DS6

Fuses

F1/F2 and F3/F4 —

Type

Table 6‐4

Hose/Gun Power Module

Description

LED (Yellow)

LED (Yellow)

LED (Yellow)

LED (Yellow)

Neon (Orange)

Neon (Orange)

Control power present for odd numbered hose

Control power present for odd numbered gun

Control power present for even numbered hose

Control power present for even numbered gun

AC power present at module for odd hose/gun pair

AC power present at module for even hose/gun pair

6.3 A, 250 V, Fast‐acting, 5 x 20 mm

Item Number

Connection Points

J1

J2

Input

Table 6‐5

6‐Hose Expansion Board (optional)

Type

Input/output

Description

Control signal between 6‐hose expansion board and main board J5

AC power input to 6‐hose expansion board from main board

J10

Part 1024496_06

2014 Nordson Corporation

Troubleshooting

6-7

Figure

6-1

Electrical components

2014 Nordson Corporation

Part 1024496_06

6-8

Troubleshooting

Figure

6-2

Power and control harness

Part 1024496_06

2014 Nordson Corporation

Troubleshooting

6-9

Figure

6-3

Location of the return port

2014 Nordson Corporation

Part 1024496_06

6-10

Troubleshooting

1

2

Figure

6-4

Pneumatic flow diagram

1. Pump air inlet

2. Pressure discharge valve

3. Melter air supply inlet

Part 1024496_06

3

2014 Nordson Corporation

Troubleshooting

6-11

Diagnostic Procedures

Use these diagnostic procedures when directed by the troubleshooting flowchart. If a diagnostic procedure fails to identify or correct the problem, return to the troubleshooting flowchart or contact your Nordson representative for technical assistance.

DP.1 Isolate a Failed Control Component

1. De‐energize the melter. Refer to Section 1,

Safety

.

See Figure 6‐1.

2. Disconnect the ribbon cable (P/N 1018283) from the main board.

3. Remove all of the hose/gun modules.

4. Re‐energize the melter.

5. Check LED DS5 on the main board, and then do

one

of the following:

If DS5 does

not

illuminate, replace the main board (P4 or P7 melters, use P/N 1028322; P10 melter, use P/N 1038323).

If DS5 does illuminate, go to step 6.

6. Complete the following steps to Isolate the cause of the problem by individually checking

each

of the components that were disconnected from the main board in steps 2 and 3 (CPU and each hose/gun module).

a. De‐energize the melter.

b. Reconnect each component (ribbon cable, and then each hose/gun module).

c. Re‐energize the melter.

d. Observe LED DS5 (main board).

Replace the component (CPU or hose/gun module) that causes LED

DS5

not

to illuminate when the melter is re‐energized.

2014 Nordson Corporation

Part 1024496_06

6-12

Troubleshooting

DP.2 Check the Tank or Manifold RTD

1. Check the left display to determine which RTD (tank or manifold) is faulting. The display indicates 1 if the tank RTD is faulting or 2 if the manifold RTD is faulting.

2. De‐energize the melter. Refer to Section 1,

Safety

.

NOTE:

If the melter has already cooled down, solidified hot melt within the pump/manifold will prevent you from removing the pump. To remove the pump, you must reheat the melter. Refer to

Reheating the Melter During an

F1 Fault

at the end of this procedure.

See Figure 6‐2.

3. Remove the RTD from its retention slot.

For the tank RTD, refer to

Remove the Tank RTD.

For the manifold RTD, refer to

Remove the Manifold RTD

.

4. Allow the RTD to cool to room temperature or use a pyrometer to accurately determine the temperature of the RTD.

5. When the temperature of the RTD is known, measure the resistance of the RTD across terminals 1 and 2 (tank RTD) or 3 and 4 (manifold RTD).

See Figure 6‐5.

6. Determine the expected resistance of the RTD at the known temperature.

Compare the expected and measured resistance values and then do

one

of the following:

If the measured resistance is within the expected resistance range, the RTD is functioning properly. Replace the main board (P4 or P7 melters, use P/N 1028322; P10 melter, use P/N 1038323).

If the measured resistance is not within the expected resistance range, the RTD is defective. Replace the RTD (P/N 1028320).

Part 1024496_06

2014 Nordson Corporation

Removing the tank RTD

Troubleshooting

6-13

Reheating the Melter During an F1 Fault

1. While holding both the

Setup

key and the

Tank

key, cycle the system control switch off and then on.

The left display will flash dashes at one second intervals to indicate that the melter is heating in the override mode. The melter will remain in the override mode for 20 minutes and then automatically switch off.

WARNING!

Risk of electrocution!

The control switch will remain in the on position when the melter automatically switches off after 20 minutes. Ensure that the control switch is moved back to the off position.

2. If necessary, repeat step 1 to continue reheating the melter.

Remove the Tank RTD

1. De‐energize the melter. Refer to Section 1,

Safety

.

2. Open the pump enclosure door.

3. While gently pulling the retention clip away from the RTD, slide the RTD out of its retention slot.

NOTE:

If the RTD is functioning properly, apply thermal compound (provided in RTD service kit P/N 1028320) to the RTD before replacing it in the retention slot.

2014 Nordson Corporation

Part 1024496_06

6-14

Troubleshooting

Remove the Manifold RTD

1. Relieve system pressure. Refer to Section 5,

Relieving System Pressure

.

See Figure 6‐6.

2. Isolate the pump from the manifold by rotating the isolation valve handle to its full vertical position (valve closed).

3. Remove the three pump‐mounting bolts from the front of the pump body.

4. Rotate the top of the pump slightly toward the front of the melter, and then pull the pump up and away from the manifold.

NOTE:

The face of the pump body contains two M6 threaded holes.

Bolts can be threaded into these holes to gain leverage when removing the pump.

5. Remove the air line from the back of the pump.

6. Lift the pump clear of the melter.

7. Remove the RTD from its retention slot.

8. To replace the RTD and pump, reverse the order of steps 2 through 7.

CAUTION!

Before replacing the pump, ensure that the cross‐over tube is in‐place between the pump and the manifold.

NOTE:

Before replacing the RTD, apply thermal compound (P/N 1023441) to the RTD and its retention slot. To avoid damage to the RTD, ensure that the RTD is correctly inserted into its retention slot before replacing the pump.

Part 1024496_06

2014 Nordson Corporation

Troubleshooting

6-15

DP.3 Check the Operation of the Power Relay or Thermostats

The pre‐conditions for this diagnostic procedure are as follows:

The heater LED is illuminated.

Indicator DS2 on the main board is

not

illuminated.

Indicators DS5 and DS6 on all hose/gun modules are

not

illuminated.

1. De‐energize the melter. Refer to Section 1,

Safety

.

2. Remove all of the hose/gun modules.

3. Re‐energize the melter.

NOTE:

If an F1 fault re‐occurs after re‐energizing the melter, reset the melter and turn the heaters back on.

4. Press the

Heaters

key.

See Figure 6‐1.

5. Check indicator DS2 on the main board, and then do

one

of the following:

If indicator DS2

does

illuminate, go to step 6.

Removing a hose/gun module

If indicator DS2 does

not

illuminate, got to step 7.

6. Locate a failed hose/gun module by

individually

replacing and checking each module as follows: a. De‐energize the melter.

b. Replace the hose/gun module.

c. Re‐energize the melter.

d. Check if LED DS5 illuminates.

Replace the hose/gun module that causes LED DS5

not

to illuminate when the melter is re‐energized.

7. Complete

one

or

both

of the following checks to determine if the main board or a thermostat has failed: a. Check for 21–27 VDC across receptacle J9, pins 1 and 6. If the voltage is

incorrect

, replace the main board, otherwise go to b.

b. Check for 21–27 VDC across receptacle J9, pins 2 and 6. If the voltage is

incorrect

, one or both of the thermostats or the wire harness connected to receptacle J7 has failed. Refer to

DP.6 Check the

Resistance of the Tank/Manifold Thermostat

. If the voltage is

correct

, replace the main board.

2014 Nordson Corporation

Part 1024496_06

6-16

Troubleshooting

DP.4 Check the Operation of the Tank or Manifold TRIAC

See Figure 6‐1.

WARNING!

Risk of electrocution! Ensure that disconnect switch that serves the melter is in the off position and locked.

1. De‐energize the melter. Refer to Section 1,

Safety

.

2. Remove the protective rubber cover from the tank or the manifold heater terminals (Whichever component is faulting).

3. Re‐energize the melter and turn the heaters back on.

4. Press the

Heaters

key.

5. While watching LEDs DS1 and DS3 on the main board, measure the voltage across the heater terminals as follows:

For an F2 fault, voltage across the terminals should be within

10 VAC of the voltage being supplied to the melter when DS1 and

DS3 are illuminated.

For an F3 fault, voltage across the terminals should be less than

5 VAC when DS1 and DS3 are

not

illuminated.

Replace the main board if either of the above voltage conditions are incorrect (P4 or P7 melters, use P/N 1028322/P10 melter, use

P/N 1038323).

Part 1024496_06

2014 Nordson Corporation

Troubleshooting

6-17

DP.5 Check the Resistance of the Tank and Manifold Heaters

WARNING!

Risk of electrocution! Ensure that disconnect switch that serves the melter is in the off position and locked.

1. De‐energize the melter. Refer to Section 1,

Safety

.

See Figure 6‐1.

2. Disconnect the power harness plug (P/N 1024529) from receptacle J6 on the main board.

3. Measure the resistance across pins 1 and 2 (tank) or pins 3 and 4

(manifold) on the power harness plug, and then do

one

of the following:

If the resistance

is

within the range shown in Table 6‐6, go to step 4.

If the resistance is

not

within the range shown in Table 6‐6, go to step

8.

NOTE:

Refer to Appendix E for 400/480 Volt heater resistance data.

Model

P4

P7

P10

Table 6‐6 Heater Resistance

Resistance

Tank

46–58 ohms

40–50 ohms

Manifold

46–58 ohms

4. Individually check the resistance between the chassis and pins

1 and 2 (tank) or pins 3 and 4 (manifold) on the power harness plug, and then do

one

of the following:

If the resistance is greater than 1 Meg ohm, return to the troubleshooting chart.

If the resistance is less than 1 Meg ohm, go to step 5.

5. Remove the front and rear panels from the melter. Refer to Section 5,

Cleaning the Melter

, for the procedure to remove the panels.

CAUTION!

Use two wrenches and minimal force when loosening or tightening the heater terminal connections. Using a single wrench or excessive force to remove or tighten the terminals nuts can damage the heater.

2014 Nordson Corporation

Part 1024496_06

6-18

Troubleshooting

DP.5 Check the Resistance of the Tank and Manifold Heaters

(contd)

6. Using two wrenches, loosen the nuts that hold the power harness leads to the tank or the manifold heater terminal posts.

7. Individually check the resistance between the chassis and

each

tank or each manifold heater terminal post, and then do

one

of the following:

If the resistance is

greater

than 1 Meg ohm, replace the power harness (P/N 1024529).

If the resistance is

less

than 1 Meg ohm for the tank heater, replace the tank. If the resistance is less than 1 Meg ohm for the manifold, replace the manifold heater. Refer to Section 7,

Parts

.

8. Remove the front and rear panels from the melter. Refer to Section 5,

Cleaning the Melter

, for the procedure to remove the panels.

9. Measure the resistance across the tank heater posts and the manifold heater posts terminals, and then do

one

of the following:

If the resistance

is

within the range shown in Table 6‐6, replace the

power harness (P/N 1024529).

If the resistance is

not

within the range shown in Table 6‐6 replace the

tank or replace the manifold heater.

NOTE:

The tank heater cannot be replaced independently.

Part 1024496_06

2014 Nordson Corporation

Troubleshooting

6-19

210

200

190

180

170

250

240

230

220

290

280

270

260

150

140

130

190

180

170

160

250

240

230

220

210

200

TEMPERATURE

Figure

6-5

RTD resistance vs. temperature

TEMPERATURE

2014 Nordson Corporation

Part 1024496_06

6-20

Troubleshooting

Figure

6-6

Removing the pump

Part 1024496_06

2014 Nordson Corporation

Start

I s the control panel illuminated?

+

Do dashes appear in both the left and the right display?

−

+

−

For 400/480V melter troubleshooting, refer to Appendix E.

Do the words “UP LOAd” or

“COnF” appear across the display?

+

Go to

T.1

Refer to Appendix C.

−

Is the fault LED illuminated?

+

−

Go to

T.2

ProBlue

Troubleshooting

Flowcharts

Is the ready LED illuminated?

−

+

Has glue output stopped from all guns?

Note: With one gun systems, both T.4 and T.5 may need to be examined to resolve the problem.

+

−

Go to

T.3

Go to

T.4

Replace the control switch.

P/N 1017947.

Turn the control switch on. Does the melter start?

−

+

Stop.

Is the wire harness that is connected to terminal J7 on the main board loose or damaged?

−

+

Turn the control switch off, secure or replace the harness, and then turn the control switch back on.

Go to

T.5

This page intentionally left blank

Quick Check: Verify that the voltage plug is correct

Is the power disconnect switch that is serving the melter turned on?

−

+

Is indicator DS4 on the main board illuminated?

See Figure 6-1.

−

+

Go to T.1.1

Turn the disconnect switch on.

Is there power at the disconnect switch?

+

Are the voltage plugs attached securely to J1 and J2 on the main board?

−

See Figure 6-1.

+

Are the wires to the electrical connector into TB1 secure?

See Figure 6-1.

−

+

Continued on next page….

−

Check/repair the plant wiring.

Connect securely.

Connect securely.

T.1

Starting Condition:

Control panel is not illuminated

Continued from previous page….

Is there voltage across the wires in the power cable from the disconnect switch to TB1?

−

+

Is there voltage on the downstream side of fuses F3 and

F4 on the main board?

See Figure 6-1.

−

+

Replace the main board assembly.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Replace the power cable.

Replace fuses F3 and F4.

P/N 1028329.

T.1

Starting Condition:

Control panel is not illuminated

Is LED DS5 on the main board illuminated?

See Figure 6-1.

−

+

Is the green power LED on the

CPU board illuminated?

See Figure 6-1.

−

+

Is the voltage across TP2 and

TP4 on the CPU board between

4.75 and 5.25 VDC?

See Figure 6-1.

+

Is the red CPU warning LED illuminated?

See Figure 6-1.

−

−

+

Replace the CPU board.

P/N 1028325.

Isolate the failed control component.

Refer to DP.1.

Replace the main board assembly.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Contact Nordson for technical assistance.

Is the ribbon cable between the main board and the CPU board improperly aligned, loose or visibly damaged?

See Figure 6-1.

+

Secure or replace the ribbon cable.

P/N 1018283.

−

T.1.1

Starting conditions:

Control panel is not illuminated

>

Disconnect switch is on

>

DS4 is illuminated

Replace the CPU.

P/N 1028325.

This page intentionally left blank

T.2

Starting Condition:

Fault LED is illuminated

Is an F1 (RTD) fault indicated in the right display?

−

+

Is an F2 (under temperature) fault indicated in the right display?

−

+

Continued on next page….

Go to T.2.1

Is an F3 (over temperature) fault indicated in the right display?

−

+

Go to T.2.2

Is an F4 fault indicated in the right display?

+

Contact Nordson for technical assistance.

−

See Table 6-1. Does replacing the component(s) listed under the respective fault code, and then resetting the melter clear the fault?

+

Stop.

Continued from previous page….

Is the tank key LED illuminated?

−

+

Confirm that the RTD has failed.

Refer to DP.2.

P/N 1028320.

Are all of the gun-to-hose and hose-to-melter electrical cordsets securely connected? (The gun or hose key LED is illuminated)

−

+

Is the ribbon cable from the

6-hose expansion board connected to the main board, aligned and functioning properly?

(J5 to J1)

+

−

Does the fault re-occur if you move the faulting hose/gun pair to a known good hose/gun module?

−

+

Replace the hose or gun RTD.

Refer to the hose or gun manual.

Secure the electrical connectors and then press the reset key.

Connect securely or replace.

Contact Nordson for technical assistance.

T.2

Starting Condition:

Fault LED is illuminated

Reset the melter and turn the heaters back on. Allow the unit to come to temperature.

Is the tank key LED illuminated?

+

−

Does the manifold fail to come to temperature?

−

+

Verify that the manifold heater has failed and replace.

Refer to DP.5.

P/N 1017723.

T.2.1

Starting Conditions:

Fault LED is illuminated

>

F2 fault exists

I s the affected gun or hose cordset loose, or are the pins bent, loose or corroded? (the gun or hose key LED is illuminated.)

−

+

Secure or repair the loose cordset then press the Reset key.

Refer to the hose or gun manual.

Are the wires to the electrical connector into TB1 secure?

+

−

Connect securely.

Connect securely.

Is the power cable that connects to J6 connected securely?

−

+

Was hot melt recently added to the tank?

−

+

Allow the unit to reach set-point temperature.

Go to

T.2.3

Is the power lead connecting the

6-hose expansion board to the main board loose or damaged?

(J10 to J2) (P10 only)

−

+

Secure or replace.

Cont.

on next page

Continued from previous page….

Is there 240 VAC across fuses

F1/F2 or F3/F4 on the affected hose/gun module, and is the hose/gun wattage properly rated?

+

−

Are the indicators DS5 or DS6 on the affected hose/gun module illuminated?

See Figure 6-1.

−

+

Are the hose and gun RTD functioning correctly?

−

Correct the house voltage or replace the hose/gun with a properly rated hose/gun.

Replace the hose or gun RTD.

+

Does the fault re-occur if you replace the affected hose/gun module with a known good module?

+

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

−

Replace the affected hose/gun module.

P/N 1028328.

T.2.1

Starting Conditions:

Fault LED is illuminated

>

F2 fault exists

Is indicator DS2 on the main board or DS5 and DS6 on any hose/gun module illuminated?

−

+

Replace fuse pairs F1/F2 or

F3/F4 on the affected hose/gun module.

P/N 1028331.

See Figure 6-1.

Check the operation of the power relay or thermostat.

Refer to DP.3.

Reset the melter and turn the heaters back on. Allow the unit to come to temperature.

Is more than one component overheating? (Check the actual temperature of the faulting component.)

−

+

Continued on next page

Is the tank key LED illuminated?

−

+

Is DS1, DS2, DS3 or DS4 on the hose/gun module illuminated continuously?

−

+

Does replacing the hose or gun

RTD solve the problem?

−

+

Stop.

T.2.2

Starting conditions:

Fault LED is illuminated

>

F3 fault exists

Replace the hose/gun

P/N 1028328.

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

−

Are the tank/manifold TRIACs operating properly?

