fulfill retrofit kit problue 4/7/10...

Fulfill� Retrofit KitProBlue� 4/7/10 Melters

Customer Product ManualPart 1098477A

Issued 1/10

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

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

Part 1098477A � 2010 Nordson CorporationAll rights reserved

For CE Declaration, refer to melter manual.

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 2010.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, cScan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen,Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI - stylized, Excel 2000, Fillmaster,

FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli-flow, Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil,Isocore, Iso-Flo, iTRAX, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet,

Millennium, Mini Squirt, Mountaingate, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Porous Coat, PicoDot, PowderGrid, Powderware,Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard,Seal Sentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean,Sure Coat, Sure-Max, Sure Wrap, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UpTime, u-TAH, Vantage, VersaBlue, Versa-Coat,

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

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, ATS, Auto-Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt, Controlled Fiberization, Control Weave, ContourCoat, CPX,cSelect, Cyclo-Kinetic, DispensLink, Drop Cure, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E-Nordson,Equalizer, Equi=Bead, FillEasy, Fill Sentry, FlowCoat, Fluxplus, Get Green With Blue, G-Net, G-Site, iON, Iso-Flex, iTrend, Lacquer Cure, Maxima, Mesa,

MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiStroke, Partnership+Plus,PatternJet, PatternPro, PCI, Pinnacle, Plasmod, 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, SureFoam,Sure Mix, SureSeal, Swirl Coat, TAH, ThruWave, TinyCure, Trade Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate,

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

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

Table of Contents i

Part 1098477A� 2010 Nordson Corporation

Table of Contents

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

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

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

Equipment Safety Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Shutdown 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Warnings and Cautions 7. . . . . . . . . . . . . . . . . . . . . . . . . Other Safety Precautions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Tags 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic & Mechanical Components 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

(1). Adhesive Storage Bin 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2). Air Pressure Regulator/Solenoid Assembly 14. . . . . . . . . . . . . . . . . . (3). Suction Lance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4). Adhesive Transfer Hose 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5). Lid Assembly 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6). Pump Inlet Screen (Not Shown) 15. . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Components 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7). Control Box 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (8). Sensor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Existing Lid, Screen and Level Sensor 19. . . . . . . . . . . . . . . . . Install the Control Box 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Tank and Lid Components 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble the Transfer Hose, Air Line, and Suction Lance 24. . . . . . . . . . . Level Sensor Adjustment and Calibration 25. . . . . . . . . . . . . . . . . . . . . . . . . .

Baseline Setting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Setting 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Settings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Refill Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1098477A � 2010 Nordson Corporation

Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refill PCA Troubleshooting Diagnostic Instructions 30. . . . . . . . . . . . . . . . . .

Parts 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Illustrated Parts Lists 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ProBlue Retrofit Kit Assemblies 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lid Assembly Parts 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Assembly with Bracket 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box Assembly 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulator/Solenoid Assembly 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kits 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Parts 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P10 Fulfill Retrofit 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P7 Fulfill Retrofit 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P4 Fulfill Retrofit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fulfill� Retrofit Kit ProBlue® 4/7/10 Melters 1


Fulfill� Retrofit Kit ProBlue� 4/7/10Melters

Safety Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation,operation, and maintenance (hereafter referred to as “use”) of the productdescribed in this document (hereafter referred to as “equipment”). 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 Symbols The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

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

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

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

Fulfill� Retrofit Kit ProBlue® 4/7/10 Melters2


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

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

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

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

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

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

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

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

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

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



User Qualifications Equipment owners are responsible for ensuring that users:

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

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

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

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

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

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

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

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

specified in this document.

� Do not modify the equipment.

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



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

referenced documents.

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

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

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

document and in the documentation provided with auxiliary devices.

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

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

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

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

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

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

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

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

and indicators.

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

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

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



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

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

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

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

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

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



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

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

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

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

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

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



General Safety Warnings and Cautions Table NO TAG contains the general safety warnings and cautions that applyto Nordson 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 NO TAG as follows:

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

PC = Process control

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

Table 1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

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

HM

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

HM, CAWARNING! 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.

Continued...



General Safety Warnings and Cautions (contd)

Table 1 General Safety Warnings and Cautions (contd)

EquipmentType Warning or Caution

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

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



Warning or CautionEquipment

Type

HMCAUTION! 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.



