altablue™ touch series adhesive melters -...

AltaBlue™ Touch Series Adhesive Melters

Customer Product ManualPart 1120350_04

Issued 3/14

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 1120350_04 � 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 2011.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+, Dage, 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, Fibrijet, 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, Micromedics,

MicroSet, Millennium, Mini Squirt, Mountaingate, Nordson, Optimum, Package of Values, Pattern View, PermaFlo, PicoDot, Porous�Coat, 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 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, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto‐Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean�Coat, Cobalt, Controlled Fiberization, Control�Weave,

ContourCoat, CPX, cSelect, Cyclo‐Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+,E‐Nordson, Equalizer, EquiBead, FillEasy, Fill�Sentry, Flow Coat, Fluxplus, Get Green With Blue, G‐Net, G‐Site, IntelliJet, iON, Iso‐Flex, iTrend,

Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix,OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Plasmod, Powder�Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray,

PURBlue, PURJet, Ready Coat, RediCoat, Royal Blue, Select�Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing,Spray Works, Summit, SureFoam, Sure�Mix, SureSeal, Swirl�Coat, TAH, ThruWave, Trade�Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart,

Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, 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 1120350_04� 2014 Nordson Corporation

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

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

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

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

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

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

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Shut-Off Valve 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valves 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modes of Operation 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating and Heaters Off (Normal Mode) 2‐6. . . . . . . . . . . . . . . . . . . . .Standby 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear‐to‐Line Capability 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Identification 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware Installation and Setup 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump 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 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Residual Current Circuit Breakers 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . .Connecting the Electrical Service 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1120350_04 � 2014 Nordson Corporation

Connecting Hoses and Applicators 3‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up Inputs/Outputs 3‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up Gear‐to‐Line Operation 3‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting and Programming the Pump for Remote Control 3‐23. . . . . .

Wiring 3‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Programming 3‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Optional Equipment 3‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting an Applicator Driver, Pattern Controller, or Timer 3‐25. . . . .Flushing the Melter 3‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposing of Melter 3‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About the Touch Screen Display and User Interface 4-1. . . . . . . . . .Overview 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Melter for the First Time 4‐2. . . . . . . . . . . . . . . . . . . . . . . .Navigating the Touch Screen Displays 4‐3. . . . . . . . . . . . . . . . . . . . . . . . .

About the Operator Display 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring the Status of the Melter 4‐5. . . . . . . . . . . . . . . . . . . . . . . .

About the Master Controls Display 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Operation and Melter Configuration 5-1. . . . . . . . . . . . . . . . . . .Overview 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating the Melter 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Melter 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling the Reservoir 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controlling the Heaters, Standby and Scheduler 5‐3. . . . . . . . . . . . . . . . .Controlling the Pumps 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Understanding Zones 5‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuring Zones 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enabling and Disabling Zones 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modifying Zone Set Point Temperatures 5‐11. . . . . . . . . . . . . . . . . . . . .Modifying Zone Names 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modifying External Zone PID Types 5‐13. . . . . . . . . . . . . . . . . . . . . . . . .

Understanding Pumps 5‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuring Pumps 5‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enabling and Disabling Pumps 5‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Pump Operation Modes 5‐19. . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Pump Speed 5‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modifying Pump Names 5‐22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Melter Configuration 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Advanced Temperature Settings 6‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessing Temperature Settings 6‐3. . . . . . . . . . . . . . . . . . . . . . . . .Defining a Global Set Point Temperature 6‐4. . . . . . . . . . . . . . . . . . . . .Defining Temperature Limits 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Ready Delay 6‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Standby Settings 6‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Standby 6‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auto Exit Standby Time 6‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Pump Settings 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessing Pump Settings 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enabling and Disabling Auto Pump 6‐13. . . . . . . . . . . . . . . . . . . . . . . . . .Defining Pump Remote Control 6‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibrating Pumps 6‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii


Advanced Input/Output Settings 6‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Settings 6‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessing System Settings 6‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Formats and Units 6‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining the Date and Time 6‐20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Service Intervals 6‐21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Language Preference 6‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defining Display Settings 6‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring Password Protection 6‐26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuring Scheduled Events 6‐28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Administrative Options and Settings 6‐33. . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessing Administration Settings and Options 6‐33. . . . . . . . . . . . .Upgrading Software and Firmware 6‐34. . . . . . . . . . . . . . . . . . . . . . . . . .

Reverting back to a Previous Version 6‐36. . . . . . . . . . . . . . . . . . . . . .Managing Recipes 6‐37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessing the Recipes Screen 6‐37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What's Being Saved in a Recipe 6‐39. . . . . . . . . . . . . . . . . . . . . . . . . .Viewing the Event Log - Save Diagnostics 6‐40. . . . . . . . . . . . . . . . . . . .Resetting to System Defaults 6‐42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resetting Password Codes 6‐43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Viewing Software Version and Heater On Hours 6‐44. . . . . . . . . . . . . .Locking Out Communications 6‐45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing RTD Types 6‐46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Default User Settings and Ranges 6‐47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving System Pressure 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Through the Applicators 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Through the Melter Drain Valves 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Schedule 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Locking Out the Motor Drives 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing the Material Type 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching the Exterior Panels 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan and Air Filter 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor and Gear Box 7‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Motor Lubricant 7‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Motor or Coupling 7‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump 7‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Pump Screws 7‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Pump Gland Bolt 7‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing a Pump 7‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Cartridge 7‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Service Kit 7‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve 7‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure/Circulation Control Valve Service Kit 7‐18. . . . . . . . . . . . . . . . . .Cleaning the Tank 7‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Material from the Tank 7‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the Tank by Hand 7‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening the Fixing Screws 7‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Main PCA Board 7‐20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record Form 7‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Touch Screen Alerts and Faults 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Touch Screen Messages 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump and Zone Alerts/Faults 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . .System Alerts 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Faults 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Drive Faults 8‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 8‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Not Functioning 8‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One Channel (Heating Zone) Does Not Heat 8‐10. . . . . . . . . . . . . . . . .

Troubleshooting Pump 8‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Material (Pump Does not Rotate) 8‐11. . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor Rotating) 8‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Too Little Material 8‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure Too High 8‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure Too Low 8‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Residue in Tank 8‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Hardens in Tank 8‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Others 8‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AltaBlue Configuration Code 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame Assembly 9‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One/Two‐Pump Melter Frame Parts 9‐6. . . . . . . . . . . . . . . . . . . . . . . .Three/Four‐Pump Melter Frame Parts 9‐8. . . . . . . . . . . . . . . . . . . . . . .