Refer to DP.4.

+

Replace the tank/manifold RTD.

P/N 1028320.

Refer to DP.2.

T.2.2

Starting conditions:

Fault LED is illuminated

>

F3 fault exists

Continued from previous page….

Is there a DC drive near the melter?

−

+

Does installing an RC snubber on the DC drive and resetting the melter clear the fault?

−

P/N 332182.

+

Stop.

Is the power cable grounded to the melter’s chassis?

−

+

Is the resistance between the ground leg and earth ground on the power cable greater than zero?

−

+

Correct or establish earth ground connection with the melter.

Ground the power cable properly to the chassis.

Does installing an RC snubber on the melter clear the fault?

P/N 332182.

−

+

Stop.

Contact Nordson for technical assistance.

Is indicator DS2 in the main board illuminated?

−

+

Is the power harness into J6 connected securely?

−

+

Is the voltage across the downstream side of fuses F1/F2 or F3/F4 on the main board between 170 and 265 VAC?

See Figure 6-1.

+

−

Connect securely.

Check/correct the house voltage.

Continued on next page

T.2.3

Starting conditions:

Fault LED is illuminated

>

F2 fault exists

>

Tank key LED is illuminated

>

Hot melt has not been added

Are indicators DS5 or DS6 illuminated on any hose/gun module?

See Figure 6-1.

+

−

Does replacing fuses F1 and F2 on the main board and then resetting the melter clear the fault?

P/N 1028329.

+

Stop.

−

Check the operation of the power relay or thermostat.

Connect securely. Refer to

DP.3

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Continued from previous page….

Is the resistance correct for the tank and the manifold heaters?

Refer to DP.5.

−

+

Are the tank and the manifold

TRIACs functioning properly?

Refer to DP.4.

−

+

Does replacing the malfunctioning tank or manifold RTD solve the problem?

−

P/N 1028320.

Refer to DP.2.

+

Stop.

Replace the manifold heater, tank, or the power harness.

Manifold heater − P/N 1017723.

Tank − P/N 1018379.

Power harness − P/N 1024529.

Replace the main board.

P4/P7 − P/N 1028322.

P/10 − P/N 1028323

Contact Nordson for technical assistance.

T.2.3

Starting conditions:

Fault LED is illuminated

>

F2 fault exists

>

Tank key LED is illuminated

>

Hot melt has not been added

Quick check: Manually activating the heater key or the pump key will override and eliminate remote inputs as the cause of a down condition.

Quick check: Save settings and reset the melter to factory default settings. If the melter functions normally, isolate the input or output problem.

Is the heater key LED illuminated?

+

Cont. on next page

T.3

Starting conditions:

No faults

>

Ready LED is not illuminated

−

Is the clock LED illuminated?

−

+

Is the clock schedule programmed correctly?

+

The current clock schedule has the heaters turned off.

−

Is a remote input being used to control the heaters?

−

+

Go to

T.3.1

Replace the operator panel.

P4/P7 − P/N 1028326.

P10 − P/N 1028327.

−

Does pressing the heater key turn the heaters on?

+

Stop.

Continued from previous page….

Is the standby LED on?

+

The melter is in the standby mode.

Refer to Section 4,

Standby

Key.

−

Is the ready delay counting down?

+

Wait for the ready delay to count down.

Refer to

Appendix B, parameter

4.

−

Confirm that the tank heater has failed and replace the tank.

Tank − P/N 1018379.

Refer to DP.5.

T.3

Starting conditions:

No faults

>

Ready LED is not illuminated

Is there a signal at the input on the mainboard or on the I/O board?

−

+

Is the programming for the input correct?

−

+

Wait for the input to initiate the heaters or use the heater key to manually turn the heaters on.

Reprogram the input.

T.3.1

Starting conditions:

No faults

>

Ready LED is not illuminated

>

Remote input is being used

Verify that the parent machine is working properly. Refer to the appropriate manual.

Is there a signal at the parent machine?

−

+

Is there power across the wires from the parent machine to the inputs on the main board or I/O board?

−

+

Does pressing the heaters key turn the heaters on?

−

+

Replace the I/O expansion board kit.

P/N 1036607.

Inspect the wires for damage or corrosion and replace if needed.

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

This page intentionally left blank

Quick check: Save settings and reset the melter to factory default settings. If the melter functions normally, isolate the input or output problem.

Quick check: Manually activating the heater key or the pump key will override and eliminate remote inputs as the cause of a down condition.

Has the pump stopped?

−

Is the pump cycling fast?

−

Is hot melt leaking from the system somewhere between the manifold and the guns?

−

T.4

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

The pump piston ball valve is stuck open.

Refer to Appendix D.

+ + +

Locate and repair the leak.

Go to T.4.1

Is there sufficient air pressure to the pump (greater than 0.7 bar/10 psi)?

−

+

Adjust the air pressure.

Continued on next page

T.4

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

Continued from previous page….

Is the tank empty?

+

Turn off the pump. Fill the tank.

Wait for the unit to heat the adhesive to operating temperature.

−

Is the isolation valve (shut off valve) closed?

See Figure 6-6.

Open the valve.

+

−

Is hot melt returning to the tank through the return port located behind the tank screen?

See Figure 6-3.

+

Replace the pressure discharge valve.

P/N 1028308.

−

Check and clean the outlet of the tank and the crossover tube or clean/replace the manifold.

Quick check: Manually activating the heater key or the pump key will override and eliminate remote inputs as the cause of a down condition.

Is the pump LED illuminated?

+

−

Does pressing the pump key turn the pump on?

−

Stop.

+

Does replacing the operator’s panel and then restarting the melter correct the problem?

P4/P7 − P/N 1028326.

P10 − P/N 1028327.

+

Stop.

T.4.1

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

>

Pump has stopped

Replace the CPU board.

P/N 1028325.

−

Is the pump LED flashing?

−

+

Are you using an optional input

(parameters 5 thru 10) to enable/disable the pump?

−

+

Continued on next page

Go to

T.4.2

Continued from previous page….

Is the power LED on the I/O board illuminated?

−

+

Are the inputs properly functioning? (Refer to table T.3.1

for diagnostic procedures)

−

+

Wait for the system controller to send a pump start signal.

Replace the I/O expansion board kit.

P/N 1036607.

Repair or replace the malfunctioning input.

T.4.1

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

>

Pump has stopped

Problem

Is the air supply to the melter turned off or is the plant air pressure low?

−

+

Turn on or adjust the plant air pressure.

Is the operating air pressure set correctly?

Refer to

Section 4.

−

+

Is air being supplied to the top of the pump?

−

+

Continued on next page….

T.4.2

Adjust the operating air pressure for the current manufacturing process.

Are the yellow and green air lines to the pneumatic assembly connected properly?

−

See Figure 6-4.

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

>

Pump has stopped

>

Pump LED is illuminated

>

Tank set-point temperature is OK

>

Pump is not controlled by a remote input

Connect securely.

+

Is 24 VDC being supplied to the solenoid valve (wire harness leads 9 and 10)?

−

+

Replace the pneumatic assembly.

P/N 1028307.

Do the wires at Pins 9 and 10 on the J7 wire harness lack continuity?

Connect securely. See Figure

6-2.

+

Replace the J7 wire harness.

P/N 1024600.

−

Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 028323.

Continued from previous page….

Does adhesive flow from the drain valve when it is open?

+

Clean or replace the manifold.

P/N 1022727.

−

Is the filter clogged?

Refer to Section 5.

+

Replace the filter.

P/N 1028305.

−

T.4.2

Starting conditions:

No faults

>

Ready LED is illuminated

>

No hot melt output from all guns

>

Pump has stopped

>

Pump LED is illuminated

>

Tank set-point temperature is OK

>

Pump is not controlled by a remote input

Replace or repair the pump.

Refer to Appendix D.

T.5

Starting conditions:

No faults

>

Ready LED is illuminated

>

Hot melt output from some guns

Is the set-point temperature correct for the hose/gun pair that has no hot melt output?

−

+

Is the displayed temperature for the stopped hose/gun changing erratically?

−

+

Check/replace the hose or the gun RTD.

Refer to the hose or gun manual.

Adjust the set-point temperature.

Are the gun solenoid, gun driver, or air supply to the gun functioning properly?

−

+

WARNING:

Relieve system pressure before continuing.

Is the gun nozzle or an inline

Saturn filter blocked?

+

Clean the nozzle or replace the filter.

−

Replace/repair the solenoid/gun driver or adjust the air supply.

WARNING:

Relieve system pressure before continuing.

Does hot melt flow from the gun body if you remove the gun module?

+

Replace the gun module.

Refer to the gun manual.

−

Replace the hose.

WARNING:

Relieve system pressure before continuing.

Does hot melt flow from the hose if you remove the gun?

−

+

Replace the gun body, heater, or RTD.

Refer to the gun manual.

This page intentionally left blank

Parts

7-1

Section 7

Parts

NOTE:

Refer to Appendix E for information about 400/480 Volt melter parts.

Using the Illustrated Parts List

The parts lists provided in this section are organized into the following columns:

Item

—Identifies illustrated parts that are available from Nordson

Corporation.

Used

—Identifies the melters in which the part is used. A blank entry indicates that the part is used in all ProBlue melters.

Part

—Provides the Nordson Corporation part number for each saleable part shown in the illustration. A series of dashes in the parts column

(‐ ‐ ‐ ‐ ‐ ‐) means the part cannot be ordered separately.

Description

—Provides the part name, as well as its dimensions and other characteristics when appropriate. Bullets in the description, indicate the relationships between assemblies, subassemblies, and parts.

Quantity

—The quantity required per unit, assembly, or subassembly.

The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model.

NOTE:

Illustrations of the model P4 are used throughout this section to represent all ProBlue melters. Refer to the

Used

column to determine the part number associated with your melter.

Fasteners

Fasteners are called out in each illustration using the convention

Fx,

where

“x” is the fastener number used in the

Schedule of Fasteners,

which is located at the end of this section.

Part 1024496_06

2014 Nordson Corporation

7-2

Parts

Tank, Pump, and Manifold Parts List

Figure

7-1

Tanks, pump and manifold

Part 1024496_06

2014 Nordson Corporation

2014 Nordson Corporation

Part

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1051033

1051034

1051035

‐ ‐ ‐ ‐ ‐ ‐

1017009

1017060

‐ ‐ ‐ ‐ ‐ ‐

1018189

1017186

941161

1017189

940133

1022747

1025885

1017892

1028320

954013

1029997

1030557

1030556

Parts

7-3

Quantity

1

2

1

1

1

1

3

3

1

1

1

1

1

1

1

2

1

1

2

1

1

1

2

1

1

Note

A, B

C

C

F

F

C

C

F

F, G

D

E

Part 1024496_06

7-4

Parts

Manifold Assembly Parts List

4

3

Figure

7-2

Manifold assembly

1

2

Part 1024496_06

2014 Nordson Corporation

Parts

7-5

Item Part Description

1 1064651

1064653

1064652

1064654

SVC KIT,MANIFOLD 4-H, W/HTR BLOCK, 230V,

PB

SVC KIT,MANIFOLD 6-H, W/HTR BLOCK, 230V,

PB

SVC KIT,MANIFOLD 4-H, W/HTR BLOCK, 480V,

PB

SVC KIT,MANIFOLD 6-H, W/HTR BLOCK, 480V,

PB

2

3

4

942111

1019515

1064649

1064650

O RING,VITON, .812X1.062X.125

ORING, VITON, .50 X .75 X .125

SVC KIT,HEATER BLOCK,230V,PROBLUE

SVC KIT,HEATER BLOCK,480V,PROBLUE

NOTE A: Refer to

Service Kits

for kit contents

1

1

1

1

1

1

1

1

Quantity

A

A

A

A

A

A

Note

2014 Nordson Corporation

Part 1024496_06

7-6

Parts

This page intentionally left blank.

Part 1024496_06

2014 Nordson Corporation

Parts

7-7

Pump Assembly Parts Lists

NOTE:

Refer to Appendix D,

SP Pump Diagnostics and Repair

, for detailed information about pump disassembly and maintenance.

15:1 Pump Assembly Parts

3

4 5 40

TIGHTEN TO

25-31 IN LBS

OF TORQUE

39 32

TIGHTEN TO

60-75 IN LBS

OF TORQUE

531

30

TIGHTEN TO

25-31 IN LBS

OF TORQUE

41 29

40 39 27

28

40 39 24

E

23

39 32

TIGHTEN TO

100-110 IN LBS

OF TORQUE

35

39 34 33

C

40 21

22

B

16 40

14

DETAIL E

SCALE 2 : 1

15

39 6

7

9

10

SECTION D-D

SCALE 2 : 1

11

1

8

2

SEE

SECTION D-D

18

17

SECTION A-A

SCALE 1 : 1

Figure 7‐3

15:1 double‐acting pump (1 of 2)

19 20 40

DETAIL B

SCALE 2 : 1

13

12

Part 1024496_06

2014 Nordson Corporation

7-8

Parts

15:1 Pump Assembly Parts

(contd)

A

36

37

40 16

38

.48

A

D

D

16 40

Figure

7-4

15:1 double-acting pump (2 of 2)

Part 1024496_06

2014 Nordson Corporation

Item Part Description Quantity

13

14

15

16

9

10

11

12

17

18

19

20

6

7

4

5

8

—

1

2

3

‐ ‐ ‐ ‐ ‐ ‐

1016863

1016339

333137

982147

983410

1017189

940133

954013

163039

983445

983446

940172

273139

1024465

‐ ‐ ‐ ‐ ‐ ‐

973543

503696

900001

1017320

945037

PUMP ASSEMBLY

BODY,PUMP-FILTER

FRAME,PUMP,MACHINED

HEAD,CYLINDER,SP,MACHINED

SCR,HEX,CAP,M6X120,ZN

WASHER,FLT,M,NARROW,M6,STL,ZN

TUBE,CROSSOVER,PUMP

O RING,VITON,.426ID X .070W,BR,10413

BACK-UP RING,SINGLE,7/16X9/16

CUP,PISTON,SP

WASHER,PISTON SEAL,SP

WASHER,PISTON CUP,SP

O RING,VITON,.676ID X .070W,BR

SEAL,PUMP

SHIFTER ASSEMBLY,G1/8

FORK,MAGNETIC,ASSY

PLUG,O RING,STR THD,7/16-20

CAGE,BALL,SIPHON

BALL,440SSTL,.500, 50

SEAT,BALL,LOWER

O RING,VITON,1 TUBE

27

NS

28

29

21

22

23

24

30

31

32

33

276024

1022779

982780

1021955

1021919

945039

1017307

982237

1022658

982135

940332

952100

VALVE ASSY,DRAIN

CHUTE,DRAIN,ASSY

SCR,SKT,M5X10,ZN

ADAPTER,FILTER,ASSY

FILTER,ASSEMBLY,100 MESH, W/ O-RING

O RING,VITON,3/4 TUBE,10456

INSULATOR,PUMP

SCR,HEX,CAP,M6X35,ZN

PISTON ASSY,HYDRAULIC,PROBLUE

SCR,HEX,CAP,M6X30,ZN

O RING,VITON, 2.000X2.125X.063

CUP,U,VITON

34

35

36

37

986331

1064157

815666

1021270

RETAINING RING,INT,100,PUSHON

NUT,HEX,LOCK,TORQUE,M6X1,DIN 980V,V3

SCR,SKT,M5 X 0.8 X 12,ZN.

PLATE,FILTER,ANTI ROTATE

2

1

1

1

38

39

985401

900493

PIN,ROLL,.188X1.000,STL,ZN

LUBRICANT,PARKER HI-TEMP,11208

2

AR

40 900344 LUBRICANT,NEVER SEEZ,8OZ CAN AR

41 983409 WASHER,LK,M,SPT,M6,STL,ZN 4

NOTE A: To replace a 15:1 pump, order kit P/N 1028303. Refer to

Service Kits

for kit contents.

B: See Figure 7-9 for exploded view.

C: Refer to

Service Kits

for kit contents.

D: O-ring service kit P/N 1028305

E: See Figure 7-10 for exploded view.

1

4

1

1

2

1

1

1

2

1

1

1

1

3

1

1

2

1

2

1

1

1

1

1

1

2

4

5

2

—

1

1

1

AR: As Required

Parts

7-9

Note

A

B

C

D

E

2014 Nordson Corporation

Part 1024496_06

7-10

Parts

15:1 Low‐Viscosity Pump Assembly Parts

Item Part Description Quantity Note

12

13

14

15

8

9

10

11

16

17

18

19

6

7

4

5

—

1

2

3

‐ ‐ ‐ ‐ ‐ ‐

1016863

1016339

333137

982147

983410

1017189

940133

954013

163039

983445

983446

940172

273139

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

973543

503696

900001

1017320

PUMP ASSY,LOW VISCOSITY

BODY,PUMP-FILTER

FRAME,PUMP,MACHINED

HEAD,CYLINDER,SP,MACHINED

SCR,HEX,CAP,M6X120,ZN

WASHER,FLT,M,NARROW,M6,STL,ZN

TUBE,CROSSOVER,PUMP

O RING,VITON,.426ID X .070W,BR,10413

BACK-UP RING,SINGLE,7/16X9/16

CUP,PISTON,SP

WASHER,PISTON SEAL,SP

WASHER,PISTON CUP,SP

O RING,VITON,.676ID X .070W,BR

SEAL,PUMP.

SHIFTER ASSEMBLY,G1/8

FORK,MAGNETIC,ASSY

PLUG,O RING,STR THD,7/16-20

CAGE,BALL,SIPHON

BALL,440SSTL,.500, 50

SEAT,BALL,LOWER

1

1

1

1

1

2

2

2

1

1

3

1

1

2

4

9

—

1

1

1

A

B

C

24

27

NS

28

20

21

22

23

29

30

31

32

945037

276024

1022779

982780

1021955

1021919

945039

1017307

982237

‐ ‐ ‐ ‐ ‐ ‐

982135

940332

O RING,VITON,1 TUBE

VALVE ASSY,DRAIN

CHUTE,DRAIN,ASSY

SCR,SKT,M5X10,ZN

ADAPTER,FILTER,ASSY

FILTER,ASSEMBLY,100 MESH, W/ O-RING

O RING,VITON,3/4 TUBE,10456

INSULATOR,PUMP

SCR,HEX,CAP,M6X35,ZN

PISTON ASSY,HYDRAULIC,LV,PROBLUE

SCR,HEX,CAP,M6X30,ZN

O RING,VITON, 2.000X2.125X.063

1

1

1

2

1

1

1

1

4

1

1

2

33

34

35

36

952100

986331

1064157

815666

CUP,U,VITON

RETAINING RING,INT,100,PUSHON

NUT,HEX,LOCK,TORQUE,M6X1,DIN 980V,V3

SCR,SKT,M5 X 0.8 X 12,ZN.