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

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

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

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

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

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

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

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

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



Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixedto the equipment. Table 2 provides an illustration of the hazard identificationsymbols that appear on each safety label and tag, the meaning of thesymbol, or the exact wording of any safety message.

1

Figure 1 Safety labels and tags

Table 2 Safety Labels and Tags

Item Part Description

1. 1021984

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



Description The ProBlue® Fulfill� Retrofit Kit converts a ProBlue 4, 7 or 10 melter intoan automatic fill system that maintains adhesive in the melter, improvingproductivity and reducing maintenance. The retrofit kit adds adhesive to thesealed tank, reducing the possibility of char, contaminants, thermal shockand incorrect adhesive temperatures that result in poor adhesive bonding.

The Fulfill system is shipped with the components illustrated in Figure 2.

2 3

1

6

7

5

4

8

Figure 2 Fulfill system components

1. Adhesive storage bin2. Transfer hose3. Suction lance

4. Control box and mounting bracketwith level sensor, filter−regulator w/gauge, and solenoid

5. Hose clamp (2)

6. Air line (4m)7. Wire tie (5)8. Lid assy

Optional accessories available for the Fulfill Retrofit include:

� a vibrator kit for the adhesive storage bin

� a remote power harness kit

� a light tower kit for audio/visual fill/fault indication of the Fulfill processes

� a powered cable kit.

Contact your Nordson representative for more information on these kits.



Theory of Operation

Overview The system adds small quantities of adhesive to the sealed tank at regularintervals, reducing the possibility of adhesive char, contaminants, thermalshock and incorrect adhesive temperatures that result in poor bonding.

A capacitance sensor located in the melter detects low adhesive level, andthen sends a signal to the system control. A delay timer prevents the fillsystem from frequently cycling on and off.

At the end of the delay the control activates the vacuum via a solenoidvalve. Air pressure flows to a suction lance that is placed in the suppliedbulk adhesive container. Using vacuum, the system conveys adhesive fromthe bulk container to the adhesive melter tank.

The controller activates the suction lance for a limited amount of time toprevent over-fill conditions. If the maximum fill time is exceeded, thecontroller activates a fault that stops the system from filling.



Pneumatic & Mechanical Components Refer to Figure 3 as you learn about the components of the ProBlue Fulfillretrofit assembly.

4

3 15

2

7

8

Figure 3 Assembled ProBlue Fulfill retrofit assembly.

(1). Adhesive Storage Bin Place adhesive in the adhesive storage bin. The bin contains a gasket thatprevents debris from entering the bin. For best results, break up theadhesive as much as possible when emptying into the bin. Do not get theadhesive wet.

(2). Air Pressure Regulator/Solenoid Assembly The supplied air pressure regulator is permanently set at 65 psig, theoptimal setting for most adhesives.

The solenoid valve turns on after the sensor indicates level state and thetime delay has been reached. The solenoid directs compressed air to flowto the suction lance.



(3). Suction Lance The suction lance draws adhesive from the adhesive storage bin. Thesuction lance includes:

� A venturi pump to draw in and transport the adhesive.

� A vibrator to keep the adhesive in loose condition. The vibrator is activeas long as compressed air is supplied to the suction lance.

Air line tubing and the adhesive transfer hose are connected to the suctionlance. The lance is placed in the PVC pipe located in the adhesive storagebin.

(4). Adhesive Transfer Hose The adhesive transfer hose connects the suction lance to the lid assembly.The transfer hose conveys adhesive from the adhesive storage bin to themelter tank.

(5). Lid Assembly The lid assembly includes the filter stack, lid, fill tube, baffle and deflector:

� The filter stack contains a replaceable filter sock to prevent adhesivefines and talc/powder in the adhesive from being emitted into theambient air.

� The fill tube attaches to the adhesive transfer hose.� The baffle prevents adhesive from entering the filter sock.� The deflector distributes adhesive evenly in the tank.

Two thumb screws mount the lid to the melter. The thumbscrews can bereplaced by Allen head screws supplied in the ship with kit. Do not removethe lid during operation, unless the system is disabled by turning power offat the control box.

(6). Pump Inlet Screen (Not Shown) The pump inlet screen is specifically designed for use with the fill system. Iteasily snaps in place, and blocks any adhesive from flowing on to thesensor from the return port in the ProBlue tank.