Reservoir/Manifold Assembly 9‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two‐Pump Melter Reservoir/Manifold Parts 9‐10. . . . . . . . . . . . . .Three/Four‐Pump Melter Reservoir/Manifold Parts 9‐12. . . . . . . . . . . .100L Melter Reservoir/Manifold Parts 9‐14. . . . . . . . . . . . . . . . . . . . . . .Manifold Parts 9‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hopper Assembly 9‐20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two‐Pump Melter Hopper Parts 9‐20. . . . . . . . . . . . . . . . . . . . . . . .Three/Four‐Pump Melter Hopper Parts 9‐24. . . . . . . . . . . . . . . . . . . . . .100L Melter Hopper Parts 9‐28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assemblies 9‐30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Module Parts 9‐30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single‐Stream Pump Adapter Parts 9‐32. . . . . . . . . . . . . . . . . . . . . . . . .Dual‐Stream Pump Adapter Parts 9‐33. . . . . . . . . . . . . . . . . . . . . . . . . .Single‐Stream Gear Pumps 9‐34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dual‐Stream Gear Pumps 9‐37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve Parts 9‐38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v


Control Valve Assemblies 9‐40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Valve Module Parts 9‐40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Cartridge Parts 9‐42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve Parts 9‐43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Pressure Control Valve Parts 9‐44. . . . . . . . . . . . . . . . . . . . .Pneumatic Pressure Control Valve Interface Parts 9‐46. . . . . . . . . . . .Manual Pneumatic Pressure Control Valve Parts 9‐48. . . . . . . . . . . . . .Flow Control Bypass Control Valve Parts 9‐50. . . . . . . . . . . . . . . . . . . .Manual Pneumatic Pressure Control Valve Cabinet 9‐52. . . . . . . . . . .Flow Control Bypass Control Valve Cabinet 9‐54. . . . . . . . . . . . . . . . . .Manual Pneumatic Pressure & Flow Control Bypass Control Valve InterfaceParts 9‐56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow Control Bypass Control Valve Solenoid Parts 9‐57. . . . . . . . . . . .Manual Pneumatic Pressure & Flow Control Bypass Control Valve MultiConnector Parts 9‐58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Build Control Parts 9‐60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circulation Control Valve Parts 9‐62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flow Control Bypass 9‐63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Schematics 9‐64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Pneumatic Pressure 9‐66. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Assembly 9‐67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Enclosure Panel Assemblies 9‐68. . . . . . . . . . . . . . . . . . . . . . . . .

400V Melter Left Panel 9‐68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two‐Pump Melter 2 Hose/Gun (400V) Back Panel Parts (15, 30L) 9‐70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two‐Pump Melter 2 Hose/Gun (400V) Back Panel Parts (50L) 9‐72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Two‐Pump Melter 2 Back Panel Parts 9‐74. . . . . . . . . . . . . . . . . . .One/Two-pump Melter 4/6 Hose/Gun (400V) Back Panel Parts (15L, 30L) 9‐76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One/Twopump Melter 4/6 Hose/Gun (400V) Back Panel Parts (50L) 9‐78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three/Fourpump 4/6 Hose/Gun (400V) Melter Back Panel Parts (30,50L) 9‐80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three/Four‐Pump Eight Hose/Gun (400V) Melter Back Panel Parts (30,50L) 9‐82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two Hose/Gun (400V) Melter Right Panel Parts 9‐84. . . . . . . . . . . . . .Four Hose/Gun(400V) Melter Right Panel Parts 9‐86. . . . . . . . . . . . . . .Six Hose/Gun (400V) Melter Right Panel Parts 9‐88. . . . . . . . . . . . . . .Eight Hose/Gun (400V) Melter Right Panel Parts 9‐90. . . . . . . . . . . . . .Two Hose/Gun (240V) Melter Right Panel Parts 9‐92. . . . . . . . . . . . . .Four Hose/Gun(240V) Melter Right Panel Parts 9‐96. . . . . . . . . . . . . . .Six Hose/Gun (240V) Melter Right Panel Parts 9‐100. . . . . . . . . . . . . . .Eight Hose/Gun (240V) Melter Right Panel Parts 9‐104. . . . . . . . . . . . . .One/Two‐Pump Melter Bottom Panel Parts 9‐106. . . . . . . . . . . . . . . . . .Three/Four‐Pump Melter Bottom Panel Parts 9‐107. . . . . . . . . . . . . . . . .

Table of Contentsvi


Control Panel Assembly 9‐108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sensor Assembly 9‐110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Level Assembly 9‐112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Accessories 9‐113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Indication 9‐113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Pressure Control Valve 9‐113. . . . . . . . . . . . . . . . . . . . . . . . . .Line‐Speed Signal Generator 9‐114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Fittings 9‐114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Spare Parts 9‐115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 10‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 10‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 10‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Data 10‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One/Two and Three/Four Pump Melters 10‐4. . . . . . . . . . . . . . . . . . . . .Electrical Schematics 10‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Schematic 10‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calculating Melter Power Requirements (Including Heater Specifications) A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 1-1

� 2014 Nordson Corporation Issued 10-11

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 product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

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

Safety Alert 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 equipment orproperty.

Safety1-2

� 2014 Nordson CorporationIssued 10−11

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

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

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

� Make safety information available to equipment users in accordance with

governing regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to the

equipment, in readable condition.

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

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

� If applicable, receive approval from your facility's engineering or safety

department, 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 being

followed.

� Re‐evaluate safety practices and procedures whenever changes are

made 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 by

governing regulations and best industry practices

� are familiar with the equipment owner's safety and accident

prevention policies and procedures

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

individual

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

� possess industry‐ and trade‐specific skills and a level of experience

appropriate to their job function

� are physically capable of performing their job function and are not

under the influence of any substance that degrades their 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 warning

labels and tags affixed to the equipment. Refer to Safety Labels and Tagsat the end of this section.

� If you are unsure of how to use the equipment, contact your Nordson

representative for assistance.

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

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will be

used. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create a

hazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installation

instructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements for

clearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and all

independently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building code

enforcement agency for specific requirements.

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

equipment.