1

2

1

1

37

38

1021270

985401

PLATE,FILTER,ANTI ROTATE

PIN,ROLL,.188X1.000,STL,ZN

1

2

39 900493 LUBRICANT,PARKER HI-TEMP,11208 AR

40 900344 LUBRICANT,NEVER SEEZ,8OZ CAN AR

NOTE A: To replace a 15:1 low-viscosity pump, order kit P/N 1073930. Refer to

Service Kits

for kit contents.

B: See Figure 7-9 for exploded view.

C: Refer to

Service Kits

for kit contents.

D: O-ring service kit P/N 1028305

E: See Figure 7-11 for exploded view.

D

E

AR: As Required

Part 1024496_06

2014 Nordson Corporation

Parts

7-11

4 40

TIGHTEN TO

25-31 IN LBS

OF TORQUE

39 32

TIGHTEN TO

100-110 IN LBS

OF TORQUE

35

39 34 33

C

39 32

TIGHTEN TO

60-75 IN LBS

OF TORQUE

5 31

30

TIGHTEN TO

25-31 IN LBS

OF TORQUE

529

40 39 27

40 39 24

28

E

23

40 21

22

14

DETAIL E

SCALE 2 : 1

1

2

DETAIL F

SCALE 4 : 1

NOTICE DIRECTION OF

CUP SEAL

15

7

8

F

18

B

16 40

39 6

17

9

10

SECTION D-D

SCALE 2 : 1

DETAIL C

SCALE 2 : 1

11

SECTION A-A

SCALE 1 : 1

19 20 40

Figure 7‐5

15:1 low‐viscosity double‐acting pump (1 of 2)

DETAIL B

SCALE 2 : 1

13

12

SEE

SECTION D-D

2014 Nordson Corporation

Part 1024496_06

7-12

Parts

15:1 Low‐Viscosity Pump Assembly Parts

(contd)

36

37

A

40 16

38

.48

A

D

D

16 40

Figure 7‐6

15:1 low‐viscosity double‐acting pump parts (2 of 2)

Part 1024496_06

2014 Nordson Corporation

This page intentionally left blank.

Parts

7-13

2014 Nordson Corporation

Part 1024496_06

7-14

Parts

6:1 Pump Assembly Parts

Item

24

27

NS

28

20

21

22

23

29

30

31

32

37

38

39

40

33

34

35

36

41

42

12

13

14

15

8

9

10

11

16

17

18

19

6

7

4

5

—

1

2

3

Part

945037

276024

1022779

982780

1021955

1021919

945039

1017307

982237

‐ ‐ ‐ ‐ ‐ ‐

982135

940332

952100

986331

1064157

815666

1021270

985401

900493

900344

983409

1065448

‐ ‐ ‐ ‐ ‐ ‐

1016863

1016339

333137

982147

983410

1017189

940133

954013

1065445

1065446

1065447

940172

273139

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

973543

503696

900001

1017320

Description

PUMP ASSY, 6:1, PROBLUE

BODY,PUMP-FILTER

FRAME,PUMP,MACHINED

HEAD,CYLINDER,SP,MACHINED

SCR,HEX,CAP,M6X120,ZN

WASHER,FLT,M,NARROW,M6,STL,ZN

TUBE,CROSSOVER,PUMP

O RING,VITON,.426ID X .070W,BR,10413

BACK-UP RING,SINGLE,7/16X9/16

CUP,PISTON,6:1

WASHER,PISTON SEAL,6:1

WASHER,PISTON CUP,6:1

O RING,VITON,.676ID X .070W,BR

SEAL,PUMP.

SHIFTER ASSEMBLY,G1/8

FORK,MAGNETIC,ASSY

PLUG,O RING,STR THD,7/16-20

CAGE,BALL,SIPHON

BALL,440SSTL,.500, 50

SEAT,BALL,LOWER

O RING,VITON,1 TUBE

VALVE ASSY,DRAIN

CHUTE,DRAIN,ASSY

SCR,SKT,M5X10,ZN

ADAPTER,FILTER,ASSY

FILTER,ASSEMBLY,100 MESH, W/ O-RING

  O RING,VITON,3/4 TUBE,10456

INSULATOR,PUMP

SCR,HEX,CAP,M6X35,ZN

PISTON ASSY,HYDRAULIC,PROBLUE

SCR,HEX,CAP,M6X30,ZN

O RING,VITON, 2.000X2.125X.063

CUP,U,VITON

RETAINING RING,INT,100,PUSHON

NUT,HEX,LOCK,TORQUE,M6X1,DIN 980V,V3

SCR,SKT,M5 X 0.8 X 12,ZN.

PLATE,FILTER,ANTI ROTATE

PIN,ROLL,.188X1.000,STL,ZN

LUBRICANT,PARKER HI-TEMP,11208

LUBRICANT,NEVER SEEZ,8OZ CAN

WASHER,LK,M,SPT,M6,STL,ZN

SLEEVE,PISTON PUMP,6:1

Quantity

1

1

1

1

1

2

1

1

1

2

4

1

1

2

AR

AR

4

1

1

2

1

1

1

1

1

1

1

2

2

2

1

1

3

1

1

2

4

5

—

1

1

1

Note

A

B

C

D

E

Continued…

Part 1024496_06

2014 Nordson Corporation

Parts

7-15

Item Part Description Quantity

43 941340 ORING,-134,VITON 2

NOTE A: To replace a 6:1 pump, order kit P/N 1088212. Refer to

Service Kits

for kit contents.

B: See Figure 7-9 for exploded view.

C: Refer to

Service Kits

for kit contents.

D: O-ring service kit P/N 1028305

E: See Figure 7-10 for exploded view.

AR: As Required

39 32

TIGHTEN TO

100-110 IN LBS

OF TORQUE

35

43

42

C

39 34 33

39 32

TIGHTEN TO

60-75 IN LBS

OF TORQUE

5 31

30

TIGHTEN TO

25-31 IN LBS

OF TORQUE

4 29

40 39 27

40 39 24

28

E

23

B

14

DETAIL E

SCALE 2 : 1

15

39 6

7

1

2

8

Note

4 40

4X

TIGHTEN TO

25-31 IN LBS

OF TORQUE

SEE

SECTION D-D

40 21

22

16 40

9

10

11

SECTION D-D

SCALE 2 : 1

17

DETAIL C

SCALE 2 : 1

18

12

DETAIL B

SCALE 2 : 1

13

SECTION A-A

SCALE 1 : 1

Figure 7‐7

6:1 double‐acting pump (1 of 2)

19 20 40

2014 Nordson Corporation

Part 1024496_06

7-16

Parts

6:1 Pump Assembly Parts

(contd)

A

36

37

Figure 7‐8

6:1 double‐acting pump (2 of 2)

Part 1024496_06

40 16

38

.48

A

D

D

16 40

2014 Nordson Corporation

This page intentionally left blank.

Parts

7-17

2014 Nordson Corporation

Part 1024496_06

7-18

Parts

Pump Shifter Assembly Parts

Figure

7-9

Pump shifter assembly/standard double-acting pump

Part 1024496_06

2014 Nordson Corporation

Item

6

7

4

5

—

1

2

3

Part

1024465

982028

1006027

1021998

333560

155057

982059

164606

Description

SHIFTER ASSEMBLY,G1/8

SCR,SKT,M5X20,BL

SERVICE KIT, VALVE ASSY SP

MANIFOLD,AIR,G1/8 PORT,PUMP

SPRING,WAVE,INCONEL,SP PUMP

DETENT,UPPER,SP

SCR,SKT,M4X8,BL

SERVICE KIT, ACTUATOR, MAGNETIC,

ASSY, SP

8

9

155068

155067

CAN,SP

DETENT,LOWER ,SP

10 986714 RETAINING RING,INT,156,BOWED

11 900493 LUBRICANT,PARKER HI-TEMP,11208

NOTE A: Refer to

Service Kits

for kit contents.

Quantity

2

1

1

1

—

4

1

1

1

0

1

1

Parts

7-19

Note

A

2014 Nordson Corporation

Part 1024496_06

7-20

Parts

Pump Piston Assembly Parts

Figure

7-10 Piston assembly/15:1 and 6:1 double-acting pumps

Item Part

—

1

2

3

1022658

1017229

985302

900000

4

5

AR: As Required

503709

900470

Description

PISTON ASSY,HYDRAULIC,PROBLUE

PISTON,PUMP,15:1

PIN,ROLL,.125X .500,STL,ZN

BALL,440SSTL,.375, 50

SEAT,BALL,PRESSURE

ADHESIVE,LOCTITE 272,RED,HI TEMP,50ML

Quantity

—

1

1

1

1

AR

Note

Part 1024496_06

2014 Nordson Corporation

Parts

7-21

1

2

3

5

4

6

BROKEN SECTION TO SHOW

DIRECTION OF CUP SEAL

Figure

7-11 Piston assembly/15:1 low-viscosity double-acting pump

Item Part

—

1

2

3

1073918

1017229

985302

900000

4

5

705975

706009

6

AR: As Required

900470

Description

PISTON ASSY,HYDRAULIC,LV,PROBLUE

PISTON,PUMP,15:1

PIN,ROLL,.125X .500,STL,ZN

BALL,440SSTL,.375, 50

SEAL,BALL,PRESSURE,HMIV PUMP

SEAL,PACKING

ADHESIVE,LOCTITE 272,RED,HI TEMP,50ML

Quantity

—

1

1

1

1

1

AR

Note

2014 Nordson Corporation

Part 1024496_06

7-22

Parts

Pneumatic Components Parts List

1

2

3

4

5

6

7

8

Figure

7-12 Pneumatic components

Part 1024496_06

2014 Nordson Corporation

Item

6

7

4

5

8

1

2

3

Used Part

1023307

1023855

1019511

1023853

1023290

1023267

1023854

‐ ‐ ‐ ‐ ‐ ‐

Description

Elbow, male, 6 mm tube x G

1

/

8

Tubing, PDV-to-pump, 6 mm tube

Tee, run, 6 mm tube, G

1

/

8

Tubing, regulator-to-PDV, 6 mm tube (yellow)

Fitting, bulkhead, 90-degree, 6 mm tube

Filter assembly, air, 6 mm BSPP

Tubing, filter-to-regulator, 6 mm tube (blue)

Pneumatic panel assembly

NOTE A: Included in service kit P/N 1028307

Parts

7-23

Quantity

1

1

1

1

1

1

1

1

Note

A

2014 Nordson Corporation

Part 1024496_06

7-24

Parts

Electrical Enclosure Parts List

Figure

7-13 Electrical enclosure

Part 1024496_06

2014 Nordson Corporation

Item

1

2

3

4

5

6

7

8

9

10

11

Used

P4, P7

P10

P4, P7

P10

P4, P7

P10

P4, P7

P10

P4, P7

P10

P4, P7

P10

Part

‐ ‐ ‐ ‐ ‐ ‐

1017223

1042411

1042414

1042412

1042415

1042410

1042413

1039649

1020572

1025470

1017896

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1039647

Description

Module assembly, power, removable

Frame, blank module

Column, rear, electrical enclosure, P4/P7

Column, rear, electrical enclosure, P10

Column, side, electrical enclosure, P4/P7

Column, side, electrical enclosure, P10

Column, front, electrical enclosure, P4/P7

Column, front, electrical enclosure, P10

Frame, machined, upper, keyed

Panel, divider, P4/P7

Panel, divider, P10

Hinge assembly

Printed circuit assembly, display/CPU

Panel assembly, front, P4/P7

Panel assembly, front P10

Mounting plate assembly, main PCA, P4/P7

Mounting plate assembly, main PCA, P10

Frame, machined, lower, keyed

12

NOTE A: Included in service kit P/N 1028328

B: Included in service kit P/N 1028325

C: Included in service kit P/N 1028326

D: Included in service kit P/N 1028327

E: Included in service kit P/N 1028322

F: Included in service kit P/N 1028323

G: If only the PCA expansion board is required, order service kit P/N 1028324.

Parts

7-25

Quantity

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

AR

AR

1

Note

A

D

E

B

C

F, G

2014 Nordson Corporation

Part 1024496_06

7-26

Parts

Exterior Panels Parts List

Figure

7-14 Exterior panels

Part 1024496_06

2014 Nordson Corporation

Used

P4, P7

P10

P4

P7, P10

P4

P7

P10

P4

P7

P10

P4

P7

P10

P4, P7

P10

P4, P7

P10

P4

P7

P10

Item

1

2

3

4

5

6

7

8

Part

1041735

1041741

1099367

1099366

1041733

1041737

1041740

1021346

1025591

1028495

1022948

1025594

1028494

1041736

1041739

1041734

1041738

1041742

1041743

1041745

1049528

Description

Cover, pump, P4/P7

Cover, pump, P10

Lid assembly, P4

Lid assembly P7/P10

Panel assembly, rear, P4

Panel assembly, rear, P7

Panel assembly, rear, P10

Panel assembly, end, P4

Panel assembly, end, P7

Panel assembly, end, P10

Panel assembly, front, P4

Panel assembly, front, P7

Panel assembly, front, P10

Door assembly, filter P4/P7

Door assembly, filter, P10

Cover assembly, ebox door, P4/P7

Cover assembly, ebox door, P10

Door, graphics, P4

Door, graphics, P7

Door, graphics, P10

Replacement hinge pin service kit P4/P7/P10

9

NOTE A: Includes hinge pin P/N 1021345

Parts

7-27

Quantity

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Note

A

A

2014 Nordson Corporation

Part 1024496_06

7-28

Parts

Chassis Components Parts List

3

2

F7

F3

1

6

7

F16

F15

F8

F3

15

10

9

F24

F6

F17

5

4

F16

8

F18

F3

14

F3

16

Figure

7-15 Chassis components

13

12

11

2014 Nordson Corporation

Part 1024496_06

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Used

P4, P7

P10

P4

P7, P10

P4

P7/P10

P4

P7

P10

P4

P7, P10

P4

P7, P10

P4

P7

P10

Part

‐ ‐ ‐ ‐ ‐ ‐

1023714

1038971

1038972

1022749

1018190

1018691

1025640

1022840

1021653

1021655

1025642

1028525

1017603

1021660

1018822

1024525

1021661

1018819

‐ ‐ ‐ ‐ ‐ ‐

1021656

1025641

1028526

1018821

1017947

Description

Electrical box assembly

Cover, wireway, electrical enclosure

Switch, level, assembly, P4/P7

Switch, level, assembly, P10

Cover, tank, P4

Cover, tank, P7/P10

Insulator, tank top, P4

Insulator, tank top , P7/P10

Brace, P4/P7/P10

Rod, retaining, cover

Bracket, panel, rear, P4

Bracket, panel, rear, P7

Bracket, panel, rear, P10

Spacer, bottom, tank

Chassis, P4

Chassis, P7/P10

Tray, drip, manifold

Sub-base, P4

Sub-base, P7/P10

Pneumatic assembly

Bracket, panel, front, P4

Bracket, panel, front, P7

Bracket, panel, front, P10

Plate, conduit, chassis

Switch, rocker, SPST, 250V, 16A

15

16

NOTE A: Refer to

Electrical Enclosure Parts List.

B: Included in service kit P/N 1038971

C: Included in service kit P/N 1038972

D: Included in service kit P/N 1028307

E: For the tank lid hinge pin, refer to

Exterior Panels Parts List

.

Parts

7-29

Quantity

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Note

A

B

C

E

D

2014 Nordson Corporation

Part 1024496_06

7-30

Parts

Ribbon Cable Parts List

Figure

7-16 Ribbon cables

Item

1

2

Used Part

1018283

1018284

Description

Cable assembly, ribbon, main

Cable assembly, serial port

NOTE A: Included in service kit P/N 1028326 (P4/P7) and kit P/N 1028327 (P10)

Quantity

1

1

Note

A

Part 1024496_06

2014 Nordson Corporation

Service Kits

15:1 Pump Replacement

Part

1028303

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, pump assembly, P4/P7/P10

Pump, piston, 15:1

O-ring, Viton, 0.50 x 0.75 x 0.125 in.

O-ring, Viton, 0.812 x 0.062 x 0.125 in.

Elbow, male, 6 mm tube, G

1

/

8

GREASE,HI − TEMP,.50OZ,SLUBE 884 − .50

15:1 Low‐Viscosity Pump Replacement

Part

1073930

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

KIT,SERVICE,PUMP ASSY,LOW VISCOSITY,15:1

PUMP ASSY,LOW VISCOSITY

ORING, VITON, .50 X .75 X .125

O RING,VITON, .812X1.062X.125

ELBOW, MALE,6 MM TUBE X G 1/8

LUBRICANT,O RING,PARKER,2 GM,S-LUBE 884

6:1 Pump Replacement

Part

1088212

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

KIT, SVCE, PUMP, 6:1, PROBLUE

PUMP ASSY, 6:1, PROBLUE

ORING, VITON, .50 X .75 X .125

O RING,VITON, .812X1.062X.125

ELBOW, MALE,6 MM TUBE X G 1/8

LUBRICANT,O RING,PARKER,2 GM,S-LUBE 884

Parts

7-31

Quantity

—

1

1

1

1

1

Quantity

—

1

1

1

1

1

Quantity

—

1

1

1

1

1

2014 Nordson Corporation

Part 1024496_06

7-32

Parts

Part

1028304

940133

940332

1019515

942111

940181

952100

954013

163039

273139

986331

1064157

982147

982237

983410

940172

‐ ‐ ‐ ‐ ‐ ‐

940261

1017849

945037

973543

211228

Pump General Service

Description

Kit, service, pump, P4/P7/P10

O-ring, Viton, 0.426 x 0.070 in.

O-ring, Viton, 2.00 x 2.125 x 0.063 in.

O-ring, Viton, 0.50 x 0.75 x 0.125 in.

O-ring, Viton, 0.812 x 0.062 x 0.125 in.

O-ring, Viton, 0.739 x 0.70 in.