Electrical Components

(7). Control Box The control box contains the membrane panel and PCA. It connects to themelter via the supplied bracket. An optional remote mount kit is available tomount the control box away from the melter.

Membrane Panel

The front panel of the electrical control box shown in Figure 4 contains threeLEDs that have different colored lights to indicate the unit condition:

� Enable LED (green light) − Indicates that the system is enabled.Pressing the Enable button will toggle the indicator.

� Enable button − Press the enable button to turn the fill system on oroff.

� Adhesive transfer LED (blue light) − Indicates adhesive delivery isactive. When a low level is detected, the indicator notes thatadhesive is being transferred from the adhesive storage bin into themelter tank through the transfer hose.

� Fault LED (red light) − activates if the system exceeds the userdefined fill time limit. The system will not resume operation until thefault is cleared with the clear fault button.

� Clear fault button − Press the clear fault button to reset fault andresume normal activity.

1 2 3

4

Figure 4 Fill system controls and indicators

1. Enable On/Off2. Filling activated symbol and blue LED

3. Fault symbol and red LED4. Clear fault



PCA

See Figure 5. The PCA is inside the control box:

Figure 5 PCA board (located inside the control box)

� Connect line voltage to the control box at the supplied terminal blockand ground. Power can be supplied from the plant service to thecontrol box or directly from the ProBlue melter using the optionalpower harness kit.

� A potentiometer labeled ”Delay” is for a fill time delay. This delay isthe time duration between the level sensor calling for more adhesiveand when the fill system activates. The delay time prevents thesystem from frequently turning on and off. The delay time is presetfrom the factory at 60 seconds, but can be adjusted from 0 to 119seconds. The factory sets the potentiometer at the 12 o’clockposition, sufficient for the majority of applications. For reference, 9o’clock is 20 seconds and 3 o’clock is 100 seconds.



PCA (contd)� A potentiometer labeled fault limits the amount of filling time in case

of level sensor failure. t is only for overflow protection. The factorysetting is at the 12 o’clock position, sufficient in most applications.The time can be adjusted from 5 to 115 seconds. For reference, the9 o’clock position is 22 seconds and the 3 o’clock position is 98seconds.

� A potentiometer labeled ”AIR” is a pre-vibrate timer for the optionalstorage bin vibrator kit. The range for this potentiometer is 0 to 20seconds. When installed, this vibrator will activate up to 20 secondsbefore the fill system activates and stay on until the level sensor issatisfied. This kit is well suited for adhesives and plant conditionsthat are prone to bridging.

� A dip switch labeled SW1 is preset at the factory. Position M1should always be OFF and position M2 should always be ON.

� A terminal block labeled ”XT2”. An optional light tower may beattached here. The functions of the light tower are

- Fill (Blue) − visual

- Fault (Red) − visual

- Fault (Alarm) − audible.

NOTE: The fault outputs will engage simultaneously.

(8). Sensor The level sensor detects the level of adhesive in the melter tank. When theadhesive falls below the set point, the level sensor sends a signal to theFulfill control box.

The sensor comes preset from the factory for an average applicationwhereby the tank is typically molten. For optimal performance based onspecific applications, see the Level Sensor Adjustment and Calibrationdetailed later in the manual.



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

Remove the Existing Lid, Screen and Level Sensor 1. Operate the melter until the tank is empty.

2. De-energize the system as directed in the Maintenance section of theProBlue manual.

3. See Figure 6. Remove the rear panel and the pump cover of the melter.Unplug the level sensor connector from the melter. Replace the rearpanel and the pump cover.

1

2

Figure 6 Unplug the level sensor

1. Rear panel 2. Pump cover



Remove the Existing Lid, Screen and Level Sensor (contd)

CAUTION! Remove dirt and debris from the melter before proceeding withthese procedures.

4. See Figure 7. Remove the tank lid by inserting a flat-head screw driverinto the slot on the spring-loaded hinge pin then pull the hinge pin outfrom its seat.

Figure 7 Removing the tank lid

5. See Figure 8. Remove the two hex nuts then remove the level switchassembly from the tank cover.

Figure 8 Removing the level sensor and screen

6. Remove the existing screen by pulling the screen horizontally out fromthe track in the tank. Discard the screen.



Install the Control Box 1. Attach the control box to the mounting bracket with the two threaded

knobs provided.