� Contact the authority having jurisdiction to determine the requirement for

installation permits or inspections.

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

and indicators.

� Confirm that the equipment, including all safety devices (guards,

interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

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

Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

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

malfunction.

Safety 1-5


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

or service the equipment.

� Perform scheduled maintenance activities at the intervals described in

this document.

� Relieve system hydraulic and pneumatic pressure before servicing the

equipment.

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

equipment.

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

� Read and comply with the manufacturer's instructions and the MSDS

supplied with equipment cleaning compounds.

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

� Confirm the correct operation of all safety devices before placing the

equipment back into operation.

� Dispose of waste cleaning compounds and residual process materials

according to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

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

labels.

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

� hot melt and cold adhesive application equipment and all related

accessories

� pattern controllers, timers, detection and verification systems, and all

other optional process control devices

Safety1-6


Equipment Shutdown

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

Relieving System Hydraulic Pressure

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

De‐energizing the System

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

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

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

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

Disabling the Applicators

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

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

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

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

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

Safety 1-7


General Safety Warnings and Cautions

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

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

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

PC = Process control

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

Table 1‐1General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

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

HM

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

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

Continued...

Safety1-8


Table 1‐1General 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, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

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

HM, CA, PC

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

HM, CA, PC

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

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.

Safety 1-9


Warning or CautionEquipment

Type

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

HM

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

HM, CA

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

HM

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

Safety1-10


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

� Check high pressure hoses daily for signs of excessive wear, damage, 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 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 1-11


Safety Labels and Tags Figure 1‐1 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.

Figure 1‐1 Safety labels and tags

Safety1-12


Safety Labels and Tags (contd)

Table 1‐2Safety Labels and Tags

Item Part Description

1. 1025795

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

2. 224906 WARNING: TAG,WARNING,ELEC SHOCK

3. 224905 WARNING: HOT

4. 1100254 CAUTION: HOT SURFACE

5. 1100256 WARNING: TAG,WARNING,HOT ADH/HYD PRESS

6. 1120127 WARNING: TAG,WARNING,HIGH LEAKAGE CURRENT

Introduction 2-1


Section 2

Introduction

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 personnel frompotential 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 tank lid

supports.

� Risk of burns when conducting maintenance and repair work for which

the 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 were

installed 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.

Figure 2-1 Key melter components

1 Touch Screen

2 Protective panel, removable

3 Tank lid

4 Main power switch

5 Motors

6 Filter cartridge

7 Pressure control valve

8 Manifold

9 Hose receptacles

10 ID plate

11 Hopper

Introduction2-4


Electrical Components

Figure 2-2 Key electrical components

1 Main board

2 Circuit breakers

3 RC suppressor

4 Fan

5 Pump controller

6 Signal conditioner

7 Expansion board

8 Power module

9 Main switch

10 Distribution block

11 Contactor

12 Lockout switch

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

Introduction 2-5


Pump Shut-Off Valve

The pump shut-off valve allows replacement of the pump without firstemptying the tank.

Figure 2-3 Location of the pump shut−off valve

Pressure Control Valves

The manual pressure control valves can be adjusted from 0-90 bar.

Figure 2-4 Location of the pressure control valves

Introduction2-6


Modes of Operation AltaBlue melters operate in the following modes.

Heating and Heaters Off (Normal Mode)

The melter operates with the heaters either on or off. The melter will trigger a“ready” condition when the heaters reach their programmed temperaturezones (hopper and reservoir) and external zones (hoses, standard and largeapplicators and air heaters) confirming all zones are within their pre‐definedsetpoint temperature range.

Standby

All internal and external zones are reduced, by the default 50°C (90°F) downfrom their setpoint temperature.

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. A line‐speed signal generator must be installed if youwant to use the gear‐to‐line capability.

Introduction 2-7


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 2-5 Location of the melter identification plate

Introduction2-8


Hardware Installation and Setup 3-1


Section 3

Hardware Installation and Setup

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. Someadditional materials must also be supplied by the customer to complete theinstallation.

If optional equipment was ordered with the melter, refer to the documentationprovided with the optional equipment for installation and operatinginstructions.

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.

Hardware Installation and Setup3-2


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. Configuring the Electrical Service.

4. Connecting Hoses and Applicators.

5. Setting Up Inputs/Outputs.

6. Setting Up Gear-to-Line Operations.

7. Installing Optional Equipment.

8. Connect an applicator driver, pattern controller, or timer.

9. 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.



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



Clearances (contd)

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



Figure 3-3 100L melter minimum installation clearances



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 exhaust ventilationslots.

Figure 3-4 Location of the ventilation openings

Electrical Power

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

Refer to Appendix A, Calculating Melter Power Requirements, for informationabout how to calculate the maximum allowable hose lengths and applicatorwattages 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.



Pump Drive Internal Filter

The AltaBlue melter is manufactured and shipped from the factory incompliance with CE regulations. If the pump drive internal filter, locatedinside each pump drive, is turned off, the melter will no longer beCE‐compliant.

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

Other Considerations

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

� The maximum distance between the melter and each applicator is

dictated by the power requirement of each hose. Refer to Appendix A,Calculating Melter Power Requirements, for information about how todetermine the maximum allowable length.

� The operator must be able to accurately monitor and safely reach the

touch screen display.

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

the hopper/reservoir.

� The melter must be installed away from areas with strong drafts or where

sudden temperature changes occur.

� The melter must be installed where it will be in conformance with the

ventilation requirements specified in the Material Safety Data Sheet forthe hot melt being used.

� The melter should not be exposed to excessive vibration.



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. Reportany 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)



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 is 86 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 the

power supply and the melter.

� Only residual current circuit breakers sensitive to pulsating current or

universal 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 10, 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 cabinet throughthe 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.



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) � � � � �



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



Connecting Hoses and Applicators

WARNING! Risk of fire or equipment damage. Before connecting hoses andapplicators to the melter, confirm that the power required by eachhose/applicator pair and each hose/applicator module, does not exceed themaximum wattages specified in Appendix A, Table A‐1, Maximum AllowableWattages.

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, themelter 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 the melterat 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 for

your 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 guide

contains important information about routing and installing the hose.

� Save all of the port plugs removed from the manifold. A port plug will

need to be reinstalled into the manifold if a hose is later removed.