Cup, U, Viton

Backup ring, single,

7

/

16 x

9

/

16

Cup, piston

Seal, pump

Retaining ring, internal, 100, push-on

NUT,HEX,LOCK,TORQUE,M6X1, DIN 980V,V3

Screw, hex, cap, M6 x 120

Screw, hex, cap, M6 x 35

Washer, flat, M6

O-ring, Viton, 0.676 x 0.070

GREASE,HI − TEMP,.50OZ,SLUBE 884 − .50

O-ring, Viton, 1.25 x 1.375 x .063

Backup ring, PTFE, 1.273 x .045 thick

O-ring, Viton, 1-inch tube

Plug, O-ring,

7

/

16

-20

Service kit, SP lubricating oil

Filter

Part

1028305

‐ ‐ ‐ ‐ ‐ ‐

945039

Filter, Saturn, 100-mesh

Filter assembly, 100-mesh

O-ring

Description

Pneumatic Panel

Part

1028307

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, pneumatic panel assembly

Pneumatic panel assembly

Screw, mounting

Part 1024496_06

Quantity

1

1

1

1

4

8

1

4

1

3

—

1

2

1

4

2

1

1

—

2

2

1

Quantity

—

Quantity

—

1

2

2014 Nordson Corporation

Pressure Discharge Valve

Part

1028308

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Kit, service, pressure discharge valve

Description

Valve assembly, pressure discharge

Screw, hex, M5 x 50

Tee, run, 6-mm tube, G

1

/

8

Manifold Service Kit

Part

1028309

1019515

‐ ‐ ‐ ‐ ‐ ‐

942111

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, manifold, P4/P7/P10

O-ring, Viton, 0.050 x. 0.75 x 0.125 in.

O-ring, Viton, 0.625 x 0.875 in.

O-ring, Viton, 0.812 x 0.062 x 0.125 in.

O-ring, Viton, 0.750 x 0.938 x 0.094 in.

Lubricant, Parker,

1

/

2 oz

RTD

Part

1028320

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1019515

942111

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, RTD, P4/P7/P10

Sensor, temperature, RTD

Screw, hex, M3 x 20

Washer, lock, spring, M3

Terminal block, 380 V

O-ring, Viton, 0.50 x 0.75 x. 0.125 in.

O-ring, Viton, 0.812 x 0.062 x 0.125 in

Compound, thermal, 1 gram

Thermostat

Part

1028321

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, thermostat, melter

Thermostat, OOR, 500 degree, push-on

Screw, hex, M4 x 6

Compound, thermal, 1 gram

2014 Nordson Corporation

Parts

7-33

Quantity

—

1

3

1

Quantity

1

2

1

—

3

1

Quantity

1

1

1

1

1

—

1

1

Quantity

—

1

2

1

Part 1024496_06

7-34

Parts

Main Circuit Board

Used

P4, P7

P10

Part

1028322

1028323

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, main PCA

Kit, service, main PCA

Mounting plate assembly, main PCA

Central Processor Unit (CPU)

Part

1028325

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Kit, service, central processor unit

PCA, display/CPU

Stand-off, hex, M3 x 8 mm

Washer, lock, M3

Description

Operator’s Panel

Used

P4, P7

P10

Part

1028326

1028327

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, operator’s panel/enclosure, P4/P7

Kit, service, operator’s panel/enclosure, P10

Panel assembly, front, electrical enclosure

Hose/Gun Module

Part

1028328

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, service, hose/gun module, P4/P7/P10

Module assembly, power, removable

Main Circuit Board Fuses

Part

1028329

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

NOTE

Description

Kit, service, fuse, main circuit board, P4/P7/P10

Fuse, 15.00, nontime-delay, 250 V

Cover, fuse, 0.25 x 1.25 in.

Fuse, time-lag, 2A, 5 x 20 mm, ceramic

Cover, fuse, 5 x 20 mm

A: Refer to Table 6-2 for fuse types and locations.

Part 1024496_06

2014 Nordson Corporation

Quantity

—

—

1

Quantity

—

1

Quantity

—

2

2

2

2

Quantity

—

—

1

Quantity

—

1

6

6

Hose/Gun Module Fuses

Part

1028331

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

NOTE

Description

Kit, service, fuse, hose/gun module, P4/P7/P10

Fuse, 6.30, fast-acting, 250 V, 5 x 2

Cover, fuse, 5 x 20 mm

A: Refer to Table 6-4 for fuse types and locations.

Basic Spare Parts

Part

1028332

1028305

1028320

1028321

1028328

1028329

1028331

Description

Kit, basic spare parts, P4/P7/P10

Filter, Saturn, melter, 100-mesh

Kit, service, RTD, P4/P7/P10

Kit, service, thermostat, melter

Kit, service, hose/gun module, P4/P7/P10

Kit, service, fuse, main circuit board, P4/P7/P10

Kit, service, fuse, hose/gun module, P4/P7/P10

Expanded Spare Parts

Part

1028333

1028305

1028320

1028321

1028328

1028329

1028331

1028304

1028309

1023267

Kit, basic expanded parts, P4/P7/P10

Description

Filter, Saturn, melter, 100-mesh

Kit, service, RTD, P4/P7/P10

Kit, service, thermostat, melter

Kit, service, hose/gun module, P4/P7/P10

Kit, service, fuse, main circuit board, P4/P7/P10

Kit, service, fuse, hose/gun module, P4/P7/P10

Kit, service, pump, P4/P7/P10

Kit, service, manifold, P4/P7/P10

Filter assembly, air, 6 mm BSPP

Level Switch

Used

P4, P7

P10

Part

1038971

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1038972

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, switch, level, P4/P7

Switch, level, assembly, P4/P7

Nut, hex, M5

Kit, switch, level, P10

Switch, level, assembly, P10

Nut, hex, M5

2014 Nordson Corporation

Parts

7-35

Quantity

—

4

4

Quantity

—

1

1

1

1

1

1

Quantity

—

5

1

1

1

1

1

1

1

1

Quantity

—

1

2

—

1

2

Part 1024496_06

7-36

Parts

Manifold Guard (P4)

Part

1032154

‐ ‐ ‐ ‐ ‐ ‐

Kit, manifold guard, P4

Shield, manifold, snap-on, P4

Description

Manifold Guard (P10)

Part

1031871

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, manifold guard, 6-hose, P10

Guard, wire frame, manifold, 6-hose

Mount, lower, wire guard, 6-hose

Mount, upper B, wire guard, 6-hose

Mount, upper A, wire guard, 6-hose

Screw, socket-head, M5 x 20

Vent Guard (P10)

Part

1048884

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Guard kit assembly, vent , screen, P10

Guard, screen, pump cover, P10

Reference drawing, guard kit, vent, screen, P10

Replacement Tank

Part

1051033

1051034

1051035

Kit, service, tank, P4, 230V

Kit, service, tank, P7, 230V

Kit, service, tank, P10, 230V

Description

Tank Lid Hinge Pin

Part

1049528

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Replacement hinge pin service kit, P4/P7, P10

Pin, hinge, lid, P4/P7/P10

Tube, spacer, pin, hinge, P4/P7/P10

Spring, compression, .360 x .038 x 1.75 long

Retaining, ring, external, 18, E-ring

Part 1024496_06

Quantity

—

1

Quantity

—

1

2

1

1

3

Quantity

—

1

1

Quantity

1

1

1

Quantity

—

1

1

1

2

2014 Nordson Corporation

Parts

7-37

Manifold (with Heater Block) Service Kit, DA Pumps — P/Ns 1064651 (4H,

230V), 1064653 (6H, 230V), 1064652 (4H, 480V), 1064654 (6H, 480V)

Description Quantity

HEATER BLOCK,PROBLUE

MANIFOLD ASSY

SCR,SKT,M5X25,BL

WASHER,LK,M,SPT,M5,STL,ZN

ORING, VITON, .50 X .75 X .125

O RING,VITON, .812X1.062X.125

O-RING,VITON,50 DURO,-116,.750X.938X.094

O RING,VITON,.426ID X .070W,BR,10413

INST, MANIFOLD/HEATER SERVICE KIT

2

2

1

5

5

2

1

1

1

Heater Block Service Kit — P/Ns 1064639 (230V), 1064650 (480V)

Description

HEATER BLOCK,PROBLUE,230V or 480V

SCR,SKT,M5X25,BL

WASHER,LK,M,SPT,M5,STL,ZN

O RING,VITON, .812X1.062X.125

INST, PROBLUE THERMAL BLOCK INSTALLATION

INST, HEATER DISPOSAL (WORDLESS)

1

5

5

1

1

1

Quantity

2014 Nordson Corporation

Part 1024496_06

7-38

Parts

Option Kits

6‐Hose Extension

Part

1028324

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, 6-hose extension, board, P10

PCA, P10, expansion

Harness, expansion, 6 hose/gun

Cable assembly, 20 position, ribbon cable

Screw, machine, pan-head, M3 x 12

Input/Output Expansion Card

Part

1036607

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

Kit, I/O expansion card

PCA, optional I/O

Terminal block connector, 10 position (1–10)

Terminal block connector, 10 position (11–20)

Screw, machine, pan-head, M3 x 6

Fill Master

Part

771415

771417

771416

NOTE

Kit, sensor, P4/P7/P10

Kit, lid, P7/P10

Kit, lid, P4

A: Requires lid kit P/N 771417 or 771416

B: Fill Master system is not included

Description

Ethernet Card

Part

1053289

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

KIT,ETHERNET CARD

PCA,ANYBUS − S,ETHERNET,17MM PINS,PROGRAMM

MACH SCRM,PAN,REC,M3X6,SEMS

Quantity

—

1

1

1

4

Quantity

—

1

1

1

8

Quantity

A, B

B

B

Quantity

—

1

3

2014 Nordson Corporation

Part 1024496_06

DeviceNet Card

Part

1053288

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

KIT,DEVICENET CARD

PCA,ANYBUS − S,DEVICENET,17MM PINS

MACH SCRM,PAN,REC,M3X6,SEMS

Profibus Card

Part

1053300

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

Description

KIT, PROFIBUS CARD

PCA,ANYBUS − S,PROFIBUS,17MM PINS

MACH SCRM,PAN,REC,M3X6,SEMS

P10 8 H/G Expansion Base

Part

1061030

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

8 H/G, BASE,EXPANSION

BASE,EXPANSION,8 H/G,P10

KIT,SHIP WITH,2 H/G BASE,P10

Description

Parts

7-39

Quantity

—

1

3

Quantity

—

1

3

Quantity

—

1

1

2014 Nordson Corporation

Part 1024496_06

7-40

Parts

Schedule of Fasteners

Number

F1

F14

F15

F16

F17

F10

F11

F12

F13

F6

F7

F8

F9

F2

F3

F4

F5

F22

F23

F24

F25

F26

F18

F19

F20

F21

F27

F28

F29

Description

Screw, socket, M6 x 120

Washer, flat, M6

Screw, socket, M5 x 10

Screw, socket, M6 x 35

Screw, socket, M5 x 12

Screw, socket, M5 x 20

Washer, lock, split, M5

Washer, lock, split, M6

Screw, socket, M5 x 10

Nut, hex, 10-32

Washer, flat, 10

Washer, flat, M5

Washer, flat, oversized, M5

Screw, socket, M5 x 50

Nut, hex, M6

Screw, socket, M4 x 10

Nut, hex, M8

Washer, lock, split, M8

Screw, socket, M4 x 8

Washer, flat, M8

Screw, socket, M6 x 16

Screw, socket, M5 x 16

Screw, socket, M4 x 6

Nut, hex, M5, Zn

Screw, socket, M5 x 12

Item no. not used

Screw, pan-head, cross-rec, M5 x 8

Washer, flat, regular, 8

Screw, socket, M5 x 25

Part 1024496_06

2014 Nordson Corporation

Technical Data

8-1

Section 8

Technical Data

General Specifications

Item

Weight of empty melter

P4

P7

P10

Weight of melter with full tank

P4

P7

P10

Weight of 3.0 kva transformer (400/480 VAC melters only)

Weight of 1.5 kva transformer (400/480 VAC melters only)

Hose ports

Melt rate

P4

P7

P10

Noise

Workplace temperature

Throughput rate

P4

P7

P10

Pump rate

42 kg (93 lb)

43 kg (95 lb)

46 kg (101 lb)

46 kg (101 lb)

50 kg (110 lb)

56 kg (123 lb)

25 kg (55 lb)

18 kg (40 lb)

4 to 6

Data

4.3 kg/hr (9.5 lb/hr)

8.2 kg/hr (18 lb/hr)

11 kg/hr (24 lb/hr)

64dB (A) at maximum pump speed

-5 to 50



C (23 to 122



F)

6.

8 kg/hr (1

5

lb/hr)

10.9 kg/hr (24 lb/hr)

12.4 kg/hr (27 lb/hr)

32.7 kg/hr (72 lb/hr)

NOTE A: Depends on the melter’s configuration and whether optional hose/gun modules are installed.

B: The noise level is measured at a distance of 1 m (3.3 ft.) from the surface of the melter.

Note

A

B

2014 Nordson Corporation

Part 1024496_06

8-2

Technical Data

Electrical Specifications

Item

Hose/gun heating capacity

Control temperature range

Control temperature accuracy

International Protection (IP) rating

Input voltage tolerance

Data

2, 4, or 6 hose/gun pairs

40 to 230



C (100 to 450



F)

1



C

IP54

+10%, -15%

NOTE A: Dependent on melter configuration and addition of optional hose/gun modules

B: Flow set-point at RTD

Note

A

B

Pump Specifications

Air pressure while running

Minimum air pressure

Viscosity range

Item

Maximum hydraulic pressure

Air consumption at 415 kPa (60 psi) and maximum pump speed

Displacement

Maximum speed

Data

70 to 689 kPa (10 to 100 psi)

0.7 bar (10 psi)

800 to 10,000 cps

15:1 pump: 10.3 MPa (1500 psi)

6:1 pump: 4.14 MPa (600 psi)

46 l/min. (1.6 scfm)

7.20 ml/stroke ( 0.44 in

3

/stroke)

90 strokes/min.

Melter Power Requirements

Melter

P4

P7

P10

Number of

Hose/Guns

2

4

6

2

4

2

4

1‐Phase Power

Draw (Amps)

18

27

35

17

26

18

27

3‐Phase Power (Amps)

Without Neutral

16

24

31

15

23

16

24

With Neutral

10

17

18

9

17

10

17

2014 Nordson Corporation Part 1024496_06

Dimensions

P4 Melter

Technical Data

8-3

Figure 8‐1

P4 Melter dimensions

2014 Nordson Corporation

Part 1024496_06

8-4

Technical Data

P7 Melter

Figure 8‐2

P7 Melter dimensions

Part 1024496_06 2014 Nordson Corporation

P10 Melter

Figure 8‐3

P10 Melter dimensions

Technical Data

8-5

2014 Nordson Corporation

Part 1024496_06

8-6

Technical Data

Sub‐base

8.7 mm

(.343 in.)

436 mm

(17.16 in.)

381mm

(15.00 in.)

P7/P10

8.0 mm

(.314 in.)

8.7 mm

(.343 in.)

249 mm

(9.8 in.)

249 mm

(9.8 in.)

1” NPT

PG − 16

PG − 21

Figure 8‐4

Sub‐base dimensions

P4

Part 1024496_06 2014 Nordson Corporation

Wiring Diagrams—200/240 VAC Melter

See next eight pages.

NOTE:

For 400/480 Volt melters, refer to Appendix E.

Technical Data

8-7

2014 Nordson Corporation

Part 1024496_06

8-8

Technical Data

Part 1024496_06 2014 Nordson Corporation

Technical Data

8-9

2014 Nordson Corporation

Part 1024496_06

8-10

Technical Data

Part 1024496_06 2014 Nordson Corporation

Technical Data

8-11

2014 Nordson Corporation

Part 1024496_06

8-12

Technical Data

Part 1024496_06 2014 Nordson Corporation

Technical Data

8-13

2014 Nordson Corporation

Part 1024496_06

8-14

Technical Data

Part 1024496_06 2014 Nordson Corporation

Technical Data

8-15

2014 Nordson Corporation

Part 1024496_06

8-16

Technical Data

Part 1024496_06 2014 Nordson Corporation

Calculating Melter Power Requirements

A-1

Appendix

A

Calculating Melter Power Requirements

Before locating the melter on the production floor or attaching hoses and guns to the melter, you must calculate the electrical power required by the hoses and guns and confirm that the required power does not exceed maximum allowable wattages. Properly calculating melter power requirements will prevent damage to the melter and identify the maximum allowable distance between the melter and the point at which the hot melt is dispensed.

The following three maximum wattages must be considered when calculating the power required by the hoses and guns.

Single‐component maximum

—The wattage of any single hose or gun

Hose/gun pair maximum

—The wattage of any hose and gun

(hose/gun pair)

Hose/gun module maximum

—The wattage of any two hoses and two guns (two hose/gun pairs)

If your Nordson representative has already calculated the hose/gun power requirements and confirmed that the maximum allowable wattages will not be exceeded, then no further calculation is necessary. However, you should re‐evaluate the hose and gun power requirements before you: add a new hose or gun to the melter that was not factored into the original wattage evaluation replace an existing hose with a longer hose or an existing gun with a larger gun

2014 Nordson Corporation

Part 1024496_06

A-2

Calculating Melter Power Requirements

To evaluate the hose/gun power requirements

1. Match each hose and gun pair and then match each pair to the hose/gun module it will be connected to on the back of the melter.

2. Examine the identification tag or plate on each hose and gun and record

the wattage of each in Table A‐1.

3. Add the sum of the wattages for each hose/gun pair and the combined total wattage for each hose/gun module.

4. Compare the wattages tabulated in Table A‐1 with the associated maximum allowable wattages listed in Table A‐2.

5. Do

one

of the following:

If each of the wattages calculated in step 3

does not

exceed the associated maximum allowable wattages listed in Table A‐2, then the power required by the hoses and guns is within acceptable limits.

If any of the wattages calculated in step 3

does

exceed an associated maximum allowable wattage listed in Table A‐2, then the configuration or position of the hose/gun pairs must be rearranged or shorter hoses must be used in order to reduce the power requirement.

Part 1024496_06 2014 Nordson Corporation

Calculating Melter Power Requirements

A-3

Module

Hose/Gun

Module 1

Table A‐1 Hose/Gun Wattages

Component

Number

Type/Size Wattage

Hose 1

Gun 1

Hose 2

Gun 2

Total wattage of hose/gun module 1 =

Hose/Gun

Module 2

Hose 3

Gun 3

Hose 4

Gun 4

Total wattage of hose/gun module 2 =

Hose/Gun

Module 3

Hose 5

Gun 5

Hose 6

Gun 6

Total wattage of hose/gun module 3 =

Total Wattage

Component

Any hose or gun

Any hose/gun pair

Any hose/gun module

Table A‐2 Maximum Allowable Wattages

Plant Voltage

200 VAC 220 VAC 230 VAC

870 W

1071 W

1740 W

957 W

1179 W

1913 W

1000 W

1233 W

2000 W

240 VAC

1043 W

1286 W

2086 W

2014 Nordson Corporation

Part 1024496_06

A-4

Calculating Melter Power Requirements

Part 1024496_06 2014 Nordson Corporation

2014 Nordson Corporation

Operating Parameters

B-1

Appendix

B

Operating Parameters

Operating parameters are organized in this appendix according to the logical

groups listed in Table B‐1. For information about selecting and editing

operating parameters, refer to Section 3,

Installation, Setting Up the Melter

.