2. See Figure 9. Place the bracket and control box onto the rear of themelter.

3. Secure the bracket with the two flat washers and nuts on the melter.

Figure 9 Install the Fulfill control box onto the melter



Install the Control Box (contd)

4. Thread a customer supplied, 14−18 AWG power cord into the controlbox.

5. See Figure 10. Connect the wiring to the terminal blocks in the controlbox.

21

3

Figure 10 Connect the customer-supplied power cord to the control box

1. L1/L2 wire power cord connection(interchangeable)

2. Ground wire power cord connection

3. Power cord strain relief

6. Tighten the strain relief.



Install the Tank and Lid Components 1. See Figure 11. Install the lid clip (2) and lid retainer (4) onto the melter

tank.

1

2

3

4

Figure 11 Installing the tank components

2. Snap in the new filter screen (1).

NOTE: The level sensor comes pre-calibrated from the factory with the fillline 2 inches from the bottom of the probe holder. The level can be reducedby loosening the holder’s hex nut, and then sliding the probe lower. Tightenthe nut to keep the probe from moving.

3. Place the level sensor and holder (3) onto the top of the melter tank.The level sensor has been positioned at the factory for optimalperformance range. Secure with two nuts.

4. Place the Fulfill lid assembly onto the top of the melter. Fit the lid clip (2)through the opening in the rear of the tank lid.

5. Secure the lid by screwing the two knobs on top of the lid into thethreaded holes in the lid retainer.



Assemble the Transfer Hose, Air Line, and Suction Lance

CAUTION! Allow for 10 in. bend radius for installation/use of the adhesivetransfer hose.

1. Using one hose clamp, attach the transfer hose (A) to the end of thesuction lance (B).

2. Insert the suction lance into the PVC pipe inside the adhesive storagebin.

3. Use the remaining hose clamp to attach the transfer hose to the feedsystem inlet tube (C). The hose should be routed without sharp bendsor kinks.

NOTE: If necessary, loosen the inlet tube retaining screws and thenreposition the inlet tube.

4. Connect the air line (D) to the suction lance air inlet (E).

5. Route the air line along the transfer hose, securing it with wire ties asyou go. The hose should be routed without sharp bends or kinks.

6. Leaving enough air line to reach the outlet (G) of the air solenoid, cut theair line to length and then insert the end of the air line into the outlet.

7. Connect plant air to the regulator. For best results, run the air pipingfrom the main header.

A

B EC

D

F

G

Figure 12 Assembling the transfer hose, air line, and suction lance



Level Sensor Adjustment and Calibration The level sensor consists of a level probe and a control box. The levelprobe permanently connects to the control box by a wire. The level probehas a black line around its diameter near the tip to note the maintainedadhesive level.

CAUTION! Do not raise the fill line of the probe above 2 inches from bottomof the probe holder. Doing so will degrade the level sensor’s performance.

Figure 13 Adjustment potentiometer

See Figure 13. The LED indicator next to the adjustment potentiometer onthe control box changes color from green to amber, depending on theadhesive level that the probe detects. When adhesive drops below thedesired level, the LED will turn green. When adhesive reaches or exceedsthe desired level, the LED will turn amber. The adjustment potentiometersets the sensitivity of the level sensor. Different adhesives require differentcalibration settings. Adhesives that build up on the level probe require lesssensitivity, while adhesives that do not build up on the level probe requiremore sensitivity. The level sensor should be recalibrated any time the levelprobe’s height is changed or the type of adhesive being used changes.



Baseline Setting Upon setting the probe’s height, calibrate the level sensor.

1. Remove the threaded plug on the front face of the level sensor controlbox to reveal the adjustment potentiometer.

2. Fill the tank with adhesive and allow it to melt completely.

3. Adjust the liquid level to coincide with the black line on the level probe.

4. If the LED on the control box is amber, turn the adjustmentpotentiometer counter-clockwise until it turns green. If the LED on thecontrol box is green, turn the adjustment potentiometer clockwise until itjust turns amber. The point at which the LED transitions from green toamber is the switching point.

5. Once the switching point is found, rotate the adjustment potentiometer1/2 turn clockwise and leave it at that position.

Final Setting 1. Begin normal operation. Check the adhesive level in the tank after 30

minutes of operation.