Figure 3-8 Location of the optional return hose fitting



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



To connect hoses (contd)







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



Pump 2: Stream 2, Output port 1








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



To connect hoses (contd)














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

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



Figure 3-13 Connecting a hose cordset



To connect applicators

Observe the following guidelines:

� AltaBlue melters with 120‐ohm nickel sensors support all Nordson T‐style

applicators. AltaBlue melters with 100‐ohm platinum sensors support allNordson M‐style applicators.

� For information about choosing the most appropriate Nordson hot melt

applicator 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 applicators.

� Refer to the user's guide that is shipped with each applicator for

information about installing the applicator and connecting a hose to theapplicator.

NOTE: AltaBlue melters are shipped with a 0.2 mm hot melt filter installed inthe manifold. Order the appropriate applicator nozzle based on this filtermesh size.

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/applicator pair

� 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 touch

screen buttons. Ensure that the control logic for any external device that

sends an input signal to the melter is programmed to prevent the creation of

an unsafe condition in the event that the operator overrides an external input

to the melter.

The melter is also equipped with three user‐configurable outputs. Outputsare used to communicate with user‐supplied production equipment or controlhardware, 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)

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



To wire inputs/outputs to the melter

See Figure 3‐14.

1. A female quick connector (32 positions + PE) is located on the melterright panel. Route a signal cable from the control equipment to the melterthrough a male quick connector (32 positions + PE). The male quickconnector has a PG-21 strain relief to fasten the signal cable. I/Oconnector designation: -17X21 Function: transmits the digitalinput/output signals and key-to-line signal between the parent machineand the Nordson melter.

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

2. Connect each pair of input and output wires to the appropriate terminalson I/O connector. Refer to table below for the terminal numbers thatcorrespond to each input.

Figure 3-14 Location of the quick connector (-17X21) for connecting input/output wiring

To set up inputs/outputs

Set up the parameter control option for each input and output that youconnected to the melter. Table 3‐2 lists the available control options.



Setting Up Inputs/Outputs (contd)

Table 3-2 Input/Output Data

Item Description ControlOptions

Terminals Notes

1 Standardinput 1

NotesA and B

-17X21:8,-17X21:9+24V

Input activated with 10 - 30 VDC. The input is notpolarity sensitive.

2 Standardinput 2

Note A -17X21:10,-17X21:11 Input activated with 10 - 30 VDC. The input is notpolarity sensitive.

3 Standard

input 3


4 Standardinput 4


5 Standardoutput 1

Note C -17X21:1,-17X21:2 The output is a electromechanical relay contactrated for 2 Amps at 240 VAC or 30 VDC.

6 Standardoutput 2


7 Standardoutput 3


8 Gear-to-line0-10V input

-17X21:15,-17X21:16 Refer to Setting Up Gear-to-line Operation.Connect the positive wire to -17X21:15. Connectthe negative wire to -17X21:16. Note that thenegative input is connected to chassis (PE).

9 Pump 1remoteon/off

-17X21:17,-17X21:18+24V

Input activated with 18 - 30 VDC. The input is notpolarity sensitive. Activating the input will turn onthe motor when the remote control feature isenabled from the user interface.


-17X21:19,-17X21:20+24V



-17X21:21,-17X21:22+24V



-17X21:23,-17X21:24+24V


13 Pump drive1 running

-17X21:25,-17X21:26 Electromechanical relay contact that indicatesmotor is running when closed. Contact rated for1.5 Amps at 240 VAC or 30 VDC.









NotesTerminalsControlOptions

DescriptionItem

NOTE A: Input Options: Disabled, Standby, Heater Control, Pump Control and External Zone 1-8. AutomaticStandby is only available for input #1.

B: Automatic Standby is only available for input #1.

C: Output Options: Disabled, Ready, Ready-Pump On, Fault, Tank Low, Alert and Service Reminder.



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. TheAltaBlue 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�9, 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 -17X21 on the electrical enclosure right panel. See Figure3‐14 for the location of terminal block -17X21. Refer to Table 3‐2 for theterminal numbers that correspond to each input/output.



Connecting and Programming the Pump forRemote Control

Complete the Wiring and Programming instructions below to remotelymonitor and run the pumps.

Wiring

To use the motor run status monitoring capability, connect wiring from theparent machine to the appropriate terminals on I/O connectors on right panelof the electrical enclosure. See Figure 3-14 for the location of I/O connectors.Refer to Table 3-2 for the terminal numbers that correspond to eachinput/output

NOTE: The relay contact between terminals-17X21:25/-17X21:26,-17X21:27/-17X21:28,-17X21:29/-17X21:30,-17X21:31/-17X21:32 are normally open. When the motor is running, these contactsshould close..

Programming

Use the keypad located on each pump drive inside the electrical enclosure toset up the pump run status monitoring.

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.



1

2

3

4

5

6

7

8

Figure 3-15 Motor drive keypad (located on each motor drive inside the electrical enclosure)

1. Graphic display

2. Mode button

3. ESC button

4. RUN button

5. Navigation keys

6. ENTer button

7. STOP button

8. Button for reversing motordirection/rotation



Installing Optional Equipment Each item of optional equipment is shipped with instructions for installing andoperating the equipment. Refer to Section 9, Parts, for equipment partnumbers.

Connecting an Applicator Driver, PatternController, or Timer

If applicable, complete the melter installation by connecting the applicators tothe desired applicator driver, pattern control, or timer. Refer to the productmanual provided with the device for information about installing andoperating the equipment.

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 accomplished byprocessing a minimum of one tank volume of hot melt through the melter,hoses, and applicators.

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

About the Touch Screen Display and User Interface 4-1


Section 4

About the Touch Screen Display andUser Interface


Overview The touch screen display replaces the membrane control panel used onprevious Nordson melters. With a touch of your finger on the display screen,you can navigate the graphical user interface to setup, operate and maintainthis melter.

The melter is shipped from the factory with most software settingspreconfigured and ready to use. However, there are some settings that youmust configure and finetune to best fit your manufacturing process.

About the Touch Screen Display and User Interface4-2


Starting the Melter for the First Time � If the melter was not configured for you from the factory, the Configuration

Wizard screen appears. Refer to Figure 4‐1.

� If the melter was configured for you from the factory, the Operator Display

appears. Refer to Figure 4‐2.

Next

Welcome

Use the Configuration Wizard to set up the following

information:

* Language

* Date/Time Format and Temperature Units

* Current Date and Time

Click Next to Continue.