NOTE:

Parameter numbers that are reserved or that are not used do not appear in this appendix.

Group

Standard

Temperature Control

Input Setup

Output Setup

Seven-day Clock

Table B‐1 Parameter Groups

Parameter s

Description

0 to 11 and 14 Frequently used parameters

20 to 26

30 to 39

Control heater function

Configure the standard and optional inputs

40 to 46

Configure the standard and optional outputs

50 to 77 Configure the clock feature

Part 1024496_06

B-2

Operating Parameters

Standard

0

Enter Password

Description:

A user‐defined password that prevents unauthorized changes to set‐point temperatures and operating parameters.

Value:

Resolution:

Default Value:

Format:

Use:

0 to 9999

1

4000

—

This parameter only appears if a password is created using parameter 11 and then enabled using parameter 10.

NOTE:

The melter remains in the password‐protected mode for two minutes after the last key press. After exiting the setup mode, attempting to re‐enter the setup mode, even before two minutes has elapsed, will require you to re‐enter the password.

1

Total Hours with Heaters On

(Noneditable)

Description:

A non editable value that indicates the total number of hours that the heaters have been on.

Value:

999,999 (using abbreviated convention described below)

Resolution:

1 hour

Default Value:

0

Format:

—

Use:

The right display indicates up to 9999 hours of heater operation. When the accumulated heater hours reaches 10,000, the display alternates every two seconds between the three left most digits (thousands) and the three right digits (hundreds). For example, 10,001 hours would be displayed as ”10,” for two seconds and then ”001” for two seconds. The comma is present if parameter 20,

Temperature Units

, is set to degrees

Fahrenheit. A period is present if parameter 20 is set to degrees

Celsius.

2

Fault Log

(Noneditable)

Description:

Stores a record of the last ten faults.

Value:

—

Resolution:

—

Default Value:

_-F0 (unused log entry)

Format:

F1, F2, F3, and F4

Use:

Use the right-display scroll keys to review the log entries for the last ten faults. Empty log entries are indicated by “_-F0.” Refer to

Monitor the

Melter

in Section 4,

Operation

.

2014 Nordson Corporation Part 1024496_06

2014 Nordson Corporation

Operating Parameters

B-3

3

Change History Log

(Noneditable)

Description:

Records the last ten changes made to either the set-point temperatures or the operating parameters.

Value:

—

Resolution:

—

Default Value:

P-_ (unused log entry)

Format:

Refer to Section 3,

Installation

.

Review Parameter and Set-point

Temperature Changes

.

Use:

Use the right-display key to review the log entries for the last ten changes that were made to the operating parameters or the set-point temperatures. Empty log entries are indicated by “P-_.”

4

Ready Delay Time

Description:

The amount of time that will elapse after all of the components have reached their set-point temperature before the ready LED will turn on.

The ready delay time only functions when the temperature of the tank, at the time the melter is turned on, is more than 27



C (50



F) from its set-point temperature. The ready delay time begins when all components are within 3



C (5



F) of their respective set-point temperature.

Value:

0 to 60 minutes

Resolution:

1 minute

Default Value:

0 minutes

Format:

Left display “rd”. Right display, minutes or seconds remaining

Use:

The ready delay allows the contents of the tank an additional amount of time to heat before pump turns on.

NOTE:

The time remaining on the ready delay is indicated in minutes in the right display at the end of every automatic scan cycle. The left display indicates “rd” whenever the time remaining appears. When the delay time reaches 1 minute, the time remaining appears in seconds.

5

Service Interval Time

Description:

The number of heater-on hours that must elapse before the service LED turns on.

Value:

0 hours (disabled) to 8736 (one year)

Resolution:

1 hour

Default Value:

500 hours

Format:

—

Use:

Set the service interval time to signal a user-defined service check or maintenance event, such as changing the filter. The service LED will turn on after the pre-set time elapses. With the melter in the scan mode, press the

Clear/Reset

key to turn off the service LED and reset the time.

Part 1024496_06

B-4

Operating Parameters

Standard

(contd)

6

Service LED Heater Hours

(Noneditable)

Description:

A timer indicates how many more hours the heaters need to remain on before the service LED illuminates (service required).

Value:

0 hours (disabled) to 9999

Resolution:

1 hour

Default Value:

0

Format:

—

Use:

The service interval time (parameter 5) must be enabled before this parameter will work.

Note:

Heater hours accumulate whenever the heaters LED is illuminated.

8

Automatic Pump On

Description:

Determines if the pump will turn on automatically when the melter is ready.

Value:

0 = disabled or 1 = enabled

Resolution:

—

Default Value:

1 (enabled)

Format:

—

Use:

If Automatic Pump On is disabled, you must press the pump key to turn the pump on.

9

Automatic Pump On Temperature

Description:

Sets the temperature at which the pump will automatically turn on.

CAUTION:

Unnecessary starting of the pump before the hot melt is fully melted can lead to premature pump wear.

Value:

0 = The pump turns on when the ready LED turns on

OR

Resolution:

1

Default Value:

0

1 C to 230 C (1 F to 450 F) = The pump turns on when the tank reaches the selected temperature.

Syntax:

—

Use:

Parameter is only used when parameter 8 is set to 1 (enabled).

If a specific temperature value is used (as opposed to the default value of 0), only enter a set-point temperature that is lower than the set-point temperatures of the tank. A set-point temperature greater than the set-point of the tank will be ignored, and the pump will turn on when the melter is ready.

2014 Nordson Corporation Part 1024496_06

2014 Nordson Corporation

Operating Parameters

B-5

10

Enable or Disable the Melter Password

Description:

Activates or deactivates the melter password. When password protection is activated, component set-point temperatures or melter operating parameters cannot be changed until a valid password is entered using parameter 0.

Value:

0 (disabled)

1 (enabled)

Resolution:

—

Default Value:

0

Format:

—

Use:

A password must first be created using parameter 11 before it can be enabled or disabled using parameter 10.

11

Create Password

Description:

A user-defined password that prevents unauthorized changes to operating parameters or set-point temperatures.

Value:

0 to 9999

Resolution:

1

Default Value:

5000

Format:

—

Use:

Refer to Section 4,

Operation Enter the Melter Password

.

NOTE:

When the password is created and enabled, parameter 10 will not appear again in the right display until the password is entered.

14

External Communications Lock-out

Description:

Used as a safety feature when performing maintenance on the melter.

Prevents external control of the melter through standard or optional inputs/outputs or network communications (optional)

Value:

0 (disabled) or

1 (enabled)

Resolution:

—

Default Value:

0 (disabled

Format:

—

Use:

Set parameter to 1 (enabled) before performing any maintenance on the melter. When enabled, all external control of the melter stops until the parameter is once again set to 0 (disabled).

Part 1024496_06

B-6

Operating Parameters

Temperature Control

20

Temperature Units

Description:

Sets the units for temperature display.

Value:

C (degrees Celsius) or F (degrees Fahrenheit)

Resolution:

1 degree

Default Value:

C

Format:

—

Use:

—

21

Over Temperature Delta

Description:

The number of degrees that the temperature of any component can increase over its assigned set-point temperature before an over temperature fault (F3) will occur.

Value:

5 C (10 F) to 60 C (110 F)

Resolution:

1 C

1 F

Default Value:

15 C (25 F)

Format:

—

Use:

—

22

Under Temperature Delta

Description:

The number of degrees that the temperature of any component can decrease from its set-point temperature before an under temperature fault (F2) occurs.

Value:

5 C (10 F) to 60 C (110 F)

Resolution:

1 C

1 F

Default Value:

25 C (50 F)

Format:

—

Use:

—

2014 Nordson Corporation Part 1024496_06

2014 Nordson Corporation

Operating Parameters

B-7

23

Standby Delta

Description:

The number of degrees by which all heated components will be decreased when the melter is placed into the standby mode.

Value:

5 C to 190 C (10 F to 350 F)

Resolution:

1 C

1 F

Default Value:

50 C (100 F)

Format:

—

Use:

A standby delta should be selected that results in a balance between melter energy savings during periods of inactivity, the amount of time and energy required to bring the melter back up to set-point temperature, and a temperature at which the hot melt can be held in the tank for extended periods of time without charring. Refer to Section 4,

Operation, Using Melter Function Keys

.

NOTE:

The standby delta does not affect the under temperature delta

(parameter 22).

24

Automatic Standby Timeout

Description:

The amount of time that must elapse after the last signal (gun driver) is sent to input 1 before the melter will enter the standby mode. The automatic standby timeout feature saves energy by allowing the melter to automatically go into the standby mode if the melter detects that the guns are no longer firing.

Value:

0 to 1440 minutes (24 hours)

Resolution:

1 minute

Default Value:

0 (disabled)

Format:

—

Use:

1. Change parameter 23 if required.

2. Set the control option for parameter 30 (input 1) to option 10

(automatic standby)

NOTE:

Only enable parameter 24 when a 24 VDC signal voltage is connected to input 1. If there is no voltage on the input contacts when the melter is ready, the melter will enter the standby mode after the automatic standby time.

Part 1024496_06

B-8

Operating Parameters

Temperature Control

(contd)

25

Automatic Heaters Off Time

Description:

The amount of time that must elapse after the automatic standby time elapses (parameter 24) before the heaters turn off.

Value:

0 to 1440 minutes (24 hours)

Resolution:

1 minute

Default Value:

0 (disabled)

Format:

—

Use:

Set parameter 24 (automatic standby timeout) to the desired value before setting parameter 25.

26

Manual Standby Time

Description:

The amount of time that the melter will remain in the standby mode after the standby key is pressed.

Value:

0 to 180 minutes

Resolution:

1 minute

Default Value:

0

Format:

—

Use:

Set the standby time when you want the operator to be able to place the melter into the standby mode for a limited period of time (break, lunch, etc.). When manual standby is enabled (value greater than 0 minutes), the standby LED blinks.

Set the standby delta (parameter 23) to the desired value before setting parameter 26.

Note:

When a time value equal to or greater than 1 minute is entered, the standby LED will flash to indicate that the manual standby timer is counting down.

Part 1024496_06 2014 Nordson Corporation

Operating Parameters

B-9

Input Setup

30

Standard Input 1

Description:

Control options that determine the function of input 1.

Value:

0 – Input Disabled

1 – Standby On/Off

2 – Heaters On/Off

3 – Pump Enable/Disable

4 – Hose/Gun 1 Enable/Disable

5 – Hose/Gun 2 Enable/Disable

6 – Hose/Gun 3 Enable/Disable

7 – Hose/Gun 4 Enable/Disable

8 – Hose/Gun 5 Enable/Disable

9 – Hose/Gun 6 Enable/Disable

10 –

Automatic standby

11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only)

Resolution:

1

Default Value:

10

Format:

—

Use:

Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

31

Standard Input 2

Description:

Control options that determine the function of input 2.

Value:

0 – Input Disabled

1 – Standby On/Off

2 – Heaters On/Off

3 – Pump Enable/Disable

4 – Hose/Gun 1 Enable/Disable

5 – Hose/Gun 2 Enable/Disable

6 – Hose/Gun 3 Enable/Disable

7 – Hose/Gun 4 Enable/Disable

8 – Hose/Gun 5 Enable/Disable

9 – Hose/Gun 6 Enable/Disable

11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only)

Resolution:

1

Default Value:

1

Format:

—

Use:

Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

2014 Nordson Corporation

Part 1024496_06

B-10

Operating Parameters

Input Setup

(contd)

32

Standard Input 3

Description:

Control options that determine the function of input 3.

Value:

0 – Input Disabled

1 – Standby On/Off

2 – Heaters On/Off

3 – Pump Enable/Disable

4 – Hose/Gun 1 Enable/Disable

5 – Hose/Gun 2 Enable/Disable

6 – Hose/Gun 3 Enable/Disable

7 – Hose/Gun 4 Enable/Disable

8 – Hose/Gun 5 Enable/Disable

9 – Hose/Gun 6 Enable/Disable

11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only)

Resolution:

1

Default Value:

2

Format:

—

Use:

Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

33

Standard Input 4

Description:

Control options that determine the function of input 4.

Value:

0 – Input Disabled

1 – Standby On/Off

2 – Heaters On/Off

3 – Pump Enable/Disable

4 – Hose/Gun 1 Enable/Disable

5 – Hose/Gun 2 Enable/Disable

6 – Hose/Gun 3 Enable/Disable

7 – Hose/Gun 4 Enable/Disable

8 – Hose/Gun 5 Enable/Disable

9 – Hose/Gun 6 Enable/Disable

11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only)

Resolution:

1

Default Value:

4

Format:

—

Use:

Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

2014 Nordson Corporation Part 1024496_06

Operating Parameters

B-11

34 – 39

Optional Inputs 5, 6, 7, 8, 9, and 10

Description:

Control options that determine the function of the six optional inputs provided when the optional I/O expansion card is installed on the CPU board.

Value:

0 – Input Disabled

1 – Standby On/Off

2 – Heaters On/Off

3 – Pump Enable/Disable

4 – Hose/Gun 1 Enable/Disable

5 – Hose/Gun 2 Enable/Disable

6 – Hose/Gun 3 Enable/Disable

7 – Hose/Gun 4 Enable/Disable

8 – Hose/Gun 5 Enable/Disable

9 – Hose/Gun 6 Enable/Disable

11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only)

Resolution:

1

Default Value:

0 (disabled)

Format:

—

Use:

Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

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Operating Parameters

Output Setup

40 — 42

Standard Outputs 1, 2, and 3

Description:

Determines the function of the output.

Value:

0 = Output Disabled

1 = Ready

2 = Ready and Pump is on

3 = Fault

4 = Low level

5 = Service LED is on

6 = Alert (Potential fault)

Resolution:

1

Default Value:

Output 1 = 1

Output 2 = 3

Output 3 = 4

Format:

—

Use:

Refer to

Installing Melter Outputs

in Section 3,

Installation

, for information on setting up outputs.

When control option 6,

Alert

is selected, the output is active whenever the melter enters the two minute fault monitoring period. If the potential fault condition clears before the end of the two minute period, the output signal ends. Refer to Section 4,

Operation, Monitor Melter Faults

, for information about fault monitoring.

43 — 46

Optional Outputs 4, 5, 6, and 7

Description:

Control options that determine the function of the four optional outputs provided when the optional I/O expansion card is installed on the CPU board.

Value:

0 = Output Disabled

1 = Ready

2 = Ready and Pump is on

3 = Fault

4 = Low level

5 = Service LED is on

6 = Alert (Potential fault)

Resolution:

1

Default Value:

0 (all optional outputs)

Format:

—

Use:

Refer to the instruction sheet provided with the optional I/O expansion card for information about wiring and setting up the optional outputs.

When control option 6,

Alert

is selected, the output is active whenever the melter enters the two minute fault monitoring period. If the potential fault condition clears before the end of the two minute period, the output signal ends. Refer to Section 4,

Operation, Monitor Melter Faults

, for information about fault monitoring.

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Operating Parameters

B-13

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Part 1024496_06

B-14

Operating Parameters

Seven‐day Clock

Before setting up the clock, refer to

Using Melter Function Keys

in Section4,

Operation

, to familiarize yourself with the function and use of the clock feature.

If you are unfamiliar with the procedure for accessing and editing operating parameters, refer to Section 3,

Installation, Setting Up the Melter

.

To set the clock

Refer to the examples on the next page.

1. Use parameter 50 to select the current day of the week.

2. Use parameter 51 to set the current time of day.

3. Create schedule 1 by: a. Setting parameters 55 and 56 to the time of the day that the heaters should turn on and off.

b. Setting parameters 57 and 58 to the time of the day that the melter should enter and exit the standby mode.

4. Using parameters 60 through 68, create schedules 2 and 3 by repeating step 3.

5. Use parameters 71 through 77 to assign which of the four schedules should be used on each day of the week. Up to three schedules may be assigned each day (to support three work shifts). Each of the eight control options (0 to 7) that is available in parameters 71 through 77 assigns a different combination of the three schedules. Option 0 is used hold the melter in the state dictated by the last clock transition until the next clock transition occurs.

6. Press the

Clock

key.

Seven‐day clock key

In order for the clock to operate continuously throughout the week, a valid schedule must be assigned to every day of the week (parameters 71 through 77).

To prevent unintentional activation of the clock the default setting for parameters 71 through

77 is schedule 0, which has no time values assigned to it. With the default set to schedule 0, unintentionally pressing the clock key will have no affect on the melter.

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Operating Parameters

B-15

Example 1

To turn the heaters on at 0600 and turn them off at 0015 every day of the week:

Par 55 = 0600

Par 56 = 0015

Par 60 = ‐ ‐ ‐ ‐

Par 61 = ‐ ‐ ‐ ‐

Par 71 through 77 = 1

Example 2

To turn the heaters on at 0700 and off at 1700 Monday through Friday, and turn the heaters off Saturday and Sunday:

Par 55 = 0700

Par 56 = 1700

Par 57 = ‐ ‐ ‐ ‐

Par 58 = ‐ ‐ ‐ ‐

Par 71 through 75 = 1

Par 76 and 77 = 0

Example 3

To turn the heaters on at 0600 each morning, go into standby for lunch at

1130, come out of standby after lunch at 1230, and turn the heaters off at

1600 at the end of the day, every day of the week:

Par 50 = 1

Par 51 =

current time

Par 55 = 0600

Par 56 = 1600

Par 57 = 1130

Par 58 = 1230

Par 71 through 75 = 1

Par 76 and 77 = 1

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Operating Parameters

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 Value:

—

Format:

—

Use:

Refer to Section 4,

Operation, Using Melter Function Keys

, for information about the use and affects of the seven-day clock feature.

51

Current Hour

Description:

Used to set the local time of the day.

