altablue adhesive melters models 15, 30, 50, and...

AltaBlue� Adhesive MeltersModels 15, 30, 50, and 100

Customer Product ManualPart 1072086A07

Issued 3/14

This document contains important safety informationBe sure to read and follow all safety information in thisdocument and any other related documentation.

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

Part 1072086A07 � 2014 Nordson CorporationAll rights reserved

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

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2006.No part of this document may be photocopied, reproduced, or translated to another language without the prior written

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

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax,Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem,

Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, Encore, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry,Fluidmove, FoamMelt, FoamMix, Fulfill, HDLV, Heli-flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, LEAN CELL,

Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan,Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism,

ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pre-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure,Signature, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure-Max, Sure Wrap, Tracking Plus, TRAK, Trends,

Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, u−TAH, Vantage, VersaBlue, Versa-Coat, 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, AquaCure, ATS, Auto-Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Controlled Fiberization, Control Weave, ContourCoat, CPX, cScan+,

cSelect, Cyclo-Kinetic, DispensLink, Drop Cure, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, Emerald,E-Nordson, EquiBead, FillEasy, Fill Sentry, FlowCoat, Fluxplus, Get Green With Blue, GreenUV, G-Net, G-Site, iON, Iso-Flex, iTrend, Lacquer Cure,

Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, Myritex, Nano, OptiStroke, Partnership+Plus, PatternJet,PatternPro, PCI, PicoDot, Pinnacle, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, RediCoat, Royal Blue,

Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Coat, SureFoam,Sure Mix, SureSeal, Swirl Coat, TAH, ThruWave, TinyCure, Trade Plus, Trilogy, TrueCoat, Ultra FoamMix, UltraMax, Ultrasmart, Universal, ValueMate,

VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation.

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

Buna-N is a registered trademark of Pittway Corps.DeviceNet is a trademark of Open DeviceNet Vendor Association, Inc.

Never Seez is a registered trademark of Bostik Inc.Parker Lubricant is a registered trademark of Parker Seal.

Profibus is a trademark of Profibus International.Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.

Windows is a registered trademark of Microsoft Corporation.

Table of Contents i

Part 1072086A07� 2014 Nordson Corporation

Table of Contents

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

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

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

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

Relieving System Hydraulic Pressure 1-6. . . . . . . . . . . . . . . . . . . . .De-energizing the System 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Guns 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Safety Labels and Tags 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic Compatibility (EMC) 2-1. . . . . . . . . . . . . . . . . . . . . . . .Examples of Unintended Use 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual Risks 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key Components 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Components 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Isolation Valve 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valves 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modes of Operation 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Scan (Normal Mode) 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear-to-Line Capability 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Identification 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1072086A07 � 2014 Nordson Corporation

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Tasks 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Experience of Installation Personnel 3-2. . . . . . . . . . . . . . . . . . . . . . . .

Installation Requirements 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clearances 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilation 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Power 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Drive Internal Filter 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Considerations 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking the Melter 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Moving the Unpacked Melter 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contents of the Installation Kit 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Customer-Supplied Materials 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the Electrical Service 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Residual Current Circuit Breakers 3-10. . . . . . . . . . . . . . . . . . . . . . . . . .Connecting the Electrical Service 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Hoses and Guns 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up the Melter 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Setup 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Parameters 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Operating Parameters 3-22. . . . . . . . . . . . . . . . . . . . . . . . .Reading or Editing Operating Parameters 3-23. . . . . . . . . . . . . . . . .

Set-point Temperature of the Tank, Hoses, and Guns 3-28. . . . . . . . . .Save and Restore Melter Settings 3-30. . . . . . . . . . . . . . . . . . . . . . . . . .Review Parameter and Set-point Temperature Changes 3-32. . . . . . .

Setting Up Inputs/Outputs 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up Gear-to-Line Operation 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up Motor Run Status Monitoring 3-41. . . . . . . . . . . . . . . . . . . . . . .

Wiring 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Programming 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Optional Equipment 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting a Gun Driver, Pattern Controller, or Timer 3-42. . . . . . . . . . . .Flushing the Melter 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposing of Melter 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii


Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Additional Information 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling the Tank 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .About Heated Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting the Melter 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manually Adjusting the Pump Speed 4-6. . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Material Pressure 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring the Melter 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Confirm that the Melter is Operating Correctly 4-9. . . . . . . . . . . . . . . .Monitor Component Temperatures 4-10. . . . . . . . . . . . . . . . . . . . . . . . . .Monitor Melter Faults 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitor the Service Interval 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Component Temperatures 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . .Entering a Password 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Function Keys 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Key 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Master Pump Enable Key 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup Key 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-Day Clock Key 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby Key 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the Melter 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record of Melter Settings 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving System Pressure 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Through the Guns 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Through the Melter Drain Valves 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Schedule 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Locking Out the Motor Drives 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing the Material Type 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching the Exterior Panels 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan and Air Filter 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor and Gear Box 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Motor Lubricant 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Motor or Coupling 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Pump Screws 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Pump Gland Bolt 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Pump 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Cartridge 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Service Kit 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure/Circulation Control Valve Service Kit 5-18. . . . . . . . . . . . . . . . . .Cleaning the Tank 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Material from the Tank 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the Tank by Hand 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Fixing Screws 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main PCA Board 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record Form 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Quick-Checks 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Returning the Melter Setup to Factory Settings 6-2. . . . . . . . . . . . . . . . .Melter Faults 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Control Faults 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing a Motor Control Parameter 6-6. . . . . . . . . . . . . . . . . . . . . . . . . .Motor Drive Faults 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing a Motor Drive Parameter 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibrating the Pump Speed Display 6-12. . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Not Functioning 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One Channel (Heating Zone) Does Not Heat 6-13. . . . . . . . . . . . . . . . .Control Panel Does Not Function 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor Does not Rotate) 6-14. . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor Rotating) 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Too Little Material 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure Too High 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure Too Low 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Residue in Tank 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Hardens in Tank 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Others 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AltaBlue Configuration Code 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame Assembly 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One/Two-Pump Melter Frame Parts 7-4. . . . . . . . . . . . . . . . . . . . . . . . .Three/Four-Pump Melter Frame Parts 7-6. . . . . . . . . . . . . . . . . . . . . . .

Reservoir/Manifold Assembly 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two-Pump Melter Reservoir/Manifold Parts 7-8. . . . . . . . . . . . . .Three/Four-Pump Melter Reservoir/Manifold Parts 7-10. . . . . . . . . . . .100L Melter Reservoir/Manifold Parts 7-12. . . . . . . . . . . . . . . . . . . . . . .Manifold Parts 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hopper Assembly 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two-Pump Melter Hopper Parts 7-18. . . . . . . . . . . . . . . . . . . . . . . .Three/Four-Pump Melter Hopper Parts 7-20. . . . . . . . . . . . . . . . . . . . . .100L Melter Hopper Parts 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assemblies 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Module Parts 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single-Stream Pump Adapter Parts 7-26. . . . . . . . . . . . . . . . . . . . . . . . .Dual-Stream Pump Adapter Parts 7-27. . . . . . . . . . . . . . . . . . . . . . . . . .Single-Stream Gear Pumps 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dual-Stream Gear Pumps 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Parts 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valve Assemblies 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Valve Module Parts 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Cartridge Parts 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve Parts 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Pressure Control Valve Parts 7-35. . . . . . . . . . . . . . . . . . . . .Circulation Control Valve Parts 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v


Parts (contd)Motor Assembly 7-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Enclosure Panel Assemblies 7-40. . . . . . . . . . . . . . . . . . . . . . . . .

One/Two-Pump Melter Left Panel Parts 7-40. . . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Melter Left Panel Parts 7-42. . . . . . . . . . .One/Two-Pump Melter Back Panel Parts 7-44. . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Six Hose/Gun MelterBack Panel Parts 7-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Eight Hose/Gun MelterBack Panel Parts 7-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two-Pump Melter Right Panel Parts 7-56. . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Six Hose/Gun MelterRight Panel Parts 7-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Eight Hose/Gun (400V) MelterRight Panel Parts 7-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Eight Hose/Gun (240V) MelterRight Panel Parts 7-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two-Pump Melter Bottom Panel Parts 7-64. . . . . . . . . . . . . . . . . .Three/Four-Pump and 100L Melter Bottom Panel Parts 7-65. . . . . . . .

Control Panel Assembly 7-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor Assembly 7-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Level Assembly 7-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Accessories 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion and Control Kits 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Indication 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Level Indication 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Pressure Control Valve 7-71. . . . . . . . . . . . . . . . . . . . . . . . . .Line-Speed Signal Generator 7-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Fittings 7-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Spare Parts 7-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Data 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One/Two and Three/Four Pump Melters 8-3. . . . . . . . . . . . . . . . . . . . .100L Melters 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematics 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Schematic 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsvi


Calculating Melter Power Requirements A-1. . . . . . . . . . . . . . . . . . . . .

Operating Parameters B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input Setup B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output Setup B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-day Clock B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PID Selection B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Communications C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Availability C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Requirements C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing the Software C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Software from Your PC C-4. . . . . . . . . . . . . . . . . . . . . . . .Connecting the PC and the Melter C-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Nordson Configuration Manager C-6. . . . . . . . . . . . . . . . . . . . . . . . .

Saving and Restoring Melter Settings C-6. . . . . . . . . . . . . . . . . . . . . . .Upgrading or Restoring Melter Firmware C-7. . . . . . . . . . . . . . . . . . . . .

Troubleshooting C-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Nordson Configuration Manager C-10. . . . . . . . . . . . . . . . . . . . . .

Safety 1-1

A1EN−01−[XX−SAFE]−10� 2014 Nordson Corporation Issued 4-02

Section 1Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation,operation, and maintenance (hereafter referred to as “use”) of the productdescribed in this document (hereafter referred to as “equipment”). Additionalsafety information, in the form of task-specific safety alert messages,appears as appropriate throughout this document.

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

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

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

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

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

Safety1-2

A1EN−01−[XX−SAFE]−10 � 2014 Nordson CorporationIssued 4-02

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

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

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

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

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

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

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

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

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

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

Safety 1-3


User Qualifications Equipment owners are responsible for ensuring that users:

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

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

� receive, equipment- and task-specific training from another qualifiedindividual

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

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

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

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

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

specified in this document.

� Do not modify the equipment.

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

Safety1-4


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

referenced documents.

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

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

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

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused and that the processing characteristics of the material will notcreate a hazardous environment. Refer to the Material Safety DataSheet (MSDS) for the material.

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

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

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

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

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

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

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

and indicators.

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

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

� Do not use equipment that is malfunctioning or shows signs of apotential malfunction.

Safety 1-5


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

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

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

� Use only new factory-authorized refurbished or replacement parts.

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

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

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

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

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

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

� hot melt and cold adhesive application equipment and all relatedaccessories

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

Safety1-6


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

Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter-specific product manual forinstructions on relieving system hydraulic pressure.

De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from allpower sources before accessing any unprotected high-voltage wiring orconnection point.

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

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

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

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

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

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

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

Safety 1-7


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

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

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

PC = Process control

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

Table 1-1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING: Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent-based material through acompatible Nordson melter, read and comply with the material’sMSDS. Ensure that the material’s processing temperature andflashpoints will not be exceeded and that all requirements for safehandling, ventilation, first aid, and personal protective equipment aremet. Failure to comply with MSDS requirements can cause personalinjury, including death.

HM

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

HM, CA

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

HM

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

Continued...

Safety1-8


General Safety Warnings and Cautions (contd)

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


HM, PC

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

HM, CA, PC

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

HM, CA, PC

WARNING: Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and should not be usedwith solvent-based adhesives that can create an explosiveatmosphere when processed. Refer to the MSDS for the adhesive todetermine its processing characteristics and limitations. The use ofincompatible solvent-based adhesives or the improper processing ofsolvent-based adhesives can result in personal injury, including death.

HM, CA, PC

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

Continued...

Safety 1-9



HM

CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces ofguns, hoses, and certain components of the melter. If contact can notbe avoided, wear heat-protective gloves and clothing when workingaround heated equipment. Failure to avoid contact with hot metalsurfaces can result in personal injury.

HM

CAUTION: Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt.If you are unsure of the equipment’s ability to process PUR, contactyour Nordson representative for assistance.

HM, CA

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

HM

CAUTION: Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipate plasticizer.Certain hot melt materials can react with Type R fluid and form a solidgum that can clog the equipment. Before using the equipment,confirm that the hot melt is compatible with Type R fluid.

Safety1-10


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

� Check high pressure hoses daily for signs of excessive wear, damage,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 melta 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 hotmelt to the medical personnel providing treatment.

Safety 1-11


Safety Labels and Tags Figure1-1 illustrates the location of the product safety labels and tags affixedto the equipment. Table 1-2 provides an illustration of the hazardidentification symbols that appear on each safety label and tag, the meaningof the symbol, or the exact wording of any safety message.

1

2

4

2

5

3

Figure 1-1 Safety labels and tags

Table 1-2 Safety Labels and Tags

Item Part Description

1. 1025795 [Tag, warning, hazardous volts]

WARNING: Hazardous voltage.Disconnect all power supplyconnections before servicing.

2. 224906

[Tag, warning, electrical shock]

3. 224905

[Tag, warning, hot]

4. 1025326 [Tag, caution, hot surface]

5. 1021983 [Tag, warning, hot adh/hyd press]

Safety1-12


Introduction 2-1


Section 2Introduction

Intended Use AltaBlue� adhesive melters may be used only to melt and convey suitablematerials, e.g. thermoplastic hot melt adhesives.

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

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

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

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

Introduction2-2


Examples of Unintended Use The melter may not be used under the following conditions:

� In defective condition

� Without insulation blanket and protective panels

� With electrical cabinet door open

� With tank lid open

� In a potentially explosive atmosphere

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

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

� Polyurethane hot melt adhesive (PUR)

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Residual Risks In the design of the unit, every measure was taken to protect personnelfrom potential danger. However, some residual risks can not be avoided:

� Risk of burns from hot material.

� Risk of burns when filling the tank, from the tank lid, and from the tanklid supports.

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

� Risk of burns when attaching and removing heated hoses.

� Material fumes can be hazardous. Avoid inhalation.

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

� The safety valve may malfunction due to hardened or charred material.

Introduction 2-3


Key Components Figure 2-1 provides the name and the location of key melter components.

3

1

7

6

2 5

4

11

10

9

28

Figure 2-1 Key melter components

1 Control panel (see Figure 2-3)2 Protective panel, removable3 Tank lid4 Main power switch

5 Motors/pumps6 Filter cartridge7 Pressure control valve8 Manifold

9 Hose receptacles10 ID plate11 Tank

Introduction2-4


Electrical Components

−7A21

−11A11 −3X11 −XM −X45

−1K31−1G21

−1N61 −9N51 −10N51 −4N21 −4N41

−9N21 −10N21

38

39−11A11

−3X1 1

−XM

−X45

−1 K31

−1 G21

−1 N61

−9N51 −1 0N51−4N21−4N41−9N21

−1 0N21

−11A31 −12A31

−XL9

11

−1M51

.

−XL7−XL6−XL5

−1K71

−1Z71

−1Q31

−XL8

1

2

5

7

8

6

4

2

9

10

113

Figure 2-2 Key electrical components

1 Main board2 Circuit breakers3 RC suppressor4 Fan

5 Motor controller6 Signal conditioner7 Expansion board8 Power module

9 Main switch10 Distribution block11 Contactor

Note: The central processing unit is not shown in this illustration. Refer to Section 7, Parts.

Introduction 2-5


Control Panel

1 21110 12 13

3 4 14 15 1716

5

6

7

8

9

Figure 2-3 Control panel (melter control panel and two motor control panels shown)

1 Pump speed arrow keys2 Pump speed display (rpm)3 Pump mode key/LED4 Pump enable key/LED5 Standby key/LED6 Master pump enable key/LED

7 Heaters key/LED8 Clock key/LED9 Setup key/LED

10 Fault light11 Ready light12 Component keys/LEDs

13 Control switch14 Left display and arrow key15 Right display and arrow keys16 Numeric keypad17 Serial port

Introduction2-6


Tank Isolation Valve The tank isolation valve allows replacement of the pump without firstemptying the tank.

Figure 2-4 Location of the tank isolation valve

Pressure Control Valves The manual pressure control valves can be adjusted from 0−90 bar.

Figure 2-5 Location of the pressure control valves

Introduction 2-7


Modes of Operation AltaBlue melters operate in the following modes.

Automatic Scan (Normal Mode) The melter automatically checks and displays the current temperature of thetank, hoses, and guns to confirm that they are within their pre-definedtemperature range. By default, the melter is always in the automatic scanmode unless it is placed into another operating mode.

Standby The temperatures of the tank, hoses, and guns are reduced down from theiroperating temperature (hereafter referred to as set-point temperature) by apre-set number of degrees.

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

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

Gear-to-Line Capability The melter is capable of delivering an adhesive output that is geared to theproduction line speed. The gear-to-line capability is enabled or disabledthrough the motor control system. A line-speed signal generator must beinstalled if you want to use the gear-to-line capability.

NOTE: The gear-to-line mode of operation is also known as automaticmode or key-to-line mode.

Introduction2-8


Melter Identification You will need the model and part number of your melter when requestingservice or ordering spare parts and optional equipment. The model and partnumber are indicated on the equipment identification plate that is located onthe front of the melter.

Figure 2-6 Location of the melter identification plate

Installation 3-1


Section 3Installation

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

Overview AltaBlue melters are factory-configured for each order and require only theassembly and set up tasks described in this section.

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

If optional equipment was ordered with the melter, refer to thedocumentation provided with the optional equipment for installation andoperating instructions.

The illustrations accompanying the procedures in this section depict adual-motor dual-stream melter.

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

Installation3-2


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. Configure the electrical service.

4. Connect hot melt hoses and guns.

5. (Optional) Configure key-to-line.

6. (Optional) Connect to the pressure control transducer.

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.

Experience of Installation Personnel The instructions provided in this section are intended to be used bypersonnel 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

Installation Requirements Before installing the melter, ensure that the desired installation locationprovides the required clearances, environmental conditions, and utilities.

Clearances Figures 3-1 through 3-3 illustrate the minimum clearances that are requiredbetween the melter and surrounding objects.

Installation 3-3


[38

.29

]

H

OP

PE

R V

ER

SIO

N9

72

.60

15

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[5.35] HOPPER VERSION 136 15L

[36]914.4

[36]914.4

[36

]9

14

.4[3

6]

91

4.4

2770[109]

OPERATION SPACE

23

50

[92

.67

]

OP

ER

AT

ION

SP

AC

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13

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37.09942

10.63 30/50L270

10

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52

5

63

.69

16

17

.80

49

.53

5

0L

12

58

14

55

57

.28

9 0

Figure 3-1 One/two-pump melter minimum installation clearances

Installation3-4


Clearances (contd)

[5.35] 30LHOPPER VERSION

136

[36

]9

14

.4[3

6]

91

4.4

[36]914.4

[36]914.4

28

00

[11

0]

OP

ER

AT

ION

SP

AC

E

2780[109]

OPERATION SPACE

14

70

37.09942

10

.63

27

0

57

.87

10.63 50L270

37

.40

95

0

53

.06

13

47

.80

38

.90

98

8

14

55

.71

9 0 5

Figure 3-2 Three/four-pump melter minimum installation clearances

Installation 3-5


[36]914.4

[36]914.4

[36

]9

14

.4[3

6]

91

4.4

28

50

[11

2.2

]

OP

ER

AT

ION

SP

AC

E

3090[121.65]

OPERATION SPACE

13

47

.87

53

.07

48.111222

25

.00

63

5

10.63270

37

.40

95

0

5.7

11

45

38

.90

98

8

14

70

57

.87

Figure 3-3 100L melter minimum installation clearances

Installation3-6


Ventilation AltaBlue melters are cooled by forced air. Air is drawn in through by theventilation fan and is exhausted out of the ventilation slots at the top of themelter.

CAUTION! Do not block the fan air intake openings or the exhaustventilation slots.

Figure 3-4 Location of the ventilation openings

Electrical Power Before installing the melter, ensure that the melter will not be overloadedand that the plant’s electrical service is rated to handle the power requiredby the melter and the hoses and guns that you plan to use.

Refer to Appendix A, Calculating Melter Power Requirements, forinformation about how to calculate the maximum allowable hose lengthsand gun wattages that can be used in your manufacturing application.

WARNING! Risk of electrocution! Install a lockable power disconnect switchbetween the electrical service and the melter. Failure to install or properlyuse the disconnect switch when servicing the melter can result in personalinjury, including death.

Installation 3-7


Motor Drive Internal FilterThe AltaBlue melter is manufactured and shipped from the factory incompliance with CE regulations. If the motor drive internal filter, locatedinside each motor drive, is turned off, the melter will no longer beCE-compliant.

Figure 3-5 Location of the motor drive internal filter inside a motor drive

Other Considerations Consider the following additional factors when evaluating where to installthe melter.

� The maximum distance between the melter and each gun is dictated bythe power requirement of each hose. Refer to Appendix A, CalculatingMelter Power Requirements, for information about how to determine themaximum allowable length.

� The operator must be able to safely reach the control panel andaccurately monitor the control panel indicators.

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

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

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

� The melter should not be exposed to excessive vibration.

Installation3-8


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

Moving the Unpacked Melter When moving the melter, always support the melter by placing any liftingdevice under the chassis.

Contents of the Installation Kit The installation kit provided with the melter contains the components shownin Figure 3-6.

The installation kit also contains a package of safety label overlays that areprinted in variety of languages. If required by local regulations, theappropriate language overlay should be applied over the English version ofthe same label. Refer to Safety Labels and Tags in Section 1, Safety, for thelocation of each safety label.

Customer-Supplied Materials The following additional materials are also required to install the melter.

� A power cable. Rigid or flexible electrical conduit will be required.

� (Optional) Gear-to-line input signal wiring

� (Optional) Input/output signal wiring

P/N 7400333

1

2

Figure 3-6 Installation kit components

1. Fuses 2. Straight hose connector (4)

Installation 3-9


This page intentionally left blank.

Installation3-10


Configuring the Electrical Service AltaBlue melters are shipped from the factory without an attached powercable. To configure the melter to function in your facility, you must connect aproperly rated power cable.

The maximum power draw of the melter for any supported service code is86 A.

Residual Current Circuit Breakers Local regulations in some geographic areas or industrial branches mayrequire residual current circuit breakers.

Then observe the following points:

� Permanent installation is required (fixed line voltage connection)

� The residual current circuit breaker is to be installed only between thepower supply and the melter.

� Only residual current circuit breakers sensitive to pulsating current oruniversal current (> 30 mA) may be used.

Connecting the Electrical Service NOTE: The melter must be installed securely (permanent power supplyconnection).

WARNING! Operate only at the operating voltage shown on the ID plate.

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

NOTE: The power cable cross-section must comply with the maximumpower consumption (refer to Section 8, Technical Data).

WARNING! Ensure that cables do not touch rotating and/or hot meltercomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

1. See Figure 3-7. Route the power cable into the electrical cabinetthrough the strain relief on the side of the base.

NOTE: Do not route any input/output wiring through this strain relief.

2. Connect the power cable to the service terminal block as indicated intable Table 3-1 and illustrated in Figure 3-7.

3. Connect the service ground lead to the ground terminal located on theDIN rail at XL0:PE.

Installation 3-11


Table 3-1 Electrical Service Wiring

Line voltageTerminals

1 2 3 N PE

230 VAC 3-phase without neutral (Delta) � � � �

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



N PE

N PE

Figure 3-7 Location of service wiring strain relief and terminal block

Installation3-12


Connecting Hoses and Guns

WARNING! Risk of fire or equipment damage. Before connecting hoses andguns to the melter, confirm that the power required by each hose/gun pairand each hose/gun module, does not exceed the maximum wattagesspecified in Appendix A, Table A-2, Maximum Allowable Wattages.

To connect hoses

See Figures 3-9 through 3-12 to properly connect the hose hydraulic fittingsbased on the manifold configuration. If hoses are not connected properly,the melter will not operate correctly.

If applicable, connect a return hose (see Figure 3-8). To do this, remove theO-ring fitting from the return hose port and install the hose connector fittingfrom the ship-with kit. The return hose port is located on the rear of themelter at the top of the hopper.

See Figure 3-13 to connect hose cordsets.

Observe the following guidelines:

� For information about choosing the correct Nordson hot melt hose foryour manufacturing process, refer to the latest edition of Nordson’s hotmelt dispensing equipment Replacement Parts Catalog or contact yourNordson representative.

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

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

Figure 3-8 Location of the optional return hose fitting

Installation 3-13


Pump 1: Output port 5



Pump 1: Output port 2 Pump 1: Output port 1



Figure 3-9 Connecting hoses—one/two-pump melter manifold with one single-stream (1 SS) pump

Note: Do not connect hoses to the top four manifold ports on any single-stream pump configuration.

Installation3-14


To connect hoses (contd)







Figure 3-10 Connecting hoses—one/two-pump melter manifold with two single-stream (2 SS) pumps

Note: Do not connect hoses to the top four manifold ports on any single-stream pump configuration.

Installation 3-15


Pump 2: Stream 2, Output port 1








Figure 3-11 Connecting hoses—one/two-pump melter manifold with two dual-stream (2 DS) pumps

Installation3-16


To connect hoses (contd)














Figure 3-12 Connecting hoses—three/four-pump melter manifolds

Installation 3-17


Figure 3-13 Connecting a hose cordset

Installation3-18


To connect guns

Observe the following guidelines:

� AltaBlue melters with 120-ohm nickel sensors support all NordsonT-style applicators. AltaBlue melters with 100-ohm platinum sensorssupport all Nordson M-style applicators.

� For information about choosing the most appropriate Nordson hot meltgun for your manufacturing process, refer to the latest edition ofNordson’s hot melt dispensing equipment Replacement Parts Catalog orcontact your Nordson representative. Refer to Appendix A, CalculatingMelter Power Requirements, for information about how to calculate thepower required by Nordson hot melt guns.

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

NOTE: AltaBlue melters are shipped with a 0.2 mm hot melt filter installedin the manifold. Order the appropriate gun nozzle based on this filter meshsize.

Installation 3-19



Installation3-20


Setting Up the Melter After physically installing the melter, it must be set up to support yourmanufacturing process. Melter setup consists of enabling or makingchanges to factory-set operating parameters that affect the use and functionof the melter. The operating temperature (set-point) of the tank and eachhose and gun is also established during melter setup.

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

Quick Setup Table 3-2 describes the most commonly used operating parameters andtheir factory settings. Review the table to determine if the factory settings foreach parameter will support your manufacturing process. If the defaultvalues for each of these operating parameters are appropriate for yourmanufacturing process, then no melter setup is required. Go directly toSet-point Temperature of the Tank, Hoses, and Guns later in this section tocomplete the installation process.

If you need to make changes to the factory setup or if you want to learnabout other operating parameters, go to the next part in this section,Operating Parameters.

Installation 3-21


Table 3-2 Common Operating Parameters

Parameter Parameter Name Purpose Default Value

4 Ready Delay Time

A timer that delays the activation of the ready LED for apre-defined time period after the tank, hoses, and guns are atthe desired set-point temperature. The ready delay timer willonly activate if the temperature of the tank, at the time themelter is turned on, is below its assigned set-pointtemperature by 27 C (50 F) or more.

0 minutes

5 Service Interval Time

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

500 hours

7 Motor Off DelayIf the switch receptacle is used, this parameter determines theamount of time the motor will remain on after the switcheddevice is turned off.

0 seconds

8 Automatic Pump OnAllows the pump to start automatically when system ready isreached, provided that the pump has been enabled bypressing the pump key.

Enabled

11 Create PasswordSets a password that must be entered before any melteroperating parameter or set-point temperature can be changed. 5000

20 Temperature UnitsSets the units of the temperature display to degreesCelsius (C) or to degrees Fahrenheit (F). C

21 Over Temperature DeltaSets the number of degrees that any heated component canexceed its assigned set-point temperature before an overtemperature fault occurs.

15 C (25 F)

22 Under TemperatureDelta

Sets the number of degrees that any heated component candrop below its assigned set-point temperature before an undertemperature fault occurs.

25 C (50 F)

23 Standby DeltaSets the number of degrees that the temperature of all heatedcomponents will be decreased when the melter is placed intothe standby mode.

50 C (100F)

26 Manual Standby TimeSets the amount of time the melter will remain in the standbymode after the standby key is pressed. Disabled

50 to 77 Seven-day ClockA group of parameters that control the melter’s clock. Theclock is used to automatically turn the heaters on and off andto place the melter into the standby mode.

Disabled

Installation3-22


Operating Parameters The melter uses operating parameters to store noneditable and editablevalues. Noneditable values are those that provide information about thehistorical performance of the melter. Editable values are either a numericset-point or a control option setting. Control options settings affect thedisplay of information or the function of the melter.

Operating parameters are stored in the melter’s firmware in the form of asequentially numbered list. The list is organized into the logical groupsdescribed in Table 3-3.

Table 3-3 Parameter Groups

Group ParameterNumbers Group Description

Standard0 to 8 and10−14

Noneditable and other frequently usedparameters

Temperature Control 20 to 29 Control heaters

Input Setup 30 to 39 Configure the standard and optional inputs

Output Setup 40 to 46 Configure the standard and optional outputs

Seven-day Clock 50 to 77 Configure the clock feature

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

Selecting Operating Parameters Table 3-4 provides a complete list of the operating parameters. Review thelist to determine which operating parameters would best support yourmanufacturing process. Refer to Appendix B, Operating Parameters, fordetailed information about each parameter. Appendix B contains a completedescription of each parameter, including its affect on the melter, defaultvalue, and format.