2. If the adhesive level is satisfactory, the calibration procedure iscomplete. Re-install the plug over the calibration pot to discouragetampering.

3. If unmelted adhesive is piled up to the top of the tank or the system hasalready faulted due to overfilling, rotate the adjustment pot 1/2 turnclockwise to increase the level sensor’s sensitivity. Wait 10 minutes andcheck the adhesive level again. If the adhesive level is still too high,repeat this process until the adhesive level is satisfactory. Whenfinished, reinstall the plug over the calibration potentiometer.

4. If unmelted adhesive has built up on the probe and the adhesive level inthe tank has dropped below the black line on the probe, rotate theadjustment potentiometer 1/2 turn counter-clockwise to decrease thelevel sensor’s sensitivity. If the adhesive level is still too low, repeat thisprocess until the adhesive level is satisfactory.



Operation Once enabled, the fill system immediately begins operation. Maintainadhesive level in the storage bin to maintain automatic operation.

NOTE: During warm-up, the melter’s ready−delay time may need to beincreased for the Fulfill to operate properly. The proper ready−delay timedepends on the tank size and shape, adhesive type, and applicationtemperature.

Time Settings See Figure 14. There are three timers found on the PCA board in thecontrol box:

� Fault − The overfill timer. A fault is generated if the Fulfill unit dispenseslonger than the time allotted. Time range is 5 to 115 seconds.

� Delay − The time duration the Fulfill unit waits to transfer adhesive fromthe storage bin to the melter once a signal from the level sensor hasbeen transmitted to the control box. Time range is 1 to 119 seconds.

� Air − Used only with the optional vibrator kit. The air timer signals theamount of time the vibrator actuates once the filling process begins.Time range is 0 to 20 seconds.

Figure 14 PCA timer settings (located inside the control box)

Use a flat head screwdriver to turn the timers clockwise to increase the timesettings, counterclockwise to decrease the timer settings.



Monitoring Refill Operation See Figure 15.

Under normal conditions, the operator need not monitor or intervene in theoperation of the fill system.

However, if the fill system is unable to satisfy the tank sensor in the timelimit set for the Fill Time, the refill alarm LED will illuminate. Refer toTroubleshooting for a list of possible fault causes and solutions.

1 2 3

4

Figure 15 Fill system controls and indicators

1. Enable On/Off2. Filling activated symbol and blue LED

3. Fault symbol and red LED4. Clear fault

Maintenance Inspect the system daily to ensure that hose fittings are secure and that theunit is free from dirt and debris. Inspect the filter sock weekly to ensure thatit’s not clogged; replace as needed.



Troubleshooting If the fill system fails and the condition cannot be corrected, to continueoperating the melter (and filling it manually), disable the fill system (ensurethat the fill system power key LED is not illuminated).

Problem Possible Cause Corrective Action

1. System overfilled Solenoid stuck open Clean or replace.

Sensor ground wire not connected Connect.

Refill board not working Replace if defective. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

2. System underfilled No adhesive Add adhesive.

No power Ensure that power is available to thesystem.

Adhesive bridging Dislodge adhesive. Add optionalvibrator kit if problem persists.

Clogged wand/hose/lid Inspect the parts for improperconnections, clogs or kinks. Replaceas needed.

Clogged filter sock Replace if needed.

No/low air pressure Verify that sufficient air pressure andflowrate is supplied to the Fulfill unitfrom your factory. Static pressureshould be 65 psi min.; operatingpressure should be 45 psi min.Replace the regulator if defective.

No power to the level sensor Verify that power is being supplied tothe level sensor (LED not lit = nopower) and that the power cord isinstalled properly.

Deflector bent Repair or replace.

No power to fill board Verify power to the control box and atthe board. Replace if needed.

Solenoid failure Verify the connections to thesolenoid. Replace if defective.

Bad fill board Replace. See Refill PCATroubleshooting Instructions shownlater in the Troubleshooting section.

Overfill timer too short Adjust timer.

Sensor not calibrated properly Calibrate the sensor. Refer to LevelSensor Adjustment and Calibrationprovided earlier.

3. Frequent overfillalarms with no cause

Timers not properly set Adjust the timer settings. See TimeSettings provided earlier.



Refill PCA Troubleshooting Diagnostic Instructions Perform the following steps, in order, to either isolate the problem within thePCA board or to eliminate the PCA board as a cause. These tests shouldonly be performed by personnel qualified to work on high voltage circuits.