Value:

0000 to 2359 (European time format)

Resolution:

1 minute

Default Value:

(Time set at factory)

Format:

Hours, 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 will turn on the heaters during schedule 1.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

0600

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn on.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

56

Schedule 1 Heaters Off

Description:

Used to set the time that the clock will turn off the heaters during schedule 1.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

1700

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn off.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

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Operating Parameters

B-17

57

Schedule 1 Enter Standby

Description:

Used to set the time that the melter will enter the standby mode during schedule 1.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will enter the standby mode during schedule

1.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an enter standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

58

Schedule 1 Exit Standby

Description:

Used to set the time that the melter will exit the standby mode during schedule 1.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will exit the standby mode during schedule

1.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an exit standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

60

Schedule 2 Heaters On

Description:

Used to set the time that the clock will turn on the heaters during schedule 2.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn on.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

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Operating Parameters

Seven‐day Clock

(contd)

61

Schedule 2 Heaters Off

Description:

Used to set the time that the clock will turn off the heaters during schedule 2.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn off.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

62

Schedule 2 Enter Standby

Description:

Used to set the time that the melter will enter the standby mode during schedule 2.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will enter the standby mode during schedule

2.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an enter standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

63

Schedule 2 Exit Standby

Description:

Used to set the time that the melter will exit the standby mode during schedule 2.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will exit the standby mode during schedule

2.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an exit standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

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Operating Parameters

B-19

65

Schedule 3 Heaters On

Description:

Used to set the time that the clock will turn on the heaters during schedule 3.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn on.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

66

Schedule 3 Heaters Off

Description:

Used to set the time that the clock will turn off the heaters during schedule 3.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hours, Hour: Minute, Minute

Use:

Set the desired time for the heaters to turn off.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

67

Schedule 3 Enter Standby

Description:

Used to set the time that the melter will enter the standby mode during schedule 3.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will enter the standby mode during schedule

3.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an enter standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

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B-20

Operating Parameters

Seven‐day Clock

(contd)

68

Schedule 3 Exit Standby

Description:

Used to set the time that the melter will exit the standby mode during schedule 3.

Value:

0000 to 2359, — — — —

Resolution:

1 minute

Default Value:

— — — —

Format:

Hour, Hour: Minute, Minute

Use:

Set the time that the melter will exit the standby mode during schedule

3.

To disable this parameter, set the parameter’s value to “- — — -” by simultaneously pressing both of the right-display scroll keys.

Note:

Do not set an exit standby time that is outside of the time period defined by the schedule’s heater on and off time. The melter cannot enter the standby mode when the heaters are off.

71

Schedules for Monday

Description:

Used to select which schedule(s) should be used on Monday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

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Operating Parameters

B-21

72

Schedules for Tuesday

Description:

Used to select which schedule(s) should be used on Tuesday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

73

Schedules for Wednesday

Description:

Used to select which schedule(s) should be used on Wednesday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

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Operating Parameters

Seven‐day Clock

(contd)

74

Schedules for Thursday

Description:

Used to select which schedule(s) should be used on Thursday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

75

Schedules for Friday

Description:

Used to select which schedule(s) should be used on Friday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

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Operating Parameters

B-23

76

Schedules for Saturday

Description:

Used to select which schedule(s) should be used on Saturday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

77

Schedules for Sunday

Description:

Used to select which schedule(s) should be used on Sunday.

Value:

0 – Remain at last clock transition

1 – Use just schedule 1

2 – Use just schedule 2

3 – Use just schedule 3

4 – Use schedule 1 and 2

5 – Use schedule 2 and 3

6 – Use schedule 1 and 3

7 – Use schedule 1, 2, and 3

Resolution:

1

Default Value:

0

Format:

—

Use:

Selects the active schedule(s) for the day.

NOTES:

If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

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Operating Parameters

Part 1024496_06 2014 Nordson Corporation

Melter Communications

C-1

Appendix

C

Melter Communications

This appendix describes the installation and use of the Nordson

Configuration Manager (NCM) communications utility. With this utility you can: transfer operating parameters and temperature set‐points between melters upgrade or reload your melter’s firmware

Software Availability

If you do not already have the NCM utility, you can download it from the internet by navigating to www.enordson.com/support.

If you do not have a connection to the internet, you can request a software

CD from your Nordson representative.

System Requirements

The following hardware and software requirements are necessary to install and run Blue Series software:

Any ProBlue adhesive melter or a DuraBlue 10/16 adhesive melter

Serial cable

Personal computer with:

CD‐RW drive or 3.5‐inch floppy drive

Available COM port

640 x 480 color monitor

Windows 95, 98 (second edition), ME, XP, or 2000

Internet Explorer version 4.0 or later (IE 5.0 is recommended)

Administrative privileges (Windows XP, 2000, and NT)

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C-2

Melter Communications

Installing the Software

To meet your specific installation conditions, two versions of the software are

available. Refer to Table C‐1 to determine which version you need.

Version

Single installation file:

BlueSeries.exe

Self-extracting span diskette set:

BlueSeriesSpan.exe

Table C‐1 Blue Series Software Versions

Use When…

You are downloading the software from www.enordson.com

and

the PC you are downloading onto is connected or can be connected to the melter

OR

You are downloading the software from www.enordson.com onto a PC that can not be connected to the melter, but the PC does have a CD-RW

and

the PC that is connected to the melter does have a CD drive

OR

You have a CD with the software

and

you have a PC with a CD drive that can be connected to the melter

You are downloading the software from www.enordson.com onto a PC that cannot be connected to the melter

and

the PC that is connected to your melter only has a 3.5-inch floppy drive

When the installation file is executed, an installation wizard will detect your operating system and start the installation routine.

NOTE:

Installing the NCM for the first time also installs the latest version of the melter’s firmware.

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Melter Communications

C-3

To install Blue Series software

1. Do

one

of the following:

If you are installing using the single file installation

, locate and double‐click on the file

BlueSeries.exe.

If you are installing from the span diskette set

, insert

Disk 1

, and then locate and double‐click on the file

Setup.exe

.

The

Blue Series Software Setup

wizard appears.

2. Click

Next

, and then follow the on‐screen instructions. If you are installing from the span disk set, you will be prompted to insert additional diskettes

(2 through 5) as required by your operating system.

NOTE:

When prompted to select an installation location, Nordson

Corporation recommends that you select the default location offered.

3. When the installation complete message appears, click

Finished

.

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Part 1024496_06

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Melter Communications

Removing the Software from Your PC

Use the

Remove

feature provided by the Blue Series InstallShield Wizard to remove the software from your PC. Removing Blue Series software from your PC will not remove melter settings files that you have saved using the

NCM. Settings files (.

ncm

extension) are stored in your Windows

My

Documents

folder.

NOTE:

Windows XP, 2000, and NT users must have administrator rights in order to remove software from their PC.

To remove Blue Series software

1. From the Windows

Start

menu, select

Settings

>

Control Panel

, and then double‐click

Add/Remove Programs

.

The

Add/Remove Programs

dialog box appears.

2. Select

Blue Series Software

from the list, and then click

Remove

.

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Melter Communications

C-5

Connecting the PC and the Melter

Connect a serial cable between the PC COM port (selected during the software installation routine) and the serial port connection (COM port) on your melter’s control panel.

ProBlue serial port

DuraBlue serial port

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C-6

Melter Communications

Using Nordson Configuration Manager

Configuration Manager is launched from your Windows desktop using the icon shown to the left.

Configuration Manager desktop icon

Use Configuration Manager when you want to…

copy melter settings from one melter to another melter create and save more than one version of melter settings upgrade or restore a melter’s firmware

Configuration Manager communicates with your melter through a PC connected to your melter’s serial port. Once connected, Configuration

Manager offers the choice of saving settings, restoring settings, or upgrading the melter’s firmware.

The first time you download and install Configuration Manager, the latest version of the melter’s firmware is also downloaded.

Saving and Restoring Melter Settings

Saving settings copies all current set‐point and operating parameter values to your PC. Saved settings can be transferred back to the same melter or to any other compatible Blue Series adhesive melter.

To save melter settings

1. Place the melter into the configuration mode by simultaneously pressing the

Standby

and

Setup

keys.

“

COnF”

appears in the right display.

2. Double‐click the

NCM

icon on the Windows desktop.

The

NCM

dialog box appears.

3. Click

Select Device

.

The

Select Product

dialog box appears.

4. Select your melter from the list, and then click

Ok

.

The

Select COM Port

dialog box appears.

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Melter Communications

C-7

5. Select the COM port you are using to connect to the melter, and then click

Ok

.

The PC and melter establish communications and a picture of the melter you selected appears in the device status area. The right side of the status area indicates “

CONNECTED

”.

6. Click

Save Settings

.

The

Save As

dialog box appears.

NOTE:

The default location for saving settings files is Windows

My

Documents

folder. To avoid losing saved settings files, Nordson

Corporation recommends that you do not change the default save location.

7. Type a file name to identify the group of settings you are saving, and then click

Save

.

The save settings progress bar indicates the status of the save. When the save is complete, the melter automatically returns to the scan mode.

NOTE:

If you are using the NCM to save multiple variations of melter settings, use a file naming convention that will allow you to easily associate each settings file (

.ncm

extension) with its related process or end‐use.

8. Click

Ok

to close the NCM.

To restore melter settings

1. Follow steps 1 through 5 of

To save melter settings

.

2. Click

Restore Settings

.

The

Open

dialog box appears.

3. Select the settings file (.

ncm

extension) that you want to restore, and then click

Open

.

The

Restore Settings

progress bar indicates the status of the restore.

When the restore is complete, the melter automatically returns to the scan mode.

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Melter Communications

Upgrading or Restoring Melter Firmware

Use the NCM to upgrade your melter to a newer version of firmware or reload the current version of the firmware. The version of Blue Series adhesive melter firmware that is currently available is posted on the internet at www.enordson.com/support.

NOTE:

The version of firmware that is loaded on your melter appears on the control panel when the melter is first switched on.

During the upgrade process, all current melter settings are downloaded and saved on your PC. After upgrading or restoring a melter’s firmware, you can use the NCM to restore the pre‐upgrade settings.

CAUTION!

The upgrade process returns the melter’s settings to factory configuration, with the exception that current heater hours data is saved.

Data in both the fault log and the change log is lost after upgrading the firmware.

To upgrade or reload melter firmware

1. Connect your PC to the melter. Refer to

Connecting the PC and the

Melter

earlier in this guide.

2. Place the melter into the upgrade mode by pressing and holding both the

Setup

and left display

Scroll

key. and then switching the melter off and then on again.

3.

UPLOAd

appears in the right display.

4. Double‐click the

NCM

icon on the Windows desktop.

The

NCM

dialog box appears.

5. Click

Select

.

The device dialog box appears.

6. Select your melter from the list, and then click

Ok

.

The

Select COM Port

dialog box appears.

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Melter Communications

C-9

7. Select the COM port you are using to connect to the melter, and then click

Ok

.

The PC and melter establish communications and a picture of the melter you selected appears in the device status area. The right side of the status area indicates

Connected

.

8. Click

Upgrade

.

The

Select Upgrade

dialog box appears.

9. In the

Available Upgrades

list, select the firmware version you want to upload to the melter, and then click

Ok

.

The upgrade warning message appears.

10. Click

OK

.

The

Upgrade in Progress

dialog box appears. The upgrade can take as long as 12 minutes. When the upgrade is complete, the

Success

dialog box appears and the melter restarts.

CAUTION!

Once the uprade progress bar appears, do not interrupt the upgrade process for any reason. Interrupting the upgrade can corrupt the melter’s firmware, which will require replacement of the IC chip

(IC service kit P/N 1018817).

11. Click

OK

.

The communications link between the melter and the PC is terminated.

12. Do

one

of the following:

To restore pre‐upgrade melter settings, go to

To restore pre‐upgrade melter settings

on the next page.

To close the NCM, click

Exit

.

To restore melter settings other than the settings that were in use by the melter before the upgrade, go to

Saving and Restoring Melter

Settings

earlier in this guide.

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Melter Communications

To restore pre‐upgrade melter settings

1. Place the melter into the configuration mode by simultaneously pressing the

Standby

and

Setup

keys.

“

COnF”

appears in the right display.

2. Click

Connect

.

The

Select COM Port

dialog box appears.

3. Select the COM port you are using to connect to the melter, and then click

Ok

.

The PC and melter establish communications and a picture of the melter you selected appears in the device status area. The right side of the status area indicates “

CONNECTED

”.

4. Click

Restore Pre‐Upgrade Settings

.

The pre‐upgrade settings are restored and the melter returns to the scan mode.

5. Click

Exit

to close the NCM.

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Melter Communications

C-11

Troubleshooting

Using Nordson Configuration Manager

Symptom/Message

After selecting a device and the COM port, an

Access Denied

message appears.

Action

PC-to-Blue communications may be running or another application may be using the COM port. Close Internet Explorer and end the communications connection (if prompted). Close all other applications.

Melter in UPLOAd mode, the update process has not been initiated, and you want to stop and exit the UPLOAd mode, but you cannot get the melter out of UPLOAd.

UPLOAd does not appear on the melter’s display when you press the Setup and left display scroll keys.

Cycle power to the melter at the local power disconnect switch.

CAUTION:

Ensure that the firmware update process is not running before taking power off of the melter.

You must cycle the control switch while holding the Setup and left display scroll keys.

Attempted a firmware update, but the melter display still indicates

UPLOAd.

OR

Attempted a firmware update, but the PC has stopped responding or was interrupted during the update process.

Using the local power disconnect switch, cycle power to the melter, and then re-attempt the update.

If the update is unsuccessful or the melter will not reboot, the central processor chip may be corrupted. Replace the CPU board.

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Part 1024496_06

C-12

Melter Communications

Part 1024496_06 2014 Nordson Corporation

SP Pump Diagnostics and Repair

D-1

Appendix

D

SP Pump Diagnostics and Repair

WARNING!

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

Introduction

This appendix provides comprehensive diagnostic and repair information for the SP pump used in all ProBlue adhesive melters. Before using the information provided in this appendix to diagnose or repair your pump, ensure that you have eliminated all conditions that might otherwise be mistaken for a failure of the pump. Refer to Section 6,

Troubleshooting.

NOTE:

The procedures and illustrations in this section are specific to 15:1 pumps, but can be used for 6:1 pumps as well. Refer to the pump‐specific parts lists in Section 7,

Parts

, when performing the procedures in this section.

Pump Function

The pump is double‐acting—material is discharged from the pump during both the upward and downward stroke of the piston.

The pump consists of an air section and a hydraulic section. Air is supplied to the pump through an air filter and a regulator. From the regulator, air flows to an air valve inside the air section. The air valve directs air into either the upper or lower portion of the air cylinder, which forces the piston assembly up or down. The lower end of the piston assembly contains a pressure ball valve. At the bottom of the hydraulic section is a siphon ball valve.

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Part 1024496_06

D-2

SP Pump Diagnostics and Repair

Pump Function

(contd)

When the air valve directs the stroke of the piston upwards, the piston creates suction within the pump body, which opens the siphon ball valve and closes the pressure ball valve. As the piston moves upwards, material is simultaneously drawn into the pump below the pressure ball valve and forced out of the pump chamber above the pressure ball valve. Material leaving the pump chamber passes through a filter and then into a manifold, where it is distributed to the hoses/guns.

Attached to the piston assembly is a shifter fork. The fork travels along the shaft of the actuator assembly that has a magnet at both ends. When the stroke of the piston carries the shifter fork upwards, a magnet in the shifter fork attracts the magnet at the end of the actuator, which shifts the position of the air valve. When the valve shifts, air is redirected to the opposite side of the air cylinder, which forces the piston downwards.

On the piston downward stroke, material pressure below the piston closes the siphon ball valve and opens the pressure ball valve. As the piston moves downwards, material below the pressure ball valve is displaced, and forced through the pressure ball valve and out of the pump chamber, where again, it passes through the filter and into the manifold.

Pump Isolation Valve

To prevent siphoning of the tank when the pump is removed from the manifold, the manifold is equipped with an isolation valve.

Pressure Discharge Valve

The manifold is equipped with a pressure discharge valve. When the pump is switched off at the control panel, air is removed from the top of the valve causing it to open. When the valve opens, pressurized material within the pump and manifold is bypassed through the pressure discharge valve back to the tank.

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D-4

SP Pump Diagnostics and Repair

Pump Diagnostics

To determine why the pump has failed, you will, in most cases, have to partially or fully disassemble the pump. To assist you in determining the

appropriate level of disassembly, Table D‐1 provides a logical breakdown of

the three types of pump failures, the potential conditions that could produce each failure, and the disassembly procedure(s) in which potential condition(s) can be examined.

Disassembly procedures are provided in

Pump Disassembly and

Reassembly.

Part 1024496_06

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Problem

1.

Pump not Stroking

2.

Pump Leaking

Adhesive

SP Pump Diagnostics and Repair

D-5

Table D‐1 Pump Diagnostics

Possible Cause

Air valve dirty or damaged

Corrective Action

Remove the Valve Spool and Sleeve

Valve sleeve O‐rings damaged or deteriorated

Remove the Valve Spool and Sleeve

Air leaking from between the cylinder head and the air cylinder or between the air cylinder and the pump frame

Remove The Actuator and the Air

Cylinder Assembly

Piston cups damaged

Shifter fork damaged, slipped out of position on piston, installed upside down, or magnets loose

Magnets on actuator assembly loose

Piston damaged or has char buildup

Remove the Piston Cups

Removing the Shifter Fork

Remove the Magnetic Actuator Assembly

Remove the Lower Ball Seat Assembly and the Piston

O‐ring and/or pump seal deteriorated or damaged

O‐rings on cross‐over tubes or between the pump and manifold damaged or deteriorated

Remove the Pump O‐ring and the Pump

Seal

Removing the Pump from the Melter

3.

Pump Strokes

Erratically

Siphon ball, seat and/or cage is damaged, deteriorated, or has char buildup

Pressure ball and/or seat has char buildup or is scratched or pitted

Piston has char buildup

Pump body dirty

Disassemble the Lower Ball Seat and

Pressure Ball Assemblies

Disassemble the Lower Ball Seat and

Pressure Ball Assemblies

Remove the Lower Ball Seat Assembly and the Piston

Remove the Lower Ball Seat Assembly and the Piston

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Part 1024496_06

D-6

SP Pump Diagnostics and Repair

Pump Disassembly and Reassembly

This part provides sequential pump disassembly procedures. Unless otherwise noted in the

Special Reassembly Instructions

, which are provided in each procedure, reassembly of the pump is the reverse of the disassembly.

Within each disassembly procedure, is a check/repair table that describes

what specific conditions (from Table D‐1) to inspect for while disassembling

the pump, service details, and component part numbers.

Melter Preparation

The melter must be brought up to operating temperature before the pump can be removed and disassembled. Once the pump is removed, the molten material within the pump will remain workable only for a short period of time.

If necessary, use a heat gun to warm the pump assembly during disassembly.