NOTE: Parameters that are used to configure optional equipment or thatare otherwise reserved in the firmware are excluded from Table 3-4 andAppendix B.

Setup key

Clear/Reset key

Enter key

Installation 3-23


Reading or Editing Operating Parameters Regardless of whether a parameter’s value is editable or not, the procedurefor accessing each parameter in order to read or edit its current value is thesame.

To read or edit a parameter

1. Place the main power and control switches on the ON position.

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 3-4 for a complete list of parameters.

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

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

4. Do one of the following:

� If the value is noneditable, refer to Monitoring the Melter inSection 4, Operation.

� 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 optioninto the right display. Refer to Appendix B, Operating Parameters, forinformation about the numeric value or control option choices for eachparameter.

NOTE: If the keypad has no affect on the right display, the melter ispassword protected. You must enter a valid password before you canedit parameters. Refer to Entering a Password in Section 4, Operation.

Installation3-24


To read or edit a parameter (contd)


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

� If the numeric set-point or control option is accepted, the left andright displays index to the next sequential parameter number andvalue.

� If the numeric set-point or control option is not accepted, the rightdisplay will indicate dashes (----) for three seconds and then it willchange back to the original value.

8. Repeat step 5 through step 7 to read or change the next sequentialparameter number or press the Setup key to exit the setup mode.

Table 3-4 Operating Parameters

Parameter Name Range of Values Default Value

Standard

0 Enter Password 0 to 9999 4000

1 Total Hours with Heaters On (noneditable) 0 to 9999 0

2 Fault Log (noneditable) — _-F0 (empty)

3 Change History Log (noneditable) — P-_ (empty)

4 Ready Delay Time 0 to 60 minutes 0 minutes

5 Service Interval Time 0 to 8736 hours 500 hours

6 Service LED Heater Hours 0 to 9999 hours 0

81 Automatic Pump On 0 (disabled) or 1 (enabled) 1 (enabled)

10 Enable or Disable Password 0 (disabled) or 1 (enabled) 0 (disabled)

11 Create Password 0 to 9999 5000

121 Change Hose 1 Output to Electric GunActivation 0 (disabled) or 1 (enabled) 0 (disabled)

131 Change Hose 2 Output to Electric GunActivation 0 (disabled) or 1 (enabled) 0 (disabled)

14 External Communications Lock-out 0 or 1 0 (disabled)

Temperature Control

20 Temperature Units (degrees �C or �F) C (degrees Celsius) or F (degreesFahrenheit) C (degrees Celsius)

21 Over Temperature Delta 5 �C (10 �F) to 60 �C (110 �F) 15 �C (25 �F)

22 Under Temperature Delta 5 �C (10 �F) to 60 �C (110 �F) 25 �C (50 �F)

23 Standby Delta 25 �C (50 �F) to 190 �C (350 �F) 50 �C (100 �F)

24 Automatic Standby Timeout 0 to 1440 minutes 0 (disabled)

25 Automatic Heaters Off Time 0 to 1440 minutes 0 (disabled)

26 Manual Standby Time 0 to 180 minutes 0 (disabled)

27 Hose Standby Delta 1 �C (1 �F) to 190 �C (350 �F) 0 (disabled)

28 Gun Standby Delta 1 �C (1 �F) to 190 �C (350 �F) 0 (disabled)

29 Internal Zone Temperate Offset 0 �C (0 �F) to -15 �C (-30 �F) 0 (disabled)

1Not used with AltaBlue melters.

Installation 3-25


Parameter Name Range of Values Default Value

Input Setup

30 Standard Input 1 0–8 and 10−14 10 (Automatic Standby)

31 Standard Input 2 0–8 and 10−14 1 (Standby on/off)

32 Standard Input 3 0–8 and 10−14 2 (Heaters on/off)

33 Standard Input 40–8 and 10−14

4 (Hose/gun 1enable/disable)

34 Optional Input 5 0–8 and 10−14 0 (disabled)






Output Setup

40 Standard Output 1 0–6 1 (Ready)

41 Standard Output 2 0–6 3 (Fault)

42 Standard Output 3 0–6 4 (Not used)

43 Optional Output 4 0–6 0 (disabled)




Seven-day Clock

50 Current Day 1 to 7 (1 = Monday) —

51 Current Hour 0000 to 2359 —

55 Schedule 1 Heaters On 0000 to 2359 06:00

56 Schedule 1 Heaters Off 0000 to 2359 17:00

57 Schedule 1 Enter Standby 0000 to 2359 —:—

58 Schedule 1 Exit Standby 0000 to 2359 —:—

60 Schedule 2 Heaters On 0000 to 2359 —:—

61 Schedule 2 Heaters Off 0000 to 2359 —:—



65 Schedule 3 Heaters On 0000 to 2359 —:—

66 Schedule 3 Heaters Off 0000 to 2359 —:—



71 Schedule for Monday 0−7 0

72 Schedule for Tuesday 0−7 0

73 Schedule for Wednesday 0−7 0

74 Schedule for Thursday 0−7 0

75 Schedule for Friday 0−7 0

76 Schedule for Saturday 0−7 0

77 Schedule for Sunday 0−7 0

Installation3-26


To read or edit a parameter (contd)

You can exit the setup mode at any time bypressing the Setup key.

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

When the right display is flashing, you canquickly set the value of the current parameterto its lowest possible value by simultaneouslypressing both of the right-display scroll keys.

While in the setup mode, if no key is pressedfor two minutes, the melter will return to theautomatic scan mode.

You can also use the right-display scroll keysto enter or change a parameter’s value orcontrol option. After entering the parameter’snumber in the left display, press either of theright-display scroll keys to change the value orcontrol option.

Using a personal computer that is connectedto the melter through the serial port, you canview and change all of the operatingparameters from a single computer screen.

Refer to Appendix C, MelterCommunications

If password protection is enabled, the melterwill return to the password protected modewhenever you exit the setup mode.

Appendix B, Parameter 10

Installation 3-27



Installation3-28


Set-point Temperature of the Tank, Hoses, and Guns The melter is shipped from the factory with the tank set-point temperature at175 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 tothe tank, hoses, and guns. Assign set-point temperatures using any of thefollowing methods:

� Global—The tank and all hoses and guns are set to the same set-pointtemperature.

� Global-by-component group—All of the hoses or all of the guns areset to the same set-point temperature.

� Individual Component—The set-point temperature of the tank andeach hose and gun is set individually.

Since most manufacturing processes will require the tank, hoses, and gunsto be set to the same temperature, only the global method of assigningset-point temperatures is described in this section. For information about theother two methods of assigning set-point temperatures, refer to AdjustingComponent Temperatures in Section 4, Operation.

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

Tank key

Left display andscroll key

Enter key

Ready LED

Installation 3-29


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.



4. Use the numeric keypad to enter the set-point temperaturerecommended by the manufacturer of the hot melt.

Refer to the technical data sheet provided by the manufacturer of thehot 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-pointtemperature and the melter returns to the automatic scan mode.

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

+

Saving current settings

+

Restoring saved settings

Installation3-30


Save and Restore Melter Settings The current value of all editable operating parameters and the set-pointtemperature of each component can be saved and, if necessary, restored ata later time. When saved settings are restored, they overwrite the settingsthat are presently in use.

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

To save current settings

With the melter in the automatic scan mode, simultaneously press thenumber 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 savedsettings, ensure that use of the restored settings will not disrupt the currentprocess or create an unsafe operating condition.

With the melter in the automatic scan mode, simultaneously press thenumber 2 key and the Setup key.

S-2 appears momentarily in the right display.

If you use the restore feature before the savefeature is used for the very first time, thefactory default set-point temperatures will berestored. This will cause the hoses and gunsto stop heating.

You can transfer melter settings from onemelter to another using the NordsonConfiguration Manager software utility.

Refer to Appendix C, MelterCommunications

Installation 3-31



Setup key


Component key LEDs

Scrolling through the log

Installation3-32


Review Parameter and Set-point Temperature Changes The melter stores in a change history log, a record of the last ten changesthat were made to either operating parameters or set-point temperatures.Since the log only stores ten changes, old log entries are overwrittenbeginning with the first log entry, by the eleventh and following log entries.

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 componentkey LEDs remain off.

or

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

and

� The right display indicates the four-digit log entry associated with thelast change that was made.

Table 3-5 provides the meaning, from left to right, of each digit in thelog entry. Following the table are two example log entries.

3. Press a right-display scroll key to review each of the remaining nine logentries. Each press of a scroll key displays a progressively older logentry.

4. Press the Setup key to return to the automatic scan mode.

Installation 3-33


Table 3-5 Change History Log

First Digit SecondDigit Third and Fourth Digits

P (Parameter)

−

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 thelocation and method of a set-point temperature change.

When this LED ison..

And the FourthDigit Indicates..

The change wasto..

And the Methodof Change was..

Tank Key 1 The tank Individual

Hose Key 1– 6 A single hose Individual

Gun Key 1– 6 A single gun Individual

All Keys 0 All components Global

Hose Key 0 All hosesGlobal-by-component

Gun Key 0 All gunsGlobal-by-component

Change History Log Examples

Example 1:

Parameter 4 (ready delay) was changed.

Example 2:

If the LED on the gun key is on, then this display wouldindicate that the global-by-component method was used to change thetemperature of the guns.

Unused log entries in the change history log areindicated by “P-_” in the right display.

To view how many heater hours have elapsedsince a specific change (displayed) was made,simultaneously press both of the right-displayscroll keys.

Installation3-34


Setting Up Inputs/Outputs AltaBlue melters are equipped with four standard inputs. Each input iscustomer-wired to the melter and then set up to provide one of the followingcontrol options:

� Place the melter into the standby mode

� Turn the heaters on and off

� Enable or disable a specific hose or gun

� Enable the motor

The input contacts use a constant 10 to 30 VDC signal voltage. The inputsare not polarity sensitive.

WARNING! The operator can override the melter inputs by using the controlpanel function keys. Ensure that the control logic for any external devicethat sends an input signal to the melter is programmed to prevent thecreation of an unsafe condition in the event that the operator overrides anexternal input to the melter.

The melter is also equipped with three user-configurable outputs. Outputsare used to communicate with user-supplied production equipment orcontrol hardware, such as a programmable logic controller.

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

� The melter is ready

� The melter is ready and the motor is enabled

� A fault has occurred

� The hot melt level is low (only if the optional level switch is installed)

� The service LED is on

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

Installation 3-35


To wire inputs/outputs to the melter

See Figure 3-14.

1. Route a 2-, 4, 6, or 8-conductor signal cable from the control equipmentto the melter and through the PG-16 penetration on side of the base.Use rigid or flexible conduit or a suitable strain relief to protect the cablefrom the sharp edge of the conduit penetration.

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

2. Connect each pair of input and output wires to the appropriate terminalson terminal block XI. Refer to Table 3-6 for the terminal numbers thatcorrespond to each input.

Figure 3-14 Location of the knockout hole and XI terminal block for connecting input/output wiring

Installation3-36


Setting Up Inputs/Outputs (contd)

To set up inputs/outputs

Set up the parameter control option for each input and output that youconnected to the melter. Table 3-6 lists the available control options. Referto Setting Up the Melter earlier in this section for information about how toselect operating parameters and edit parameter control options.

With the exception of the motorenable/disable control option (Table 3-6,Input/Output Data), All inputs aretransition-based.

Input Setup in Appendix B

The input capacity of the melter may beincreased from four inputs to a total often inputs by adding an optional I/Oexpansion card that is available fromNordson Corporation.

Section 7, Parts

The output capacity of the melter may beincreased from three outputs to seven outputsby adding an optional I/O expansion card thatis available from Nordson Corporation.

Section 7, Parts

Installation 3-37


Table 3-6 Input/Output Data

Item Description OperatingParameter Control Options Terminals Notes

1 Standard input 1 30 0 − Input Disabled1 − Standby On/Off2 − Heaters On/Off3 − Motor 1 Enable/Disable4 − Hose/Gun 1 Enable/Disable5 − Hose/Gun 2 Enable/Disable6 − Hose/Gun 3 Enable/Disable7 − Hose/Gun 4 Enable/Disable8 − Hose/Gun 5 Enable/Disable9 − Hose/Gun 6 Enable/Disable10 – Automatic standby (Default)11 − Motor 2 Enable/Disable

XI:1, XI:2 A, B

C

D

C

2 Standard input 2 31 0 − Input Disabled1 − Standby On/Off (Default)2 − Heaters On/Off3 − Motor 1 Enable/Disable4 − Hose/Gun 1 Enable/Disable5 − Hose/Gun 2 Enable/Disable6 − Hose/Gun 3 Enable/Disable7 − Hose/Gun 4 Enable/Disable8 − Hose/Gun 5 Enable/Disable9 − Hose/Gun 6 Enable/Disable11 − Motor 2 Enable/Disable

XI:3, XI:4

C

C

3 Standard input 3 32 Same as parameter 31(Default=2)

XI:5, XI:6

4 Standard input 4 33 Same as parameter 31(Default=4)

XI:7, XI:8

5 Standard output 1 40 0 − Output Disabled XI:9, XI:10 F

1 − Ready (Default) F

2 − Ready and the Motor is On F

3 − Fault G

4 − Tank Low Level

5 − Service LED is On

6 − Alert H

NOTE A: Parameter 30 has 12 control options. parameters 31, 32, and 33 each have only 11 control options.

B: Parameters 34 through 39 are reserved for the six inputs created when the optional I/O expansion card is installed. Thesix optional inputs have the same control options as parameter 31.

C: Parameters are disabled in AltaBlue melters. Refer to parameters 9−12 in this table.

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

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

H: 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.

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

Continued...

Installation3-38


Setting Up Inputs/Outputs (contd)

Table 3-6 Input/Output Data (contd)


6 Standard output 2 41 Same as parameter 40(Default=3)

XI:11, XI:12

7 Standard output 3 42 Same as parameter 40(Default=4)

XI:13, XI:14

8 Key-to-line0−10V input

— XI:15 (+),XI:16 (−)

Refer to SettingUp Gear-to-LineOperation

9 Motor 1remote start

— XI:17, XI:18 Connect amomentary,normally opencontact to theterminals.

10 Motor 1remote stop






Continued...

Installation 3-39


Table 3-6 Input/Output Data (contd)



(See Note J)



(See Note J)



(See Note J)



(See Note J)


17 Motor drive 1running (optional)

— XI:25, XI:26 Refer to SettingUp Motor RunStatus Monitoring.18 Motor drive 2

running (optional)— XI:27, XI:28


(See Note J)

— XI:37, XI:38 Refer to SettingUp Motor RunStatus Monitoring.


(See Note J)

— XI:39, XI:40

J: Motors 3 and 4 are present only on three/four pump or 100L melters.

Installation3-40


Setting Up Gear-to-Line Operation If you want to use the gear-to-line capability, install a (customer-supplied)line-speed signal generator to measure the speed of the production line.The AltaBlue motor control accepts a 0−10 VDC analog input signal.

NOTE: Nordson offers a 0−10 VDC line-speed signal generator. Refer toOptional Accessories in Section 7, Parts, for the part number.

To use the gear-to-line capability, connect a 0−10 VDC signal from acustomer-supplied line-speed signal generator to the appropriate terminalson terminal block XI inside the electrical enclosure. See Figure 3-14 for thelocation of terminal block XI. Refer to Table 3-6 for the terminal numbersthat correspond to each input/output.

Motor drive keypad (located oneach motor drive inside theelectrical enclosure)

Installation 3-41


Setting Up Motor Run Status Monitoring If desired, you can set up the melter to allow remote monitoring of the runstatus (running or not running) of the pump motors.

Wiring To use the motor run status monitoring capability, connect wiring from theparent machine to the appropriate terminals on terminal block XI inside theelectrical enclosure. See Figure 3-14 for the location of terminal block XI.Refer to Table 3-6 for the terminal numbers that correspond to eachinput/output.

NOTE: The relay contact between terminals XI:25/XI:26 and XI:27/XI:28 isnormally open. When the motor is running, these contacts should close.

Programming Use the keypad located on each motor drive inside the electrical enclosureto set up the motor run status monitoring for each motor. Refer to Changinga Motor Drive Parameter in Section 6, Troubleshooting, for a more detailedprocedure for changing a motor drive parameter.

1. Press ENT until I−O is displayed.

2. Press ENT again to access the I/O parameters.

3. Press the arrow keys until parameter r2 is displayed.

4. Press ENT to access this parameter.

5. Press the arrow keys until rUn is displayed.

6. Press ENT to save this value.

7. Press ESC twice to return to the monitoring mode.

Installation3-42


Installing Optional Equipment Each item of optional equipment is shipped with instructions for installingand operating the equipment. Refer to Section 7, Parts, for equipment partnumbers.

Connecting a Gun Driver, Pattern Controller, orTimer

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

Flushing the Melter Before using the melter for production, it should be flushed to remove anyresidue left over from factory-testing. Flushing the melter is accomplishedby 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 andoperating the melter.

Disposing of Melter When your Nordson product has reached the end of its useful life, disposeof it in accordance with local regulations.

Operation 4-1


Section 4Operation


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

� Filling the melter tank

� Starting the melter

� (Optional) Adjusting the speed of the motor(s)

� (Optional) Adjusting material pressure

� 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 thecontrol panel. Refer to Key Components in Section 2, Introduction, forthe location of the controls and indicators described in this section.

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

Filling the tank

Component keys(tank, hose, and gun)

Operation4-2


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

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

1. Use a scoop to pour material into the tank, leaving a minimum of2.54 cm (1 in.) of space between the top of the material and the top ofthe tank.

2. Close the lid after filling the tank.

About Heated Components The melter contains three groups of heated components. These are thetank group, which contains tank, the grid, and the reservoir; the hose group;and the gun group. Component groups are represented on the control panelby the component keys shown to the left.

Heated components within each group are identified by their positionnumber. The position of the tank group is fixed at 1. Hose and gun positionnumbers are automatically assigned based on the hose/gun receptacle theyare connected to.

NOTE: In some installations, auxiliary devices (such as a heated airmanifold) may be connected to a hose/gun receptacle. In such cases, youshould label (or otherwise identify) the auxiliary device as to the hose or gunposition number that represents the device. The control panel will identifysuch devices as a hose or gun, regardless of what the device actually is.

Main power switch

Control switch

Heaters LED

Automatic scan sequence

Ready LED

Operation 4-3


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, or timers.

� melter’s operating parameters are set up to support thecurrent manufacturing process.

Refer to Section 3, Installation, if any of the items listed above arenot complete.

To start the melter1. Place the main power switch in the ON position.

2. Place the control switch in the ON position.

The melter:

� Tests the control panel LEDs

� Turns on the heaters (the heaters LED turns green)

� Begins to automatically scan through and display theactual temperature of the tank and each hose and gun that has aset-point temperature that is greater than zero degrees. Thesequence 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 thehoses and guns are within 3 �C (5 �F) of their assignedset-point temperature.

Master pump enable key/LED

Pump mode key and LED

Motor start/stop key and LED

Operation4-4


Starting the Melter (contd)

CAUTION! Do not operate Nordson pumps without material. Beforeenabling the motor(s), ensure that the tank is filled.

3. Press the master pump enable key to enable the pump(s).

The LED on the key turns yellow to indicate that a pump is enabled, butnot running.

4. Melters equipped with the optional motion switch: Place the motionswitch in the ON position.

5. Press the pump mode key(s) to select the manual (LED on) or automatic(LED off) mode.

6. Press the pump enable key(s) on the motor control panel(s) to enablethe motor(s). The LEDs turn on when a motor is enabled:

Manual Mode—If the system is at ready status (master pump enablekey LED is green) at the time a pump enable key is pressed, then themotor(s) will start. If the system is not at ready status (master pumpenable key LED is yellow), wait until the LED is green, and then repressthe pump enable key(s).

Automatic Mode—If the system is at ready status (master pump enablekey LED is green) at the time a pump enable key is pressed, then themotor(s) will start. If the system is not at ready status (master pumpenable key LED is yellow), the motor(s) will start automatically when thesystem reaches ready.

NOTE: If any one of standard inputs 1−4 (parameters 30−33) are beingused and if either control option 3 (Motor 1 Enable/Disable) or controloption 11 (Motor 2 Enable/Disable) is selected, the pump enable keyshave no effect. Refer to Setting Up Inputs/Outputs in Section 3,Installation, for information on connecting and setting up inputs/outputs.

Operation 4-5


If the melter is switched on when thetemperature of the tank is 27 �C (50 �F) orgreater below its assigned set-pointtemperature (cold start condition), the readyLED will not turn on until the ready delay(defined when the melter was set up) haselapsed.

Appendix B, parameter 4

The time remaining on the ready delay (inminutes) appears in the right display at theend of every scan cycle. When only oneminute remains in the ready delay time, theright display counts down in seconds.


You can by-pass the ready delay time bypressing the Heaters key twice.

The appearance of F4 in the right displayimmediately after the melter is switched onindicates a problem with the melter’sprocessor or main board.

Monitor Melter Faults

The appearance of F1 in the right displayimmediately after starting the melter indicatesthat a hose or gun cordset may be loose ordisconnected.

Section 6, Troubleshooting

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

Installing Melter Inputs in Section 3,Installation

If the seven-day clock feature was set up andturned on when the melter was last switchedoff, the clock will automatically turn on the nexttime the melter is switched on.

Function Keys

If a power failure occurs, the melter will restartin its normal heat-up cycle, even if the heaterswere off or the melter was in standby prior tothe power failure. If the seven-day clock wason prior to the power failure, the melter willrestart in the mode dictated by the clockschedule at the time the melter restarts.

Pump speed arrow keys

Operation4-6


Manually Adjusting the Pump Speed When the motor control is set to manual operation, the pump speed can beadjusted from 0−94 rpm.

NOTE: When the motor control is set to automatic operation, pressing themotor speed arrow keys will alter the ratio of the line speed reference signalto allow for fine-tuning of the adhesive output rate.

To adjust the motor speed for manual operation

CAUTION! To ensure adequate motor control and cooling, therecommended minimum pump speed is 18 rpm or greater. To preventexcessive wear on the pump, avoid prolonged operation of the pump atspeeds greater than 80 rpm.

1. Use the following formula to determine the best pump speed:

pump�speed�[rpm] �desired�flow�rate�[g�min]

adhesive�density�[g�cc]� pump�output�rate�[cc�rev]

2. Press the pump speed arrow keys to adjust the motor(s) to the desiredspeed (rpm). Each press of an arrow key increases/decreases the motorspeed by 1 rpm.

The current motor speed is indicated on the display.

NOTE: You can change the amount by which the motor speedincreases or decreases (1%, 1 rpm, 0.5 rpm, etc.) upon each press ofan arrow key by changing the value of the motor control SEt parameter.Refer to Changing a Motor Control Parameter in Section 6,Troubleshooting.

Pressure control valves

Operation 4-7


Adjusting Material Pressure The pressure of each material stream can be independently adjusted from0−103 bar (0−1500 psi).

To adjust the pressure, loosen the set screw, and then turn the pressureadjustment screw clockwise. When the pressure adjustment is set to its fullcounterclockwise position, 100% of the material is recirculated.

Operation4-8


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 tank group and each hoseand gun

� Monitor the speed of the motor(s)

� Identify melter faults

� Determine when service is required

The melter automatically determines the number and receptacle of allhoses and guns that are connected to it. Refer to Heated Components,earlier in this section, for information on identification of heatedcomponents.

Ready LED

Operation 4-9


Confirm that the Melter is Operating Correctly The ready LED turns on (green) when all of the heated componentsare within 3 �C (5 �F) of their set-point temperature.

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

� The ready delay is still counting down.

� The operator or a remote input places the melter in the standbymode.

� The seven-day clock places the melter in the standby mode.

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

Refer to Monitor Melter Faults and Using Function Keys in this section forinformation about melter faults and using the seven-day clock and standbyfunctions. Refer to parameter 4 in Appendix B, Operating Parameters, forinformation about the ready delay.

Heated components with a set-pointtemperature of zero degrees are skippedduring the automatic scan cycle.

The set-point temperature of the tank andthe pump cannot be set independently.

The time remaining on the ready delayappears in the right display at the end of eachscan cycle.


You can override the seven-day clock at anytime. If the clock has turned the heaters off,pressing the heaters key will turn the heatersback on. If the clock has placed the melter intothe standby mode, pressing the standby keywill return the heated components to theirassigned set-point temperature.

Function Keys

LEDs on component keys

Operation4-10


Monitor Component Temperatures The actual temperature of each heated component—the tank and eachhose and gun—can be checked via normal mode or by manually selectingand 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 zerodegrees

� A fault occurs

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 componentgroup (tank, hose, or gun) turns on, observe the left display until itindicates the position number of the specific component you want tocheck.

3. When the position number of the desired component appears in theleft display, observe the right display to determine the component’sactual temperature.


Component temperature display

Operation 4-11


To manually check a component’s temperature1. 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 numberof the first sequential component in the selected component group. Theright display indicates the component’s actual temperature.

NOTE: When the tank key is pressed, the left display does notindicate a component number (blank display).

2. If the first sequential component is not the component you wantto check, use the left-display scroll key to change to the correctcomponent number.

The right display indicates the actual temperature of theselected component.

3. Press the Setup key twice to return to the automatic scan mode.

When you scroll the left display past thenumber of the last sequential component in acomponent group, the number of the firstsequential component in the next componentgroup appears in the left display.

The melter will return to the automatic scanmode two minutes after the last key ispressed.

When you press the Tank key, it is the pumptemperature that is actually indicated in theright display. To check the actual temperatureof the tank, simultaneously press the Tankkey and the left-display scroll key.

The default unit for temperature display isdegrees Celsius (C). This may be changed todegrees Fahrenheit using operatingparameter 20.


The LEDs on each component key will changefrom green to yellow if any component in thecomponent group drops more than 3 �C (5 �F)below its assigned set-point temperature.

You can check the set-point temperature of acomponent at any time, by pressing theright-display UP scroll key. Holding down thescroll key while the melter is in the automaticscan mode reveals the set-point of eachcomponent that is scanned.

Operation4-12


Monitor Melter Faults The melter alerts the operator to the faults listed in Table 4-1.

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

Table 4-1 Melter Faults

DisplayCode/Sub-code Name Affect on Melter Cause Corrective Action

F1/None RTD Heaters turn off

The RTD for thecomponent indicatedhas failed or thecomponent wasdisconnected fromthe melter.

Replace RTD

Check hose/gunconnections

F2/NoneUndertemperature Heaters turn off

The actual temperatureof the componentindicated has droppedbelow the undertemperature delta,which was set usingparameter 22.

Check for conditionsthat may cause a dropin ambient temperature

Replace RTD

F3/None Over temperature Heaters turn off

The actual temperatureof the componentindicated has increasedbeyond the overtemperature delta,which was set usingparameter 21.

Replace RTD

F4/1 RAM testMelter stopsfunctioning Internal RAM failure Replace CPU

F4/2Internal Clocktime

Heaters remain on,but fault conditionpersists

Internal clock failure Replace CPU

F4/3RAM backupbattery

Clock does notfunction

Insufficient voltage fromRAM backup battery Replace CPU

F4/4Internal clockbattery backedRAM


Battery-backed RAMfailure Replace CPU

F4/5Internal clockbattery


Battery-backed RAMbattery dead Replace CPU

F4/6 Analog-to-digitalMelter stopsfunctioning

RTD analog-to-digitalconverter failed

Replace main board orCPU

Continued...

Operation 4-13


Table 4-1 Melter Faults (contd)


F4/7Analog-to-digitalcalibration

Melter stopsfunctioning

Failed hose or gun

RTD analog-to-digitalconverter could not becalibrated (groundedRTD in system)

Replace hose or gun.Note: Set setpoint tozero to avoid F1 fault.

Replace main board orribbon cable, or CPU

F4/8Main boardfeedback


Communication failurebetween main boardand CPU

Replace main board,ribbon cable, or CPU

F4/9Expansion boardfeedback


Communication failurebetween expansionboard and main board

Check the ribbon cableconnections betweenthe expansion boardand the main board.

F4/A ThermostatMelter stopsfunctioning

Tank or manifoldthermostat is open

Replace thermostat, J7harness, or main board

F4/dCommunicationswith optional I/Ocard


Communication failurebetween CPU and theoptional I/O card

Replace the I/O card orCPU

F4/EFieldbuscommunicationsfailure

Alert output (ifoutput option 6 isselected)Melter continues tooperate normally.

Fieldbus card failure.Replace the Fieldbuscard

Fault LED (red)

Operation4-14


F1, F2 and F3 Faults

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

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

2. The LED on the affected component key (tank, hose, or gun) turns on toindicate 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 1for the tank or 2 for the pump.

� If the LED on the hose or gun key is on, the left display will indicatethe number of the affected hose or gun.

5. If the fault condition still exists at the end of the two-minute monitoringperiod, the ready LED will turn off, the red fault LED will turn on, theheaters turn off, and the melter records the fault in the fault log. Refer toMonitor Melter Faults in this section.

To be able to put the melter back into operation, the fault must be remediedand the melter reset (reset key). Refer to Section 6, Troubleshooting, forinformation about diagnosing and correcting fault conditions. Also refer toReturning the Melter to Factory Settings.