1. Verify input power is reaching the PCA. Measure line voltage across theinput side (side of the fuse closest to the input connectors J1 and J2) offuses F1 and F2. The input voltage should be between 100−240 VAC.If input voltage not present, correct input power.

2. Verify that the 24 VDC power supply on the Refill PCA board is workingby measuring the voltage between XT1 pin ”24V” and XT1 pin ”COM”. Itshould be 24 VDC (+/− 5%). If not 24 VDC, verify fuses are not blown. Iffuses have been blown, replace fuses. If fuses blow again, replaceRefill PCA. If fuses OK but 24 VDC not present, replace Refill PCA.

3. Check to make sure the DIP switch settings have not been changed.SW1 DIP switch settings: M1 should be OFF; M2 should be ON.

4. Make sure the timer potentiometers are set as expected:

� FAULT potentiometer adjustment range: 5 to 115 seconds (60seconds at 12:00 position),

� DELAY potentiometer adjustment range: 1 to 119 seconds (60seconds at 12:00 position),

� AIR (optional pre-vibrator) potentiometer adjustment range: 0 to 20seconds (10 seconds at 12:00 position).

5. Make sure the Refill PCA is enabled by verifying that the ”ENA” LEDclose to the membrane panel connector (X1) is illuminated. If not, pressthe ENABLE button on the membrane panel to enable the Refill PCA. Ifthe ”ENA” LED does not turn on with the membrane panel, themembrane panel or PCA may be bad. With a piece of wire, briefly touchX1 pin 1 to X1 pin 2 (the membrane tail will need to be unplugged toperform this test). If the ”ENA” LED illuminates after this test, replacethe membrane panel. If not, then replace the Refill PCA.

6. To ensure that the level sensor signal is getting to the Refill PCA with thelevel sensor calling for adhesive, verify that there is 24 VDC (+/− 5%)between XT1 pin ”SIG” and XT1 pin ”COM”. If not, repair the levelsensor cable, recalibrate level sensor, or replace level sensor.

7. To ensure that the Refill PCA fill output is working correctly with the levelsensor calling for adhesive and after waiting the DELAY time duration,verify that 24 VDC (+/−5%) is applied to the fill control output (XT2 pin”FILL” measured to any ”COM” pin). Verify with the level sensor is NOTcalling for adhesive that the fill control output is 0 to 0.5V.

If the problem has not be isolated to this point, replace the Refill PCA and/ormembrane panel.



This page intentionally left blank.



Parts This section provides information about parts that are associated with the fillsystem. Refer to the melter manual for information about all other meltercomponents.

Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your localNordson representative. Use these five-column parts lists, and theaccompanying illustrations, to describe and locate parts correctly. Thefollowing chart provides guidance for reading the parts lists.

The number in the Item column corresponds to the circled item number in theparts list illustration. A dash in this column indicates that the item is anassembly.

The number in the Part column is the Nordson part number you canuse to order the part. A series of dashes indicates that the part isnot saleable. In this case, you must order either the assembly inwhich the part is used or a service kit that includes the part.

The Description column describes the part and sometimesincludes dimensions or specifications.

The Note column contains letters that refer to notes at thebottom of the parts list. These notes provide importantinformation about the part.

The Quantity column tells you how many of the part isused to manufacture the assembly shown in the partslist illustration. A dash or AR in this column indicatesthat the amount of the item required in the assembly isnot quantifiable.

Item Part Description Quantity Note— 0000000 Assembly A —1 000000 � Part of assembly A 2 A2 - - - - - - � � Part of item 1 13 0000000 � � � Part of item 2 AR

NS 000000 � � � � Part of item 3 2NOTE A: Important information about item 1

AR: As Required

NS: Not Shown



ProBlue Retrofit Kit Assemblies

Item Part Description Quantity Note— 1098840 Kit, Fulfill retrofit, ProBlue 4 −−−−−−— 1098841 Kit, Fulfill retrofit, ProBlue 7 −−−−−−— 1098842 Kit, Fulfill retrofit, ProBlue 10 −−−−−−1 1098047 � Lid assembly, P4 1 A1 1097985 � Lid assembly, P7/P10 1 A2 — � Ctl. assy. w//brkt, P4/P7 1 B2 — � Ctl. assy. w//brkt, P10 1 B3 1099781 � Screen, inlet, pump, P4, push−on 13 1098375 � Screen, inlet, pump, P7, push−on 13 1099782 � Screen, inlet, pump, P10, push−on 14 1097584 � Retainer,lid 15 1097660 � Clip,lid 16 1097984 � Kit,container,wand and hose assy 17 1079193 � Adapter, 1/4 BSPP female X 1/4 NPT male 18 939955 � Fuse, time−lag, 2A, 5X20 mm, ceramic 29 1088282 � Filter, sock, 200 micron 1