Required Tools and Materials

Tools

Heat gun

4‐mm hex wrench

5‐mm hex wrench

6‐mm hex wrench

1

/

8

‐in. steel rod or equivalent tool

8 mm open‐end wrench

10 mm socket and ratchet

Bench vise or suitable mount to hold the pump during repairs

Suitable vessel to heat Type‐R fluid

WARNING!

Do not heat Type R fluid with an open flame or in an unregulated heating device. Do not heat Type R fluid above 246 C (475 F).

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Part 1024496_06

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SP Pump Diagnostics and Repair

D-7

Service Parts

In most cases, you will need the pump service kit P/N 1028304 to complete pump repairs. This kit contains all of the seals, O‐rings, and other parts that are necessary to service the pump. Refer to the pump‐specific parts lists in

Section 7,

Parts

, for a complete listing of pump‐related parts.

Supplies

The following table described the lubricants and other compounds that are required during the re‐assembly of the pump. Lubricants and other compounds are indicated in the illustrations by the symbols shown in

Table D‐2.

Description

Table D‐2 Lubricants and Compounds

Part Number Symbol

Never‐Seez 900344

Parker Hi‐Temp

Lubricant

Loctite 272

Threadlocking Adhesive

SP Lubricating Oil

Type‐R Fluid (1 gal)

1029063

900470

211228

270755 —

Part 1024496_06

D-8

SP Pump Diagnostics and Repair

Remove the Pump from the Melter

1. Relieve system pressure. Refer to

Relieving System Pressure

in

Section 5.

See Figure D‐1.

2. Isolate the pump from the manifold by rotating the isolation valve handle to its full vertical position (valve closed).

3. Remove the three M8 pump‐mounting bolts from the front of the pump body.

4. Rotate the top of the pump slightly toward the front of the melter while pulling the pump away from the manifold.

NOTE:

The face of the pump body contains two M6 threaded holes.

Bolts can be threaded into these holes to gain leverage when removing the pump.

5. Remove the air line from the back of the pump.

6. Lift the pump clear of the melter, and place it in a bench vise or other suitable mount.

Pump‐to‐manifold

O‐rings

P/N 1019515

P/N 942111

Cross‐over tube O‐rings

P/N 940133 (2)

PTFE back‐up ring

P/N 954013

Check/Repair

Inspect for nicks, gouging, or swelling

Inspect for nicks, gouging, or swelling

Apply Parker lubricant during reassembly

Apply Parker lubricant during reassembly

Special Reassembly Instructions

Before reinstalling the pump, lubricate the O‐rings on the cross‐over tubes and the two O‐rings between the pump and the manifold.

Part 1024496_06

2014 Nordson Corporation

SP Pump Diagnostics and Repair

D-9

Figure

D-1

Removing the pump

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Part 1024496_06

D-10

SP Pump Diagnostics and Repair

Remove the Actuator and Air Manifold and the Cylinder Assembly

See Figure D‐2.

1. Remove the four M6 screws (1) and washers (2) from the cylinder head

(3), and then separate the cylinder head from the cylinder (4).

2. Lift the cylinder off of the piston cups (7), and then rotate the cylinder/can assembly (4 and 5) away from the shifter fork assembly (6).

3. Remove the two O‐rings (8).

O‐rings

P/N 940332

Check/Repair

Inspect for nicks, gouging, or swelling

Apply Parker lubricant during reassembly

Special Reassembly Instructions

Slide the cylinder over the half of the piston cup assembly (Which was installed as described in

Removing the Piston Cup Assembly

,

Special

Reassembly Instructions

); and then remove the torque nut, assemble the remaining piston cup (cupped side facing up) and seal washer, and then replace the torque nut.

Before rotating the cylinder/can assembly onto the shifter fork, center the fork inside the pump frame.

Part 1024496_06

2014 Nordson Corporation

5–6 N

 m (45–55 in.‐lb)

1

8

7

Figure

D-2

1. M6 screw (4)

2. M6 washer (4)

4. Cylinder

5. Can

6. Shifter fork assembly

7. Piston cup/seal washers

SP Pump Diagnostics and Repair

D-11

2

3

4

5

6

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Part 1024496_06

D-12

SP Pump Diagnostics and Repair

Remove the Magnetic Actuator Assembly

See Figure D‐3.

1. Remove the two M5 screws (3), and then pull the can (2) off of the actuator assembly (1).

See Figure D‐4.

2. Pull the actuator assembly away from the upper detent (4) to expose the small tool hole in the shaft (3).

3. Place a

1

/

8

‐in. steel rod or similar tool into the tool hole to prevent the actuator from rotating.

4. With the actuator assembly held in position with the

1

/

8

‐in. steel rod/tool, remove the valve spool nut (1), and then remove the bumper assembly

(2).

See Figure D‐5.

5. While holding the valve spool by the wrench flats (1) to prevent the spool from rotating, unscrew the actuator assembly (2).

Magnetic Actuator

P/N 164606

Bumper assembly

P/N 1014650

Check/Repair

Magnets are secured to the actuator shaft, undamaged, and free of debris

Check for wear

Clean, tighten the magnets, or replace as needed

Replace if worn

Part 1024496_06

2014 Nordson Corporation

SP Pump Diagnostics and Repair

D-13

2014 Nordson Corporation

2

3–4 N

 m (28–36 in.‐lb)

3

Figure

D-3

2. Can

1

3. M5 screw (2)

9–11 N

 m (81–99 in.‐lb)

2

1

4

Figure

D-4

1. Valve spool nut

3

Part 1024496_06

D-14

SP Pump Diagnostics and Repair

Remove the Magnetic Actuator Assembly

(contd)

1

2

Figure

D-5

9–11 N

 m (81–99 in.‐lb)

Part 1024496_06

2014 Nordson Corporation

SP Pump Diagnostics and Repair

D-15

Remove the Valve Spool and Sleeve

CAUTION:

Handle the valve spool with care. Damaging the precision machined surface of the spool can cause the air valve to seeze.

See Figure D‐6.

1. Carefully slide the valve spool (1) out of the valve sleeve (2). Set the valve spool aside onto a clean cloth.

See Figure D‐7.

2. Remove the two M4 screws (5), and then separate the upper detent (6) and spring (4) from the air manifold (3).

3. Remove the two M5 screws (2), and then remove the flange (1).

See Figure D‐8.

4. Use a socket or similar object to push the valve sleeve out of the air manifold.

NOTE:

The valve spool and sleeve are a matched set and cannot be exchanged with parts from another air valve assembly. If either the spool or sleeve is damaged, they must be replaced with a new valve assembly.

CAUTION!

Do not scrape the valve spool or sleeve. Clean them with mineral spirits or any non‐chlorinated cleaning solvent and a soft cloth. Do not use abrasives such as sandpaper or emery cloth. Be careful not to round off the sharp edges of the spool lands.

Valve spool*

Valve sleeve*

Check/Repair

Spool lands are nicked, gouged, corroded, or dirty

Broken, corroded, or dirty

Clean with mineral spirits or any non‐chlorinated solvent and a soft cloth.

Apply SP lubricating oil to the lands before inserting the spool back into the sleeve

Clean with mineral spirits or any non‐chlorinated solvent and a soft cloth

O‐rings

P/N 940181

Inspect for nicked, gouged, or swollen

Apply Parker lubricant during reassembly

*Available only as part of valve assembly P/N 1006027

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Part 1024496_06

D-16

SP Pump Diagnostics and Repair

Special Reassembly Instructions

Use the flange to press the sleeve back into the air manifold.

Apply only one drop of lubricating oil to each spool land.

Ensure that the valve spool slides freely inside the sleeve.

1

2

Figure

D-6

Part 1024496_06

2014 Nordson Corporation

2014 Nordson Corporation

SP Pump Diagnostics and Repair

D-17

2

3.2–4.1 N

 m (28–36 in.‐lb)

1

4

3

6

5

Figure

D-7

1. Flange

2. M5 screws (2)

1.82–2.27 N

 m (16–20 in. lb)

4. Spring

2

Figure

D-8

1

Part 1024496_06

D-18

SP Pump Diagnostics and Repair

Remove the Shifter Fork

CAUTION!

Handle the shifter fork with care. Dropping or otherwise mishandling the shifter fork may damage the magnet.

See Figure D‐9.

1. Remove the hex‐head screw (2) and the washer (1 ) from the shifter fork (3).

2. Remove the shifter fork from the piston by sliding the fork up to the narrowest point on the piston.

Shifter fork assembly

P/N 166880

Check/Repair

Word “UP” is facing upwards

Securely attached to piston

Resting on piston shoulder

Bent

Magnets secure/undamaged

Replace fork if bent or magnet is damaged

Special Reassembly Instructions

The fork must be resting on the shoulder of the piston (See Figure D‐9,

item 4).

The word “UP” must be facing the top of the pump frame.

Part 1024496_06

2014 Nordson Corporation

3

4

SP Pump Diagnostics and Repair

D-19

1

2

7–8.5 N

 m (60–70 in.‐lb)

Figure

D-9

1. Washer 3. Shifter fork assembly

2014 Nordson Corporation

Part 1024496_06

D-20

SP Pump Diagnostics and Repair

Remove the Piston Cups

See Figure D‐10.

1. While holding the piston in‐place by its wrench flats, remove the M6 torque nut (1).

2. Remove the two piston cups (4) and the piston seal washers (2 and 3).

Piston cups

P/N 163039

Check/Repair

Not torn or deteriorated

Pliable

Apply Parker lubricant during reassembly

Special Reassembly Instructions

To prevent damage to the upper piston cup when reinstalling the cylinder, install only the bottom seal washer, the bottom piston cup, center seal washer, and the torque nut (loose). The remaining piston cup and washer are not installed until after the cylinder is in‐place.

Refer to

Remove the Actuator and Air Manifold and the Cylinder

Assembly

.

Part 1024496_06

2014 Nordson Corporation

11.3–13.6 N

 m (100–120 in.‐lb)

1

SP Pump Diagnostics and Repair

D-21

2

3

4

2

Figure

D-10

2. Piston cup washer (2)

3. Piston seal washer

4. Piston cup (2)

2014 Nordson Corporation

Part 1024496_06

D-22

SP Pump Diagnostics and Repair

Remove the Pump Frame and the Insulator

See Figure D‐11.

1. Remove the four hex‐head screws (1) and washers (4).

2. Lift the pump frame (2) and the insulator (3) off of the piston.

See Figure D‐12.

3. If necessary (see Checks/Repairs), remove the retaining ring (1) and the

U‐cup (2) from the frame.

Pump insulator

P/N 1017307

U‐cup piston seal

P/N 952100

Check/Repair

Cracked or warped

Nicked, cut, or deteriorated

Apply Parker lubricant during reassembly

Special Reassembly Instructions

Before reinstalling the insulator and pump frame, place the O‐ring and piston seal over the piston.

NOTE:

Install the pump seal with the open side facing the pump body.

Install the insulator with the words “This side up” facing upwards.

Use the insulator to seat the O‐ring and pump seal into the groove in the pump body.

The tapered end of the insulator and pump frame face the filter.

Part 1024496_06

2014 Nordson Corporation

3–3.5 N

 m (25–31 in.‐lb)

1

4

SP Pump Diagnostics and Repair

D-23

3

2

Figure

D-11

1. Hex‐head screw (4)

3. Insulator

2014 Nordson Corporation

Part 1024496_06

D-24

SP Pump Diagnostics and Repair

Remove the Pump Frame and the Insulator

(contd)

1

2

Figure

D-12

2. U‐cup

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SP Pump Diagnostics and Repair

D-25

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Part 1024496_06

D-26

SP Pump Diagnostics and Repair

Remove the Lower Ball Seat Assembly and the Piston

CAUTION:

Handle the piston with care. Damaging the precision machined surface of the piston can result in failure of the pump.

See Figure D‐13.

1. Unscrew the lower ball seat assembly (2) from the pump body.

2. Pull the piston (1) out of the bottom of the pump body.

Pump body

P/N 1016863

Piston

P/N 1022658

Check/Repair

Remove solidified adhesive before reassembly

Nicked or worn

Remove solidified adhesive before reassembly

Special Reassembly Instructions

Apply Never‐seez to the threads of the lower ball seat before reinstalling the seat into the pump body.

Apply O‐ring lubricant to the lower ball seat O‐ring.

Part 1024496_06

2014 Nordson Corporation

1

2

Figure

D-13

1. Piston

2. Lower ball seat assembly

SP Pump Diagnostics and Repair

D-27

2014 Nordson Corporation

Part 1024496_06

D-28

SP Pump Diagnostics and Repair

Disassemble the Lower Ball Seat and the Pressure Ball Assemblies

See Figure D‐14.

1. Pull the siphon ball cage (1) off of the lower ball seat (4), and then remove the siphon ball (2).

2. Remove the O‐ring (3) from the lower ball seat.

See Figure D‐15.

3. Unscrew the pressure ball seat (3) from the piston (1), and then remove the pressure ball (2).

Siphon ball

P/N 900001

Pressure ball

P/N 900000

Ball seats

P/N 1017320

Siphon ball cage

P/N 503696

Lower ball seat O‐ring

P/N 945037

Check/Repair

Char buildup

Char buildup or damage Apply Never‐seez during reassembly

Char buildup or damage

Nicked, gouged, deteriorated, or swollen

Apply Parker lubricant during reassembly

NOTE:

Clean all hydraulic components in a container of Type R fluid before reassembling them.

Special Reassembly Instructions

If the siphon ball cage does not fit tightly onto the lower ball seat, gently bend the legs of the cage together to create a spring‐fit onto the seat.

Part 1024496_06

2014 Nordson Corporation

2014 Nordson Corporation

4

3

Figure

D-14

1. Siphon ball cage

3. O‐ring

4. Lower ball seat

1

SP Pump Diagnostics and Repair

D-29

2

1

2

3

Figure

D-15

1. Piston

3. Pressure ball seat

5.6–6.78 N

 m (50–60 in.lb)

Part 1024496_06

D-30

SP Pump Diagnostics and Repair

Remove the O‐ring and the Pump Seal

See Figure D‐16.

Remove the O‐ring (1) and pump seal (2) from the pump body.

O‐ring

P/N 940172

Check/Repair

Nicked, cut, deteriorated, or swollen

Apply Parker lubricant during reassembly

Pump Seal

P/N 273139

Nicked, cut, deteriorated, or deformed

Apply Parker lubricant during reassembly

Special Reassembly Instructions

The O‐ring and the pump seal are replaced after the piston is reinstalled, but before the insulator and pump frame are installed. Refer to

Removing the Pump Frame and the Insulator

for information about reinstalling the

O‐ring and the pump seal.

1

2

Figure

D-16

1. O‐ring

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SP Pump Diagnostics and Repair

D-31

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D-32

SP Pump Diagnostics and Repair

Pump Assembly Parts List

F1

F2

31

30

F4

F2

15

28

32

29

33

35

34

37

36

20

17

18

19

16

21

22

27

26

25

F25

24

23

12

9

14

13

11

1

F6

2

3

4

5

F19

6

F6

7

8

10

4401005A

2014 Nordson Corporation

Part 1024496_06

SP Pump Diagnostics and Repair

D-33

NOTE:

These parts lists are specific to standard 15:1 pumps, but can be used for the other ProBlue melter pump options as well. Refer to the pump‐specific parts lists in Section 7,

Parts

, as needed.

Item

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

35

36

37

31

32

33

34

11

12

13

14

7

8

9

10

—

1

2

3

4

5

6

NOTE A: Included in service kit P/N 1028303

B: Included in service kit P/N 1028305

Part

166880

1017320

900001

503696

945037

1022658

900000

503709

1016863

973543

1021270

273139

940172

1017307

1016339

940332

‐ ‐ ‐ ‐ ‐ ‐

1006027

1021998

333560

155057

164606

155068

155067

986714

984092

983446

163039

983445

986331

952100

333137

‐ ‐ ‐ ‐ ‐ ‐

1021955

1017849

940261

276024

1022779

Description

Pump, piston, 15:1

Service kit, valve assembly, G2SP

Manifold, air, G

1

/

8 in. port

Spring, wave, Inconel,

Detent, upper

Service kit, magnetic actuator

Can

Detent, lower

Retaining ring, internal, 156, bowed

Nut, hex, lock, torque, M6, class 10

Washer, piston cup

Cup, piston

Washer, piston seal

Retaining ring, internal, 100, push‐on

Cup, U, Viton

Service kit, fork magnetic

Seat, ball, lower

Ball, 440 stainless steel, 0.500 in.

Cage, ball, siphon

O‐ring, Viton, 1 in. tube

Piston assembly

  Ball, 440 stainless steel, 0.375 in.

  Seat, ball, pressure

Body, pump filter

Plug, O‐ring, straight thread,

7

/

16–

20

Plate, filter, anti‐rotation

Seal, pump

O‐ring, Viton, 0.676 x 0.070

Insulator, pump

Frame, pump

O‐ring, 2.000 x 2.125 x 0.063 in.

Head, cylinder

Filter assembly, 100‐mesh, with O‐ring

  Adapter, filter assembly

  Backup ring, PTFE, 0.273 x 0.045

O‐ring, Viton, 1.250 x 0.375 x 0.063 in.

Valve assembly, drain

Chute assembly, drain

Note

A

B

Quantity

1

1

1

2

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

1

1

2014 Nordson Corporation

Part 1024496_06

D-34

SP Pump Diagnostics and Repair

Pump Service Kit

Part

1028304

940133

940332

1019515

942111

940181

952100

954013

163039

273139

986331

984092

982147

982237

983410

940172

‐ ‐ ‐ ‐ ‐ ‐

940261

1017849

945037

973543

211228

Description

Kit, service, pump, P4/P7/P10

O‐ring, Viton, 0.426 x 0.070 in.

O‐ring, Viton, 2.00 x 2.125 x 0.063 in.

O‐ring, Viton, 0.50 x 0.75 x 0.125 in.

O‐ring, Viton, 0.812 x 0.062 x 0.125 in.

O‐ring, Viton, 0.739 x 0.70 in.

Cup, U, Viton

Backup ring, single,

7

/

16 x

9

/

16

Cup, piston

Seal, pump

Retaining ring, internal, 100, push‐on

Nut, hex, lock, torque, M6

Screw, hex, cap, M6 x 120

Screw, hex, cap, M6 x 35

Washer, flat, M6

O‐ring, Viton, 0.676 x 0.070

Lubrication, Parker,

1

/

2 oz.