Operation 4-15


To view the temperature of a heated componentwhen an F2 or F3 fault exists, simultaneouslypress and hold both of the right-display scrollkeys.

You can temporarily dismiss an F1 fault (RTD)and return to the automatic scan mode bypressing the Clear/Reset key. The heaters will,however, remain off. If the fault condition stillexists two minutes after pressing the clear/resetkey, the fault LED will turn back on.

When an F1 fault code appears, you candetermine whether the fault was caused by anopen or a shorted RTD by simultaneouslypressing both of the right-display scroll keys. Ifthe right display indicates OP, the RTD is open, ifit indicates SH, the RTD has shorted.

If, for any reason, a component reaches 235 �C(458 �F), an immediate F3 fault will occur (notwo-minute monitoring period).

F4 Fault

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 asbeing fatal or nonfatal. The affect on the melter of each of these twoclasses of F4 faults is:

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

Nonfatal—The fault LED turns on for five seconds, but the heaters andpump continue to operate normally. Nonfatal faults affect the internalclock.

5. The melter records the fault in the fault log. Refer to Monitor MelterFaults in this section.

Clear/Reset key

Heater key

Operation4-16


Resetting the melter1. Diagnose and correct the fault condition. Refer to Section 6,

Troubleshooting, for information about diagnosing and correcting faultconditions.

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

3. Press the Clear/Reset key.

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

If F4 appears in the right display when you press theclock key, the internal clock function has failed.

Setup Key

Left display and scroll key

Scrolling through the fault log

Operation 4-17


Reviewing the Fault Log1. Press and hold the Setup key.

The automatic scan stops and operating parameter 1 appears in theleft 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 onthe affected component key turns yellow.

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

� The right display indicates the log entry for the last fault tooccur. Table 4-2 provides the meaning of each digit in the logentry. Following the table are two example fault log entries.

3. Press the right-display scroll key to review each of the remainingnine log entries. Each press of the scroll key displays a progressivelyolder log entry.

NOTE: The fault log only stores the last ten faults. After ten faultsoccur, the existing log entries are overwritten, beginning with the oldestentry, by the eleventh and following log entries.

4. Press the Setup key to return to the automatic scan mode.

Table 4-2 Fault Log

First Digit Second and ThirdDigits

Fourth Digit

Component:

- F

Type of fault:

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

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

3 = Hose 3 or gun 3 2 = Component under temperature

4 = Hose 4 or gun 4 3 = Component over temperature

5 = Hose 5 or gun 5 4 = Processor or electrical failure

6 = Hose 6 or gun 6

Operation4-18


Fault Log examples

Example 1:

An unused log entry.

Example 2:

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

To view the number of heater hours that haveelapsed since a log entry was created,simultaneously press both of the right-displayscroll keys. The hours are indicated in the rightdisplay.

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

When an F1 fault is the result of a hose/gun pairbeing disconnected from the melter, two fault logentries are created. The first entry is for the gunand the second entry is for the hose.

Service LED (yellow)

Clear/Reset key

Operation 4-19


Monitor the Service Interval The melter can be set up so that the service LED located on the left sideof the control panel turns on after a customer-defined time period haselapsed. The service LED may be used to signal the need to change thehot melt filter or to complete any other customer-specified maintenanceactivity. Once the specified maintenance is performed, the service LED mustbe reset.

To reset the service LED

With the melter in the scan mode, press the Clear/Reset key to turn off theservice LED and reset the service interval time.

The default setting for the service interval time is500 hours.


Tank key


Enter key

Ready LED

Operation4-20


Adjusting Component Temperatures You can adjust the set-point temperature of heated components using thefollowing methods:

� Global—The tank and all hoses and guns are set to the sameset-point temperature.

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

� Individual Component—The set-point temperature of the tankand each hose and gun is adjusted independently.

Before adjusting set-point temperatures, confirm that each hose/gun pairis connected to the correct hose/gun receptacle. For example,hose/gun pair 1 should be connected to the receptacle 1. Refer to HeatedComponents earlier in this section for information about hose/gun positions.

NOTE: For additional temperature control features, refer toparameters 20−29 in Appendix B, Operating Parameters.

To adjust the setpoint temperature using the global method1. 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 ofthe component keys turn green.



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt.

NOTE: If the keypad or the right-display scroll keys have no affecton the right display, the melter is password protected. You must entera valid password before you can change set-point temperatures. Referto Entering a Password in this section.

5. Press the Tank key.

All components begin to heat or cool to the new globalset-point temperature. When all of the components reach theirset-point temperature, the ready LED turns on (green).

Tank, hose, and gun keys

Operation 4-21


To adjust the setpoint temperature using the global-by-componentmethod1. Press and hold the Hose or Gun key for three seconds.

The left display indicates the number of the first sequential hose orgun. The right display indicates the current set-point temperature of thehose or the gun.

2. Scroll the left display to 0.

The right display indicates all dashes (- - - -).



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt.



The hoses or the guns begin to heat or cool to their newset-point temperature.

Operation4-22


To adjust the setpoint temperature of an individual component1. 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 ahose or gun key was pressed, the left display indicates the number ofthe first sequential hose or gun (Flashing). The right display indicatesthe current set-point temperature of the component indicated in the leftdisplay.

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

The right display indicates the current set-point temperature of thecomponent that you selected in the left display.



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt. Refer to the technical datasheet provided by the manufacturer of the hot melt to determine theoptimal set-point temperature.



� To register the new set-point temperature and then move on tochange 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 automaticscan mode, go to step 6.

6. Press any component key (tank, hose, or gun).

The selected component begins to heat or cool to its newset-point temperature.

Operation 4-23


If you enter a valid set-point temperature for ahose/gun that is not connected to the melter or if youenter a set-point temperature that is out of range, theright display will indicate dashes (----) for threeseconds and then change back to the originalset-point temperature.

When the right display is flashing, you can quicklychange the current set-point temperature to 0 degrees(off) by simultaneously pressing both of right-displayscroll keys.

After removing a hose or a gun, use the individualcomponent method of set-point temperatureadjustment to set the component’s temperature to zerodegrees (off). This will avoid causing an F1 fault. Whena hose or gun is added, use the individual componentmethod to set the desired temperature.

The factory set-point temperature of the tank is 175 �C(350 �F). The factory set-point temperature of allothers components is zero degrees (off).

When the units of temperature is set to degreesCelsius, the minimum and maximum set-pointtemperatures are 40 �C and 230 �C. When the units oftemperature are set to degrees Fahrenheit, theminimum and maximum set-point temperatures are100 �F and 450 �F.

When using the right-display scroll keys to adjust aset-point temperature, the right display automaticallyincrements between 0, 175, and 230 �C or between 0,350, and 450 �F.

If you make a mistake while you are changing aset-point temperature, but you have not yet pressedthe enter key, press the Clear/Reset key to reset theright display to the original temperature.

The melter will exit the setup mode and return to theautomatic scan mode two minutes after the last key ispressed.

A global set-point temperature of zero degrees(Celsius or Fahrenheit) turns all components off.

When scrolling through component numbers in the leftdisplay, component numbers that are associatedwith unused hose/gun receptacles are skipped.

The melter stores a record of the last ten changesmade to the set-point temperatures (and operatingparameters) in the change history log.

Section 3, Installation, ReviewParameter and Set-pointTemperature Changes

You can save set-point temperature changes bysimultaneously pressing the 1 key and the Setup key.

Section 3, Installation, Save andRestore Melter Setting

Operation4-24


Entering a Password If the melter is password protected, a valid password must beentered before any set-point temperature or melter parameter can bechanged.

To enter a melter password1. Press the Setup key.

The left display indicates parameter 0 (flashing) and the rightdisplay indicates 4000.


The right display begins flashing.

3. Use the keypad to enter the melter password.


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 theright display momentarily indicates dashes (----) and then returns to4000.

If the password is incorrect, re-enter it and then press the Enter key.

The melter will automatically revert back to thepassword-protected mode two minutes afterthe last key press (any key). To force themelter back into the password protected modebefore two minutes has elapsed, press theSetup key twice.

The melter password is created andenabled/disabled during system setup.

Setting Up the Melter in Section 3,Installation

Heater key

Master pump enable key/LED

Operation 4-25


Using Function Keys The control panel provides the following standard and special function keys:

Standard function keys

� Heater

� Pump (1 and 2)

� Setup

Special function keys

� Seven-day clock

� Standby

CAUTION! Unintentionally activating function keys can, under thecorrect circumstances, have undesirable effects on the melter or themanufacturing process. Only personnel who are familiar with the melter’ssetup and its connection with the manufacturing process should use thefunction keys. Improper use of the function keys can result in erratic processbehavior or personal injury.

Heater Key Use the heater key to manually turn the component heaters on andoff. Pressing the heater key overrides the control (on or off) of the heatersby either the seven-day clock feature or a remote input. The LED on theheater key illuminates when the heaters are on.

When a fault occurs (refer to Monitor Melter Faults in this section) theheaters automatically turn off. The heater key is used to turn theheaters back on after correcting a fault condition.

Master Pump Enable Key Use the master pump enable key to enable and stop the pumps. The LED isgreen when the pumps are enabled and the melter is ready.

If the automatic pump on feature (parameter 8) is disabled, then the masterpump enable key must be used to start the pumps when the melter is ready.

If any of the inputs are set up to use the pump enable/disable control option,the pump motor will not start until the pump is enabled and the correctvoltage is applied to the input contacts. If the pump is enabled, but the inputvoltage is not present, the master pump enable key LED will flash green.

Setup key

Seven-day clock key

Operation4-26


Setup Key Use the setup key to place the melter into and take the melter out ofthe setup mode. When the melter is placed into the setup mode, theautomatic scan stops and the left and right displays are used to select andread or edit operating parameters.

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 isautomatically regulated based on a set of user-defined schedules.

To accommodate daily shift work and non-working days, fourclock schedules are available. Schedules 1, 2, and 3 are used to specifywhen the heaters should turn on and off or when the melter should enterand exit the standby mode. Schedule 0 is used to keep the melter in the lastcondition dictated by the clock (heaters on or off, or standby).

When a clock schedule calls for the heaters to be on, the heatersare regulated at their pre-assigned set-point temperatures. When theclock activates the standby mode, the set-point temperature of eachcomponent is temporarily reduced by a pre-set standby delta.

Refer to Appendix B, Operating Parameters, for information about setting upthe 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 nexttime the melter is switched back on.

If the heaters are manually turned off at the timethat a clock schedule calls for the heaters to beon, the heaters will not turn back on until the nextclock schedule calls for them to be on.

The clock will still operate when the melteris faulting or is in the setup mode.

If F4 appears in the right display when you pressthe clock key, the internal clock function hasfailed.

Section 7, Troubleshooting

Standby key

Operation 4-27


Standby Key Use the standby key to manually place the melter into, and take it out of, thestandby mode. Using the standby mode during periods of time when themelter is inactive helps conserve energy and allows heated components toquickly return to their set-point temperatures when the melter is once againneeded.

When the melter is placed into the standby mode, the temperatures of allcomponents are reduced down from their set-point temperature by a pre-setstandby delta. The melter will remain in the standby mode until the standbykey is pressed or the function of one of the operating parameters takes themelter 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 theperiod of time specified by the timer. After the manual standby time haselapsed, the melter will once again begin heating all of the components totheir assigned set-point temperature.

Using the standby key overrides the control of the melter (on or off) by theseven-day clock or a remote input.

Refer to Section 3, Installation, Setting Up the Melter, and to Appendix B,Operating Parameters, for information about setting the standby delta andthe standby timer.

The melter may also be set up to automaticallyenter the standby mode using a variety ofoperating parameters.

Appendix B, Parameters 25, 26, 57,30–33, 62, and 67

Whenever manual standby is enabled, thestandby LED blinks.


Operation4-28


Shutting Down the Melter Shut the melter down when it will not be used for an extended period oftime.

To shut the melter down1. Press the pump enable key(s) to disable the motor(s).

2. Place the control switch in the OFF position.

3. Place the main power switch in the OFF position.

4. 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.

Operation 4-29


Record of Melter Settings Production information:

Material: Manufacturer

Processing Temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Processing temperatures (Setpoint temperatures):

Tank/Grid/Reservoir

Hose 1) 2) 3) 4) 5) 6)

Gun 1) 2) 3) 4) 5) 6)

Pump speeds:

Pump 1) 2)

Notes:

Name Date

Operation4-30


Service 5-1


Section 5Service


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

Relieving System Pressure

WARNING! System and material pressurized. Relieve system of pressurebefore disconnecting hoses, guns and hot melt handguns. Failure toobserve can result in serious burns.

Through the Guns 1. Disable the motor(s). Refer to Section 4, Operation.

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

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

4. Re-use the material or properly dispose of it according to localregulations.

Service5-2


Through the Melter Drain Valves 1. Disable the motor(s). Refer to Section 4, Operation.

2. Place a container under the drain valve ports located on the bottom ofthe manifold.

3. Open all the drain valves. Adhesive will drain from the valves.

4. When adhesive stops draining, close the drain valves.

5. Re-use the material or properly dispose of it according to localregulations.

Figure 5-1 Location of the melter drain valves

Service 5-3


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

Melter part Activity Interval Refer To

Complete melter External cleaning Daily External Cleaning

Inspect for externaldamage

Daily

Purge with cleaning agent When material is changed Changing theMaterial Type

Fan and air filter Check filter, clean orreplace if necessary

Clean fan screen

Depending on dust accumulation;daily if necessary

Fan and Air Filter

Power cable Inspect for damage Every time the melter is serviced

Air hoses Inspect for damage Every time the melter is serviced

Pump Tighten the gland bolt (ifpresent)

After initial startup Pump

Check for leakage, tightengland bolt (if present) ifnecessary

Dependent on hours of operation,pump speed and pumptemperature

Recommendation: Monthly

Tighten fixing screws Every 500 hours of operation

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

Motor and GearBox

Change lubricant Every 15000 hours of operation orevery 2 to 3 years

Pressure control valve Disassemble and clean Every six months Pressure ControlValve

Filter cartridge Replace filter cartridge

Disassemble and cleanfilter cartridge

Depending on degree of materialpollution

Recommendation: Every 1000hours of operation

Filter Cartridge

Tank Clean tank by hand When there is material residue intank

Cleaning the Tank

Tighten fixing screws Every 500 hours of operation

Location of the optional motionswitch

Service5-4


Locking Out the Motor Drives To perform some troubleshooting and repair activities, the main power to themelter needs to be on and/or the melter needs to be at applicationtemperature. To prevent injury, the optional motion switch can be used tolock out the motor drives while leaving the main power on.

To lock out the motor drives but leave the main power on, place the motionswitch in the OFF position. The main power to the melter will remain on andthe melter will stay at application temperature.

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

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

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

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

Service 5-5


Changing the Material Type 1. Run the melter until empty.

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

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

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

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

Detaching the Exterior Panels Open the protective panels with a 4 mm Allen key.

On the inside

Fan and Air Filter The air filters must be cleaned (knocked out) or replaced, depending ondust accumulation.

Refer to Section 7, Parts, for the filter part number.

Service5-6


Motor and Gear Box

Changing the Motor Lubricant Remove the gear motor assembly from the melter.

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

� Drain lubricant when warm.

� Properly dispose of the old lubricant according to local regulations.

CAUTION! Never mix different types of lubricants.

Lubricant Changing Interval

Operating temperature < 100 �C / 212 �F:

Every 15000 hours of operation or at least every 4 years.

Lubricant Capacity

Ensure that the upper gears and rolling bearings are properly lubricated.

Lubricant Selection

Lubricant manufacturer Mineral oil CLP 220

AGIP Blasia 220

ARAL Degol BMB 220 or Degol BG 220

BP Energol GR-XP 220

DEA Falcon CLP 220

ESSO Spartan EP 220 or GP 90

KLÜBER Klüberoil GEM 1-220

OPTIMOL Optigear 220

SHELL Omala Oil 220

TEXACO Geartex EP-A SAE 85 W-90

Service 5-7


Replacing a Motor or Coupling Follow this procedure to replace a motor or coupling. You will need thefollowing items:

� appropriate tools� replacement motor or coupling� anti-seize lubricant (if needed)

1. Disconnect and lock out electrical power to the melter.

2. Remove the hydraulic side covers and the left and right control cabinetside covers. Refer to Detaching the Exterior Panels earlier in this sectionas needed.

3. Disconnect the motor cable wires, noting their terminal positions.

4. See Figure 5-2. Loosen the screws that secure the motor to the base ofthe melter and then slide the motor back.

5. Slide the coupling sleeve (2) off of the coupling hubs (1 and 3), loosenthe hub set screws, and remove the hubs.

1 32

Figure 5-2 Coupling assembly components

1 Motor coupling hub2 Coupling sleeve

3 Pump coupling hub

Service5-8


Replacing a Motor or Coupling (contd)

6. Remove the protective coating from the new motor shaft, slide thereplacement (if applicable) motor coupling hub onto the motor shaft, andtighten the hub set screws.

7. Install the replacement (if applicable) pump coupling hub on the pumpshaft, ensure that it is flush with the pump shaft, and tighten the hub setscrews.

8. Loosely install the replacement motor assembly and slide the assembly,including the motor coupling hub and sleeve, toward the pump until thecoupling sleeve engages with pump coupling hub.

9. Ensure that the coupling sleeve cannot move, then slide the motorassembly back 4 mm (0.16 in.), as indicated in Figure 5-3.

4 mm (0.16 in.)

Figure 5-3 Moving the motor assembly back 4 mm (0.16 in.)

10. Tighten the screws that secure the motor to the base of the melter

11. To ensure proper motor and pump shaft alignment, ensure that you canfreely slide the coupling sleeve back and forth by about 4 mm (0.16 in.)each way.

12. Reconnect the motor cable wires to the same terminals from which theywere disconnected.

13. Reinstall the melter covers and restore the system to normal operation.

Service 5-9


Pump

Tightening the Pump Screws 1. Ensure that the melter is turned off and that power has been

disconnected and locked out.

2. Ensure that the melter, tank, manifold, and pump are cold.

3. See Figure 5-4. Tighten the screws to 25 N�m (222 in.-lb).

Figure 5-4 Tightening the pump screws

4. Restore the system to normal operation.

Pump gland bolt

Service5-10


Tightening the Pump Gland Bolt NOTE: This procedure applies only to pumps with a gland bolt.

On pumps with a gland bolt, adhesive may leak from the self-sealing pumpshaft packing at regular intervals. When leakage occurs, tighten the pumpgland bolt.

1. Heat the pump to application temperature using a heated air blower.

2. See Figure 5-5. Using a 24-mm short-handle, open-end wrench (with a15-degree offset), tighten the pump gland bolt approximately 1/4 of a turnclockwise (in the direction of pump rotation). When the bolt can nolonger be tightened, replace the pump.


Figure 5-5 Tightening the pump gland bolt (clockwise)

Service 5-11


Replacing a Pump Follow this procedure to replace a pump. You will need the following items:

� tool kit, including a torque wrench� drain pan� cleaning supplies� replacement pump� replacement pump O-rings� O-ring lubricant� anti-seize lubricant

NOTE: To rebuild a pump, contact your Nordson representative forassistance.

1. Ensure the melter is at operating temperature.

2. Relieve system pressure. Refer to Section 1, Safety.

3. See Figure 5-6. Close the tank isolation valve.

Figure 5-6 Location of the tank isolation valve

Service5-12


Replacing a Pump (contd)

4. Remove the hydraulic side covers. Refer to Detaching the ExteriorPanels earlier in this section as needed.

5. Place a drain pan under the pump.

6. See Figure 5-7. Loosen the screws that secure the motor to the base ofthe melter and then slide the motor back.

7. Slide the coupling sleeve (2) off of the coupling hubs (1 and 3), loosenthe pump coupling hub set screws, and remove the pump coupling hub.

1 32

Figure 5-7 Coupling assembly components

1 Motor coupling hub2 Coupling sleeve

3 Pump coupling hub

Service 5-13


8. See Figure 5-8. Remove the pump screws (3) and then remove thepump (2) and O-rings (1).

440300046

1

2

3

1 2

3

Figure 5-8 Replacing a pump (single-stream and dual-stream pumps shown)

1 O-rings 2 Pump 3 Pump screw

9. Clean the surface of the manifold where the pump mates to it.

10. Allow the melter to cool to room temperature.

11. Install the pump coupling hub on the pump shaft, ensure that it is flushwith the pump shaft, and tighten the hub set screws.

12. Apply O-ring lubricant to new pump O-rings and install them on thepump.

13. Apply anti-seize lubricant to the pump screws and secure the new pumpto the manifold with the screws. Use a torque wrench to tighten thescrews in a criss-cross manner to 25 N�m (222 in.-lb).

Service5-14


Replacing a Pump (contd)

14. Slide motor assembly, including the motor coupling hub and sleeve,toward the pump until the coupling sleeve engages with pump couplinghub.

15. Ensure that the coupling sleeve cannot move, then slide the motorassembly back 4 mm (0.16 in.), as indicated in Figure 5-9.

4 mm (0.16 in.)

Figure 5-9 Moving the motor assembly back 4 mm (0.16 in.)

16. Tighten the screws that secure the motor to the base of the melter

17. To ensure proper motor and pump shaft alignment, verify that you canfreely slide the coupling sleeve back and forth by about 4 mm (0.16 in.)each way.


Service 5-15


Filter Cartridge

To replace the filter cartridge



M10

SW 24

3. Apply high temperature grease to all threads and O-rings.

4. Insert the filter cartridge and tighten it to approximately 15 N�m(133 in.-lb).

5. Feed material by allowing the pump to run until the material comes outof the hose connection or gun free of bubbles.

6. Properly dispose of material according to local regulations.

Service5-16


Filter Service Kit Each kit contains three O-rings, filter sheath, filter screen andhigh-temperature grease.

Service Kit, for P/N refer to Section 7, Parts.

Required tools:Open-jawed wrench, size 24 and size 13

3

2

2

2

Size 13

1

Size 24

1. Disassemble the hot filter cartridge (material must be fluid).

2. Replace filter sheath (1), O-rings (2) and filter screen (3).

3. Clean all other parts.

4. Apply grease to all threads and O-rings.

+−

Adjusting the set screw

Service 5-17


Pressure Control Valve

To replace the pressure control valve

X

Figure 5-10 Pressure control valve set screw insertion depth

NOTE: Screw in only when valve and pump are warm and material is soft.



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

4. To prevent adhesive from leaking into the valve bore, drain the tank.Refer to Draining Material from the Tank later in this section as needed.

5. Remove the old pressure control valve.

6. Apply high temperature grease to all threads and O-rings.

7. Slide the valve into the hole and tighten with torque wrench(15 N�m / 133 in.-lb).

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

� Turning to the right increases material pressure.

� Turning to the left decreases material pressure.

Service5-18


Pressure/Circulation Control Valve Service Kit Each kit contains two O-rings and high-temperature grease.

Service kit P/N: 394600

Required tools:Open-jawed wrench, size 24PliersTorque wrench

1. Heat melter to operating temperature.

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

2. Relieve melter pressure.

3. Measure insertion depth. Refer to Pressure Control Valve.

4. Use an open-jawed wrench to screw out the pressure control valve, then extract with apliers.

5. Remove old O-rings and disassemble and clean pressure control valve. Refer toSection 7, Parts, for a detailed drawing.

NOTE: Disassemble valve only when warm.

6. Install new O-rings. Apply grease to all threads and O-rings.

7. Guide pressure control valve into the hole when the melter is warm and tighten withtorque wrench.

Starting torque: 15 N�m (133 in.-lb)

8. Adjust set screw. Refer to Pressure Control Valve.

Service 5-19


Cleaning the Tank

Draining Material from the Tank Pump material out of the melter.

CAUTION! Do not feed charred material though the gun. Particles can blockthe gun. Instead unscrew hose (refer to Section 3, Installation).

Cleaning the Tank by Hand Cold material can usually be peeled off of the sides of the tank. If necessary,first heat tank to material softening temperature, usually approximately70 °C / 158 °F.

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

Tightening the Fixing Screws Heating and cooling that occurs during daily operation can cause the fixingscrews to loosen. Tighten screws as indicated in the table below.

NOTE: Tighten fixing screws only using a torque wrench and when themelter is cold.

Connection Thread Torque

Tank/reservoir M 6 6−8 N�m / 53−71 in.-lb

Manifold/reservoir (high melt) M 8 5−7 N�m / 44−62 in.-lb

Service5-20


Main PCA Board

To replace the main PCA board 1. Disconnect power to the melter at the local disconnect switch.

2. Switch the melter off.

3. See Figure 5-11. Open the electrical enclosure access panel and locatethe main PCA board.

Figure 5-11 Location of the main PCA board

4. Disconnect all of the power and control cables from the board.

5. Remove the four fastening screws that hold the board on the mountingstuds and then remove the board.

NOTE: Before installing the new board, you must ensure that the boardis properly configured for the type of temperature sensors present on themelter. If the melter uses 100-ohm platinum sensors, the jumpersconnected to the JP1 terminal on the old board must be removed andthen installed on the new board. Figure 5-12 shows the location ofterminal JP1 on the main PCA board. Figures 5-13 and 5-14 show thejumpers installed and not installed, as appropriate for each type ofmelter.

Service 5-21


R108

R7

R65

C55

R92

C6

C66

C32

C74

R127

R88

R72

R9

R61

R14

R11 DS5

R82

R49

D10R

79

R12

R102

R69

R90

DS16

R130

R87

RV

13

RN3

R103

R53

R47

Q5

Q12

R78

R59

+ C82

Q24

R129

R73

C80

C22

RV 5

RN

9

C79

R56

C69

R100

C84

R34

C8

C3

RV

7C

4

RV

12

C72

RV

11C

10 C23

C25

C26

R115

R112

Q7

Q9

C28

C29

R67

R66

R71

R117

L4

R58

R52

R36

R33

C53

RV 6C1

R80

R136

R133D8

R134 R135U5

C7 RN10

R106

R51

R57

Q14

R39R42

R83R37

R74

U12

R44R45C77

R38

R4R3

Q26

Q17

R99Q18

R121 R101

R8

R118

Q25

R6DS3

C47

DS4

L3

R96

C43

C44

R70

Q23

R93 R5

R55

Q8

R16

R10DS7

D12

C54

R84

R85

Q22

R17

R109

Q10

DS6

R76

R122

R131

D11

R132

Q13

1J2

R86

RV

10

R26

XP5

+C58

R111

R123 U26

C51

L2

U4

+C12

RN5

R89

XP6

C31RN6RN4

DS13

R104

R54

R48

DS8

DS12

R35

R60

R64

DS10

DS11

R116

R94

Q16

R40 R41C39

U23

D5

R2

R43R46

C2

R128R1

+

C40

R75

R119

R120

C37

C18

RN

1

C15

RN

11

C17

R95

Q20

Q19

C21 C20R15

RN

2

C19

R77

R113

1

X2

C70 C71

R62

1

X3

D3

R50

C46

C83

C68 C73

R97

R124

U21

C48 C49

RV

9

C61

XP

2

R110

R98

C36

C24

C9

C5

U3

U25

DS15

+C

35

DS14

DS9

C27

C30

C75

U2

+

C16

DS17

R13

C67

C62RV 1

R68

RV 3

C76

C11

R91D4

RN

7

C60

R81 R20

Q15

DS2

XT1

C42

C41

RV 8

C50

D17

R19

R107

U20

U10

U19

U15

U18

U9

1XP3

RV 2

X7

D1

D6

RV 4

1XP4

C65

D2

D7

D14

U1

U17

U14

JP2

C63

R22

R63

U16

C56

D16

R18

51

26JP1

1 33

J1

1

X1

C52

C64

C45

L1

R114

R105

U24

U13

3

12

1

X5

U7

T1

HSNK1

C78

+

C59

X6

XP

1

D18

+

C57

3

12

1

X4

K1

++

U22

F3

F4

F6 F5

F1F2

F11

F12

F7

F8 F10F95A

10A

6.3A

2A

2A

5A

10A

6.3A

6.3A

6.3A 6.3A6.3A

+

Q6 Q11

Figure 5-12 Location of the JP1 terminal on the main PCA board

Service5-22


Main PCA Board (contd)

6. If 100-ohm platinum sensors are present on the melter:

a. Locate the JP1 terminal on the replacement board.

NOTE: For 120-ohm nickel melters, temperature sensor jumpersare not required in this location, as shown in Figure 5-14.

b. Install one of the jumpers removed from the old board betweenterminals 1 and 2.

c. Install the second jumper between terminals 5 and 6. Figure 5-13shows the jumpers installed.

Figure 5-13 100-ohm platinum melter—jumpers installed

Figure 5-14 120-ohm nickel melter—no jumpers installed

7. Install the replacement board inside the melter electrical enclosure usingthe fastening screws removed previously.

8. Reconnect all of the power and control cables to the replacement boardand close the electrical access panel.

9. Restore power to the melter and switch the melter on. Verify that themelter starts normally.

Service 5-23


Maintenance Record Form Melter part Date / Name Date / Name Date / Name

Pump

Motor / gear box

Fixing screws on pump andtank

Air filter

Tank

Pressure control valve

Filter cartridge

Service5-24


Troubleshooting 6-1


Section 6Troubleshooting


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

Safety� Never disconnect cables from, or reconnect cables to, the main board

while the melter is energized.

� Before breaking any hydraulic connection, always relieve systempressure. Refer to Relieving System Pressure in Section 5, Service.

� Refer to the safety information provided with optional equipment.