10 1098864 � Kit, lid fasteners 1NOTE A: Components for lid assemblies are shown later in this section.

B: Components for control assemblies are shown later in this section.



Lid Assembly Parts See Figure 16.

Item Part Description Quantity— 1097985 Lid assembly, P7/10, Fulfill retrofit −−−−−— 1098047 Lid assembly, P4, Fulfill retrofit −−−−−1 1095342 � Enclosure assy ,filter, lid, Easy Pac 12 1097016 � Tube, inlet 13 982025 � Scr, skt, M4X14, bl 34 983163 � Washer, flt, M, oversized, M4, zn 35 1088282 � Filter, sock, 200 micron 16 982374 � Scr, skt, M5X40, bl 47 1096978 � Collar, lid 18 1097055 � Retainer, filter housing 19 1097018 � Tube, exhaust 1

10 1097668 � Lid, outer, P7/P10 110 1097794 � Lid, outer, P4 111 1097663 � Spacer, lid 112 1097737 � Insulation, lid, P7/P10 112 1097796 � Insulation, lid, P4 113 1097585 � Lid, inner, P7/P10 113 109795 � Lid, inner, P4 114 1097738 � Baffle, exhaust 115 982780 � Scr, skt, M5X10, zn 416 1097739 � Deflector 117 1098021 � Knob, black plastic with M5X30 lg stud 218 983408 � Washer, flt, M, narrow, M5, stl, zn 219 940073 � O-ring ,Viton, .145ID X .070W.BR, 10407 2



18

2

3

4

5

6

7

9

10

11

12

13

14

15

16

8

17

1

19

Figure 16 Lid assembly parts



Control Assembly with Bracket See Figure 17.

Item Part Description Quantity Note— 1098263 Ctl. assy. w/ brkt, P4/P7 −−−−−−— 1098510 Ctl. assy. w/ brkt, P10 −−−−−−1 1098169 � Control box assy. 1 A2 1099135 � Bracket, ctl. assy, P4/P7 12 1099136 � Bracket, ctl. assy, P10 13 1098491 � Level sensor, capacitive, w/ 150 mm probe 14 1098106 � Plastic knob, M5 x 25 25 982780 � Skt scr, M5 x 10 16 933476 � Lug , 45, single ,.250, .4 17 1098248 � Regulator/sol. assy 18 1040003 � Scr, skt, M4X25, zn 29 984715 � Nut, hex, M4, stl, zn 6

10 983163 � Washer, flt, M, oversized, M4, zn 411 1098913 � Harness, solenoid 112 1098745 � Bracket, ctl. box, P4/P7 112 1098746 � Bracket, ctl. box, P10 113 982680 � Scr, hex, washhd, tf, M5 x 12, blk 414 1099250 � Holder assy, level probe, 16 mm 1NS 939171 � Strap, cable, .18−4.00, natural 3

NOTE A: Parts for the control box are provided later in this section.

NS: Not Shown



13

3

5

2

10

8

11

6

9

7

1

4

14

Figure 17 Control assy. with bracket parts (P4/P7 unit shown)



Control Box Assembly See Figure 18.

Item Part Description Quantity— 1098169 Control box assy, Fulfill retrofit −−−−−−1 1097912 � Enclosure, poly, machined 12 982360 � Scr, skt, M3X10, zn 43 983520 � Washer, lk, M, int, M3, stl, zn 44 982604 � Scr, panhd, thd form, M4X12, bl 45 982780 � Scr, skt, M5X10, zn 16 983401 � Washer, lk, M, spt, M5, stl, zn 17 230261 � Termlug, ground, 6−14 AWG 18 982157 � Scr, skt, M3X14, B 19 933747 � Block, terminal, 2 station 1

10 1098483 � Domeplug, .500 in. D, .250 in. pnl thk 211 1098015 � Membrane panel 112 1097950 � Panel, mtg, ckt. bd. 113 1094486 � Block, heat sink, Easy−Pac 114 1054073 � Scr, skt, hd, M3x20 mm, steel, zn 115 1093698 � PCA, refill controller 116 1098484 � Domeplug, .750 in.D, .250 in. pnl thk 117 1046998 � Connector, strain relief, PG7, nylon 218 933607 � Connector, strain relief ,PG11 119 1098475 � Harness, AC power 1



17

Figure 18 Control box assembly



Regulator/Solenoid Assembly See Figure 19.