O‐ring, Viton, 1.25 x 1.375 x .063

Backup ring, PTFE, 1.273 x .045 thick

O‐ring, Viton, 1‐inch tube

Plug, O‐ring,

7

/

16

‐20

Service kit, SP lubricating oil

Other Pump Maintenance Kits

Part

1006027

164606

166880

Service kit, valve assembly, G2SP

Service kit, magnetic actuator

Service kit, fork magnetic

Description

Schedule of Fasteners

Part

F1

F2

F4

F6

F19

Screw, hex, cap, M6 X 120 mm

Washer, flat, M, narrow, M6

Screw, hex, cap, M6 X 35 mm

Screw, hex, cap, M5 X 20 mm

Screw, hex, cap, M4 X 8 mm

Description

Part 1024496_06

2014 Nordson Corporation

Quantity

1

1

1

1

4

8

1

4

1

3

—

1

2

1

4

2

1

1

—

2

2

1

Quantity

—

—

—

400/480 Volt ProBlue Adhesive Melters

E-1

Appendix

E

400/480 Volt ProBlue Adhesive Melters

WARNING!

Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment.

This appendix provides information about the 400/480 volt versions of the

ProBlue adhesive melter. Key information provided in this appendix, which does not appear in the body of this manual, includes:

Installation instructions that are specific to the 400/480 volt melters and transformers

Transformer sizing guidance

Transformer troubleshooting

Parts and service kits that are specific to the 400/480 volt melters and transformers

For setup, operation, troubleshooting, and parts information that is common to all ProBlue adhesive melters, refer to the appropriate section of this manual.

2014 Nordson Corporation

Part 1024496_06

E-2

400/480 Volt ProBlue Adhesive Melters

Introduction

Safety

Before installing or operating the transformer or melter, read the safety information provided in Section 1,

Safety

.

Intended Use

The 1.5 kVA and 3.0 kVA transformers can only be used with ProBlue adhesive melters that are specifically designed for 400/480 volt electrical service.

Use an input electrical service rated at 400 volts 3‐phase without a neutral or 480 volts 3‐phase without a neutral.

Unintended Use

Water wash‐down environments

Explosive atmospheres

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-3

Transformer Sizing

Review the following transformer sizing procedure to ensure that your transformer is correctly sized for the number and type of hoses/guns you intend to use.

To size your transformer

1. Determine the total power consumption (in watts) at 230 volts for all of

your hoses and guns. Table E‐1 lists the wattages of common hoses and

guns that are sold by Nordson Corporation. If your hose or gun is not

listed in Table E‐1, refer to the identification tag that is affixed to the

hose/gun.

2. Calculate the kVA rating of the required transformer by dividing the total wattage calculated in step 1 by 1000.

Example

From Table E‐1, an application requires two 1.8 m Auto hoses at 155

watts each and two H‐402 (T‐LP) guns at 185 watts each.

The combined wattage of the selected hoses and guns is 680 watts.

680 B 1000

=

0.68 kVA

In this example, the 1.5 kVA transformer would be adequate.

2014 Nordson Corporation

Part 1024496_06

E-4

400/480 Volt ProBlue Adhesive Melters

Table E‐1 Hose and Gun Power Consumption

Hose/Gun

Hoses

Auto hose 0.6 m (2 ft.)

Wattage (230 Volts)

Auto hose 1.2 m (4 ft.)

Auto hose 1.8 m (6 ft.)

Auto hose 2.4 m (8 ft.)

Auto hose 3 m (10 ft.)

51.5

110

169

228

287

Auto hose 3.6 m (12 ft.)

Auto hose 4.8 m (16 ft.)

Auto hose 7.2 m (24 ft.)

Manual hose 2.4 m (8 ft.)

Manual hose 4.8 m (16 ft.)

345

463

698

228

463

Guns

H‐201 or 401 (T or T‐L)

H‐202 or 402 (T or T‐L)

H‐204 or 404 (T or T‐L)

H‐208 or 408 (T or T‐L)

H‐202 or 402 (T‐E or T‐E‐L)

H‐204 or 404 (T‐E or T‐E‐L)

H‐202 or 402 (T‐LP or T‐LP‐L)

H‐204 or 404 (T‐LP or T‐LP‐L)

H‐208 or 408 (T‐LP or T‐LP‐L)

H‐20 (T or T‐L0)

H‐20 w/micro (T)

140

210

260

405

335

350

185

285

390

135

160

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-5

Transformer Function

Input electrical service of 400 or 480 volts is split between the melter heaters and the transformer(s). The melter’s manifold and tank heaters operate on line voltage, which is passed through the transformer to the melter using a special wire harness. The melter’s CPU controls the duty cycle of the heaters. No change in melter programming is required in order for the transformer to operate.

The transformer(s) reduces the input electrical service to 230 volts and directs the reduced voltage to the melter’s main circuit board. The main circuit board uses this voltage to power the hoses and guns and provide control power to the CPU.

CPU‐generated control signals are fed to a driver board in the transformer which uses high‐power TRIACs to switch power to the manifold and tank heaters.

2014 Nordson Corporation

Part 1024496_06

E-6

400/480 Volt ProBlue Adhesive Melters

Installation

Before installing the transformer, familiarize yourself with the Section 3,

Installation

.

NOTE:

ProBlue 400/480 volt transformers can only be used in conjunction with ProBlue adhesive melters that are specifically designed for use with

440/480 volt electrical service.

Clearances

Figure E‐1 illustrates the

minimum

clearances that are required between the melter and surrounding objects. Table E‐2 describes each clearance.

A

C

B

D

Figure E‐1

Minimum installation clearances (P4 top and front views shown)

A

B

C

D

Item

Table E‐2 Installation Clearances

Description

The distance from the outside edge of a

5

/

16

‐inch Nordson hose to the front face of the melter when a short 90‐degree hose fitting is to connect the hose to the melter

The clearance required to open the pump enclosure door

The distance from the melter sub‐base to the front edge of the tank lid when the lid is at its highest point.

The clearance required on the left side of the melter to open the electrical enclosure door or remove a hose/gun module.

Required Clearance

P4 = 370 mm (14.5 in.)

P7 = 370 mm (14.5 in.)

P10 = 391 mm (15.4 in.)

P4 = 243 mm (9.6 in.)

P7 = 243 mm (9.6 in.)

P10 = 268 mm (10.55 in.)

P4 = 575 mm (22.6 in.)

P7 = 637 mm (25.1 in.)

P10 = 729 mm (28.7 in.)

P4 = 689 mm (27.1 in.)

P7 = 752 mm (29.6 in.)

P10 = 755 mm (29.7 in.)

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-7

Installation Kit Components

The following components are shipped with the transformer.

NOTE:

These components are in addition to the components that are provided in the melter installation kit.

Figure E‐2

Installation Kit

1. Voltage plug, 400 volt (Black wires)

2. Voltage plug, 480 volt (White wires)

5. M5 x 10 screws

2014 Nordson Corporation

Part 1024496_06

E-8

400/480 Volt ProBlue Adhesive Melters

Prepare the Transformer for Installation

See Figure E‐3.

1. Remove the transformer lid.

NOTE:

The lid is connected to the transformer by a ground lead.

2. Disconnect the ground lead from the sub‐base.

3. Turn both locking screws counter‐clockwise until they stop.

4. Remove the transformer from the sub‐base by pulling the transformer forward approximately

1

/

2 inch, and then lifting it clear of the sub‐base.

See Figure E‐4.

5. Attach the 400‐volt plug (P/N 1039789/Black wires) or the 480‐volt plug

(P/N 1039790/White wires) to the power distribution module.

2

1

Figure E‐3

Preparing the transformer

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-9

Figure E‐4

Installing the voltage plug

2014 Nordson Corporation

Part 1024496_06

E-10

400/480 Volt ProBlue Adhesive Melters

Mount the Transformer to the Parent Machine

The transformer is shipped with a sub‐base that is used to mount the transformer/melter to the parent machine.

NOTE:

If you are converting an existing 230 volt ProBlue melter installation to a 400/480 volt ProBlue installation, you must use the sub‐base provided with the transformer.

NOTE:

The transformer (with sub‐base) can be mounted directly to any parent machine that is already configured for mounting either a model 3100V or a model 3400V adhesive melter.

Sub‐base

To mount the transformer

See Figure E‐5.

1. Attach the sub‐base to the parent machine using four 8‐mm (

5

/

16

‐inch) bolts with locking hardware (customer supplied).

2. Remove the 1‐inch conduit knockout from the sub‐base and install the cable clamp that is provided in the installation kit.

3. Mount the transformer onto the sub‐base, and then lock the transformer to the sub‐base by turning both of the locking screws clockwise until they stop.

NOTE:

Ensure that the ground leads between the transformer chassis and the power distribution module and between the transformer chassis and the transformer lid are connected before replacing the lid.

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-11

Figure E‐5

Mounting the sub‐base and the transformer

2014 Nordson Corporation

Part 1024496_06

E-12

400/480 Volt ProBlue Adhesive Melters

Connect the Electrical Service to the Transformer

1. Select a 3‐wire (plus ground) power cable rated for the maximum amperage required by the melter. Ensure that the power cable meets

applicable electrical codes and standards. Table E‐3 lists the maximum

amperages (per line) for 400/480 volt ProBlue adhesive melters.

Table E‐3 Maximum Melter Amperages

Transformer Maximum Amperage

1.5 kVA

3.0 kVA

8 A

11 A

WARNING!

Risk of electrocution! ProBlue melters must be installed with a lockable power disconnect switch that completely de‐energizes the melter by isolating it from its power source. Failure to de‐energize the melter when required can result in personal injury, including death.

WARNING!

Risk of electrical shock or short circuit. Use rigid or flexible conduit or an appropriately sized strain relief to protect the power cable from the sharp edge of the conduit knockout.

2. Route the power cable between the power disconnect switch and the transformer. Secure the power cable to the transformer sub‐base using the cable clamp provided in the installation kit (P/N 331872).

See Figure E‐6.

3. Flip the splash shield away from the terminal block, and then connect the power cable to the terminal block (terminals 1, 2, and 3).

4. Connect the power cable ground lead to the ground lug that is located on the transformer chassis.

5. Re‐connect the ground lead on the transformer chassis to the ground post on the sub‐base.

6. Replace the transformer lid.

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-13

Figure E‐6

Connecting the electrical service

3. Sub‐base ground post

2014 Nordson Corporation

Part 1024496_06

E-14

400/480 Volt ProBlue Adhesive Melters

Mount the Melter to the Transformer

1. Coil the three transformer wire harnesses and temporarily stow them in the area of the terminal block.

See Figure E‐7.

CAUTION!

Ensure that the transformer wire harnesses are not pinched between the transformer and the melter.

2. Set the melter down onto the transformer so that the four tabs on the transformer enter the slots in the base of the melter.

3. Secure the melter to the transformer using the four M5 X 10 screws that are provided in the installation kit.

See Figure E‐8.

4. Connect the ground lead from the melter to the ground connection on the transformer chassis.

Part 1024496_06

Figure E‐7

Mounting the melter to the transformer

2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-15

Figure E‐8

Connecting the melter ground lead to the transformer chassis

2014 Nordson Corporation

Part 1024496_06

E-16

400/480 Volt ProBlue Adhesive Melters

Connect the Transformer to the Melter

1. Route the three wire harnesses from the transformer up into the melter’s electrical enclosure.

See Figure E‐9.

2. Connect the power harness to terminal J1 on the melter main board.

3. Connect the control harness to terminal J9 on the melter main board.

4. Connect the heater power harness from the transformer to the heater power harness plug that enters the bottom of the melter’s electrical enclosure.

See Figure E‐10.

5. Use the conduit plate, M5 screws, and washers provided in the installation kit to cover the service entrance on both the transformer and the melter.

6. Refer to the ProBlue adhesive melter product manual, Section 3,

Installation

,

Setting Up the Melter

.

Part 1024496_06 2014 Nordson Corporation

J9

J1

400/480 Volt ProBlue Adhesive Melters

E-17

Figure E‐9

Connecting the transformer electrical harnesses

3. Heater power harness

2014 Nordson Corporation

Part 1024496_06

E-18

400/480 Volt ProBlue Adhesive Melters

Connect the Transformer to the Melter

(contd)

Figure E‐10

Covering the service entrance

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-19

Troubleshooting

The following table provides transformer‐specific troubleshooting guidance.

Refer to Section 6,

Troubleshooting

, for general melter troubleshooting information.

1.

Problem

No power to melter

Possible Cause

Problem with customer power source

No voltage plug installed

Loose/disconnected cables

Blown fuse

Problem with transformer

Corrective Action

Check all three phases at terminal block

Install correct voltage plug

Check cable between transformer and J1 on main board

Check connections between transformer service terminal block and J2 on power distribution module

Check fuses F3, F4, F5, and F6

Check voltage into primary of transformer(s) and voltage at secondaries.

2.

Tank and/or manifold not heating, but power to melter

Programming/control issue

Loose/disconnected cables

Problem in heater

Blown fuse

Power problem

Problem with power distribution module

Turn heaters on/check that tank set‐point is correct (not 0)

Check connection at J9 on main board

Check connections along heater harness

(intermediate connections, terminals of heaters, connection back to J3 on power distribution module

Check for open or short. Cold resistance values are:

Manifold

175 to 203 ohms

Tank

P4 — 175 to 203 ohms

P7 — 145 to 169 ohms

P10 -145 to 169 ohms

Check F1/F2 on main board

Check all three phases at terminal block

Replace module

3.

Fuse(s) fail frequently

F1 or F2 fault: short circuit in heater or harness

F3, F4, F5, or F6: Transformer is overloaded

Locate and correct short

Verify that total hose/gun power does not exceed capability of transformer

4.

F3 fault on tank or manifold

Shorted TRIAC(s)

Noise problem

Replace power distribution module

Isolate sources of noise, change phases of incoming supply, or add filter/snubber to incoming supply line

2014 Nordson Corporation

Part 1024496_06

E-20

400/480 Volt ProBlue Adhesive Melters

Parts

Transformer Assembly

25

33

NS

NS

NS

NS

19

22

23

24

8

10

11

12

13

15

17

Item

—

—

1

4

5

6

7

Part

1039840

1039841

1040005

1018819

‐ ‐ ‐ ‐ ‐ ‐

1039994

‐ ‐ ‐ ‐ ‐ ‐

1040056

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1040002

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

‐ ‐ ‐ ‐ ‐ ‐

1040015

1039789

1039790

1040013

Description

Base assembly, 1.5 kVA, transformer, ProBlue

Base assembly, 3.0 kVA, transformer, ProBlue

Cover, assembly, encl, transformer, ProBlue

Sub‐base, P7/P10

Screw, socket, M5 x 10

Base, transformer, ProBlue

Module assembly, power, distribution

Panel, terminal block, 3‐position, 750 V, 76 A

Screw, socket, M4 x 25

Nut, hex, M5

Washer, lock, spit, M5

Terminal lug, ground, 6–14 AWG

Shield assembly, water, transformer, ProBlue

Power transformer, automatic, 1.5 kVA

Washer, flat, regular, M5

Wire assembly, ground, 10 gauge

Lug, 45 degree, single, M5 x .032

Nut, hex, M5

Nut, hex, external tooth, M4

Shield, splash, terminal

Harness assembly, transformer

Plug, voltage, 400 V

Plug, voltage, 480 V

Plate, conduit

Quantity

2

1

1

1

1

1

4/8

4

2

6

1

2

4/8

14

1

1

1/2

1

1

8

1

1

Note

B

A

A/B

A

NOTE A: The first number in the quantity column is for 1.5 kVA transformer base assemblies, the second is for

3.0 kVA transformer base assemblies.

B: Refer to

Service Kits.

NS: Not Shown

2014 Nordson Corporation Part 1024496_06

400/480 Volt ProBlue Adhesive Melters

E-21

2014 Nordson Corporation

Part 1024496_06

E-22

400/480 Volt ProBlue Adhesive Melters

Transformer Assembly

(contd)

Part 1024496_06 2014 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-23

400/480‐Volt Melter‐Specific Components

The following table lists melter components that are specific to 400/480 volt melters. Refer to the ProBlue product manual, Section 7,

Parts

, for information about melter components that are common to both standard and

400/480 volt melters.

Item

NS

NS

NS

NS

NS

Part

1032085

1037490

1037491

1037492

1033838

Description

Heating element, manifold, 480 V

Weldment, tank, machined, P4, 480 V

Weldment, tank, machined, P7, 480 V

Weldment, tank, machined, P10, 480 V

Harness, heater, transformer, P4, P7, P10

Quantity

1

1

1

1

1

Note

Service Kits

Part

1041660

1041662

1041661

Description

Service kit, transformer, 400/480 V, ProBlue

Power transformer, automatic, 1.5 kVA, 400/480 volt

Service kit, driver board, 400/480 volt, ProBlue

Module assembly, power distribution

Service kit, fuse, 400/480 volt, ProBlue

Fuse, 8A, fast‐acting, 600 V, CC‐REJ

Fuse, 5A, time‐delay, 600 V, CC‐REJ

Quantity

—

1

—

1

—

2

4

Wiring Diagram

The wiring diagram on the next page is provided for your reference as needed.

2014 Nordson Corporation

Part 1024496_06

E-24

400/480 Volt ProBlue Adhesive Melters

Part 1024496_06 2014 Nordson Corporation

EC Declaration of Conformity

for Adhesive and Sealant Application Equipment conforming to European Council Directives

PRODUCTS:

AltaBlue Melters, Models 15, 30, 50, 100

AltaBlue TT Melters, Models A4, A10, A16

AltaPail Melters

Cobalt GR Series Bulk Material Unloaders

DuraBlue Melters

FoamMelt FM‐200 Melter

Freedom Hot Melt Adhesive System

Fulfill Retrofit Kit

Mesa Melters

MiniPUR Melters

ProBlue Melters, Models P4, P7, P10, P15, P30 and P50

ProBlue Fulfill , Models P4F, P7F, P10F

PURBlue Melters

Series 3000V Melters

SureFoam Foam Dispensing System

Model Number_________________________

Serial Number______________________________________

APPLICABLE DIRECTIVES: STANDARDS USED TO VERIFY COMPLIANCE:

Machinery Directive: 2006/42/EC

Electromagnetic Compatibility Directive: 2004/108/EC

EN ISO 12100

EN ISO 13732‐1

EN 60204‐1

EN 61000‐6‐2

EN 61000-6-4

EN 55011

(Class A, Group 1 for industrial environments. Use in other environments may pose potential difficulty ensuring electromagnetic compatibility due to conducted as well as radiated disturbances.)

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directives and standards described above.

Gregory P. Merk, Senior Vice President

Adhesives Dispensing Systems

Date: 20 March 2014

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANY

Nordson Corporation 28601 Clemens Road Westlake, Ohio

1105311A05

DOC074R6