� If the melter is removed from its sub-base for diagnostic checks orservice, ensure that the ground lead between the chassis and thesub-base is re-attached when the melter is reconnected to the sub-base.

Troubleshooting6-2


Troubleshooting Quick-Checks Before using the troubleshooting charts confirm:

� whether or not service was recently performed on the melter or themelter’s settings were recently adjusted.

� external inputs (if used) are functioning properly.

� the standby or clock functions are not turned on (if not required orexpected at the current time).

Returning the Melter Setup to Factory Settings By returning the melter to its factory setting many common melter problemscan be isolated to either a problem with the melter settings or the melterhardware.

To return the melter to its factory settings, simultaneously press and holdthe Setup key and the right-display DOWN arrow key, and then, whileholding down these keys, cycle the control switch off and on. When themelter restarts, release the two keys.

Troubleshooting 6-3


Melter Faults Table 6-1 lists the four types of melter faults, potential causes, and expectedcorrective actions.

Table 6-1 Melter Faults


F1/None RTD Heaters turn off

The RTD for thecomponent indicatedhas failed or thecomponent wasdisconnected fromthe melter.

Replace RTD

Check hose/gunconnections

F2/NoneUndertemperature Heaters turn off

The actual temperatureof the componentindicated has droppedbelow the undertemperature delta,which was set usingparameter 22.

Check for conditionsthat may cause a dropin ambient temperature

Replace RTD

F3/None Over temperature Heaters turn off

The actual temperatureof the componentindicated has increasedbeyond the overtemperature delta,which was set usingparameter 21.

Replace RTD

F4/1 RAM testMelter stopsfunctioning Internal RAM failure Replace CPU

F4/2Internal Clocktime


Internal clock failure Replace CPU

F4/3RAM backupbattery

Clock does notfunction

Insufficient voltage fromRAM backup battery Replace CPU

F4/4Internal clockbattery backedRAM


Battery-backed RAMfailure Replace CPU

F4/5Internal clockbattery


Battery-backed RAMbattery dead Replace CPU

F4/6 Analog-to-digitalMelter stopsfunctioning

RTD analog-to-digitalconverter failed

Replace main board orCPU

Continued...

Troubleshooting6-4


Melter Faults (contd)

Table 6-1 Melter Faults (contd)


F4/7Analog-to-digitalcalibration


Failed hose or gun

RTD analog-to-digitalconverter could not becalibrated (groundedRTD in system)

Replace hose or gun.Note: Set setpoint tozero to avoid F1 fault.

Replace main board orribbon cable, or CPU

F4/8Main boardfeedback


Communication failurebetween main boardand CPU

Replace main board,ribbon cable, or CPU

F4/9Expansion boardfeedback


Communication failurebetween expansionboard and main board

Check the ribbon cableconnections betweenthe expansion boardand the main board.

F4/A ThermostatMelter stopsfunctioning

Tank or manifoldthermostat is open

Replace thermostat, J7harness, or main board

F4/dCommunicationswith optional I/Ocard


Communication failurebetween CPU and theoptional I/O card

Replace the I/O card orCPU

F4/EFieldbuscommunicationsfailure

Alert output (ifoutput option 6 isselected)Melter continues tooperate normally.

Fieldbus card failure.Replace the Fieldbuscard

Pump speed display

Troubleshooting 6-5


Motor Control Faults Table 6-2 lists the motor control fault codes that may appear on the pumpspeed display(s).

Table 6-2 Motor Control Faults

Motor Control Fault Possible Cause Corrective Action

no EnA (motor control fault codeshown on pump speed display)

Master pump enable key notturned on

Press the Master pump enablekey until the LED is illuminated.

hOt (motor control fault codeshown on pump speed display)

Motor thermostat open Wait for the motor to cool, ensurethat the pump speed setting isnot too low, and then restart thepump. If the hOt code continuesto appear, troubleshoot theproblem that is causing themotor to overheat, such asbinding or blockage in the pump,a locked pump rotor, etc.

Displayed rpms do not matchmotor speed

Pump speed display notcalibrated

Calibrate the pump speeddisplay. Refer to Calibrating thePump Speed Display.

Motor control not operating asexpected

Improper motor controlparameter settings

Check motor control parametersettings. Refer to Changing aMotor Control Parameter in thissection.

Main power switch

Control switch


Troubleshooting6-6


Changing a Motor Control Parameter The motor control parameters are factory set and do not need to bechanged. Use this procedure only if a motor control parameter isinadvertently changed and needs to be changed back to the factory settingshown in Table 6-3. The motor control parameters are changed through themotor control panels located on the front of the melter.

To change the a motor control parameter 1. Place the main power switch in the OFF position.

2. Place the control switch in the OFF position.

3. Press and hold both Pump speed arrow keys and then switch thecontrol switch back on. When the pump speed display indicates SEt,release the keys.

4. Use the Pump speed arrow keys to select a value for the parametershown on the pump speed display. Refer to Table 6-3 for a parameterlist.


Troubleshooting 6-7


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

6. Repeat steps 3−4 for each parameter you want to change.

7. To exit the setup mode, press the Pump mode key one additional timeafter the last parameter has been displayed.

Table 6-3 Motor Control Parameter Factory Settings

Parameter Factory Setting Description Explanation

SEt 94 Maximum pump rpm This parameter controls the increment ofchange in motor speed that occurs uponeach press of a pump speed up or downarrow key when the melter is operatingin the manual mode. To change the rpmin increments of 1, set this parameter tothe maximum pump rpm.

Srt 0 Motor start mode This parameter controls the methodused to start the motor(s):

To start a motor by pressing the pumpstart/stop key on a motor control panel,enter 0. This setting is typically used if amelter has more than one motor.

If you want a motor to start when thepump enable signal is activated, enter 1.This setting is typically used if a melterhas only one motor.

LoS 0 Minimum pump speedin gear-to-line mode

If the melter will be operated in themanual mode, enter 0.

If the melter will operated in thegear-to-line mode, enter a minimum linespeed. The motor speed will not fallbelow this valve even if the signal dropsto 0 V.

Troubleshooting6-8


Motor Drive Faults The display on the motor drive located inside the electrical enclosure alertsthe operator to abnormal motor drive/motor operation. Motor drive faultscause the pump to stop. Refer to Table 6-4 for the motor drive fault codes.

To clear a motor drive fault, correct the problem that caused the fault andthen remove power from the motor drive by turning the heaters off and waituntil the motor drive display is completely blank.

1

2

Figure 6-1 Motor drive power LED and display

1. Motor drive power LED (steady=OK,flashing=fault, off=no power)

2. Display

Table 6-4 Motor Drive Faults

Fault Code Probable Cause Corrective Action

CrF

Capacitor load circuit

Motor drive hardware failure Replace the motor drive.

EEF

EEPROM fault

Internal memory fault � Check the environment(electromagnetic compatibility).

� Replace the motor drive.

InF

Internal fault

Internal fault � Check the environment(electromagnetic compatibility).

� Replace the motor drive.

Continued...

Troubleshooting 6-9


Table 6-4 Motor Drive Faults (contd)

Fault Code Probable Cause Corrective Action

OCF

Overcurrent� Adhesive too cold

� Pump or drive failure

� Foreign object in pump

� Verify temperature setpoints andchange as needed. The temperaturesetpoints should be within the rangerecommended by the materialmanufacturer.

� Replace the pump or the driveassembly.

� Replace the pump.

SCF

Motor short-circuit

Short-circuit or earthing at themotor drive output

Check the cables between the motordrive and the motor; also check themotor insulation.

OHF

Motor drive overheated

Motor drive temperature too high � Check the motor load, the motordrive ventilation, and theenvironment. Wait for the motor driveto cool down before restarting.

� Ensure that the unit ambienttemperature does not exceed 50 �C(120 �F), that the electrical enclosurevents are not blocked, and that theelectrical enclosure fan is operatingproperly.

OLF

Motor overload� Material exceeds the operating

viscosity range

� Excessive motor current

� Overpressure condition causedby pressure control valvefailure

� Use a material that falls within theallowable viscosity range. Refer toSection 8, Technical Data, forviscosity ranges.

� Check the motor load. Wait for themotor drive to cool down beforerestarting.

� If the operating hydraulic pressureexceeds the maximum allowablepressure, replace the pressurecontrol valve. Refer to Section 8,Technical Data, for pressure ranges.

OPF

Motor phase loss

Loss of one or more phases atmotor drive output

Check the connections between themotor drive and the motor.

OSF

Overvoltage� Line voltage too high

� Disturbed line supply

Check the unit input line voltage. Referto Section 8, Technical Data, forallowable input voltage range.

CFF

Configuration fault

Motor drive parameter(s) changed Contact your Nordson representative.

USF

Undervoltage� Line supply too low

� Transient voltage dip

Check the unit input line voltage. Referto Section 8, Technical Data, forallowable input voltage range.

Troubleshooting6-10


Changing a Motor Drive Parameter The motor drive parameters are factory set and do not need to be changed.Use this procedure only if a motor drive parameter is inadvertently changedand needs to be changed back to the factory setting shown in Table 6-5.The motor drive parameters are changed through the keypad, shown inFigure 6-3, present on each motor drive located inside the electricalenclosure. Figure 6-2 shows how to change a motor drive parameter.

The following figure illustrates how to access parameters and assign their values. To store the parameter valuee, press the key. The displayflashes when a value is stored.

All of the menus are drop-down type menus. Once you have reached the last parameter in a list, press the keyy to return to the first parameter.From the first parameter in the list, press the key to jump to the lastparameter.

If you have modified a parameter in a menu and you return to that menu without accessing another menu in the meantime, you will be taken directly to the parameter you last modified. See the illustration below. If you haveaccessed another menu or have restarted the drive controller since the modification, you will be taken to the first parameter in the menu. See the illustration above.

ENT

ACC 15.0

ENT

ESC

ENT

ESC

26.0 26.0

ESC

dECENT

SEt−

Menu Parameter Value Assignment

The display flashes when avalue is stored.

Next Parameter

ENT

ESC

1st

nth

last

Menu

ENT

ESC

1st

nth

last

Menu

Figure 6-2 Changing a motor drive parameter

Troubleshooting 6-11


Figure 6-3 Motor drive keypad (located on each motor drive present inside the electrical enclosure)

1. Status LEDs2. Exit/clear3. Enter4. Stop/Reset

5. Run6. Reference potentiometer7. Advance display/decrease setting8. Advance display/increase setting

9. Display10. DC bus On

Table 6-5 Motor Drive Parameter Factory Settings

Code Pr. Description Setting Note

drC UFt Type of voltage/frequency ratioL

n SN1710 pump(s) only

SEt UFr lr Compensation/Voltage Boost 5

SEt SLP Slip compensation 35 SN1710 pump(s) only

SEt HSP High Speed 102

drC bFr Standard Motor Frequency 50

drC Uns Nominal Motor Voltage on Name Plate 230

drC FrS Nominal Motor Frequency on Name Plate 102

drC nCr Nominal Motor Current on Name Plate 2.7

drC nsP Nominal Motor Speed on Name Plate 1350

drC nrd Random Switching Frequency No

drC SFr Switching Frequency 4.0

drC tFr Maximum Output Frequency 102

1−0 tCC 2 Wire/3 Wire Control 2C

1−0 tCt Type of 2 Wire Control LEL

1−0 AOlt Configuration of Analog Output IOU

1−0 dO Analog/Logic Output OFR

CtL Fr1 Configuration Reference 1 AI1



Troubleshooting6-12


Calibrating the Pump Speed Display The melter is shipped with the pump speed display calibrated to show thepump rpm. If recalibration becomes necessary, follow this procedure.

1. Ensure that the motor is running at 50 percent speed or higher.

2. Press and hold both Pump speed arrow keys.

3. When the pump speed display indicates CAL, release the keys.

4. Enter the actual pump rpm.

5. Press the Pump mode key.



Troubleshooting Tables

Melter Not Functioning

Possible Cause Possible Fault / Troubleshooting Corrective Action

1. No line voltage — Connect line voltage

2. Main power switchnot switched on

— Place main power switch in ONposition

3. Main power switchdefective

— Replace main power switch

4. Main circuit breakeractivated

— Switch on main circuit breaker

5. Main circuit breakeractivated again

Check for short circuit in melter oraccessories

—

6. 24 VDC power supplydefective

— Replace

7. Frequent meltershutdown

Electromagnetic compatibilitydisruptions

Add mains filter

One Channel (Heating Zone) Does Not Heat


1. Channel is disabled /switched off

— Enable / switch on

Control Panel Does Not Function

Problem Possible Cause Corrective Action

1. Display is blank SPS broad-band cable notconnected

Connect

Troubleshooting6-14


No Material (Motor Does not Rotate)


1. Melter not yet readyfor operation (heatupphase)

— Wait until the melter has heated upand the green indication lamp is lit

2. Melter at present notready for operation(undertemperatureduring operation)

Material was refilled Wait until the melter has heated upand the green indication lamp is lit

3. Motor not enabled — Enable motor

4. Speed (rpm) not set — Set speed (rpm)

5. Standby entered — Exit or wait until standby period hasexpired

6. Motor overheated Ambient temperature too high Decrease ambient temperature bycooling or airing out

Fan cap dirty Clean

Pump blocked by foreign matter Replace pump

Pump operates too sluggish Replace pump

Material too cold Set temperature accordingly

7. Motor defective — Replace

8. Motor not suppliedwith voltage

— Technical inspection

9. Motor drive fault — Switch melter off and on again withmain power switch

Motor overheated See above

Motor controller overheated Decrease ambient temperature bycooling or airing out

Clean cooling section of motorcontroller

Short circuit Check motor cable

Overload (pump blocked byforeign matter, pump too sluggish,material too cold)

Refer to 6.

10. Motor drive defective — Replace



No Material (Motor Rotating)


1. Tank empty — Fill tank

2. Filter cartridgeclogged

— Clean or replace filter screen

3. Material supply holeto pump or pumpsuction hole clogged

— Detach pump and clean supply holeor suction hole

4. Pressure controlvalve defective

— Replace pressure control valve

5. Safety valve defective — Replace safety valve

6. Pump defective — Replace pump

7. Pressure controlvalve setting too low

— Adjust pressure control valve

Too Little Material


1. Material supply holeto pump or pumpsuction hole partiallyclogged

— Detach pump and clean supply holeor suction hole

2. Filter cartridge partlyclogged

— Clean or replace filter screen


— Clean or replace

4. Processingtemperature set toolow

— Correct temperature setting

5. Pump block is worn — Replace pump

6. Safety valve defective — Replace safety valve

7. Pump defective — Replace pump

8. Pressure controlvalve setting too low

— Adjust pressure control valve

Troubleshooting6-16


Material Pressure Too High


1. Pressure controlvalve dirty and thusblocked

— Disassemble and clean or replace


— Replace

3. Pressure controlvalve set incorrectly

— Set to default

Material Pressure Too Low


1. Pump is worn — Replace pump

2. Pressure controlvalve does not closeany more

— Replace

3. Pressure controlvalve dirty and thusclogged

— Disassemble and clean or replace


— Replace

5. Pressure controlvalve set incorrectly

— Set to default



Material Residue in Tank


1. Tank setpointtemperature set toohigh


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

Consult material supplier

Material Hardens in Tank


1. Tank setpointtemperature set toohigh/too low


Others

Problem Possible Cause Corrective Action

1. Leakage at pumpshaft seal

Pump shaft seal is worn Tighten the gland bolt

— Replace pump

2. Material pressure toolow, output quantitytoo low

Pump is worn Replace pump

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

Foreign material in pump Replace pump

4. Leakage at gunduring heatup phase

Safety valve does not open(expansion pressure)

Replace safety valve

Troubleshooting6-18


Parts 7-1


Section 7Parts

Using the Illustrated Parts List The parts lists provided in this section are organized into the followingcolumns:

Item—Identifies illustrated parts that are available from NordsonCorporation.

Part—Provides the Nordson Corporation part number for each saleablepart 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 andother characteristics when appropriate. Bullets in the description,indicate the relationships between assemblies, subassemblies, andparts.

Quantity—The quantity required per unit, assembly, or subassembly.The code AR (As Required) is used if the part number is a bulk itemordered in quantities or if the quantity per assembly depends on theproduct version or model.

Parts7-2


AltaBlue Configuration Code Use the following tables to determine the configuration of your melter.

VoltagePump

1Pump

2 3Pump

4Hose/Gun \

FlowControl

Low Motion

A BBox

2Box

3Box

4Box

5Box

6Box

7Box

8Box

9Box10

Box11

Box12

Box13

Box14

Box15

Box16

Box17

Box18

Box19

Box20

Box21

Box22

Box23

Box24

Box25

Base Melter Options

Melter Capacity

\ X X X X X−Level I/O SpareSpare Comm.

HostPort

ReturnSwitch Sensor Spare Spare Spare

Pump

Box1

Box Item Code Options Description1−2 Melter AB — AltaBlue adhesive melter3 Hyphen - — —

4−6 Tank capacity 015 15 l 15 l holding capacity030 30 l 30 l holding capacity050 50 l 50 l holding capacity100 100 l 100 l holding capacity

7 Operatingvoltage

3 240 VAC 3-phase Delta 240 VAC 3-phase Delta electrical service4 380−415 VAC Wye 380−415 VAC Wye electrical service5 400 VAC Delta 400 VAC Delta electrical service6 480 VAC Delta 480 VAC Delta electrical service

8−11 Pump selection A SN0030, 1.4 kg/hr Single-stream gear pumpB SN0046, 2.2 kg/hr

C SN0062, 2.9 kg/hrD SN0093, 4.5 kg/hrE SN0186, 8.9 kg/hrF SN0371, 17.8 kg/hrG SN0773, 37.1 kg/hrH SN1710, 82.1 kg/hr9 SH0371, 17.8 kg/hr Stainless-steel gear pumpZ SH0773, 37.1 kg/hr2 DN0030, 1.4 kg/hr/stream Dual-stream gear pump3 DN0048, 2.2 kg/hr/stream4 DN0062, 2.9 kg/hr/stream5 DN0093, 4.5 kg/hr/stream6 DN0186, 8.9 kg/hr/stream7 DN0557, 13.4 kg/hr/streamX None No pump at this location.

12 Hose/gun pairs 6 6 hose/gun pairs 6 hose/gun pairs (12 channels) forexternal temperature control (standard)

8 8 hose/gun pairs 8 hose/gun pairs (16 channels) forexternal temperature control

13 Slash \ — —Continued...

Parts 7-3


DescriptionOptionsCodeItemBox14 Flow control A Pneumatic PCV Pneumatic PCVs are installed, allowing

the bypass pressure to be adjusted usinga customer-supplied air pressureregulator.

V Circulation control valve Circulation control valves are installed,allowing recirculated adhesive to becontrolled when a single adhesive streamis split between multiple applications inwhich the adhesive flow to eachapplication needs to be balanced becauseof differing add-on rates.

X Manual PCV Standard manual PCVs are installed,allowing the manual adjustment ofadhesive pressure.

15 Spare X — —16 Low-level

indicationL Low-level indication present The low-level indication provides a signal

when the level of adhesive in the tank fallsbelow a specified value.

X None No low-level indication17 I/O and

indicationY I/O expansion card present The optional I/O expansion card (digital) is

installed.

X None No optional I/O expansion card18 Spare X — —19 Host

communicationE Ethernet card present The optional Ethernet card is installed.D PROFIBUS card present The optional PROFIBUS card is installed.V DeviceNet card present The optional DeviceNet card is installed.X None No communication card

20 Return port R 1 hose return port One hose return port is installed.X None No hose return port

21 Motion switch M Motion switch present The motion switch is a lockable motordisconnect switch that removes powerfrom the motor drives, allowing the pumpand motor to be service without turning offthe melter heat.

X None No motion switch22 Sensor type N 120-ohm nickel sensors Requires Nordson T-style hose/gun

connectors

P 100-ohm platinum sensors Requires Nordson M-style hose/gunconnectors

23−25 Spare X — —

Parts7-4


Frame Assembly The frame assembly parts vary depending on the size of the melter:one/two-pump or three/four-pump. Refer to the correct parts list for yourmelter.

One/Two-Pump Melter Frame Parts See Figure 7-1.

Item Part Description Quantity Note

901- - - - - - - Panel assembly, tank side, 15L and 30L 2- - - - - - - Panel assembly, tank side, 50L 2

902 - - - - - - - Panel assembly, motor cover, side 2903 - - - - - - - Panel assembly, motor cover front 1904 - - - - - - - Panel assembly, electrical cover, front 1905 224906 Tag, warning, electrical shock 2906 - - - - - - - Rivet, pop, 1/8 x 0.187 8907 - - - - - - - Plug, button, M16, plastic 1908 - - - - - - - Nameplate, information 1909 1025326 Tag, caution, hot surface, 1.19 x 6.544 1910 1021983 Tag, warning, hot adh/hyd press, 1.6 x 6.5 1911 1025795 Tag, warning, hazardous volts 1914 7400868 Cable gland, clamp, M32, 15−22 mm 1NS 7400342 Kit, ship with, one/two-pump 1

NS: Not Shown

Parts 7-5


901

905 906

908

909

910

907

906 916

917

902

903

904

911

914

Figure 7-1 One/two-pump melter frame assembly parts

Parts7-6


Three/Four-Pump Melter Frame Parts See Figure 7-2.

Item Part Description Quantity Note

901- - - - - - - Panel assembly, tank side, 30L and 50L 2- - - - - - - Panel assembly, tank side, 100L 2

902 - - - - - - - Panel assembly, motor cover, side 2903 - - - - - - - Panel assembly, motor cover, front 1904 - - - - - - - Panel assembly, electrical cover, front 1905 224906 Tag, warning, electrical shock 2906 - - - - - - - Rivet, pop, 1/8 x 0.187 8907 - - - - - - - Plug, button, M32, plastic 1908 - - - - - - - Nameplate, information 1909 1025326 Tag, caution, hot surface, 1.19 x 6.544 1910 1021983 Tag, warning, hot adh/hyd pressure, 1.6 x 6.5 1911 1025795 Tag, warning, hazardous volts 1

9147400354 Cable gland, clamp, M32, 18−25 mm 17401255 Cable gland, clamp, M40, 24−30 mm 1

NS 7400821 Kit, ship-with, three/four-pump, 100L 1NS: Not Shown

Parts 7-7


905906

901

908

909

910

907

906

902

916

917

911

904

903

914

Figure 7-2 Three/four-pump melter frame assembly parts

Parts7-8


Reservoir/Manifold Assembly The reservoir/manifold assembly parts vary depending on the size of themelter: one/two-pump, three/four-pump, or 100L. Refer to the correct partslist for your melter.

One/Two-Pump Melter Reservoir/Manifold Parts See Figure 7-3.

Item Part Description Quantity Note— - - - - - - - Assembly, manifold/reservoir, one/two pump —

101 - - - - - - - � Base 1102 - - - - - - - � Manifold assembly 1 A103 - - - - - - - � Spacer, manifold to base 4104 - - - - - - - � Plate, insulator, manifold 1105 - - - - - - - � Support, hydraulics 2106 - - - - - - - � Washer, lock, split, M8 24107 - - - - - - - � Washer, flat, narrow, M8 24108 - - - - - - - � Screw, socket, M8 x 45 4109 - - - - - - - � Screw, socket, M8 x 25 20110 - - - - - - - � Nut, hex, M8 16111 7400293 � Castor, swivel, 100 mm, 130 kg 2112 7400294 � Castor, swivel, with lock, 100 mm, 130 kg 2113 256800 � O-ring, 26 x 2 2114 7400132 � O-ring, Viton, 45 x 2 2115 - - - - - - - � Reservoir, machined 1116 - - - - - - - � Screw, socket, M8 x 90 6117 - - - - - - - � Spring washer, 16 mm OD 6118 7400339 � Plug, M16, O-ring, Viton 4119 7400297 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X

13.75 (all melter manifolds)3

120 7400569 � SERVICE KIT, HEATER, 240V, 400W, 1/2 X13.75 (one/two pump melter reservoirs)

3

121 - - - - - - - � Washer, flat, oversize, M6, 22 OD 12122 - - - - - - - � Washer, lock, split, M6 12123 - - - - - - - � Screw, pan, recessed, M6 x 10 12124 - - - - - - - � Screw, pan, recessed, M3 x 8 2125 - - - - - - - � Lock washer, external, M3 2126 7401366 � THERMOSWITCH, ALTABLUE 1127 - - - - - - - � Deflector, adhesive 1128 1058990 � Cordstock, 3 mm OD, Viton, 75 D 1129 900298 � Compound, heat sink, 5 oz tube 1130 900344 � Lubricant, Never Seez, 8 oz can 1131 900223 � Lubricant, O-ring, Parker, 4 oz 1132 900413 � Sealant, RTV, red, 2.8 oz. tube 1

NOTE A: Refer to Manifold Parts.

Parts 7-9


126, 129

120, 129

128, 132

123, 130102

123, 130

119, 129

115

116, 117, 130

121

122

121

122

127

114, 131

113, 131

108, 106, 107, 130

107

106

110

109

109, 106, 107, 130

112

111

101

103

105

104

125

124

Figure 7-3 One/two-pump melter reservoir/manifold assembly parts (30L, 2 SS assembly shown)

Parts7-10


Three/Four-Pump Melter Reservoir/Manifold Parts See Figure 7-4.

Item Part Description Quantity Note— - - - - - - - Assembly, manifold/reservoir, three/four pump —

101 - - - - - - - � Base 1102 - - - - - - - � Manifold assembly 2 A103 - - - - - - - � Spacer, manifold/base 8104 - - - - - - - � Plate, insulator, manifold 2105 - - - - - - - � Support, manifold 1106 - - - - - - - � Washer, lock, split, M8 12107 - - - - - - - � Washer, flat, narrow, M8 12108 - - - - - - - � Screw,socket, M8 x 45 8109 - - - - - - - � Screw,socket, M8 x 25 4110 - - - - - - - � Screw, socket, M10 x 25 16111 7400478 � Castor, swivel, 100 mm, 280 kg 2112 7400479 � Castor, swivel, with lock, 100 mm, 280 kg 2113 256800 � O-ring, 26 x 2 4114 7400132 � O-ring, Viton, 45 x 2 4115 - - - - - - - � Reservoir, machined 1116 - - - - - - - � Screw, socket, M8 x 100 12117 - - - - - - - � Spring washer, 16 mm OD 12119 7400297 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X


120 7400874 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X27.5 (three/four pump melter and 100L melterreservoirs)

3

121 - - - - - - - � Washer, flat, oversize, M6, 22 OD 18123 - - - - - - - � Screw, pan, recessed, M6 x 10 18124 - - - - - - - � Screw, pan, recessed, M3 x 8 2125 - - - - - - - � Lock washer, external, M3 2126 7401366 � THERMOSWITCH, ALTABLUE 1127 - - - - - - - � Plate deflector 2128 1058990 � Cordstock, 3 mm OD, Viton, 75 D 2.4129 900298 � Compound, heat sink, 5 oz tube 1130 900344 � Lubricant, Never Seez, 8 oz can 1131 900223 � Lubricant, O-ring, Parker, 4 oz 1132 900413 � Sealant, RTV, red, 2.8 oz. tube 1133 - - - - - - - � Washer, lock, split, M10 16134 - - - - - - - � Washer, flat, M10 16136 - - - - - - - � Tag, pump number 2137 - - - - - - - � Rivet, pop, 1/8 x 0.187 16


Parts 7-11


127

128, 132

120, 129

121

123, 130

126, 129

125

124

119, 129

121

123, 130

104

103

112

110

133

134

111

101

106, 107, 108, 130

105

106, 107, 109, 130

102

123, 130

121

113, 131

114, 131

116, 117, 129

136, 137

115

Figure 7-4 Three/four-pump melter reservoir/manifold assembly parts (50/100L, 2SS/2SS assembly shown)

Parts7-12


100L Melter Reservoir/Manifold Parts See Figure 7-5.

Item Part Description Quantity Note— - - - - - - - Assembly, manifold/reservoir, 100L —

101 - - - - - - - � Base 1102 - - - - - - - � Manifold assembly 1 A103 - - - - - - - � Spacer, manifold/base 8104 - - - - - - - � Plate, insulator, manifold 2105 - - - - - - - � Support, manifold 1106 - - - - - - - � Washer, lock, split, M8 12107 - - - - - - - � Washer, flat, narrow, M8 12108 - - - - - - - � Screw,socket, M8 x 45 8109 - - - - - - - � Screw,socket, M8 x 25 4110 - - - - - - - � Screw, socket, M10 x 25 16111 7400478 � Castor, swivel, 100 mm, 280 kg 2112 7400479 � Castor, swivel, with lock, 100 mm, 280 kg 2113 256800 � O-ring, 26 x 2 4−8114 7400132 � O-ring, Viton, 45 x 2 4115 - - - - - - - � Reservoir, machined 1116 - - - - - - - � Screw, socket, M8 x 100 12117 - - - - - - - � Spring washer, 16 mm OD 12119 7400297 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X


120 7400874 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X27.5 (three/four pump melter and 100L melterreservoirs)

6

121 - - - - - - - � Washer, flat, oversize, M6, 22 OD 18123 - - - - - - - � Screw, pan, recessed, M6 x 10 18124 - - - - - - - � Screw, pan, recessed, M3 x 8 2125 - - - - - - - � Lock washer, external, M3 2126 7401366 � THERMOSWITCH, ALTABLUE 1127 - - - - - - - � Plate deflector 1128 1058990 � Cordstock, 3 mm OD, Viton, 75 D 2.5129 900298 � Compound, heat sink, 5 oz tube 1130 900344 � Lubricant, Never Seez, 8 oz can 1131 900223 � Lubricant, O-ring, Parker, 4 oz 1132 900413 � Sealant, RTV, red, 2.8 oz. tube 1133 - - - - - - - � Washer, lock, split, M10 16134 - - - - - - - � Washer, flat, M10 16135 - - - - - - - � Manifold assembly, 2 SS 1 A136 - - - - - - - � Tag, pump number 2137 - - - - - - - � Rivet, pop, 1/8 x 0.187 16


Parts 7-13


104

106, 107, 108, 130

106, 107, 109, 130

133, 134, 110112

114, 131

111

116, 117, 129

115

129, 117, 116

129, 117, 138

119, 129

120, 129

109, 107, 106

130, 123, 121

127

129, 126

125, 124

132, 128

136, 137

139, 140, 141

142

103

102

101

143, 107, 106

130, 123, 121

135

113, 131

118, 130

144, 130

105

Figure 7-5 100L melter reservoir/manifold assembly parts (2 DS/2 SS assembly shown)

Parts7-14


Manifold Parts See Figures 7-6 through 7-8.