Figure 4‐1 The Configuration Wizard

Figure 4‐2 The Operator Display



Navigating the Touch Screen Displays The AltaBlue Touch Series Melter consists of the following primary displays:

� The Operator Display

� Master Control Display

About the Operator Display

The Operator Display is the default display.

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Pump 1Manual

45 RPMSet Point: 45 RPM

Pump 3Manual


Pump 4GLT


Pump 2Manual


Heaters: On

Pump: On

Password: Disabled

Melter Status:

Ready \ OK

Recipes

Nothing Loaded

MasterControls

Pumps

Monitor

Navigation

Zones




The Operator Display is divided into 4 sections:

Section Description

Zones � Enable\disable

� Create or modify zone name

� Define individual set point temperatures

� Modify default channel associations

� View state and status for each zone

Pumps � Enable\disable

� Create or modify pump name

� Define pump operation mode

� View state and status for each pump

Monitor � View melter status

� View state of the master heater and pump

controls, as well as whether or not passwordprotection is enabled

� View and manage recipes

Navigation � Access the Master Control Display



Monitoring the Status of the Melter

You can view the status of the melter from the following:

� The Operator Display, see Figure 4‐4

� Screen Saver, see Figure 4‐5

NOTE: The screen saver appears after 5 minutes (the default) of no userinteraction with the touchscreen. The Operator Display re-appears when youtouch anywhere on the screen saver.

Middle Melter Status Indicator


System Status:

Ready\OK

Figure 4‐5 The Screen Saver

NOTE: Touch the middle melter status indicator to view the event log, ifthere was an alert, fault, low tank or service reminder.



What the Melter Statuses Indicate

The following table details the melter and zone\pump status messages.

Button Color Heaters Pumps Description

System Status: Ready\OK

Darkgreen

On On All available and enabled zones andpumps are at their set points and/orhave a status of Ready\OK.

System Status:

Ready \ Low Level

DarkGreen

On On Same as Ready\OK, but the reservoiris almost empty and requires refilling.

System Status:

Ready \ Service

DarkGreen

On On Same as Ready\OK, but a componentrequires regular scheduled servicing.

System Status:

Heaters Off

LightGreen

Off On/Off Zones at set point temperatures,pumps ready, but the master Heatercontrol is Off.

NOTE: This could be the result ofa zone or pump fault.

System Status:

Alert

Yellow On On The melter continues to work, butsome functions may not be available.Melter requires servicing.

Zone Alert:

Zone 1A

Yellow On On The system has detected a zone orpump alert condition. The meltercontinues to operate normally, butsome functions may not be available.Melter requires servicing.

NOTE: You have 2 minutes fromthe time the system detects anRTD and\or an over\undertemperature alert before it isupgraded to a Fault condition.

System Status:

Fault

Red Off Off A system fault condition has beendetected. The melter has stoppedworking.

Zone Fault:

Zone 1A

Red Off Off The system has detected a zone orpump fault condition. The melter hasstopped working.

System Status:

Heating

Orange On Off The system is in the process of heatingall available and enabled zones to theirset point temperatures.



Button Color Heaters Pumps Description

System Status:

Ready Delay

LightBlue

On Off Although all available and enabledzones are at their set pointtemperatures, the Ready\OK isdelayed until the user-defined time haselapsed.

System Status:

Standby Mode

Blue On Off The system has been manually orautomatically placed into Standbymode.



About the Master Controls Display

Use the Master Controls Display to switch on/off primary melter controls,including the heater, pump and scheduler as well as to manually place themelter into standby mode. You can also access advanced melter settings.

From the Operator Display, touch Master

Controls

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Pump 1Manual


Pump 1Manual


Pump 1GLT


Pump 1Manual


Melter Status:

Ready\OK

Recipes

SMALL SIZE

Done

Scheduler

Pump ControlHeater Control

Standby

Settings System

Master Controls

Scheduler: Off

Pumps: OnHeaters: On

Standby: Off

MasterControls

Heaters: On

Pump: On

Password: Disabled

Figure 4‐6 The Master Controls Display

What you can do from Master Controls | Settings

Settings Description

Temperature � Global Set Point

� Temperature Limits

� Ready Delay

� Standby

Pumps � Auto Pump

� Remote Control

� Pump Calibration

Inputs/Outputs � Configure standard and expanded inputs/outputs



What you can do from Master Controls | System

Settings Description

Formats/Units � Time

� Date

� Temperature

� Pressure

Date/Time � Current data and time

Password � Create/Modify (codes)

� Timeout

� Set Security Level

Display � Brightness

� Screen Saver Delay

� Calibrate Screen

� Wipe Display

Language � Current Language

Scheduler � Define daily heat and standby events

Administration � System Reset

� Display/Save Diagnostics

� Reset Password

� Firmware Version

� Create, modify, delete or not make use of a Recipe

� RTD Options

� Lockout Communications

� Hours Heaters On



This page intentionally left blank.

Basic Operation and Melter Configuration 5-1


Section 5

Basic Operation and Melter Configuration


Overview The melter is shipped from the factory with most temperature, pump andmelter (system) settings preconfigured and ready to use. However, there aresome settings that you must configure and finetune to best fit yourmanufacturing process.

The following are basic melter configuration topics discussed in this chapter.

Topic Tasks

Operating theMelter

� Switching the melter On

� Filling the reservoir

ConfiguringZones

� Enabling and disable zones

� Creating or modifying zone names

� Defining individual set point temperatures

� Modifying default channel associations

ConfiguringPumps

� Enabling and disable pumps

� Creating or modifying pump names

� Defining pump mode operation

Filling the reservoir

Basic Operation and Melter Configuration5-2


Operating the MelterWhen the melter and its hardware are installed you are ready to start themelter start configuring the various software settings.

Starting the Melter

Turn the main power switch to the On position.

The Operator Display appears.

The System Status indicates Green or Ready/OK

� When all enabled zones reach their set point temperatures.

� The Ready Delay option is disabled or when the userdefined Ready

Delay time has elapsed.

Filling the Reservoir 1. Use a scoop to pour hot melt material into the hopper, leaving a minimum

of 2.54 cm (1 in.) of space between the top of the material and the top ofthe hopper.

2. After filling, close the lid.

CAUTION! Before filling the reservoir, make sure both the hopper and thehot melt material are clean and free of foreign substances.

CAUTION! Do not operate the melter on an empty or near empty reservoir. Ifthere is too little hot melt in the reservoir, it can overheat and char, potentiallycausing a fault or alert condition.