Item Part Description Quantity— 1098248 Regulator/sol. assy..,Fulfill 11 1093650 � Valve, solenoid, 3-way, 24V, 1/4 in. NPT 12 1058059 � Muffler, polyethylene, 1/4 in. NPT, Saturn 13 233785 � Elbow, male, 1/4 in. NPT 14 1096668 � Regulator/filter, 40 mic, 1/4 in. NPT, 65 PSIG 15 972125 � Conn, male, elbow, 10mm tube X 1/4 in. NPT union 1

3

2

4

5

1

Figure 19 Regulator/solenoid assembly



Service Kits Part Description

1099525 Kit, membrane panel

1099526 Kit, service, level sensor

1096221 Kit, service, PCA

1082942 Kit, service, sock filter, 5 pc

Accessories Part Description

1098479 Kit, cable, ProBlue, powered

1098962 Kit, vibrator, adhesive container

1099057 Kit, light tower

1099106 Kit, remote mount

Service Parts Part Description

1098248 Regulator/solenoid assy

1096668 Regulator/filter, 40 mic, 1/4 NPT, 65 psig

1093639 Regulator/filter, 40 mic, 1/4 NPT, 5-100 psig

1093650 Valve, solenoid, 3-way, 24V, 1/4 NPT

1099781 Screen, inlet, pump, P4, push−on



1097983 Container assembly, 120L

7408012 Suction wand

7408022 Vibrator, Suction Wand

1095962 Hose, transfer, 15 ft

1095965 Tubing, 10mm X 8mm, nylon, 15 ft

1095983 Cable tie, 14.5 ,nylon 6.6, 4.0 bundle

231362 Clamp, hose, worm dr, 1.06−2 in., ss

1097985 Lid assembly, P7/10

1098047 Lid assembly, P4

939955 Fuse, time−lag, 2A, 5X20 mm, ceramic

1099544 Gasket, container



Specifications Parameter Specification

Adhesive Forms

Maximum size

Pellets, pastilles, mini-slats

� Pastilles: 12 mm (0.472 in.) diameter

� Mini-slats:12 mm X 12 mm (0.472 in. X 0.472 in.) in length

Input voltage 100−240/1∅ VAC, 1 A

Power cord Customer supplied, 14−18 AWG

Adhesive Transfer Maximum Rate 227 kg (500 lb)/hour (dependent on adhesive type)

Transfer Hose Length 4 m (13 ft)

Operating Air Minimum 4.5 bar (0.45 MPa or 65 psi)Maximum 8.6 bar (0.86 MPa or 125 psi)

Total Air Consumption 679 Liters/min (24 SCFM) when feeding

Conditioning Dry, non−lubricated

Inlet Air Connection 1/4 in. NPT female

Pump Type Venturi

Noise Emission 76 dBA

Suction Lance Dimensions (L) 615 mm x max (W) 105 mm(24.21 in. x max 4.14 in.)

Storage Bin Capacity 60 Kg (132 lb)

Enclosure rating IP54



Dimensions

P10 Fulfill Retrofit

(25.60 IN.)

LID C

LOS

ED

(24.08 IN.)

(1.46 IN.)

(.40 IN.)

(13.92 IN.)

PO

WE

R C

ON

NE

CT

ION

(28.35 IN.)

CLE

AR

AN

CE

RE

QU

IRE

DT

O R

EM

OV

E LID

10.16 MM

353.57 MM

611.63 MM

650.24 MM

37.08 MM

720 MM

Allow

for 10 in. bend radius for installation/use of the adhesive transfer hose



P7 Fulfill Retrofit

Allow




P4 Fulfill Retrofit

Allow




Wiring Diagram

2 1

fulfill retrofit kit problue 4/7/10...

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