Item Part Description Quantity Note— - - - - - - - Assembly, manifold/reservoir —

1

7400057 � MANIFOLD, 2 DUAL STREAM, DURA 17400058 � MANIFOLD, 1 SINGLE STREAM, DURA 17400059 � MANIFOLD, 2 SINGLE STREAM, DURA 1

2 313742 � O-RING 12X2 VITON B 1,2 or 4

3

7400408 � PLATE, DRAIN, 2DS 17400410 � PLATE, DRAIN, 1SS 17400409 � PLATE, DRAIN, 2SS 1

4 982031 � SCR,SKT,M6X25,BL 105 983409 � WASHER,LK,M,SPT,M6,STL,ZN 106 983410 � WASHER,FLT,M,NARROW,M6,STL,ZN 107 973480 � PLUG, O RING,STD THD,M14X1.5 88 7400339 � PLUG,M16 ,O-RING,VITON 6 or 89 7400340 � PLUG,M22,O-RING,VITON 3 or 610 7400341 � ADAPTER,M22 TO M16,O-RING PORT 2 or 411 7400355 � ORING,VITON,FOR M22 O-RING PLUG 2 or 412 900223 � LUBRICANT,O RING,PARKER,4 OZ,30122-5 0.0213 900344 � LUBRICANT,NEVER SEEZ,8OZ CAN 0.01

Parts 7-15


12

01

03

05

06

08

02 12

APPLY 0.5−0.7 Nm TORQUE

1208

12

04 13

07 12

08

APPLY 35−40 Nm TORQUE


Figure 7-6 Manifold assembly parts—one single-stream pump

Parts7-16


Manifold Parts (contd)

1208

04 13

07 12

06


08

05

03

1211

09 12

01

09 12

02 12

10 12 APPLY 35−40 Nm TORQUE

APPLY 0.5−0.7 nm TORQUE





Figure 7-7 Manifold assembly parts—two single-stream pumps

Parts 7-17


13

07 12

08 12

01

08

05

06

03

12

1208

1211

09 12

1209

09 12

02 12

10

04

APPLY 55−60 Nm TORQU

APPLY 0.5−0.7 Nm TORQ








Figure 7-8 Manifold assembly parts—one or two dual-stream pumps

Parts7-18


Hopper Assembly The hopper assembly parts vary depending on the size of the melter:one/two-pump, three/four-pump, or 100L. Refer to the correct parts list foryour melter.

One/Two-Pump Melter Hopper Parts See Figure 7-9.

Item Part Description Quantity Note— - - - - - - - Assembly, hopper, one/two pump —

201 - - - - - - - � Hopper/grid, machined 1202 - - - - - - - � Washer, flat, narrow, M6 20203 - - - - - - - � Washer, lock split, M6 40204 - - - - - - - � Screw, socket, M6 x 25 20

2057400135 � Gasket, hopper, 30L/50L, one/two pump 17400134 � Gasket, hopper, 15L, one/two pump 1

206 - - - - - - - � Screw, pan, recessed, M3 x 8 2207 - - - - - - - � Lock washer, external, M3 2208 7401366 � THERMOSWITCH, ALTABLUE 1

2097400298 � SERVICE KIT, HEATER, 240V, 800W, 1/2 X

11.65 (one/two pump melter 30/50L hopper)4 or 8

7400876 � SERVICE KIT, HEATER, 240V, 500W, 1/2 X6.38 (two-pump hopper) 4

210 - - - - - - - � Washer, flat, oversize, M6, 22 OD 8211 - - - - - - - � Screw, socket, M6 x 10 8212 - - - - - - - � Frame, tank, paint 2213 - - - - - - - � Washer, flat, regular, M6 12214 - - - - - - - � Nut, hex, M6 12215 - - - - - - - � Washer, flat, regular, M8 4216 - - - - - - - � Washer, lock, split, M8 4217 - - - - - - - � Nut, hex, M8 4218 - - - - - - - � Panel, rear, hydraulic 1219 - - - - - - - � Panel, front, hydraulic 1220 - - - - - - - � Bracket, heater terminal 1221 - - - - - - - � Screw, flat, socket, M4 x 12 2222 - - - - - - - � Heater, terminal block assembly 1223 - - - - - - - � Washer, flat, regular, M5 6224 - - - - - - - � Washer, lock split, M5 6225 - - - - - - - � Nut, hex, M5 2226 - - - - - - - � Panel, top, hydraulic 1227 - - - - - - - � Lid, outer 1228 - - - - - - - � Lid, inner 1229 - - - - - - - � Screw, pan, slotted, M3 x 6 8230 - - - - - - - � Washer, lock, split, M3 8231 - - - - - - - � Washer, flat, regular, M3 8232 7400047 � Hinge, lid 2233 - - - - - - - � Screw, flat, recessed, M5 x 12 8234 - - - - - - - � Screw, button, socket, M5 x 10 12235 779664 � Handle, lid 1

Continued...

Parts 7-19


NoteQuantityDescriptionPartItem236 - - - - - - - � Screw, pan, M5 x 16 2237 900298 � Compound, heat sink, 5 oz tube 1238 900413 � Sealant, RTV, red, 2.8 oz. tube 1239 - - - - - - - � Rivet, pop, 1/8 x 0.187 2240 224905 � Tag, warning, hot 1241 - - - - - - - � Nut, hex, jam, M5 4242 931074 � Tape, insulation 75243 - - - - - - - � Insulation, foil backed, 600W x 1200L x 25 mm 1244 - - - - - - - � Marker, SAKD 2.5 N 1245 - - - - - - - � Sleeving, insulation, 0.500 ID 1

SEE DETAIL ’A’

202, 203, 204 205, 238

221 220223, 224, 225 222

237, 209

201

239, 240

234

237, 208

236 235

223, 224, 241

233

232

229, 230, 231

228

227

226

219

218

215, 216, 217

213, 203, 214

212

203, 211, 210 206, 207

Figure 7-9 One/two-pump melter hopper assembly parts (30L hopper without hose return shown)

Parts7-20


Three/Four-Pump Melter Hopper Parts See Figure 7-10.

Item Part Description Quantity Note— - - - - - - - Assembly, hopper, three/four pump —

201 - - - - - - - � Hopper, machined 1202 - - - - - - - � Washer, flat, narrow, M6 30203 - - - - - - - � Washer, lock, split, M6 66204 - - - - - - - � Screw, socket, M6 x 25 30205 7400326 � Gasket, hopper, three/four pump, 50L 1NS 7400327 � Gasket, hopper, three/four pump, 30L 1206 - - - - - - - � Screw, pan, recessed, M3 x 8 2207 - - - - - - - � Lock washer, external, M3 2208 7401366 � THERMOSWITCH, ALTABLUE 1209 7400875 � SERVICE KIT, HEATER, 240V, 750W, 1/2 x

11.85 (50L hopper)9

NS 7400876 � SERVICE KIT, HEATER, 240V, 500W, 1/2 X6.38 (30L hopper)

9

210 - - - - - - - � Washer, flat, oversize, M6, 22 OD 18211 - - - - - - - � Screw, socket, M6 x 10 18212 - - - - - - - � Frame, tank, paint 2213 - - - - - - - � Washer, flat, regular, M6 18214 - - - - - - - � Nut, hex, M6 12215 - - - - - - - � Washer, flat, regular, M8 4216 - - - - - - - � Washer, lock, split, M8 4217 - - - - - - - � Screw, socket, M8 x 20 4218 - - - - - - - � Panel, rear, hydraulic 1219 - - - - - - - � Panel, front, hydraulic 1220 - - - - - - - � Bracket, heater terminal 2221 - - - - - - - � Screw, flat, socket, M4 x 12 4222 - - - - - - - � Heater, terminal block, left 1223 - - - - - - - � Washer, flat, regular, M5 8224 - - - - - - - � Washer, lock, split, M5 8225 - - - - - - - � Nut, hex, M5 4226 - - - - - - - � Panel, top, hydraulic 1227 - - - - - - - � Lid, outer 1228 - - - - - - - � Lid, inner 1229 - - - - - - - � Screw, pan, split, M3 x 6 8230 - - - - - - - � Washer, lock, split, M3 8231 - - - - - - - � Washer, flat, regular, M3 8232 7400047 � Hinge, lid 2233 - - - - - - - � Screw, flat, recessed, M5 x 12 8234 - - - - - - - � Screw, button,socket, M5 x 10 12235 779664 � Handle, lid 1236 - - - - - - - � Screw, pan, M5 x 16 2237 900298 � Compound, heat sink,5 oz tube 1238 900413 � Sealant, RTV, red, 2.8 oz tube 1239 - - - - - - - � Rivet, pop, 1/8 x 0.187 2240 224905 � Tag, warning, hot 1241 - - - - - - - � Nut, hex, jam, M5 4242 931074 � Tape, insulation 200

Continued...

Parts 7-21


NoteQuantityDescriptionPartItem243 - - - - - - - � Insulation, foil backed, 600W x 1200 L x 25 mm 1245 - - - - - - - � Sleeving, insulation, 0.500 ID 1246 7400540 � O-ring, Viton, 51.5 x 2.65 1247 - - - - - - - � Plate, machined, hose return 1248 - - - - - - - � Screw, socket, M6 x 20 6249 7400337 � Fitting, hose,45deg, M16x9/16-18, O-ring, Viton 1250 - - - - - - - � Heater, terminal block assembly, 400V,

three/four-pump, WYE1

NS: Not Shown

201

204, 203, 202

206, 207208, 237

209, 237 210, 203, 211

212

213, 203, 214

215, 216, 217

218

219

220221 222225, 224, 223

226

227

228

229, 230, 231

232

233

234

235236

240, 239

241, 224, 223

246 247

213, 203, 248

238, 205

249

250

Figure 7-10 Three/four-pump melter hopper assembly parts (50L hopper with hose return shown)

Parts7-22


100L Melter Hopper Parts See Figure 7-11.

Item Part Description Quantity Note— - - - - - - - Assembly, hopper, 100L —

201 - - - - - - - � Hopper, machined 1202 - - - - - - - � Washer, flat, narrow, M6 38203 - - - - - - - � Washer, lock, split, M6 74204 - - - - - - - � Screw, socket, M6 x 25 38205 7400901 � Gasket, hopper, 100L 1206 - - - - - - - � Screw, pan, recessed, M3 x 8 2207 - - - - - - - � Lock washer, external, M3 2208 7401366 � THERMOSWITCH, ALTABLUE 1209 7401316 � Heater, 240V, 1000W, 0.50 D x 22.75 long 9210 - - - - - - - � Washer, flat, oversize, M6, 22 OD 18211 - - - - - - - � Screw, socket, M6 x 10 18212 - - - - - - - � Frame, tank, paint 2213 - - - - - - - � Washer, flat, regular, M6 18214 - - - - - - - � Nut, hex, M6 12215 - - - - - - - � Washer, flat, regular, M8 4216 - - - - - - - � Washer, lock, split, M8 4217 - - - - - - - � Screw, socket, M8 x 20 4218 - - - - - - - � Panel, rear, hydraulic 1219 - - - - - - - � Panel, front, hydraulic 1220 - - - - - - - � Bracket, heater terminal 2221 - - - - - - - � Screw, flat, socket, M4 x 12 4222 - - - - - - - � Heater, terminal block, left 1223 - - - - - - - � Washer, flat, regular, M5 8224 - - - - - - - � Washer, lock, split, M5 8225 - - - - - - - � Nut, hex, M5 4226 - - - - - - - � Panel, top, hydraulic 1227 - - - - - - - � Lid, outer 1228 - - - - - - - � Lid, inner 1229 - - - - - - - � Screw, pan, split, M3 x 6 8230 - - - - - - - � Washer, lock, split, M3 8231 - - - - - - - � Washer, flat, regular, M3 8232 7400047 � Hinge, lid 2233 - - - - - - - � Screw, flat, recessed, M5 x 12 8235 779664 � Handle, lid 1236 - - - - - - - � Screw, pan, M5 x 16 2237 900298 � Compound, heat sink,5 oz tube 1238 900413 � Sealant, RTV, red, 2.8 oz tube 1239 - - - - - - - � Rivet, pop, 1/8 x 0.187 2240 224905 � Tag, warning, hot 1241 - - - - - - - � Nut, hex, jam, M5 4242 931074 � Tape, insulation 260243 - - - - - - - � Insulation, foil backed, 600W x 1200 L x 25 mm 1245 - - - - - - - � Sleeving, insulation, 0.500 ID 1246 7400540 � O-ring, Viton, 51.5 x 2.65 1247 - - - - - - - � Plate, machined, hose return 1

Continued...

Parts 7-23


NoteQuantityDescriptionPartItem248 - - - - - - - � Screw, socket, M6 x 20 6249 7400337 � Fitting, hose,45 degree, M16 x 9/16-18, O-ring,

Viton1

250 - - - - - - - � Heater, terminal block, right 1

212

221

218 220 222 214, 213, 209

252, 253, 254

236239 240

255

223, 224, 241227235 232

241224

233 228 229, 230, 231226

205, 238

250

246

201

249 203, 213, 248

219247208, 206,252,251203,

202, 203, 204

209,

223, 224, 225215, 216, 217

256

210.211

253,254

237 207237

Figure 7-11 100L melter hopper assembly parts (100L hopper with hose return shown)

Parts7-24


Pump Assemblies The pump assembly parts vary depending on the type of pump:single-stream or dual-stream. Refer to the correct parts lists for your melter.

Pump Module Parts See Figure 7-12.

Item Part Description Quantity Note— - - - - - - Assembly, pump module —

301 256800 � O-ring, 26 x 2 1 302 250269 � O-ring, 35 x 2 1

303- - - - - - � Adapter assembly, single-stream, with shutoff 1 A- - - - - - � Adapter assembly, dual-stream, with shutoff 1 B

304 - - - - - - � Spring washer,16 mm OD 4305 - - - - - - � Screw, socket, M8 x 110 4

306- - - - - - � Gear pump, single-stream 1 C- - - - - - � Gear pump, dual-stream 1 D

308 900344 � Lubricant, Never Seez, 8 oz can 1 309 900223 � Lubricant, O-ring, Parker, 4 oz 1

NOTE A: Refer to Single-Stream Pump Adapter Parts.

B: Refer to Dual-Stream Pump Adapter Parts.

C: Refer to Single-Stream Gear Pumps for pump part numbers.

D: Refer to Dual-Stream Gear Pumps for pump part numbers.

NS: Not Shown

Parts 7-25


THIS V IEW SHOW S THE SINGLE STREAM PUMP

THIS V IEW SHOW S THE DUAL STREAM PUMP

309, 302

303304 309, 302

309, 301

TIGHTEN SCREWS20 TO 25 N−M306, 307, 308 305, 308 304 303

309, 301

306, 307, 308 305, 308

TIGHTEN SCREWS20 TO 25 N−M

THIS VIEW SHOWS THE BLANK

308, 305304303

302, 309

309, 301

Figure 7-12 Pump module parts

Parts7-26


Single-Stream Pump Adapter Parts See Figure 7-13.

Item Part Description Quantity Note— - - - - - - Adapter assembly, single-stream, with shut off —01 - - - - - - � Adapter, pump, single-stream 102 - - - - - - � Valve, rotary 103 - - - - - - � Plate, stop 104 - - - - - - � Screw, socket, M5 x 12 405 - - - - - - � Washer, flat, narrow, M5 406 - - - - - - � Washer, lock, split, M5 407 207932 � Valve, safety 1 A08 973480 � Plug, O-ring, straight-thread, M14 x 1.5 409 900223 � Lubricant, O-ring, Parker, 4 oz 110 900341 � Lubricant, Never-Seez, 16 oz can 112 250267 � O-ring, 32 x 2 113 985022 � Pin, dowel, M6 x 20 long, hose and gun 1

NOTE A: Refer to Safety Valve Parts.

08 10

1007

10040605

01

1209

08 10

03

13

02

Figure 7-13 Single-stream pump adapter parts

Parts 7-27


Dual-Stream Pump Adapter Parts See Figure 7-14.

Item Part Description Quantity Note— - - - - - - - Adapter assembly, dual-stream, with shut off —01 - - - - - - - � Adapter, pump, dual-stream 102 - - - - - - - � Valve, rotary 103 - - - - - - - � Plate, stop 104 - - - - - - - � Screw, socket, M5 x 12 405 - - - - - - - � Washer, flat, narrow, M5 406 - - - - - - - � Washer, lock, split, M5 407 207932 � Valve, safety 2 A08 973480 � Plug, O-ring, straight-thread, M14 x 1.5 509 900223 � Lubricant, O-ring, Parker, 4 oz 110 900341 � Lubricant, Never-Seez, 16 oz can 111 973459 � Plug, O-ring, straight-thread, M22 x 1.5 112 250267 � O-ring, 32 x 2 113 985022 � Pin, dowel, M6 x 20 long, hose and gun 1

NOTE A: Refer to Safety Valve Parts.

01

02

03

05 06 04

13

09 12

11 10

0810

10

07 10

08 10

08 10

0810

Figure 7-14 Dual-stream pump adapter parts

Parts7-28


Single-Stream Gear Pumps See Figure 7-15.

Item Gland SealPart

VarisealPart

Description Quantity Note

— 259598 7109715 Gear pump SN0030 (0.30 cc/rev) 1








— 253992 7131840 Gear pump SH0773, hardened (7.73 cc/rev) 1

— 259600 7130225 Gear pump SH0371, hardened (3.71 cc/rev) 1

— 394589 Refer toTable 7-1

SERVICE KIT for gland seal pump sizes SN0030 to SN0773

1

— - - - - - — � O-ring 10 x 1.5, PTFE 1

— - - - - - — � Sealing paste, Stucarit 203, 100 ml 1

— - - - - - — � High-temp. grease, GLS 595/N2, 10 g 1


SERVICE KIT for gland seal pump size SN1710

1

— - - - - - — � O-ring 15 x 1.5 1



Table 7-1 Variseal Pump Service Kits (Except SN1710)

Item Part Description Quantity NoteNS 7136920 SEALING KIT,PUMP F.SHAFT D12,7

(pump seal service kit)—

NS - - - - - - � O-RING 22X3 VITON 70 SHORE A BLACK 2NS - - - - - - � RING ID 12,7 1NS - - - - - - � TURCON-ROTO-VARISEAL D12,7 INSIDE SEAL 1NS - - - - - - � ALLEN HEAD CAP SCREW M5X16 DIN912 A2-70 3NS - - - - - - � HIGH-TEMP.GREASE GLS 595/N2 CAN:10G 1NS 7146229 � IN-ASSEMBLY TOOLS 7136915, 7136918,EN/GE 1 ANS 7136915 ASSY TOOL F.SHAFT SEALING D12,7

(assembly tool service kit)—

NS - - - - - - � ASSY MANDREL F.SHAFT SEALING D12,7 1NS - - - - - - � ASSY BUSHING F.SHAFT SEALING D12,7 1NS 7146229 � IN-ASSEMBLY TOOLS 7136915, 7136918,EN/GE 1 A

NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordsonrepresentative.

NS: Not Shown

Parts 7-29


Table 7-2 Variseal Pump SN1710 Service Kit

Item Part Description Quantity Note— 7136921 SEALING KIT, PUMP F.SHAFT D16

(pump seal service kit)—

NS - - - - - - � O-RING 28X3 VITON 70 SHORE A SCHWARZ 2NS - - - - - - � BUFFER RING ID 16 1NS - - - - - - � TURCON-ROTO-VARISEAL D16 INSIDE SEAL 1NS - - - - - - � ALLEN HEAD CAP SCREW M6X20 DIN912 SST 4NS - - - - - - � HIGH-TEMP.GREASE GLS 595/N2 CAN:10G 1— 7136918 ASSY TOOL F.SHAFT SEALING D16

(assembly tool service kit)— —

NS - - - - - - � ASSY MANDREL F.SHAFT SEALING D16 1NS - - - - - - � ASSY BUSHING F.SHAFT SEALING D16 1NS 7146229 � IN-ASSEMBLY TOOLS 7136915, 7136918,EN/GE 1 A

NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordsonrepresentative.

NS: Not Shown

Figure 7-15 Single-stream gland seal (left) and Variseal (right) gear pumps

Parts7-30


Dual-Stream Gear Pumps See Figure 7-16.

Item Gland SealPart

VarisealPart

Description Quantity Note

— 291995 7116580 Gear pump DN0030 (2 x 0.30 cc/rev) 1







SERVICE KIT for gland seal pump sizes DN0030 to DN0279

1

— - - - - - — � Seal, PU6/12, 94 x 80 x 0.8 2



Figure 7-16 Dual-stream gland seal gear pump

Parts 7-31


Safety Valve Parts See Figure 7-17.

Item Part Description Quantity Note— 207932 Valve, safety, 85 bar 1— 394592 SERVICE KIT 1

1 - - - - - � O-ring 11 x 2 12 - - - - - � O-ring 9 x 2 1— - - - - - � High-temp. grease, GLS 595/N2, 10g 1

1

2

Figure 7-17 Safety valve parts

Parts7-32


Control Valve Assemblies The control valve assemblies vary depending on the type of pressurecontrol valve: pressure control valve, pneumatic pressure control valve,circulation control valve, or blank. Refer to the correct parts lists for yourmelter.

Control Valve Module Parts See Figure 7-18.

Item Part Description Quantity Note— - - - - - - - Assembly, control valve module —

401 7104265 � Filter cartridge, MW0, complete 1 A401 - - - - - - - � Plug, filter 1

402

203059 � Valve, pressure control, adjustable, 90 bar 1 B207300 � Valve, pressure control, pneumatic 1 C1070961 � Valve, circulation control 1 D- - - - - - - � Plug, pressure control valve (blank) 1

403 - - - - - - - � Ball, 8 mm, stainless-steel 1 404 - - - - - - - � Screw, drain valve 1 405 - - - - - - - � Retaining ring, internal, 51, basic 1

NOTE A: Refer to Filter Cartridge Parts.

B: Refer to Pressure Control Valve Parts.

C: Refer to Pneumatic Pressure Control Valve Parts.

D: Refer to Circulation Control Valve Parts.

403

401402

404405

402 401

404

Figure 7-18 Pressure control module parts

Parts 7-33


Filter Cartridge Parts See Figure 7-19.

Item Part Description Quantity Note— 7104265 Filter cartridge, mesh Size 0.2 mm, complete 1— 394590 SERVICE KIT Filter 0.2 mm 1

— - - - - - � Filter sleeve Mesh Size 0,2 complete 1— - - - - - � � Filter sheath D40 1— - - - - - � � Filter sleeve MS 0,2 L104 1— - - - - - � � O-ring 31x1 1— - - - - - � � O-ring 44x3 1— - - - - - � � O-ring 48x2 1— - - - - - � High-temp. grease, GLS 595/N2, 10g 1

Figure 7-19 Filter cartridge parts

Parts7-34


Pressure Control Valve Parts See Figure 7-20.

Item Part Description Quantity Note— 203059 Valve, pressure control, adjustable, 90 bar 11 - - - - - Body, valve 12 - - - - - Piston, valve, supporting ring 13 - - - - - Set screw, black, 90 bar 14 - - - - - Compression spring, 2.2 x 7.4 x 34.4 15 - - - - - O-ring, 6 x 2 16 - - - - - O-ring, 11 x 2 17 - - - - - O-ring, 9 x 2 18 - - - - - Supporting ring, Da10, Di6.7, spiral 1— 394600 SERVICE KIT Pressure control valve 16 - - - - - � O-ring 11 x 2 17 - - - - - � O-ring 9 x 2 1— - - - - - � High-temp. grease, GLS 595/N2, 10 g 1

7

3

4

2

8

5

6

1

Figure 7-20 Pressure control valve parts

Parts 7-35


Pneumatic Pressure Control Valve Parts See Figure 7-21.

Item Part Description Quantity Note— 207300 Valve, pressure control, pneumatic —1 - - - - - � Piston, pressure control valve 1

2 - - - - - � Valve body, bypass 300 degree 1

3 - - - - - � Cylinder, bypass pneu., Di19.3 1

4 - - - - - � Valve body, bypass pneumatic, 6 bar (90 psi) 1

5 - - - - - � Piston, bypass pneu., Da19.3 1

6 - - - - - � Piston, bypass pneu., Da19.3 1

7 - - - - - � Seal, 19.7 x 0.6 1

8 - - - - - � O-ring, 11 x 2 1

9 - - - - - � O-ring, 9 x 2 1

10 - - - - -

- - - - -

� Fitting, quick thread-in, -W-d04-G1/8-TURN

� Fitting, quick thread-in, -W-d08-R1/8-TURN

1

1

11 - - - - - � Inside seal, Turcon-Variseal-M2S 1

— 394600 SERVICE KIT Pressure control valve 1

8 - - - - - � O-ring, 11 x 2 1

9 - - - - - � O-ring, 9 x 2 1

— - - - - - � High-temp. grease, GLS 595/N2, 10 g 1

9

6

7

5

1

118

2

4

3

10

Figure 7-21 Pneumatic pressure control valve parts

Parts7-36


See Figure 7-22.

Item Part Description Quantity Note1 207300 Valve, pressure control, pneumatic 1 2 - - - - - - - Hose, air-operated, D4, 0 D2, 5 PTFE 1.5 3 - - - - - - - Fitting, quick-thread, W-D04-G 1/8-turn 1 4 - - - - - - - Reducer 1 5 - - - - - - - Sealing ring, R1/4-type, PD 5 6 - - - - - - - T-piece 1 7 - - - - - - - Nipple, double 1 8 - - - - - - - Bulkhead connection, iG1/4 1 9 - - - - - - - Street el, G1/4 x RP1/4 1 10 279615 Bypass valve 1 11 — Item no. not used — 12 - - - - - - - Sign, max 6.0 1 13 — Item no. not used — 14 - - - - - - - Air coupling, male, AG1/4 L3 1 15 - - - - - - - Air coupling, female, D6 NE7.2 L60 1 16 - - - - - - - Hose, air-operated, D8.0, D6.0 PU blue 2 17 - - - - - - - Fitting, straight 1 18 - - - - - - - Grease, high-temperature, GLS 595/N2, can 1

14 5 1218

1 2

3 184 1817 16 56781859 101815

ITEM 10 MUST BE VERTICAL

THIS VALVE CONNECT TO MAINFOLD

Figure 7-22 Pneumatic pressure control valve interface parts

Parts 7-37


Circulation Control Valve Parts See Figure 7-23.

Item Part Description Quantity Note— 1070961 Valve, circulation control 11 - - - - - Body, circulation valve 12 - - - - - Spool, circulation valve 13 - - - - - Nut, hex, M12 14 - - - - - O-ring, 9 x 2 15 - - - - - O-ring, 11 x 2 16 - - - - - O-ring, Viton, 0.239 ID x 0.070 W 17 - - - - - Screw, set, cup, M4 x 4, stainless-steel 1— 394600 SERVICE KIT Circulation control valve 14 - - - - - � O-ring 9 x 2 15 - - - - - � O-ring 11 x 2 1— - - - - - � High-temp. grease, GLS 595/N2, 10g 1

1 2

3

4

5

5

7

Figure 7-23 Circulation control valve parts

Parts7-38


Motor Assembly See Figure 7-24.

Item Part Description Quantity Note— - - - - - - Assembly, motor, standard —

501 7402299 � COUPLING, M24, DAN/NORMAL 17402293 � COUPLING, M24, DAN/SN1710 (SN1710

pumps only)1

502 7402295 � SERVICE KIT,MOTOR,BG06-31/D06LA4TOF 1503 - - - - - - � Plate, mount, motor 1504 - - - - - - � Washer, flat, regular, M8 8505 - - - - - - � Washer, lock, split, M8 8506 - - - - - - � Screw, socket, M8 x 25 3507 - - - - - - � Nut, hex, M8 3NS - - - - - - � Cable assembly, motor 1NS - - - - - - � Harness, internal 1

NS: Not Shown

504505506

503 502

508504 505 507

INSTALLATION GAP IS 4mm

Figure 7-24 Motor assembly parts (four-pump melter shown)

Parts 7-39



Parts7-40


Electrical Enclosure Panel Assemblies The electrical enclosure panel assembly parts vary depending on the size ofthe melter: one/two-pump, three/four-pump, or 100L. Refer to the correctparts lists for your melter.