Controlling the Heaters, Standby and SchedulerUse the Master Controls to switch on/off the following:

� Heaters

� Standby (manual)

� Scheduler

NOTE: Refer to Controlling Pumps for more information.

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Pump 1Manual


Pump 1Manual


Pump 1GLT


Pump 1Manual


Melter Status:

Ready\OK

Recipes

SMALL SIZE

Done

Scheduler


Standby

Settings System

Master Controls

Scheduler: Off


Standby: Off

MasterControls

Heaters: On

Pump: On

Password: Disabled

Figure 5‐1 The Master Controls Display



1. From the Operator Display touch Master

Controls

2. Touch the color coded button to switch On or Off the following:

Master Control Description

Heater Control Manually switch the heaters On/Off. By default, themaster heater control is On.

NOTE: The master heater control automaticallyswitches Off, along with the pumps when the melter isin a Fault condition.

Standby Control Manually switch the melter in or out of standby mode.

NOTE: Refer to Auto Exit Standby Time for moreinformation.

SchedulerControl

Manually switch the scheduler option On/Off.

NOTE: Refer to Configuring Scheduled Events formore information.

3. Touch the color coded button to enable or disable the zone. Touch Done.

What the Button Colors Indicate

The following table details what the Heater, Standby and Scheduler master control

button indicate.

Button Color Description

Green On

White Off



Controlling the PumpsUse the Master Pump Control to switch all pumps on/off.

NOTES:

� The master pump and heater controls automatically switches Off, when

the melter is in a Fault condition.

� You must wait until the melter status indicates Ready\OK before you can

manually or remotely switch the Pump Control to On.

� You can enable the Auto Pump option, which automatically switches the

pump Control to On before the melter status indicates Ready\OK. Refer to Defining Pump Remote Control for more information.

� The Pump Control button uses different colors to indicate Remote Control

and if the Auto Pump option is enabled. Refer to the table below for moreinformation.Refer to Enabling and Disabling Auto Pump for more information.

1. From the Operator Display touch Master

Controls

Refer to Figure 5‐1.

2. Touch the color coded button to continue.


Green On

White Off

Orange Auto Pump enabled

Half green, Half white

Remote (master) PumpControl setup andenabled



Understanding ZonesThere are two types of zones.

Type Default Name Notes

InternalZones

� Hopper

� Reservoir

� Internal zones include only the hopper and reservoir.

� Although the Hopper and Reservoir are displayed as two

separate zones, when modifying either set point, the systemallows you to modify both set points together.

ExternalZones

Zone (# + letter)for example Zone 1A

� External zones include hoses, applicators and optional air

heaters.

� Default name consists of the word Zone, and its corresponding

channel number. Typically, these are pairs, where the letter Arepresents a hose and the letter B represents the applicator. Youcan change these default channel associations.

� At least one external zone is required for normal operation.

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Melter Status:

Ready \ OK

InternalZones

ExternalZones

MasterControls

Figure 5‐2 About External and Internal Zones



About Zone States and Statuses

Figure 5‐3 details what an enabled zone displays. Refer to Tables 5‐1 and5‐2 for a detailed list and explanation of each zone state and status.

Name of zone

Real-time temperature indicator

Set point temperature

Zone 1ASet Point: 145� C

145� C

Figure 5‐3 Zone button details

Table 5‐1 Zone State and Status Color Reference

Zone States

Button Color State Notes

Disabled

Zone 1AWhite Disabled The zone is available, but disabled.

Zone 1A

Unavailable

Gray Unavailable The system cannot detect the zone.



Table 5‐2 Zone State and Status Color Reference

Zone Status

Button Color Status Notes

Zone 1A

Set Point 175�C

145�C

Dark green Ready/OK The zone is enabled and has reached its set pointtemperature.

Zone 1A

Set Point 175�C

145�C

Light green Waiting forReady

The zone is enabled and is in the process of heating to itsset point temperature.

� The zone is enabled and is in the process of heating to

its set point temperature.

� The system is in either Standby or Ready Delay mode.

� A zone or pump is in an alert or fault condition.

� The system itself is in an alert or fault condition.

Zone 1A

Alert

Yellow Alert The zone is enabled, but the system has detected an alertcondition. Touch the zone with the alert to view systemmessage.

NOTE: In an alert condition, both the master Heaterand Pump controls remain On.

You have two minutes from the time the systemdetects an RTD or an over/under temperaturecondition before the alert condition is upgraded to afault condition.

Zone 1A

Fault

Red Fault The zone is enabled, but the system has detected a faultcondition. Touch the zone with the alert to view systemmessage.

NOTE: In a fault condition, both the master Heaterand Pump controls are switched Off.

NOTES:

� You can modify zones at any time.

� Changes to set point temperatures and PID Type take effect when the

zone is enabled and when the melter itself is in a Ready/OK state.

� Changes to the zone name and enabling/disabling take effect when you

touch Done.

� The default name is displayed unless you modify it.

� The state of a zone is independent of the overall status of the melter.



Configuring ZonesConfiguring zones include the following tasks:

� Enabling and disable external zones

� Defining individual set point temperatures

� Creating or modifying external zone names

� Modifying default channel PID types

NOTE: Refer to the appropriate section for more information.



Enabling and Disabling Zones

NOTE: Enabling or disabling a zone takes effect when you touch Done.

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Melter Status:

Ready \ OK

Pump 1Manual


Pump 1Manual


Pump 1GLT


Pump 2Manual


Zone 1ADone

Zone 1A

Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

MasterControls

Heaters: On

Pump: On

Password: Disabled

Zone 1A

Zone State: Enabled

Color coded Enable\Disablebutton

Name of zone

Current zone state

1. Access the Operator Display and touch a zone that you want to enableor disable.

2. Touch the color coded button to enable or disable the zone. Touch Done.


Green On

White Off



Modifying Zone Set Point Temperatures

Zone 1ADone

Zone 1A

Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

Done

Cancel

7 8 9

4 5 6

1 2 3

0

Zone 1A - Set Point

175

�C

Home

1. Access the Operator Display and touch a zone that you want to modifyits set point temperature.

2. Touch Adjust Set Point and enter the temperature you want for thiszone. Touch

3. Touch Done.

NOTES:

� To minimize charring the adhesive material, you can define the hopper

set point temperature up to 15�C (30�F) cooler than the reservoir setpoint temperature.

� The Hopper set point temperature cannot exceed that of the reservoir.

� Although the Hopper and Reservoir are displayed as two separate zones,

when modifying either set point, the system allows you to modify both setpoints together.



Modifying Zone Names

Zone 1ADone

Zone 1A

Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

Q

Zone 1A - Set Point

W E R T Y U I O P

A S D F G H J K L

Z X C V B N M

123… Zone 1A

Done

Cancel

Home

1. Access the Operator Display and touch an external zone that you wantto modify its name. Refer to Accessing the Zone Configuration Screen formore information.

2. Touch Create/Modify Name and enter the name you want for this zone.The name can be up to 10 characters long. Spaces, dashes, underscoreand numbers count as a single character.

3. Touch Done to continue.

NOTE: Internal zone names cannot be modified.

NOTE: Upper case only.



Modifying External Zone PID Types

By default, the system assigns PID types as follows:

� Zones ending with a letter A are associated with a Hose

� Zones ending with a letter B are associated with a Standard

Applicator.

NOTE: PID types optimize the performance of the device.

Zone 1ADone

Zone 1A

Enabled

Adjust Set Point

Create/Modify Name

Zone 1A

Change PID Type

Hose175�C

External Zone 1ADone

Hose

Home

Standard Gun

Large Gun

Air Heater

1. Access the Operator Display and touch the external zone that you wantto change its PID types.

2. Touch Change PID Type and select the appropriate button for theselected zone.

3. Touch Done.

NOTE: You cannot modify internal zone PIDs.



Understanding PumpsThe number of pumps depends on the number of installed Motor ControlBoards. Each Motor Control Board controls up to 2 pumps. The default is 1Motor Control Board. The maximum is two Motor Control Boards per melter.

Pump 1Manual


Pump 3Manual


Pump 4GLT


Pump 2Manual


Melter Status:

Ready \ OK

Pumps

MasterControls

Figure 5‐4 About Pumps

About Pump States and Statuses

Figure 5‐5 details what an enabled pump displays. Refer to Tables 5‐3 and5‐4 for a detailed list and explanation of each pump state and status.

Name of pump

Real-time pump speed

Operation Mode Pump 1Manual

45 RPM

Set Point: 45 RPMSet Point

Figure 5‐5 Pump button details



Table 5‐3 Pump State Color Reference

Pump States

Button Color State Notes

Disabled

Pump 1White Disabled The pump is available, but disabled.

Pump 1

Unavailable

Gray Unavailable The system cannot detect the pump.

Table 5‐4 Pump Status Color Reference

Pump Statuses

Button Color Status Notes

Pump 1Manual

24 RPMSet Point 34 RPM

Dark green Ready/OK The pump is enabled and has reached its set point speed.

Pump 1ManualSet Point 34 RPM

24 RPM

Light green Waiting forReady

The pump is enabled and…

� is waiting for the melter to reach its Ready/OK status

before you can manually switch On the master PumpControl.

� Auto Pump is enabled and is waiting for the melter to

reach its Ready/OK status before automaticallyswitching On the Master Pump Control.

� The system is in either Standby or Ready Delay mode.

� A zone or pump is in an alert or fault condition.

� The system itself is in an alert or fault condition.

Pump 1Alert

Yellow Alert The pump is enabled, but the system has detected analert condition. Touch the pump with the alert to viewsystem message.

NOTE: In an alert condition, both the master Heaterand Pump controls remain On.

Pump 1Fault

Red Fault The Pump is enabled, but the system has detected a faultcondition. Touch the pump with the alert to view systemmessage.

NOTE: In a fault condition, both the master Heaterand Pump controls are switched Off.



Requirements for Running a Pump

The following lists the system requirements before running a pump:

� The melter status must indicate Ready/OK.

� The pump must be enabled.

� In addition to the internal zones, at least one external zone must be

enabled.

� The Master Heater Control switch must indicate On.

� The Master Pump Control switch must indicate On.

‐ Refer to Advanced Pump Settings for more information.

Basic Pump Operation Modes

There are two default pump operation modes:

Operation Mode Description

Manual (default)

Delivers adhesive at a constant speed you manuallyenter.

Gear-to-Line Delivers adhesive at a rate proportional to the linespeed.

Extended Pump Operation Modes

Contact to your Nordson sales representative for more information aboutexpanding your pump operation modes to include the following:


Pressure Controland Monitoring

Delivers consistent adhesive by varying pumpspeed to control system pressure that isproportional to the line speed.

Flow Control andMonitoring

Delivers an accurate flow rate of adhesive based oninline measurements of consumption, add-onweights and application pressure that is proportionalto the line speed.

NOTE: Extended Pump Operation Modes require additional hardware.



Configuring PumpsThe number of pumps depends on the number of installed Motor ControlBoards. Each Motor Control Board controls up to 2 pumps. The default is 1Motor Control Board. The maximum is two Motor Control Boards, is zones.

NOTES:

� The default name is displayed unless you modify it.

� The state of a pump is independent of the overall status of the melter.

� Make sure to save your changes to a recipe. Refer to Managing

Recipes for more information.

Configuring pumps include the following:

� Enable\disable

� Change operation mode

� Adjust speed

� Create or modify name



Enabling and Disabling Pumps

NOTE: Enabling or disabling a zone takes effect when you touch Done.

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Melter Status:

Ready\OK

MasterControls

Pump 1Manual


Pump 1Manual


Pump 1GLT


Pump 1Manual


Pump 1Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

MAN

Total Adhesive Used

Manage Channel

Monitor

Test Graphing

Heaters: On

Pump: On

Password: Disabled

Settings

Mode

Pump 1

Pump State: Enabled

Color coded Enable\Disablebutton

Name of pump

Current pump state

1. Access the Operator Display and touch a pump that you want to enableor disable.

2. Touch the color coded button to enable or disable the pump.


Green On

White Off



Changing Pump Operation Modes

The default available pump operation modes are Manual and Gear-to-Line.

Pump 1Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

MAN

Total Adhesive Used

Manage Channel

Monitor

Test Graphing

Settings

Mode

Pump 1 \ Operation Mode Done

Manual

Gear-to-Line

Pressure Control

Flow Control

Home

1. Access the Operator Display and touch a pump that you want to modifyits operation mode.

2. Touch Change Operation Mode and select which pump mode you wantto use.

3. Decide which pump operation mode you want to use, then touch Done.


Manual Pump runs at a constant Speed.