One/Two-Pump Melter Left Panel Parts See Figure 7-25.

Item Part Description Quantity Note— - - - - - - - Assembly, electrical, panel, left, one/two-pump —1 - - - - - - - � PANEL,LEFT,INNER,ELECT CAB,4D 13 - - - - - - - � WIREWAY,45X65X330,ALTABLUE 14 - - - - - - - � WIREWAY,25X65X180,ALTABLUE 15 - - - - - - - � WIREWAY,25X65X260,ALTABLUE 26 - - - - - - - � WASHER,FLT,M,REG,M3,ZINC PLATE 117 - - - - - - - � WASHER,LK,M,SPT,M3,STL,ZN 118 - - - - - - - � NUT,ACORN,M3,STL,ZN 1110 - - - - - - - � DIN RIAL, 280 LG 211 - - - - - - - � WASHER,FLT,M,REG,5,STL,ZN 812 - - - - - - - � WASHER,LK,M,SPT,M5,STL,ZN 813 - - - - - - - � NUT,HEX,M5,STL,ZN 814 202794 � MAIN SWITCH (400V MELTER) 1

7400378 � MAIN SWITCH (240V MELTER) 115 7401321 � SERVICE KIT,FILTER,FAN,ELECT.CAB 116 7400483 � MAIN CONTACTOR 40A 220V DIN MTG 1

7400762 � MAIN CONTACTOR 80A (240V MELTERS) 117 7400482 � R-C NOISE 240V SUPPRESS 118 254244 � CIRCUIT BREAKER 50A (400V MELTERS) 1

7104855 � CIRCUIT BREAKER 90A (240V MELTERS) 119 1032329 � BLOCK, DISTR, 250A, 600V 420 779662 � END STOP,TERMINAL BLOCK 921 7400369 � LOCKOUT SWITCH 63A 3POLE 600V 1 A23 - - - - - - - � PANEL,LEFT,OUTSIDE,ELECT CAB,W/LK 124 - - - - - - - � SPACER SLEEVE, ALTABLUE 525 - - - - - - - � Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 526 - - - - - - - � NUT,HEX,M6,STL,ZN 527 - - - - - - - � MARKER, WIRE, PUSH ON, 16−22AWG 3628 - - - - - - - � MARKER, WIRE, PUSH ON, 10−16AWG 3533 - - - - - - - � PANEL,COVER,FILTER 1

NOTE A: Present only on melters with the optional lockout switch.

Parts 7-41


19

14

21

10

18

20

20

20

11 12 13

16

01

23

04

05

242526

03

15

33

11 12 13

17

06 07 08

−XL7−XL6−XL5

−1K71−1Z71

−1Q31

−1Q22

−1Q21

−XL8

Figure 7-25 One/two-pump melter left panel assembly parts (400V melter shown)

Parts7-42


Three/Four-Pump and 100L Melter Left Panel Parts See Figure 7-26.

Item Part Description Quantity Note— - - - - - - - Assembly, electrical, panel, left, three/four-pump,

100L, six hose/gun—

01 - - - - - - - � Panel, left, inner, electrical cabinet 103 - - - - - - - � Wireway, 50 x 50 x 330 104 - - - - - - - � Wireway, 25 x 50 x 180 105 - - - - - - - � Wireway, 25 x 50 x 257 206 - - - - - - - � Washer, flat, M3 1107 - - - - - - - � Washer, lock, M3 1108 - - - - - - - � Nut, acorn, M3 1110 - - - - - - - � DIN rail, 35 x 7.5 x 250 111 - - - - - - - � Washer, flat, M5 212 - - - - - - - � Washer, lock, M5 213 - - - - - - - � Nut, hex, M5 214 7400378 � Main switch, 100 A, 3-pole 115 7401321 � SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 1

16

7400483 � Main contactor, 40 A (400V three/four pump sixhose/gun melters)

1

7400762� Main contactor, 80 A (240V three/four pump six

hose/gun melters, 400V three/four pump eighthose/gun melters, and 400V 100L melters)

1

7400319 � Main contactor, 95 A (240V three/four pumpeight hose/gun melters and 240V 100L melters)

1

17 7400482 � RC suppressor, 110−250 VAC 1

187400380 � Main breaker, 70 A (400V three/four pump six

hose/gun melters)1

7104855 � Main breaker, 90 A (400V three/four pumpeight hose/gun melters and 100L melters)

1

19 - - - - - - - � Block, distribution, 250 A, 600V 420 - - - - - - - � End stop, terminal 521 7400369 � Switch, lockout (240V melters) 1 A23 - - - - - - - � Panel, left, outer, electrical cabinet 124 - - - - - - - � Washer, flat, regular, M6 925 - - - - - - - � Washer, lock, split, M6 926 - - - - - - - � Nut, hex, M6 527 - - - - - - - � Marker, wire, push on, 16−22 AWG 3628 - - - - - - - � Maker, wire, push on, 10−16 AWG 2931 - - - - - - - � Screw, pan, recessed, M4 x 16 4

NOTE A: Present only on melters with the optional lockout switch.

Parts 7-43


−XL3

01

−XL3

02

−XL3

02

01

03

04

05

06 07 08

10

11 12 13

14

15

16

17

18

2526

−1K71

−1Z71

−1Q31

−XL5 −XL6 −XL7

21−1Q22

24 25 31

−1Q21

29 30

19

20

23

24

−XL3

00

SEE DETAIL ’B’

222

3

11

2

4

11

24

1

13

2

DETIAL ’A’

DETIAL ’B’

SEE DETIAL ’A’

Figure 7-26 Three/four-pump and 100L melter left panel assembly parts (240V melter shown)

Parts7-44


One/Two-Pump Melter Back Panel Parts See Figure 7-27.

Item Part Description Quantity Note— — ASSEMBLY, ELECTRICAL ENCLOSURE, BACK

PANEL, ONE/TWO PUMP—

1 - - - - - - � PANEL,BACK,INNER,ELECT CAB, 2D 101A 171856 � � SHUNT,0.1 IN.,2-POSITION 2 A

2 - - - - - - � WIREWAY,50 X 50 X 500,ALTA 23 - - - - - - � WIREWAY,25 X 50 X 290,ALTA 34 - - - - - - � WASHER,FLT,M,REG,M3,ZINC PLATE 175 - - - - - - � WASHER,LK,M,SPT,M3,STL,ZN 176 - - - - - - � NUT,ACORN,M3,STL,ZN 177 - - - - - - � RAIL,DIN,290 LG 28 - - - - - - � WASHER,FLT,M,REG,5,STL,ZN 69 - - - - - - � WASHER,LK,M,SPT,M5,STL,ZN 610 - - - - - - � NUT,HEX,M5,STL,ZN 611 1078624 � SVCE KIT,DURABLUE,MAIN,PCA 112 - - - - - - � SCR,PAN,REC,M4X10,ZN 413 - - - - - - � WASHER,LK,M,EXT,M4,STL,ZN 414 1031201 � SVCE KIT, DURABLUE, EXPANSION PCA 115 - - - - - - � SCR,PAN,REC,M3X8,ZN 716 - - - - - - � LOCKWSHRM,EXT,M3,STL,ZN 717 227569 � JUMPER,3/N/PE AC,400−230V 1

227568 � JUMPER,3/PE AC,200−240V 118 - - - - - - � TBCONN, 7POS, MCVR, LBL1−7, KEYED 119 - - - - - - � TBCONN, ASSY, 7POS, MCVR, LBL8−14,

KEYED1

20 7400071 � CIRCUIT BREAKER, 32A (400V melters) 27400320 � CIRCUIT BREAKER, 32A (240V melters) 2

21 7400072 � CIRCUIT BREAKER,13A,1 POLE(400V melters)

4

7400321 � CIRCUIT BREAKER,13A,2-POLE(240V melters)

4

22 251364 � CIRCUIT BREAKER 16A 1-POLE(400V melters)

1

7400322 � CIRCUIT BREAKER 16A 2-POLE(240V melters)

1

23 256141 � CIRCUIT BREAKER, 16A 3-POLE 124 256227 � CIRCUIT BREAKER 2A,1-POLE

(400V melters)1

7400323 � CIRCUIT BREAKER 2A,2-POLE(240V melters)

1

25 - - - - - - � TERMINAL BLOCK ZTR 2.5-2 1926 - - - - - - � TERMINAL BLOCK, END PLATE ZAP/TW7 627 - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/2 328 - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/3 129 - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/5 235 - - - - - - � END STOP,TERMINAL BLOCK 436 7400318 � SERVICE KIT,MOTOR CONTROL,ALTA BLUE 1 or 238 7140101 � INTERFERENCE FILTER 230VAC/2X6A B 139 - - - - - - � WASHER,FLT,M,NARROW,M4,STL,ZN 2

Continued...

Parts 7-45


NoteQuantityDescriptionPartItem40 - - - - - - � WASHER,LK,M,SPT,M4,STL,ZN 241 - - - - - - � NUT,HEX,M4,STL,ZN 244 - - - - - - � MARKER, WIRE, PUSH ON, 16−22AWG 15045 - - - - - - � MARKER, WIRE, PUSH ON, 10−16AWG 5046 - - - - - - � SCR,PAN,SLT,M4X12MM LG 247 - - - - - - � SPACER SLEEVE, ALTABLUE 448 - - - - - - � Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 449 - - - - - - � NUT,HEX,M6,STL,ZN 450 - - - - - - � PANEL,BACK,OUTER,ELECT CAB, 2D 151 933320 � CONNECTOR,PLUG,3 CIRCUIT 1 or 252 939327 � SOCKET,ELECT.CONN,GND 1 or 253 939697 � CONNECTOR,SOCKET,16−18AWG,GOLD 2 or 454 933321 � CONNECTOR, RECEPTACLE 1 or 255 939326 � PIN,ELECT.CONN,GND 1 or 256 939696 � CONNECTOR,PIN,16−18AWG,GOLD 2 or 4

NOTE A: See Figure 7-28 for the location of this part on the main board.

Parts7-46


One/Two-Pump Melter Back Panel Parts (contd)

20 22 35

21 23 35

14

07

07

0504 06

03

09 1008

02

15 16

17

02

18

36

1119

−4Q41

50

−4Q11 −9Q21

−9Q51

−10Q21

−1Q32

−11Q31

−10Q51

−XL11

−1Q31

−XL12

−XL1

5

−XL1

4

−XL1

3

−11V31

−12A31−11A31

4947 48

−XL9

11

39 40

01

13

38

41

12

100908

35

SEE DETAIL ”B”

SEE DETAIL ”C”

16

A

DETAIL ”B”

32

A

32

A

13

A

13

A

13

A

13

A

16

A

H10.754.51R%NR%F%N1,A,B,C,D,E,F,G,H,J,K,L,M,N1,A,B,C,D,E,F,G,H,J%N0.52.02.0A11−10WIRESWIRENOWIRECOPY1.01.0WIREFIXEDTERMSDESCXREFTAGSLOCPOS0XREFCHILDDESCCHILDMISC11LINKSYMS%N01TAGFIXEDWIREREF1_MULTI_WIRELOCBOX10.1250.090.12510.3750.2510.1250.3750.125%Np8_10.3750.1250.0000.000PSYMSPTAGPITEMPDESCPMFGPCATPLOCPMNTPGRPPTERMPWIREPRTGPMISCPBALPNPGPNPTPNPD0PASSY1.00.00.00.01.00

2A

16

A

16

A

35282929

27

DETAIL ”C”

2735

26

25

3212121121 234554321

RUNGHORVREFNUMSRUNGDISLADWWINCWIREMODEWIREFMTTAGMODETAGFMTWIRE−STARTWIRE−RSUFTAG−STARTTAG−RSUFXREFFMTPH3SPACEDATUMXDATUMYDISTHDISTVCHAR_HCHAR_VHORIZ_FIRSTSHEETXY_DELIMRUNGINCDRWRUNGWIRELAYSWIRENO_LAYWIRECOPY_LAYUNIT_SCLFEATURE_SCLWIREFIXED_LAYTERM_LAYDESC_LAYXREF_LAYTAG_LAYLOC_LAYPOS_LAYWLEADERSCXREF_LAYCDESC_LAYMISC_LAYPLC_STYLEARROW_STYLELINK_LAYCOMP_LAYSHEETDWGNAMEALT_XREFFMTMISC_FLAGSGAP_STYLETAGFIXED_LAYIEC_LOCIEC_INSTIEC_PROJWIREREF_LAYMISC_DATAFAN_INOUT_STYLEFAN_INOUT_LAYSLOCBOX_LAYITEM_NUMBALL_TSZBALL_TGAPBALL_ATYPBALL_ASZBALL_TYPEBALL_CDIABALL_EGAPBALL_EFITBALL_EVTBALL_EHZBALL_CFITBALL_CGAPITEM_FMTBALL_PSHPBALL_PDIABALL_PFITBALL_PGAPPX_SPCPY_SPCPCOMP_LAYSPTAG_LAYPITEM_LAYPDESC_LAYPMFG_LAYPCAT_LAYPLOC_LAYPMNT_LAYPGRP_LAYPTERM_LAYPWIRE_LAYPRTG_LAYPMISC_LAYPBAL_LAYPNPG_LAYPNPT_LAYPNPD_LAYPLAY_FLGPASSY_LAYUNIT_SCLWCON_OFFSET_XWCON_OFFSET_YWCON_OFFSET_ZATTRSCALEPMISC_FLAGSWDLEV

Figure 7-27 One/two-pump melter back panel assembly parts (400V melter shown)

Parts 7-47


1A

R108

R7

R65

C55

R92

C6

C66

C32

C74

R127

R88

R72

R9

R61

R14

R11 DS5

R82

R49

D10

R79

R12

R102

R69

R90

DS16

R130

R87

RV

13

RN3

R103

R53

R47

Q5

Q12

R78

R59

+ C82

Q24

R129

R73

C80

C22

RV 5

RN

9

C79

R56

C69

R100

C84

R34

C8

C3

RV

7C

4

RV

12

C72

RV

11C

10 C23

C25

C26

R115

R112

Q7

Q9

C28

C29

R67

R66

R71

R117

L4

R58

R52

R36

R33

C53

RV 6C1

R80

R136

R133D8

R134 R135U5

C7 RN10

R106

R51

R57

Q14

R39R42

R83R37

R74

U12

R44R45C77

R38

R4R3

Q26

Q17

R99Q18

R121 R101

R8

R118

Q25

R6DS3

C47

DS4

L3

R96

C43

C44

R70

Q23

R93 R5

R55

Q8

R16

R10DS7

D12

C54

R84

R85

Q22

R17

R109

Q10

DS6

R76

R122

R131

D11

R132

Q13

1J2

R86

RV

10

R26

XP5

+C58

R111

R123 U26

C51

L2

U4

+C12

RN5

R89

XP6

C31RN6RN4

DS13

R104

R54

R48

DS8

DS12

R35

R60

R64

DS10

DS11

R116

R94

Q16

R40 R41C39

U23

D5

R2

R43R46

C2

R128R1

+

C40

R75

R119

R120

C37

C18

RN

1

C15

RN

11

C17

R95

Q20

Q19

C21 C20R15

RN

2

C19

R77

R113

1

X2

C70 C71

R62

1

X3

D3

R50

C46

C83

C68 C73

R97

R124

U21

C48 C49

RV

9

C61

XP

2

R110

R98

C36

C24

C9

C5

U3

U25

DS15

+C

35

DS14

DS9

C27

C30

C75

U2

+

C16

DS17

R13

C67

C62RV 1

R68

RV 3

C76

C11

R91D4

RN

7

C60

R81 R20

Q15

DS2

XT1

C42

C41

RV 8

C50

D17

R19

R107

U20

U10

U19

U15

U18

U9

1XP3

RV 2

X7

D1

D6

RV 4

1XP4

C65

D2

D7

D14

U1

U17

U14

JP2

C63

R22

R63

U16

C56

D16

R18

51

26JP1

1 33

J1

1

X1

C52

C64

C45

L1

R114

R105

U24

U13

3

12

1

X5

U7

T1

HSNK1

C78

+

C59

X6

XP

1

D18

+

C57

3

12

1

X4

K1

++

U22

F3

F4

F6 F5

F1F2

F11

F12

F7

F8 F10F95A

10A

6.3A

2A

2A

5A

10A

6.3A

6.3A

6.3A 6.3A6.3A

+

Q6 Q11

Figure 7-28 Location of the shunt on the main board

Parts7-48


Three/Four-Pump and 100L Six Hose/Gun Melter Back Panel Parts See Figure 7-29.

Item Part Description Quantity Note— — ASSEMBLY, ELECTRICAL ENCLOSURE, BACK

PANEL, THREE/FOUR PUMP, 100L, SIXHOSE/GUN

—

1 - - - - - - � PANEL,BACK,INNER,ELECT CAB,4D 101A 171856 � � SHUNT,0.1 IN.,2-POSITION 2 A

2 - - - - - - � WIREWAY,45X65X590,ALTABLUE 23 - - - - - - � WIREWAY,25X65X690,ALTABLUE 44 - - - - - - � WASHER,FLT,M,REG,M3,ZINC PLATE 24 45 - - - - - - � WASHER,LK,M,SPT,M3,STL,ZN 24 46 - - - - - - � NUT,ACORN,M3,STL,ZN 24 47 - - - - - - � RAIL,DIN,35X7.5X690,ALTABLUE 28 - - - - - - � WASHER,FLT,M,REG,5,STL,ZN 49 - - - - - - � WASHER,LK,M,SPT,M5,STL,ZN 410 - - - - - - � NUT,HEX,M5,STL,ZN 411 1078624 � SVCE KIT,DURABLUE,MAIN,PCA 112 - - - - - - � SCR,PAN,REC,M4X10,ZN 413 - - - - - - � WASHER,LK,M,EXT,M4,STL,ZN 414 1031201 � SVCE KIT, DURABLUE, EXPANSION PCA 115 - - - - - - � SCR,PAN,REC,M3X8,ZN 716 - - - - - - � LOCKWSHRM,EXT,M3,STL,ZN 717 227569 � JUMPER,3/N/PE AC,400−230V 1

227568 � JUMPER,3/PE AC,200−240V 118 - - - - - - � TBCONN, 7POS, MCVR, LBL1−7, KEYED 119 - - - - - - � TBCONN, ASSY, 7POS, MCVR, LBL8−14,

KEYED1

20 7400071 � CIRCUIT BREAKER, 32A (400V melters) 27400320 � CIRCUIT BREAKER, 32A (240V melters) 2


7


7


2


2


(400V melters)1


1

25 - - - - - - � TERMINAL BLOCK ZTR 2.5-2 62 or 6826 - - - - - - � TERMINAL BLOCK, END PLATE ZAP/TW7 827 - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/2 10 or 1128 - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/3 129 - - - - - - � TERMINAL CONNECTOR ZQV2,5/10 234 - - - - - - � CLIP,RELAY 135 - - - - - - � END STOP,TERMINAL BLOCK 1036 7400318 � SERVICE KIT,MOTOR CONTROL,ALTA BLUE 3 or 4

Continued...

Parts 7-49


NoteQuantityDescriptionPartItem38 7140101 � INTERFERENCE FILTER 230VAC/2X6A B 239 - - - - - - � WASHER,FLT,M,NARROW,M4,STL,ZN 240 - - - - - - � WASHER,LK,M,SPT,M4,STL,ZN 241 - - - - - - � NUT,HEX,M4,STL,ZN 244 - - - - - - � MARKER, WIRE, PUSH ON, 16−22AWG 20045 - - - - - - � MARKER, WIRE, PUSH ON, 10−16AWG 8046 - - - - - - � TERMINAL BLOCK,GRAY,IEC,22−10 AWG,J4 1047 - - - - - - � End barrier, AB, 1492-EBJ3 148 1053122 � MODULE, CONDITIONER, SIGNAL, 0−10V,

1K OHM1

49 1049720 � BOARD, BREAKOUT, DURABLUE, EXPAND,TB, 20POS

1

50 171234 � RELAY,OMRON,24VDC,4PDT 151 172857 � SOCKET,OMRON,4PDT,DIN,TOUCHPRF 153 - - - - - - � PANEL,BACK,OUTER,ELECT CAB,4D 154 - - - - - - � SPACER SLEEVE, ALTABLUE 455 - - - - - - � Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 456 - - - - - - � NUT,HEX,M6,STL,ZN 457 - - - - - - � SCR,PAN,SLT,M4X12MM LG 258 - - - - - - � MARKER, SAKD 2.5 N, 4 PUMP 159 933320 � CONNECTOR,PLUG,3 CIRCUIT 3 or 460 939327 � SOCKET,ELECT.CONN,GND 3 or 461 939697 � CONNECTOR,SOCKET,16−18AWG,GOLD 6 or 862 933321 � CONNECTOR, RECEPTACLE 3 or 463 939326 � PIN,ELECT.CONN,GND 3 or 464 939696 � CONNECTOR,PIN,16−18AWG,GOLD 6 or 8


Parts7-50


Three/Four-Pump and 100L Six Hose/Gun Melter Back Panel Parts (contd)

−13V31

−12A31−11A31

0908

−14A31

10

39 40 41

06

35 21 22 2123

24

20 49

2535 25 2646

47 27 29

5150 34

−XL1

4

27

28

29

−XL9

11

26 26 4825

−XM

03

02

01

08

07

05 04

14

09

11

10

1715 16 12 131918

36 54

53

38 5655

−11V31

−13A31

SEE DETAIL ’A’ DETAIL ”A”

SEE DETAIL ’B’

SEE DETAIL ’C’

DETAIL ”C”

DETAIL ”B”

−11Q31−4Q11 −10Q21−9Q21

−4Q41 −10Q51−9Q51

16

A

13

A

13

A

13

A

13

A

13

A

13

A

16A

16A

16A

−1Q11

2A

32A

32A

13A

−3X11−1Q32 −16Q21 −16Q61

−XL4

−XL3

−XL2

−XL1

XL4

00

XL3XL2XL1

007

X45

6

X45

−XL166

−XL1

65

X166

00

XL165

−XL164

XL1 64

0

−XL1

63

0

XL1 63XL162XL1 61

00

−XL162

−XL1

61

10

XM

9

XM

1

XM

2

XM

3

XM

4

XM

5

XM

6

XM

7

XM

8

XM

−X45

5

X45

4

X45

3

X45

2

X45

1

X45 XL11

1

XL11

2

XL11

3

XL11

4

XL11

5

XL12

1

XL12

2

XL12

3

XL12

4

XL12

5

−XL12

XL13

1

XL13

2

XL14

1

XL14

2

XL15

1

XL15

3

XL15

2

−XL13 −XL15

XL911

2

XL911

1

−1K31

XL11

10

XL11

9

XL11

8

XL11

7

XL11

6

XL12

10

XL12

9

XL12

8

XL12

7

XL12

6

34

0

11

9112 11

1

5678

4

−XL11

−16Q41−11A11

Figure 7-29 Three/four-pump and 100L six hose/gun melter back panel assembly parts (400V melter shown)

Parts 7-51



Parts7-52


Three/Four-Pump and 100L Eight Hose/Gun Melter Back Panel Parts See Figure 7-30.

Item Part Description Quantity Note— - - - - - - - ASSEMBLY, ELECTRICAL ENCLOSURE, BACK

PANEL,THREE/FOUR PUMP, 100L, EIGHTHOSE/GUN

—

1 - - - - - - - � PANEL,BACK,INNER,ELECT CAB,4D 101A 171856 � � SHUNT,0.1 IN.,2-POSITION 2 A

2 - - - - - - - � WIREWAY,45X65X590,ALTABLUE 23 - - - - - - - � WIREWAY,25X65X690,ALTABLUE 44 - - - - - - - � WASHER,FLT,M,REG,M3,ZINC PLATE 245 - - - - - - - � WASHER,LK,M,SPT,M3,STL,ZN 246 - - - - - - - � NUT,ACORN,M3,STL,ZN 247 - - - - - - - � RAIL,DIN,35X7.5X690,ALTABLUE 28 - - - - - - - � WASHER,FLT,M,REG,5,STL,ZN 109 - - - - - - - � WASHER,LK,M,SPT,M5,STL,ZN 1010 - - - - - - - � NUT,HEX,M5,STL,ZN 1011 1078624 � SVCE KIT,DURABLUE,MAIN,PCA 112 - - - - - - - � SCR,PAN,REC,M4X10,ZN 413 - - - - - - - � WASHER,LK,M,EXT,M4,STL,ZN 414 1031201 � SVCE KIT, DURABLUE, EXPANSION PCA 115 - - - - - - - � SCR,PAN,REC,M3X8,ZN 716 - - - - - - - � LOCKWSHRM,EXT,M3,STL,ZN 717 227569 � JUMPER,3/N/PE AC,400−230V 1

227568 � JUMPER,3/PE AC,200−240V 118 - - - - - - - � TBCONN, 7POS, MCVR, LBL1−7, KEYED 119 - - - - - - - � TBCONN, ASSY, 7POS, MCVR, LBL8-14,

KEYED1


11


11


2


2


(400V melters)1


1

25 - - - - - - - � TERMINAL BLOCK ZTR 2.5-2 62 or 6826 - - - - - - - � TERMINAL BLOCK, END PLATE ZAP/TW7 827 - - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/2 10 or 1128 - - - - - - - � TERMINAL CONNECTOR ZQV 2, 5/3 129 - - - - - - - � TERMINAL CONNECTOR ZQV2,5/10 230 - - - - - - - � BOARD,ASSY,8 H/G EXP. BASE,PB II 134 - - - - - - - � CLIP,RELAY 135 - - - - - - - � END STOP,TERMINAL BLOCK 1236 7400318 � SERVICE KIT,MOTOR CONTROL,ALTA BLUE 3 or 438 7140101 � INTERFERENCE FILTER 230VAC/2X6A B 2

Continued...

Parts 7-53


NoteQuantityDescriptionPartItem39 - - - - - - - � WASHER,FLT,M,NARROW,M4,STL,ZN 240 - - - - - - - � WASHER,LK,M,SPT,M4,STL,ZN 241 - - - - - - - � NUT,HEX,M4,STL,ZN 244 - - - - - - - � MARKER, WIRE, PUSH ON, 16−22AWG 20045 - - - - - - - � MARKER, WIRE, PUSH ON, 10−16AWG 8046 - - - - - - - � TERMINAL BLOCK,GRAY,IEC,22−10 AWG,J4 1047 - - - - - - - � End barrier, AB, 1492-EBJ3 148 1053122 � MODULE, CONDITIONER, SIGNAL, 0−10V,

1K OHM1

49 1049720 � BOARD, BREAKOUT, DURABLUE, EXPAND,TB, 20POS

2

50 171234 � RELAY,OMRON,24VDC,4PDT 151 172857 � SOCKET,OMRON,4PDT,DIN,TOUCHPRF 153 - - - - - - - � PANEL,BACK,OUTER,ELECT CAB,4D 154 - - - - - - - � SPACER SLEEVE, ALTABLUE 455 - - - - - - - � Lock Washer,External Tooth,, 6,Zi, 36M.3.1.A 456 - - - - - - - � NUT,HEX,M6,STL,ZN 457 - - - - - - - � SCR,PAN,SLT,M4X12MM LG 258 - - - - - - - � MARKER, SAKD 2.5 N, 4 PUMP 159 - - - - - - - � RAIL,DIN 35mm, 7.5mm 0.160 933320 � CONNECTOR,PLUG,3 CIRCUIT 3 or 461 939327 � SOCKET,ELECT.CONN,GND 3 or 462 939697 � CONNECTOR,SOCKET,16−18AWG,GOLD 6 or 863 933321 � CONNECTOR, RECEPTACLE 3 or 464 939326 � PIN,ELECT.CONN,GND 3 or 465 939696 � CONNECTOR,PIN,16−18AWG,GOLD 6 or 8


Parts7-54


Three/Four-Pump and 100L Eight Hose/Gun Melter Back Panel Parts (contd)

2535 46 25 345150

47

29

29 28

26 26

−XL9

11

−XL1

4

2725

2721 21 2121 2321 24222035 21

48

−XL11

12 13

−XM

19 11171815 14160910 08

53

01

3049

03

08

59

35

SEE DETAIL ’B’

10 09

04

07

02

SEE DETAIL ’C’

0506

38 36 55 56

SEE DETAIL ’A’

5408 09 10

39 40 41

26

−13V31

DETAIL ”C”

−XL4

−XL3

−XL2

−XL1

XL4

00

XL3XL2XL1

007

X45

6

X45

−XL166

−XL1

65

X166

00

XL165

−XL164

XL1 64

0

−XL1

63

0

XL1 63XL162XL1 61

00

−XL162

−XL1

61

10

XM

9

XM

1

XM

2

XM

3

XM

4

XM

5

XM

6

XM

7

XM

8

XM

−X45

5

X45

4

X45

3

X45

2

X45

1

X45 XL11

1

XL11

2

XL11

3

XL11

4

XL11

5

XL12

1

XL12

2

XL12

3

XL12

4

XL12

5

−XL12

XL13

1

XL13

2

XL14

1

XL14

2

XL15

1

XL15

3

XL15

2

−XL13 −XL15

XL911

2

XL911

1

−1K31

XL11

10

XL11

9

XL11

8

XL11

7

XL11

6

XL12

10

XL12

9

XL12

8

XL12

7

XL12

6

34

0

11

9112 11

1

5678

4

−16Q41

32A

32A

−16Q21

−18Q51

−18Q21

−10Q51−4Q41

−4Q31

13A

−11Q31

−17Q51

−1Q32

−9Q51

−17Q21−10Q51

−1Q11

16A

13A

13A

2A13A

13A

13A

13A

13A

13A

13A

13A

−4Q21

−9Q21

16A

16A

16A

−11A11

DETAIL ’A’

DETAIL ’B’

−13A31

−7A21

−3X11 −3X51

−3A21−2A21

−11V31

−11A31 −12A31 −14A31

Figure 7-30 Three/four-pump and 100L eight hose/gun melter back panel assembly parts (400V melter shown)

Parts 7-55



Parts7-56


One/Two-Pump Melter Right Panel Parts See Figure 7-31.

Item Part Description Quantity Note— - - - - - - - Assembly, electrical enclosure, right panel,

one/two pump—

01 - - - - - - - � Panel, right, electrical cabinet 102 - - - - - - - � Wireway, 50 x 50 x 500 203 - - - - - - - � Wireway, 25 x 50 x 250 404 - - - - - - - � Washer, flat, regular, M3 2005 - - - - - - - � Washer, lock, split, M3 2006 - - - - - - - � Nut, acorn, M3 2007 - - - - - - - � Rail, DIN, 250 long 308 - - - - - - - � Washer, flat, regular, M5 609 - - - - - - - � Washer, lock, split, M5 610 - - - - - - - � Nut, hex, M5 611 1031175 � SVCE KIT, DURABLUE, 2H TO 4H

CONVERSION1

12 - - - - - - - � Screw, pan, slotted, M4 x 10 413 - - - - - - - � Washer, lock, external, M4 414 1053122 � Module, conditioner, signal, 0−10 V, 1k ohm 115 1049720 � Board, breakout, expand, terminal block,

20-position1

16 - - - - - - - � Terminal block, ZTR 2.5-2 2117 - - - - - - - � Terminal connector, ZQV 2 5/2 418 - - - - - - - � Terminal block, end plate 219 779392 � Socket,relay mount 120 777604 � Relay, 24 VDC, DPDT 121 - - - - - - - � Clip, relay 122 159684 � Power supply, 24 VDC, 0.6 A, 15 W 123 207396 � Solid-state relay, 100−260 VAC, 15 A,

DC trigger5

24 7400070 � Solid state relay, 100−260 VAC, 35 A,DC trigger

2

25 - - - - - - - � End stop,terminal block 926 7401320 � SERVICE KIT, FAN, 240VAC, 170 CFM 127 7401321 � SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 128 - - - - - - - � Screw, socket, cap, M4 x 45 229 - - - - - - - � Terminal, block, jumper, 10-position 431 - - - - - - - � Label, wiring 132 - - - - - - - � Marker, SAKD 2.5N 133 - - - - - - - � Marker, wire, push on, 16−22 AWG 22034 - - - - - - - � Maker, wire, push on, 10−16 AWG 16

Parts 7-57


1.0

12345 543212 1121212 3

4XDETAIL ”A”

DETAIL ”B”

DETAIL ”C”

431 1

129

85

41

S82K−01524

123

L

V. ADJ

IN P U T MADE IN JAPAN

N

EPOW ER SUPPLY

DV

−V

DC ON

4

OMRON

V+

56

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD G3PB−235−VD

OMRON

G3PB−235−VD

OMRONOMRON

G3PB−215−VD

H10.754.51R%NR%F%N1,A,B,C,D,E,F,G,H,J,K,L,M,N1,A,B,C,D,E,F,G,H,J%N0.52.02.0A11−10WIRESWIRENOWIRECOPY1.01.0WIREFIXEDTERMSDESCXREFTAGSLOCPOS0XREFCHILDDESCCHILDMISC11LINKSYMS%N01TAGFIXEDWIREREF1_MULTI_WIRELOCBOX10.1250.090.12510.3750.2510.1250.3750.125%Np8_10.3750.1250.0000.000PSYMSPTAGPITEMPDESCPMFGPCATPLOCPMNTPGRPPTERMPWIREPRTGPMISCPBALPNPGPNPTPNPD0PASSY1.00.00.00.00

SEE DETAIL ’C’

SEE DETAIL ’B’

SEE DETAIL ’A’

0111

26

12 13

293007

03

23

21

−4N21−4N41

−9N21−10N21

−1M51

−X45

27

1817

1615

−10N51−9N51−1N61

−XL911−XL14−XL12

−1G21−1K31−XL15−XL13−XL11

−XM

−3X11−11A11

−7A21

28

08 09 10

04 05 06

17

18

25

25

25

2219 20

24

14

16

02

Figure 7-31 One/two-pump melter right panel assembly parts

Parts7-58


Three/Four-Pump and 100L Six Hose/Gun Melter Right Panel Parts See Figure 7-32.


three/four pump, 100L, six hose/gun—

01 - - - - - - - � Panel, right, inner, electrical cabinet 102 - - - - - - - � Wireway, 25 x 50 x 337 103 - - - - - - - � Wireway, 25 x 50 x 291 304 - - - - - - - � Washer, flat, M3 1205 - - - - - - - � Washer, lock, M3 1206 - - - - - - - � Nut, acorn, M3 1207 - - - - - - - � Rail, DIN, 35 x 7.5 x 220 208 - - - - - - - � Washer, flat, M5 409 - - - - - - - � Washer, lock, M5 410 - - - - - - - � Nut, hex, M5 411 1031175 � SVCE KIT, DURABLUE, 2H TO 4H

CONVERSION1

12 - - - - - - - � Screw, M4 x 10 413 - - - - - - - � Washer, lock, external, M4 414 159684 � Power supply, 24 VDC, 0.6 A, 15 W, TP 115 7400070 � Solid state relay, 100−260 VAC, 35 A,

DC trigger2

16 207396 � Solid state relay, 100−260 VAC,15 A,DC trigger

8 or 9

17 - - - - - - - � End stop, terminal 518 7401320 � SERVICE KIT, FAN, 240VAC, 170 CFM 119 7401321 � SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 120 - - - - - - - � Screw, M4 x 45 long 221 - - - - - - - � Washer, flat, narrow, M4 422 - - - - - - - � Panel, right, outer, electrical cabinet 123 - - - - - - - � Nut, hex, M6 424 - - - - - - - � Washer, flat, M6 425 - - - - - - - � Washer, lock, split, M6 426 - - - - - - - � Marker, wire, push on, 16−22 AWG 22027 - - - - - - - � Marker, wire, push on, 10−16 AWG 1628 - - - - - - - � Label, wiring 129 - - - - - - - � Cover, fuse, 5 x 20 mm 4

Parts 7-59


16

15

16

17

14

OMRON

G3PB−235−VD

OMRON

G3PB−235−VD

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

+

OUT P UT

24V D C − 0. 6A − 15W

100. . . 240V A C

Te le me c anique

V.Out

−−−

A B L 7C E M 24006

NL

NC −

22

G 3P B −215−V D

OMRON

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

11

03

01

−1M51

18

20

19

060504

07

100908

−16N21

−7A21

−1N61

−9N51

−16N41 −1G21

−9N21

−4N41−10N51

12

−16N61−4N21−10N21

2425 23

02

29

1321

−4N16

17

SEE DETAIL ’A’

SEE DETAIL ’B’

DETAIL ’B’

DETAIL ’A’

Figure 7-32 Three/four-pump and 100L six hose/gun melter right panel assembly parts

Parts7-60


Three/Four-Pump and 100L Eight Hose/Gun (400V) Melter Right PanelParts

See Figure 7-33.


three/four pump, 100L, eight hose/gun—

01 - - - - - - - � Panel, right, inner, electrical cabinet 102 - - - - - - - � Wireway, 25 x 50 x 337 103 - - - - - - - � Wireway, 25 x 50 x 291 304 - - - - - - - � Washer, flat, M3 1205 - - - - - - - � Washer, lock, M3 1206 - - - - - - - � Nut, acorn, M3 1207 - - - - - - - � Rail, DIN, 35 x 7.5 x 220 208 - - - - - - - � Washer, flat, M5 409 - - - - - - - � Washer, lock, M5 410 - - - - - - - � Nut, hex, M5 414 159684 � Power supply, 24 VDC, 0.6 A, 15 W, TP 115 7400070 � Solid state relay, 100−260 VAC, 35 A,

DC trigger2


12 or 13

17 - - - - - - - � End stop, terminal 518 7401320 � SERVICE KIT, FAN, 240VAC, 170 CFM 119 7401321 � SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 120 - - - - - - - � Screw, M4 x 45 long 222 - - - - - - - � Panel, right, outer, electrical cabinet 123 - - - - - - - � Nut, hex, M6 424 - - - - - - - � Washer, flat, M6 425 - - - - - - - � Washer, lock, split, M6 426 - - - - - - - � Marker, wire, push on, 16−22 AWG 22027 - - - - - - - � Marker, wire, push on, 10−16 AWG 1628 - - - - - - - � Label, wiring 1

Parts 7-61


−10N51 −4N71

16

1516

17

17 14

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

OMRON

G 3P B −235−V D

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

G 3P B −215−V D

OMRON

G 3P B −215−V D

OMRON

+

OUT P UT

24V D C − 0. 6A − 15W

100. . . 240V A C

Te le me c anique

V.Out

−−−

A B L 7C E M 24006

NL

NC −

OMRON

G3PB−235−VDG3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

01

22

03

−1M51

18

20

19

04

09

0605

08

−1N61

07

10

−16N41 −1G21

23

−16N21

24

02

25

−17N21

−4N21

−4N31

−18N51

−18N21

−17N51

−10N21

−9N51

−9N21 −4N51

2X

2X

SEE DETAIL ’B’

SEE DETAIL ’C’

DETAIL ’B’

DETAIL ’C’

Figure 7-33 Three/four-pump eight hose/gun (400V) melter right panel assembly parts

Parts7-62


Three/Four-Pump and 100L Eight Hose/Gun (240V) Melter Right PanelParts

See Figure 7-34.


three/four pump, 100L, eight hose/gun, 240V—

01 - - - - - - - � Panel, right, inner, electrical cabinet 102 - - - - - - - � Wireway, 25 x 50 x 337 103 - - - - - - - � Wireway, 25 x 50 x 291 304 - - - - - - - � Washer, flat, M3 1205 - - - - - - - � Washer, lock, M3 1206 - - - - - - - � Nut, acorn, M3 1207 - - - - - - - � Rail, DIN, 35 x 7.5 x 220 208 - - - - - - - � Washer, flat, M5 409 - - - - - - - � Washer, lock, M5 410 - - - - - - - � Nut, hex, M5 411 - - - - - - - � Rail, DIN, 35 mm x 7.5 mm 0.1112 7400320 � Circuit breaker, 32 A, 3-pole 213 7400321 � Circuit breaker, 13 A, 2-pole 114 159684 � Power supply, 24 VDC, 0.6 A, 15 W, TP 115 7400070 � Solid state relay, 100−260 VAC, 35 A,

DC trigger2


12 or 13

17 - - - - - - - � End stop, terminal 718 7401320 � SERVICE KIT, FAN, 240VAC, 170 CFM 119 7401321 � SERVICE KIT, FILTER, FAN, ELECT. CAB (2) 120 - - - - - - - � Screw, M4 x 45 long 222 - - - - - - - � Panel, right, outer, electrical cabinet 123 - - - - - - - � Nut, hex, M6 424 - - - - - - - � Washer, flat, M6 425 - - - - - - - � Washer, lock, split, M6 426 - - - - - - - � Marker, wire, push on, 16−22 AWG 22027 - - - - - - - � Marker, wire, push on, 10−16 AWG 1628 - - - - - - - � Label, wiring 1

Parts 7-63


1617

16 14

17 13

17

1212

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

G3PB−215−VD

OMRON

G 3P B −215−V D

OMRON

32A

13A

13A

32A

32A

32A

32A

13A

13A

32A

32A

32A

G3PB−215−VD

OMRON

+

OUT P UT

Te le me c anique

V.Out

−−−

A B L 7C E M 24006

NL

NC −

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

OMRON

G3PB−235−VD

G 3P B −215−V D

OMRON

G3PB−215−VD

OMRON

OMRON

G 3P B −235−V D

G 3P B −215−V D

OMRON

G 3P B −215−V D

OMRON

G 3P B −215−V D

OMRON

22

03

01

18

−1M51

19

20

08

060504

07

1009

−1N61 −16N21

−16Q21

−1G21

23

−16N41

02

25 24

−16Q41−4Q41

11

−4N21

−17N21

−4N31

−17N51 −18N51

−18N21 −10N21

−9N51

−9N21

−4N71

−4N51

−10N51

15

SEE DETAIL ’B’

SEE DETAIL ’C’

SEE DETAIL ’A’

DETAIL ’C’

DETAIL ’B’

DETAIL ’A’

Figure 7-34 Three/four-pump eight hose/gun (240V) melter right panel assembly parts

Parts7-64


One/Two-Pump Melter Bottom Panel Parts See Figure 7-35.

Item Part Description Quantity Note— - - - - - - - Assembly, electrical enclosure, bottom panel,

one/two pump—

01 - - - - - - - � Panel, bottom electrical cabinet 102 - - - - - - - � Rail, DIN, 210 long 103 - - - - - - - � Washer, flat, regular, M5 404 - - - - - - - � Washer, lock, split, M5 405 - - - - - - - � Nut, hex, M5 406 - - - - - - - � End stop,terminal block 207 - - - - - - - � Terminal block, ZDU 16 3 or 408 - - - - - - - � Grommet, rubber, 0.812 ID x 1.25 OD 209 - - - - - - - � Tag, ground 110 - - - - - - - � Terminal block, end plate, ZAP/TW ZDU16 111 - - - - - - - � Terminal block, ZPE 16 114 - - - - - - - � Terminal, 28 position, I/O 118 - - - - - - - � Wire, vinyl, 22 AWG, dark blue,105C, 600V 11019 - - - - - - - � Ferrule, wire, 22 AWG, insulated, white 5621 - - - - - - - � Marker, wire, push on, 16−22 AWG 168

PEL1

−XE−XI−XL0

22

23

09

03

04

05

14111008

01

09

07

L2 L3

Figure 7-35 One/two-pump melter bottom panel assembly parts

Parts 7-65


Three/Four-Pump and 100L Melter Bottom Panel Parts See Figure 7-36.

Item Part Description Quantity Note— - - - - - - - Assembly, electrical enclosure, bottom panel,

three/four pump, 100L—

01 - - - - - - - � Panel, bottom electrical cabinet 102 - - - - - - - � Grommet, rubber, ID32 504 - - - - - - - � Washer, flat, regular, M5 605 - - - - - - - � Washer, lock, split, M5 606 - - - - - - - � Nut, hex, M5 608 - - - - - - - � Terminal block, ZDU 16 3 or 410 - - - - - - - � Terminal block, ZPE 16 111 - - - - - - - � Terminal block, ZDK2,5/1.5 PE 412 - - - - - - - � Terminal block, end plate, ZAP/TWZDK2.5 113 - - - - - - - � Terminal block, 40-position, I/O 114 - - - - - - - � End stop,terminal block 415 - - - - - - - � Marker, wire, push on, 16−22 AWG 3616 - - - - - - - � Marker, wire, push on, 10−16 AWG 29

0405

DETAIL C

10

01

−XLO

−XL

09 13

−XE

−XE

14

02

08

061211

THIS PART ONLYUSED IN 30L/50L

15 ~20145~150

54

4

3

3

1

15 2

2

SEE DETAIL ”C”

L1 L2 L3 N PE

Figure 7-36 Three/four-pump and 100L melter bottom panel assembly parts (400V melter shown)

Parts7-66


Control Panel Assembly See Figure 7-37.

Item Part Description Quantity Note— - - - - - - - Assembly, control panel —01 � PANEL,CONTROL,2 MOTORS, 2D 102 1085183 � MEMBRANE PANEL MOTOR CONTROL,STD

ALTA2

03 1085104 � PCA, MOTOR,ALTABLUE 206 1025743 � MEMBRANE PANEL, W/KEYPAD, FINAL,

DURABLUE1

07 1017947 � SWITCH,ROCKER,SPST,250V,16A,GOLD 109 1029938 � CABLE ASSY, RIBBON, SERIAL PORT,

9-POS, DURA1

10 1028325 � KIT,SERVICE,CPU BOARD 111 - - - - - - - � THRDSPCRMM,MALE/FEM,SS,HEX,M3,8MM

LG14

12 - - - - - - - � WASHER,LK,M,INT,M3,STL,ZN 1413 - - - - - - - � CONNHDWE,SCREWLOCK,#4-40,D-SUB

CONNECTOR2

14 - - - - - - - � CAP,D-SHELL CONNECTOR,9 PIN,FEM 116 - - - - - - - � LATCH, QUARTER TURN, DURA PANEL 217 - - - - - - - � WASHER,FLT,M,REG,M3,ZINC PLATE 418 - - - - - - - � WASHER,LK,M,SPT,M3,STL,ZN 419 - - - - - - - � NUT,HEX,M3,STL,ZN 420 - - - - - - - � CLAMP,RIBBON CABLE 3NS - - - - - - - � MARKER, WIRE, PUSH ON, 16−22AWG 60

NS: Not Shown

Parts 7-67


01

19

07

13

14

06

11A61

17

11

12A61

10

12

09

20

16

03

11 12

18

02

REAR VIEWFRONT VIEW

Figure 7-37 Control panel assembly parts (four-pump melter shown)

Parts7-68


Sensor Assembly See Figure 7-38. The sensors on your melter may be one of two types:120-ohm nickel or 100-ohm platinum.

Item Part Description Quantity Note— - - - - - - - Assembly, sensors, with hose/gun channels —

801 - - - - - - - � 6 hose connector assembly, NI120,one/two-pump

1

NS - - - - - - - � 6 hose connector assembly, PT100,one/two-pump

1

NS - - - - - - - � 6 hose connector assembly, NI120,three/four-pump/100L

1

NS - - - - - - - � 6 hose connector assembly, PT100,three/four-pump/100L

1

NS - - - - - - - � 8 hose connector assembly, NI120,three/four-pump, 100L

1

NS - - - - - - - � 8 hose connector assembly, PT100,three/four-pump, 100L

1

802 7401367 � RTD assembly, reservoir, NI120 1NS 7400281 � RTD assembly, reservoir, PT100 1803 7401368 � RTD assembly, grid, NI120 1NS 7400280 � RTD assembly, grid, PT100 1804 - - - - - - - � Washer, flat, regular, M6 4805 - - - - - - - � Washer, lock, split, M6 4806 - - - - - - - � Nut, hex, M6 4807 - - - - - - - � Screw, button, socket, M6 x 12 1808 171856 � Shunt, 1 in., 2 position 2 A809 - - - - - - - � Panel, cover, manifold, three/four-pump 2NS - - - - - - - � Panel, cover, manifold, one/two-pump 2

NOTE A: This part is present only on PT100 melters. See Figure 7-28 for the location of this part on the main board.

NS: Not Shown

Parts 7-69


REF MAIN PCB BOARD

802 809

ITEM 808 SHUNT REQUIREDWITH PT100 SENSORS

JP1

801 807803

804, 805, 806 804, 805, 806

Figure 7-38 Sensor assembly parts (four-pump 100-ohm platinum melter shown)

Parts7-70


Low Level Assembly See Figure 7-39.

Item Part Description Quantity Note— 7400563 Low level indication, 15/30L, one/two pump —— 7401273 Low level indication, 50L, one/two pump —— 7401274 Low level indication, 30/50L, three/four pump —— 7401275 Low level indication, 100L —

1201 - - - - - - - � Wire harness, low level 11202 - - - - - - - � Low level assembly, 169 mm 1NS - - - - - - - � Cable tie, 4 in., 302 degrees F 5

NS: Not Shown

12021201

GASCKETROUTE WIRE FROM SWITCHASSEMBLY BETWEEN THEHOPPER GASKET AND TOP COVER.

Figure 7-39 Low level assembly parts

Parts 7-71


Optional Accessories To optimize the use of your system, Nordson Corporation recommendsthese optional accessories.

Expansion and Control Kits

Part Description Quantity1036607 Kit, I/O expansion card (digital)

1063740 Kit, analog I/O board

1053288 Kit, DeviceNet card

1053289 Kit, Ethernet card

1053300 Kit, PROFIBUS card

Pressure Indication

Part Description Note1030537 Kit, gauge, analog pressure, 1500 psi

Low Level Indication

Part Description Note7400563 Low level indication, 15/30L, one/two pump

7401273 Low level indication, 50L, one/two pump

7401274 Low level indication, 30/50L, three/four pump

7401275 Low level indication, 100L

NOTE: Refer to Low Level Assembly earlier in this section for a parts list and illustration.

Pneumatic Pressure Control Valve

Part Description Note1079939 Kit, pressure control valve, pneumatic

NOTE: Refer to Pneumatic Pressure Control Valve Parts earlier in this section for a parts list and illustration.

Parts7-72


Line-Speed Signal Generator To use the gear-to-line capability of the melter, you must install a device thatmeasures the speed of the production line. The default type of line-speedsignal input is 0−10 VDC, although other inputs can be accepted. NordsonCorporation offers the following 0−10 VDC generator.

Part Description Note119560 Generator, 0−10 VDC, with bracket and cable

Optional Fittings See Figure 7-40. These fittings can be used at the melter end of a hose.

Hose Size FittingPart Number Fitting Type Fitting Size,

Melter SideFitting Size,Hose Side

8-mm

7400333 Straight M16 x 1.5 9/16-18 JIC

7400337 45-degree M16 x 1.5 9/16-18 JIC

7400335 90-degree M16 x 1.5 9/16-18 JIC

12-mm

7401279 Straight M16 x 1.5 3/4-16 JIC

7401278 45-degree M16 x 1.5 3/4-16 JIC

7401277 90-degree M16 x 1.5 3/4-16 JIC

16-mm (see Note)

7400334 Straight M22 x 1.5 11/16 JIC

7400338 45-degree M22 x 1.5 11/16 JIC

7400336 90-degree M22 x 1.5 11/16 JIC

1 2 3

Figure 7-40 Typical non-swivel fittings

1. Straight fitting 2. 45-degree fitting 3. 90-degree fitting

Parts 7-73


Recommended Spare Parts

Table 7-3 Recommended Spare Parts

P/N DescriptionAll Melters

7402299 COUPLING, M24, DAN/NORMAL (except for melters with pump SN1710)7402293 COUPLING, M24, DAN/SN1710 (melters with pump SN1710 only)7400298 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 11.65 (one/two pump melter 30/50L

hopper)

7400876 SERVICE KIT, HEATER, 240V, 500W, 1/2 X6.38 (one/two pump melter 15L hoppersand three/four pump melter 30L hoppers)

7400875 SERVICE KIT, HEATER, 240V, 750W, 1/2 x11.85 (three/four pump melter 50L hoppers)7401316 SERVICE KIT HEATER, 240V, 1000W, 1/2X22.75 (100L melter hoppers)7400297 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 13.75 (all melter manifolds)7400569 SERVICE KIT, HEATER, 240V, 400W, 1/2 X 13.75 (one/two pump melter reservoirs)7400874 SERVICE KIT, HEATER, 240V, 800W, 1/2 X 27.5 (three/four pump melter and 100L

melter reservoirs)

7401366 THERMOSWITCH ASSY, ALTABLUE777604 RELAY, 24VDC, DPDT779392 SOCKET, RELAY MOUNT7401321 SERVICE KIT, FILTER, FAN, ELECT.CAB7401320 SERVICE KIT, FAN, 240VAC, 170 CFM7400318 SERVICE KIT, MOTOR CONTROL, ALTABLUE7140101 INTERFERENCE FILTER 230VAC/2X6A B1078624 SVCE KIT, DURABLUE, MAIN, PCA1031201 SVCE KIT, DURABLUE, EXPANSION PCA1031175 SVCE KIT, DURABLUE, 2H TO 4H CONVERSION1028325 KIT, SERVICE, CPU BOARD207396 SOLID-STATE RELAY, 100−260VAC, 15A, DC TRIGGER7400070 SOLID STATE RELAY, 100−260VAC, 35A, DC TRIGGER203059 SAFETY VALVE 100 BAR TKZU ADJUSTABLE207300 SAFETY VALVE 90 BAR PNEU.1070961 VALVE, CIRCULATION CONTROL, ALTABLUE207932 Safety valve, 85 bar, VB/DB7400299 SERVICE KIT, O-RING, VITON, 45 X 27400300 SERVICE KIT, O-RING, VITON, 26 X 21058990 CORDSTOCK, 3 MM OD, VITON, 75D7400134 GASKET, HOPPER, 15L (one/two pump melters)7400135 GASKET, HOPPER, 30/50L, ALTA7400326 GASKET, 50L, HOPPER, 4D7400327 GASKET, 30L, HOPPER, 4D7400901 GASKET, HOPPER, 100L7402295 SERVICE KIT, MOTOR, BG06-31/D06LA4TOF

Pumps394589 SERVICE KIT, PUMP O-RING, SINGLE-STREAM, PUMP SIZE SN0030−SN0773394596 SERVICE KIT, PUMP O-RING, SINGLE-STREAM, PUMP SIZE SN17107104645 SERVICE KIT, PUMP O-RING, DUAL-STREAM

Continued...

Parts7-74


Recommended Spare Parts (contd)

Table 7-3 Recommended Spare Parts (contd)

P/N DescriptionSelect Based on Specific Melter Configuration

One/Two-Pump Melters, 240 VAC7400762 Main contactor, 600V/50hz/60hz, 3-pole, 80 A7104855 Circuit breaker, 90 A, 3-pole7400320 Circuit breaker, 32 A, 2-pole7400321 Circuit breaker, 13 A, 2-pole7400322 Circuit breaker, 16 A, 2-pole, inductive load7400323 Circuit breaker, 2 A, 2-pole, inductive load256141 Circuit breaker, 16 A, 3-pole, inductive load

One/Two-Pump Melters, 400 and 480 VAC7400483 Contactor, 40 A, 440V, 3-phase, 240 VAC coil254244 Circuit breaker, 50 A, 3-pole7400071 Circuit breaker, 32 A, 1-pole7400072 Circuit breaker, 13 A, 1-pole251364 Circuit breaker, 16 A, 1-pole, inductive load256227 Circuit breaker, 2 A256141 Circuit breaker, 16 A, 3-pole, inductive load

Three/Four-Pump and 100L Melters, 240 VAC7400762 Main contactor, 600V/50hz/60hz, 3-pole, 80 A7400319 Main contactor, 95 A7104855 Circuit breaker, 90 A, 3-pole7400320 Circuit breaker, 32 A, 2-pole7400321 Circuit breaker, 13 A, 2-pole7400322 Circuit breaker, 16 A, 2-pole, inductive load7400323 Circuit breaker, 2 A, 2-pole, inductive load7400760 Circuit breaker, 25 A, 3-pole, inductive load

Three/Four-Pump and 100L Melters, 400 and 480 VAC7400762 Main contactor, 600V/50hz/60hz, 3-pole, 80 A7400483 Contactor, 40 A, 440V, 3-phase, 240 VAC coil7400380 Main breaker, 70 A, 3-pole7104855 Circuit breaker, 90 A, 3-pole7400071 Circuit breaker, 32 A, 1-pole7400072 Circuit breaker, 13 A, 1-pole251364 Circuit breaker, 16 A, 1-pole, inductive load256227 Circuit breaker, 2 A256141 Circuit breaker, 16 A, 3-pole, inductive load

PT100 Melters7400281 RTD assembly, reservoir, PT1007400280 RTD assembly, tank, PT100

Ni120 Melters7401367 RTD assembly, reservoir, Ni1207401368 RTD assembly, tank, Ni120

Technical Data 8-1


Section 8Technical Data

General Data Storage temperature − 45° C to + 75 ° C

− 49 ° F to + 167 ° F

Type of heating Cartridge-type resistance heating elementsTemperature sensor Ni120 and PT100 � 1 ° C— Measuring precisionMaterial pressure 5 to 85 bar 0.5 to 8.5 MPa 72.5 to 1233 psiMelting capacity 1 tank-full per hourDegree of protection IP 33Noise emission 1 motor: 60 dBA

2 motors: 62 dBA

Motor type 3 ph AC motorGear box type Helical gearMotor/pump speeds 94 rpmHeatup time <45 min

Temperatures Min. ambient temperature - 5 °C 23 °FMax. ambient temperature 40 ° C 104 °FHumidity 10 to 95 %, not condensingMin. operating temperature(setpoint)

40 ° C 100 °F

Max. operatingtemperatures

230 ° C 450 °F

Overtemperature shutdownby thermostat

260 ° C 500 °F

Technical Data8-2


Electrical Data WARNING! The unit is designed for only one operating voltage. Operateonly at the operating voltage shown on the ID plate.

Available operatingvoltages

230 VAC 3-phase without neutral (Delta)

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



Maximum melter powerrequirements

One/two-pump melter 15 L: 15,037 W

30 L: 16,237 W

50 L: 19,437 W

Three/four-pump melter, sixhose/gun

30 L: 22,257 W

50 L: 24,507 W

Three/four-pump melter, eighthose/gun

30 L: 26,257 W

50 L: 28,507 W

100L melter, six hose/gun 29,157 W

100L melter, eight hose/gun 33,157 W

Operating voltagefrequency

50/60 Hz

Fuse protection Refer to ID plate

Max. load per hosereceptacle (2 channels),six hose/gun melters

1000 W, any single hose or gun

1200 W, any hose/gun pair

2000 W, sum of hose/gun pairs 1 and 2


2000 W, any single hose, or gun 5 or 6

2000 W, hose/gun pair 5 or 6


NOTE: Total external wattage must not exceed 8,000 W.

Max. load per hosereceptacle (2 channels),eight hose/gun melters

1000 W, any single hose or gun

1200 W, any hose/gun pair










Technical Data 8-3


Mechanical Data

One/Two and Three/Four Pump Melters

Item 15L 30L 50L

Weight 200 kg (441 lb) One/two pump:225 kg (496 lb)

Three/four pump:440 kg (970 lb)

One/two pump:250 kg (551 lb)

Three/four pump:472 kg (1,041 lb)

Tank opening (length andwidth)

145 x 270 mm 270 x 270 mm 270 x 270 mm

Approximate tank volume 15 L 30 L 50 L

Number of pumps(one/two-pump melter)

1−2 single-stream

1−2 dual-stream

1−2 single-stream

1−2 dual-stream

1−2 single-stream

1−2 dual-stream

Number of pumps(three/four-pump melter)

Not applicable 3−4 single-stream 3−4 single-stream

Number of hose connections One single-stream manifold: 7 connections

Two single-stream manifolds: 3 connections per pump stream

Dual-stream manifold: 2 connections per pump stream

100L Melters

Item Specification

Weight 590 kg (1,301 lb)

Tank opening (length andwidth)

270 x 635 mm

Approximate tank volume 100 L

Number of pumps Up to four single-stream or dual-stream pumps

Number of hose connections One single-stream manifold: 7 connections

Two single-stream manifolds: 3 connections per pump stream

Dual-stream manifold: 2 connections per pump stream

Electrical Schematics Refer to the electrical schematics provided with the melter.

Technical Data8-4


Hydraulic Schematic

ÉÉÉÉÉÉ

HOPPER

GRID

ADHESIVETCS

GEAR

MOTORCONTROL

FILTER

PUMP

CV

PRV

ÉÉÉÉÉÉ

GEAR

FILTER

PUMP

CV

PRV

MOTORCONTROL

DRAIN VALVE

DRAIN VALVE

MOTOR MOTOR

Figure 8-1 Hydraulic system schematic

Calculating Melter Power Requirements A-1


Appendix ACalculating Melter Power Requirements

Before locating the melter on the production floor or attaching hoses andguns to the melter, you must calculate the electrical power required by thehoses and guns and confirm that the required power does not exceedmaximum allowable wattages. Properly calculating melter powerrequirements will prevent damage to the melter and identify the maximumallowable distance between the melter and the point at which the hot melt isdispensed.

The following three maximum wattages must be considered whencalculating melter power requirements.

� Single-component maximum—The wattage of any single hose orgun

� Hose/gun pair maximum—The combined wattage of any hose andgun (hose/gun pair)

� Two hose/gun pair maximum—The combined wattage of hose/gunpairs 1 and 2 or hose/guns pairs 3 and 4

If your Nordson representative has already calculated the hose/gun powerrequirements and confirmed that the maximum allowable wattages will notbe exceeded, then no further calculation is necessary. However, you shouldre-evaluate the hose and gun power requirements before you:

� add a new hose or gun to the melter that was not factored into theoriginal wattage evaluation

� replace an existing hose with a longer hose or an existing gun with alarger gun

Calculating Melter Power RequirementsA-2


To evaluate the hose/gun power requirements

1. Identify all hose/gun pairs based on the hose/gun receptacle to whichthey are connected.

2. Examine the identification tag or plate on each hose and gun and recordthe wattage of each in Column A of Table A-1. Enter a zero for any hoseor gun that is not installed.

3. Add the wattages of each hose/gun pair and place the sum in Column Bof Table A-1.

4. Add the wattages of the hose/gun pairs and place the sum in Column Cof Table A-1.

5. Compare each of the wattages tabulated in Columns A, B, and C ofTable A-1 with the associated maximum allowable wattages in Table A-2or Table A-3, as appropriate.


� If each of the wattages calculated in step 5 do not exceed theassociated maximum allowable wattages listed in Table A-2 orTable A-3, then the power required by the hoses and guns is withinacceptable limits.

� If any of the wattages calculated in step 5 does exceed anassociated maximum allowable wattage listed in Table A-2 orTable A-3, then the configuration or position of the hose/gun pairsmust be rearranged, shorter hoses must be used, or lower powerguns must be used in order to reduce the power requirement.

Calculating Melter Power Requirements A-3


Table A-1 Hose/Gun Wattages

ComponentNumber Type/Size

A B C

ComponentWattage

Hose/Gun PairWattage

Two Hose/GunPair Wattage

Hose 1

Gun 1

Hose 2

Gun 2

Hose 3

Gun 3

Hose 4

Gun 4

Hose 5

Gun 5

Hose 6

Gun 6

Hose 7

Gun 7

Hose 8

Gun 8

Table A-2 Maximum Allowable Hose/Gun Wattages(Six Hose/Gun Melters)

Column inTable A-1 Component Maximum Wattage

A Any single hose or gun 1000 W

B Any hose/gun pair 1200 W

CSum of hose/gun pairs 1 and 2 2000 W

Sum of hose/gun pairs 3 and 4 2000 W

D Any single hose, or gun 5 or 6 2000 W

E Hose/gun pair 5 or 6 2000 W

F Sum of hose/gun pairs 5 and 6 4000 W


Calculating Melter Power RequirementsA-4


To evaluate the hose/gun power requirements (contd)

Table A-3 Maximum Allowable Hose/Gun Wattages(Eight Hose/Gun Melters)

Column inTable A-1 Component Maximum Wattage

A Any single hose or gun 1000 W

B Any hose/gun pair 1200 W

CSum of hose/gun pairs 1 and 2 2000 W

Sum of hose/gun pairs 7 and 8 2000 W

DAny single hose, or gun 3 or 4

Any single hose, or gun 5 or 62000 W

EHose/gun pair 3 or 4

Hose/gun pair 5 or 62000 W

FSum of hose/gun pairs 3 and 4

Sum of hose/gun pairs 5 and 64000 W


Operating Parameters B-1


Appendix BOperating Parameters

Operating parameters are organized in this appendix according to thelogical groups listed in Table B-1. For information about selecting andediting operating parameters, refer to Section 3, Installation, Setting Up theMelter.

NOTE: Parameter numbers that are reserved or that are not used do notappear in this appendix.

Table B-1 Parameter Groups

Group Parameters Description

Standard 0 to 13 Frequently used parameters

Temperature Control 20 to 29 Control heater function

Input Setup 30 to 33 Configure the inputs

Output Setup 40 to 42 Configure the outputs

Seven-day Clock 50 to 77 Configure the clock feature

PID Selection 80 to 91 Change preset PID settings

Operating ParametersB-2


Standard

0 Enter PasswordDescription: A user-defined password that prevents unauthorized changes to set-point

temperatures and operating parameters.

Value: 0 to 9999

Resolution: 1

Default Value: 4000

Format: —

Use: This parameter only appears if a password is created using parameter 11 andthen enabled using parameter 10.

NOTE: The melter remains in the password-protected mode for two minutesafter the last key press. After exiting the setup mode, attempting to re-enter thesetup mode, even before two minutes has elapsed, will require you to re-enterthe password.

1 Total Hours with Heaters On (Noneditable)

Description: A non editable value that indicates the total number of hours that the heatershave been on.

Value: 9999 (control panel) and 999,999 on the web browser

Resolution: 1 hour

Default Value: 0

Format: —

Use: The display registers up to 9999 hours and then rolls over to 0000.

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 Section4, Operation.



3 Change History Log (Noneditable)

Description: Records the last ten changes made to either the set-point temperatures or theoperating parameters.

Value: —

Resolution: —

Default Value: P-_ (unused log entry)

Format: Refer to Section 3, Installation. Review Parameter and Set-point TemperatureChanges.

Use: Use the right-display key to review the log entries for the last ten changes thatwere made to the operating parameters or the set-point temperatures. Emptylog entries are indicated by “P-_.”

4 Ready Delay TimeDescription: 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 delaytime only functions when the temperature of the tank, at the time the melter isturned on, is more than 27 C (50 F) from its set-point temperature. Theready delay time begins when all components are within 3 C (5 F) of theirrespective set-point temperature.

Value: 0 to 60 minutes

Resolution: 1 minute

Default Value: 0 minutes

Format: —

Use: The ready delay allows the contents of the tank an additional amount of timeto heat before pump turns on.

NOTE: The time remaining on the ready delay is indicated in minutes in theright display at the end of every automatic scan cycle. When the delay timereaches 1 minute, the time remaining appears in seconds.

5 Service Interval TimeDescription: 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 ormaintenance event, such as changing the filter. The service LED will turn onafter the pre-set time elapses. With the melter in the scan mode, press theClear/Reset key to turn off the service LED and reset the time.



Standard (contd)

6 Service LED Heater HoursDescription: 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 parameterwill work.

Note: Heater hours accumulate whenever the heaters LED is illuminated.

7 Motor Off DelayDescription: Not being used, only displayed.

8 Automatic Pump On(Not used with AltaBlue melters)

Description: Determines if the pump can be enabled before the melter is ready.

Value: 0 = disabled or 1 = enabled

Resolution: —

Default Value: 1 (enabled)

Format: —

Use: If enabled, the pump can be enabled before the melter is ready. Once enabled,the pump will start automatically when the melter is ready.

If disabled, the pump must be started by pressing the pump key(s) after themelter is ready.

NOTE: If automatic pump on is disabled (0) while the pump is running, thepump will remain on until the pump key is pressed.



10 Enable or Disable the Melter PasswordDescription: Activates or deactivates the melter password. When password protection is

activated, component set-point temperatures or melter operating parameterscannot 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 enabledor disabled using parameter 10.

11 Create PasswordDescription: 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 Password.

NOTE: When the password is created and enabled, parameter 10 will notappear again in the right display until the password is entered.

12 Change Hose 1 Output to Electric Gun Activation(Not used with AltaBlue melters)

Description: Changes the proportioned 240 VAC current that is provided to the hose 1heater to a switched 240 VAC current that is used to activate amanifold−mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default Value: 0 (disabled)

Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installed and aswitching device is connected to the melter’s switch receptacle. Refer to theelectric gun manual for information on mounting and using the gun.



Standard (contd)

13 Change Hose 2 Output to Electric Gun Activation(Not used with AltaBlue melters)

Description: Changes the proportioned 240 VAC current that is provided to the hose 1heater to a switched 240 VAC current that is used to activate amanifold−mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —


Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installed and aswitching device is connected to the melter’s switch receptacle. Refer to theelectric gun manual for information on mounting and using the gun.

20 Temperature UnitsDescription: Sets the units for temperature display.

Value: C (degrees Celsius) or F (degrees Fahrenheit)

Resolution: 0 = Celsius

1 = Fahrenheit

Default Value: 0

Format: —

Use: —

21 Over Temperature DeltaDescription: 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 DeltaDescription: 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


Format: —

Use: —

23 Standby DeltaDescription: The number of degrees by which all heated components will be decreased

when the melter is placed into the standby mode.

Value: 25�C to 190�C (50�F to 350�F)

Resolution: 1�C 1�F


Format: —

Use: A standby delta should be selected that results in a balance between melterenergy savings during periods of inactivity, the amount of time and energyrequired to bring the melter back up to set-point temperature, and atemperature at which the hot melt can be held in the tank for extended periodsof time without charring. Refer to Section 4, Operation, Function Keys.

NOTE: The standby delta does not affect the under temperature delta(parameter 22).



Standard (contd)

24 Automatic Standby TimeoutDescription: 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 standbytimeout feature saves energy by allowing the melter to automatically go into thestandby mode if the melter detects that the guns are no longer firing.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: 1. Change parameter 23 if required.

2. Set the control option for parameter 30 (input 1) to option 10 (automaticstandby)

NOTE: Only enable parameter 24 when a 24 VDC signal voltage is connectedto 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.

25 Automatic Heaters Off TimeDescription: 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)



Format: —

Use: Set parameter 24 (automatic standby timeout) to the desired value beforesetting parameter 25.

26 Manual Standby TimeDescription: The amount of time that the melter will remain in the standby mode after the

standby key is pressed.

Value: 0 to 180 minutes


Default Value: 0

Format: —

Use: Set the standby time when you want the operator to be able to place the melterinto the standby mode for a limited period of time (break, lunch, etc.). Whenmanual standby is enabled (value greater than 0 minutes), the standby LEDblinks.

Set the standby delta (parameter 23) to the desired value before settingparameter 26.

Note: When a time value equal to or greater than 1 minute is entered, thestandby LED will flash to indicate that the manual standby timer is countingdown.



27 Hose Standby DeltaDescription: The number of degrees by which all heated hoses will be decreased

when the applicator is placed into the standby mode.

Value: 1 �C to 190 �C (1 �F to 350 �F)

Resolution: 1 �C 1 �F

Default Value: 0

Format: —

Use: This parameter functions like parameter 23 except when it is set to 0, inwhich case it reverts to the setting for parameter 23.


28 Gun Standby DeltaDescription: The number of degrees by which all heated guns will be decreased when

the applicator is placed into the standby mode.

Value: 1 �C to 190 �C (1 �F to 350 �F)


Default Value: 0

Format: —

Use: This parameter functions like parameter 23 except when it is set to 0, inwhich case it reverts to the setting for parameter 23.


29 Internal Zone Temperature OffsetDescription: The difference in the number of degrees by which the melter’s internal

zones will operate. If this parameter is used, the primary internal zone willoperate at a lower temperature than the secondary internal zone asdetermined by the value of this parameter.

Value: 0 �C to -15 �C (0 �F to -30 �F)


Default Value: 0

Format: —

Use: Melter internal zones are designated as follows:

DuraBlue D10/D16: primary=tank; secondary=pumpDuraBlue D4L/D10L/D16L: primary=tank; secondary=pumpAltaBlue TT: primary=tank; secondary=pumpDuraBlue 25/50/100: primary=grid; secondary=reservoirAltaBlue 15/30/50/100: primary=grid; secondary=reservoirDuraDrum: primary=platen; secondary=pump



Input Setup

30 Input 1Description: Control options that determine the function of input 1.

Value: 0 − Input Disabled1 – Standby On/Off2 – Heaters On/Off3 – Motor 1 Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable10 – Automatic standby11 − Motor 2 Enable/Disable

Resolution: 1

Default Value: 10

Format:

Use: If Motor Enable/Disable (3) is selected, the motor will turn on whenever voltageis present on the input contacts. To require that the pump key be pressed(pump enabled) and that there be voltage on the input contacts before themotor can turn on, set the value of parameter 8, Automatic Pump On to 0(disabled).

Refer to Installing Melter Inputs in Section 3, Installation, for information aboutsetting up inputs.

NOTE: Only Input 1 offers control option 10.

Multiple inputs can be set to the same input value. After one or more inputs thathave the same input value are energized, the input functionality will not beconsidered inactive (off) until all of the inputs with the same input value arede-energized (Multiple inputs set to the same input value are logical ORed.).




Value: 0 − Input Disabled1 – Standby On/Off2 – Heaters On/Off3 – Motor 1 Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable11 − Motor 2 Enable/Disable

Resolution: 1

Default Value: 1

Format: —

Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless thepump is enabled and the correct voltage is present on the input contacts.


NOTE: Multiple inputs can be set to the same input value. After one or moreinputs that have the same input value are energized, the input functionality willnot be considered inactive (off) until all of the inputs with the same input valueare de-energized (Multiple inputs set to the same input value are logicalORed.).


Value: 0 − Input Disabled1 – Standby On/Off2 – Heaters On/Off3 – Motor 1 Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable11 − Motor 2 Enable/Disable

Resolution: 1

Default Value: 2

Format: —






Input Setup (contd)


Value: 0 − Input Disabled1 – Standby On/Off2 – Motor 1 On/Off3 – Motor Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable11 − Motor 2 Enable/Disable

Resolution: 1

Default Value: 4

Format: —




34 – 39 Optional Inputs 5, 6, 7, 8, 9, and 10Description: Control options that determine the function of the six optional inputs provided

when the optional I/O expansion card is installed on the main board.

Value: 0 − Input Disabled1 – Standby On/Off2 – Motor 1 On/Off3 – Motor Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable11 − Motor 2 Enable/Disable

Resolution: 1

Default Value: 0 (Disable)

Format: —



NOTE: When more than one input is set to the same value, the controllerfollows the state of the active input.



Output Setup

40 − 42 Outputs 1, 2, and 3Description: Determines the function of the output.

Value: 0 = Output Disabled1 = Ready2 = Ready and Pump is on3 = Fault4 = Low level5 = Service LED is on6 = Alert

Resolution: 1

Default Value: Output 1 = 1Output 2 = 3Output 3 = 4

Format: —

Use: Refer to Installing Melter Outputs in Section 3, Installation, for information onsetting up outputs.

When control option 6, Alert is selected, the output is active whenever themelter enters the two minute fault monitoring period. If the potential faultcondition clears before the end of the two minute period, the output signal ends.Refer to Section 4, Operation, Monitor Melter Faults, for information about faultmonitoring.

43 − 46 Optional Outputs 4, 5, 6, and 7Description: Control options that determine the function of the four optional outputs provided

when the optional I/O expansion card is installed on the main board.

Value: 0 = Output Disabled1 = Ready2 = Ready and Pump is on3 = Fault4 = Low level5 = Service LED is on6 = Alert (Potential fault)

Resolution: 1

Default Value: 1 (all optional outputs)

Format: —

Use: Refer to the instruction sheet provided with the optional I/O expansion card forinformation about wiring and setting up the optional outputs.

When control option 6, Alert is selected, the output is active whenever themelter enters the two minute fault monitoring period. If the potential faultcondition clears before the end of the two minute period, the output signal ends.Refer to Section 4, Operation, Monitor Melter Faults, for information about faultmonitoring.



Seven-day Clock Before setting up the clock, refer to Function Keys in Section 4, Operation,to familiarize yourself with the function and use of the clock feature.

If you are unfamiliar with the procedure for accessing and editing operatingparameters, refer to Section 3, Installation, Setting Up the Melter.

To Set the Clock

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 heatersshould turn on and off.

b. Setting parameters 57 and 58 to the time of the day that the meltershould enter and exit the standby mode.

4. Using parameters 60 through 68, create schedules 2 and 3 by repeatingstep 3.

5. Use parameters 71 through 77 to assign which of the four schedulesshould be used on each day of the week. Up to three schedules may beassigned each day (to support three work shifts). Each of the eightcontrol options (0 to 7) that is available in parameters 71 through 77assigns a different combination of the three schedules. Option 0 is usedhold the melter in the state dictated by the last clock transition until thenext clock transition occurs.

In order for the clock to operate continuouslythroughout the week, a valid schedule mustbe assigned to every day of the week(parameters 71 through 77).

To prevent unintentional activation of the clockthe default setting for parameters 71 through77 is schedule 0. which has no time valuesassigned to it. With the default set to schedule0, unintentionally pressing the clock key willhave no affect on the melter.



50 Current DayDescription: 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, Function Keys, for information about the use andaffects of the seven-day clock feature.

51 Current TimeDescription: Used to set the local time of the day.

Value: 0000 to 2359 (European time format)


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 OnDescription: Used to set the time that the clock will turn on the heaters during schedule 1.

Value: 0000 to 2359, - - - -


Default Value: 0600


Use: Set the desired time for the heaters to turn on.

To disable this parameter, set the parameter’s value to “- - - -” bysimultaneously pressing both of the right-display scroll keys.

56 Schedule 1 Heaters OffDescription: Used to set the time that the clock will turn off the heaters during schedule 1.

Value: 0000 to 2359, - - - -


Default Value: 1700


Use: To disable this parameter, set the parameter’s value to “- - - -” bysimultaneously pressing both of the right-display scroll keys.



Seven-day Clock (contd)

57 Schedule 1 Enter StandbyDescription: Used to set the time that the melter will enter the standby mode during

schedule 1.

Value: 0000 to 2359, - - - -


Default Value: - - - -

Format: Hour, Hour: Minute, Minute

Use: Set the time that the melter will enter the standby mode during schedule 1.


Note: Do not set an enter standby time that is outside of the time period definedby the schedule’s heater on and off time. The melter cannot enter the standbymode when the heaters are off.

58 Schedule 1 Exit StandbyDescription: Used to set the time that the melter will exit the standby mode during schedule

1.

Value: 0000 to 2359, - - - -




Use: Set the time that the melter will exit the standby mode during schedule 1.


Note: Do not set an exit standby time that is outside of the time period definedby the schedule’s heater on and off time. The melter cannot enter the standbymode when the heaters are off.


Value: 0000 to 2359, - - - -









Value: 0000 to 2359, - - - -






schedule 2.

Value: 0000 to 2359, - - - -








2.

Value: 0000 to 2359, - - - -









Seven-day Clock (contd)


Value: 0000 to 2359, - - - -







Value: 0000 to 2359, - - - -






schedule 3.

Value: 0000 to 2359, - - - -










3.

Value: 0000 to 2359, - - - -







71-77

Schedules for the Days of the Week

Description: Used to select which schedule(s) should be used on a specific day ofthe week.

Value: 0 – Remain at last clock transition1 – Use just schedule 12 – Use just schedule 23 – Use just schedule 34 – Use schedule 1 and 25 – Use schedule 2 and 36 – Use schedule 1 and 37 – 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 onagain until the next scheduled heaters on time arrives.



PID Selection

80−91 PID Selection for Receptacles, Hose/Gun 1, 2, 3 and 4Description: Used to change the preset PID selections. Use parameter 80 to select the

value for hose 1, parameter 81 to select the value for gun 1, and so on.

Value: 0 = Hose1 = Standard gun2 = Large gun3 = Air heater

Resolution: —

Default Value: 0 or 1 depending on the channel type (hose or gun)

Format: —

Use: Consult your Nordson representative before changing PID settings.

Melter Communications C-1


Appendix CMelter Communications

This appendix describes the installation and use of the NordsonConfiguration Manager (NCM) communications utility. With this utility youcan:

� transfer operating parameters and temperature set-points betweenmelters

� upgrade or reload your melter’s firmware

Software Availability If you do not already have the NCM utility, you can download it from theinternet by navigating to www.enordson.com/support.

If you do not have a connection to the internet, you can request a softwareCD from your Nordson representative.

System Requirements The following hardware and software requirements are necessary to installand run Blue Series software:

� Any AltaBlue, ProBlue, or 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)

Melter CommunicationsC-2


Installing the Software To meet your specific installation conditions, two versions of the softwareare available. Refer to Table C-1 to determine which version you need.

Table C-1 Blue Series Software Versions

Version Use When...

Single installation file:

BlueSeries.exe

You are downloading the software from www.enordson.com and the PC you aredownloading 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 beconnected to the melter, but the PC does have a CD-RW and the PC that is connected tothe 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 beconnected to the melter

Self-extracting span diskette set:

BlueSeriesSpan.exe

You are downloading the software from www.enordson.com onto a PC that cannot beconnected to the melter and the PC that is connected to your melter only has a 3.5-inchfloppy drive

When the installation file is executed, an installation wizard will detect youroperating system and start the installation routine.

NOTE: Installing the NCM for the first time also installs the latest version ofthe melter’s firmware.



To install Blue Series software1. Do one of the following:

� If you are installing using the single file installation, locate anddouble-click on the file BlueSeries.exe.

� If you are installing from the span diskette set, insert Disk 1, andthen 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 areinstalling from the span disk set, you will be prompted to insert additionaldiskettes (2 through 5) as required by your operating system.

NOTE: When prompted to select an installation location, NordsonCorporation recommends that you select the default location offered.

3. When the installation complete message appears, click Finished.



Removing the Software from Your PCUse the Remove feature provided by the Blue Series InstallShield� Wizardto remove the software from your PC. Removing Blue Series software fromyour PC will not remove melter settings files that you have saved using theNCM. Settings files (.ncm extension) are stored in your Windows MyDocuments folder.

NOTE: Windows XP, 2000, and NT users must have administrator rights inorder 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.

11 22

00

44 55

33

66

99

AltaBlue serial port



Connecting the PC and the Melter

Connect a serial cable between the PC COM port (selected during thesoftware installation routine) and the serial port connection (COM port) onyour melter’s control panel.

Configuration Managerdesktop icon



Using Nordson Configuration ManagerConfiguration Manager is launched from your Windows desktop using theicon shown to the left.

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 PCconnected to your melter’s serial port. Once connected, ConfigurationManager offers the choice of saving settings, restoring settings, orupgrading the melter’s firmware.

The first time you download and install Configuration Manager, the latestversion of the melter’s firmware is also downloaded.

Saving and Restoring Melter Settings Saving settings copies all current set-point and operating parameter valuesto your PC. Saved settings can be transferred back to the same melter or toany 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.

5. Select the COM port you are using to connect to the melter, and thenclick Ok.

The PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates “CONNECTED”.

6. Click Save Settings.

The Save As dialog box appears.

NOTE: The default location for saving settings files is Windows MyDocuments folder. To avoid loosing saved settings files, NordsonCorporation recommends that you do not change the default savelocation.



7. Type a file name to identify the group of settings you are saving, andthen click Save.

The save settings progress bar indicates the status of the save. Whenthe save is complete, the melter automatically returns to the scan mode.

NOTE: If you are using the NCM to save multiple variations of meltersettings, use a file naming convention that will allow you to easilyassociate each settings file (.ncm extension) with its related process orend-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, andthen click Open.

The Restore Settings progress bar indicates the status of the restore.When the restore is complete, the melter automatically returns to thescan mode.

Upgrading or Restoring Melter Firmware Use the NCM to upgrade your melter to a newer version of firmware orreload the current version of the firmware. The version of Blue Seriesadhesive melter firmware that is currently available is posted on the internetat www.enordson.com/support.

NOTE: The version of firmware that is loaded on your melter appears onthe control panel when the melter is first switched on.

During the upgrade process, all current melter settings are downloaded andsaved on your PC. After upgrading or restoring a melter’s firmware, you canuse the NCM to restore the pre-upgrade settings.

CAUTION! The upgrade process returns the melter’s settings to factoryconfiguration, with the exception that current heater hours data is saved.Data in both the fault log and the change log is lost after upgrading thefirmware.



Upgrading or Restoring Melter Firmware (contd)

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 switching the melter off andthen on again, and then immediately pressing and holding both theSetup and left display Scroll key.

UPLOAd appears in the right display.

3. Double-click the NCM icon on the Windows desktop.

The NCM dialog box appears.

4. Click Select.

The device dialog box appears.

5. Select your melter from the list, and then click Ok.



The PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates Connected.

7. Click Upgrade.

The Select Upgrade dialog box appears.

8. In the Available Upgrades list, select the firmware version you want toupload to the melter, and then click Ok.

The upgrade warning message appears.

9. Click OK.

The Upgrade in Progress dialog box appears. The upgrade can takeas long as 12 minutes. When the upgrade is complete, the Successdialog box appears and the melter restarts.



To upgrade or reload melter firmware (contd)

CAUTION! Once the uprade progress bar appears, do not interrupt theupgrade process for any reason. Interupting the upgrade can corrupt themelter’s firmware, which will require replacement of the IC chip(IC service kit P/N 1018817).

10. Click OK.

The communications link between the melter and the PC is terminated.


� To restore pre-upgrade melter settings, go to To restore pre-upgrademelter settings.

� To close the NCM, click Exit.

� To restore melter settings other than the settings that were in use bythe melter before the upgrade, go to Saving and Restoring MelterSettings earlier in this guide.

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 PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates “CONNECTED”.

4. Click Restore Pre-Upgrade Settings.

The pre-upgrade settings are restored and the melter returns to the scanmode.

5. Click Exit to close the NCM.



Troubleshooting

Using Nordson Configuration Manager Symptom/Message Action

After selecting a device and the COM port, an Access Deniedmessage appears.

PC-to-Blue communications may be running or anotherapplication may be using the COM port. Close Internet Explorerand end the communications connection (if prompted). Close allother applications.

Melter in UPLOAd mode, the update process has not beeninitiated, and you want to stop and exit the UPLOAd mode, butyou cannot get the melter out of UPLOAd.

Cycle power to the melter at the local power disconnect switch.

CAUTION: Ensure that the firmware update process is notrunning before taking power off of the melter.

UPLOAd does not appear on the melter’s display when you pressthe Setup and left display scroll keys.

You must cycle the control switch while holding the Setup and leftdisplay scroll keys.

Attempted a firmware update, but the melter display still indicatesUPLOAd.

OR

Attempted a firmware update, but the PC has stopped respondingor was interrupted during the update process.

Using the local power disconnect switch, cycle power to themelter, and then re-attempt the update.

If the update is unsuccessful or the melter will not reboot, thecentral processor chip may be corrupted. Replace the CPUboard.

Technical File Contact:

Dieter Ziesmer

Nordson Engineering GmbH

Lilienthalstrasse 6

21337 Lueneburg

GERMANYDate: 20 March 2014

Gregory P. Merk, Senior Vice PresidentAdhesives Dispensing Systems

1105311A05

DOC074R6

Nordson Corporation � 28601 Clemens Road ��Westlake, Ohio

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

APPLICABLE DIRECTIVES:

Machinery Directive: 2006/42/EC

Electromagnetic Compatibility Directive: 2004/108/EC

STANDARDS USED TO VERIFY COMPLIANCE:

EN ISO 12100 EN 60204‐1 EN 61000-6-4

EN ISO 13732‐1 EN 61000‐6‐2

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.

Model Number_________________________

Serial Number______________________________________