Gear-to-Line Pump runs runs at a variable speed based on linespeed signal.

Note:

� Refer to About Gear-to-Line for more

information.

Pressure Control Delivers consistent adhesive output by varyingpump speed to control system pressure proportionalto the line speed.

Note:

� Requires additional hardware.

Flow Control dispenses an accurate flow rate of adhesive, basedon inline measurements of consumption, add-onweights and application pressure proportional to theline speed.

Note:

� Requires additional hardware.



4. Touch Adjust Speed and enter the required information.

� Refer to Figure 5‐6

� Refer to Figure 5‐7

5. Touch Done.

Pump 1Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode MAN

Total Adhesive Used

Manage Channel

Settings

Monitor

TestGraphing

Done

Cancel%

7 8 9

4 5 6

1 2 3

0

Pump 1\ Gear-to-Line

100

% Line Speed

Desired Pump RPM

Min Pump Speed

RPM

RPM

9494

0

Figure 5‐6 Configuring and adjusting Gear-to-Line mode

Pump 1Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode MAN

Total Adhesive Used

Manage Channel

Settings

Monitor

TestGraphing

Done

Cancel

7 8 9

4 5 6

1 2 3

0

Pump 1\Pump Speed (RPM)

0

RPM

Home

Figure 5‐7 Configuring and adjusting Manual mode



About Gear-to-Line

Gear-to-Line uses a single set point on a curve for pump control.

Fig 5‐8 indicates the following:

� At 80% maximum line speed, the pump set point RPM speed is 60 RPM.

� At 20% minimum line speed, the pump set point RPM speed is 15 RPM.

% Line Speed

0% 20% 40% 60% 80% 100%

Mo

tor

Sp

ee

d (

RP

M)

0

10

20

30

40

50

60

70

20%, 15 RPM

80%, 60 RPM

Figure 5‐8 Gear-to-Line, single-point on a curve



Adjusting Pump Speed

You can modify the speed of the pump in Manual and Gear-to-Line operationmodes.

1. Access the Operator Display and touch the pump that you want tochange its speed.

2. Touch Adjust Speed.

3. Do the following to continue:

� Refer to Figure 5‐6 for Gear-to-Line mode.

� Refer to Figure 5‐7 for Manual mode.

4. Touch Done to continue.

Modifying Pump Names

Pump 1Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode MAN

Total Adhesive Used

Manage Channel

Settings

Monitor

TestGraphing

Done

Cancel

Q

Pump 1

W E R T Y U I O P

A S D F G H J K L

Z X C V B N M

123… Pump 1Home

1. Access the Operator Display and touch the pump you want to modify itsname.

2. Touch Create/Modify Name and enter the name you want for this pump.The name can be up to 10 characters long. Spaces, dashes, underscoreand numbers count as a single character.

3. Touch Done.

NOTE: Upper case only.

Advanced Melter Configuration 6-1


Section 6

Advanced Melter Configuration


Overview The melter is shipped from the factory with most temperature, pump andmelter (system) settings preconfigured and ready to use. However, there aresome settings that you must configure and finetune to best fit yourmanufacturing process.

Advanced Melter Configuration6-2


The following are advanced melter configuration topics discussed in thischapter.

Section Tasks

AdvancedTemperatureSettings

� Defining a global set point temperature

� Defining temperature limits

� Defining ready delay

� Defining standby settings

Advanced PumpSettings

� Enabling\Disabling Auto Pump

� Defining Pump Remote Control

� Calibrating pumps

AdvancedInput/OutputSettings

Defining input\output functionality

System Settings � Defining format and units

� Defining data and time

� Defining service intervals

� Defining language preferences

� Defining display options

ConfiguringPasswordProtection

� Establishing password protection

� Creating/modifying password level codes

ConfiguringScheduled Events

� Creating/modifying heater and standby events

� Switching On/Off the master scheduler controller

AdministrativeOptions andSettings

� Managing recipes

� Viewing the event log

� Resetting to System Defaults

� Resetting password level codes

� Viewing firmware version information

� Viewing heaters On hours

� Locking out melter communication

� Changing RTD types



Advanced Temperature SettingsThe following sections detail the following:

� Defining a global set point temperature

� Defining temperature limits

� Defining ready delay

� Defining standby settings

Accessing Temperature Settings

Manual

Done

Heater Control Pump Control

Standby Master Scheduler

Settings System

Master Controls

Done

Home

Settings

Temperature

Pump

Inputs/Outputs

Standby: Off

Heaters: On Pumps: On

1. Access the Operator Display and touch Master

Controls

2. Touch Settings, then Temperature.

Refer to the following sections for more information.



Defining a Global Set Point Temperature

Use global set point temperature to configure all zones with a uniform setpoint temperature.

Default Minimum Maximum

175°C (350°F) 100°C (200°F) 225°C (450°F)

NOTE: To minimize charring the adhesive material, you can define thehopper set point temperature up to 15°C (30°F) cooler than the reservoir setpoint temperature.

NOTE: Defining a global set point temperature enables previously disabledzones.

Pump 1\ Operation Mode Done

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode Manual

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home

Done

Cancel

�C 7 8 9

4 5 6

1 2 3

0

Global Set Point Temperature

15 Home



Pump 1\ Operation ModeDone

Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode Manual

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home


Controls


3. Touch Global Set Point and enter the global set point temperature youwant for all available zones.

4. Touch Done.



Defining Temperature Limits

Use Temperature Limits to define the number of degrees a zone canincrease or decrease from its assigned set point temperature before atemperature alert\fault occurs.

Setting Default Minimum Maximum

Over Temperature

15°C (25°F)

5°C (10°F) 60°C (110°F)

UnderTemperature

25°C (50°F)

NOTE: The system displays an Alert message if either an over or undertemperature event occurs to any zone.

NOTE: The zone itself changes to yellow

Zone 1AAlert

If you do notresolve the over\under alert condition within two minutes of it being detected,the Alert changes to a Fault condition, causing both Heater and PumpControls to automatically switch Off.


Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode Manual

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home

Done

Cancel

�C 7 8 9

4 5 6

1 2 3

0

Temperature Limits

15

Over Temperature

Under Temperature�C

25

Home


Controls


3. Touch Temperature Limits and enter temperature thresholds you wantto enforce.

4. Touch Done.



Defining Ready Delay

Use Ready Delay to define the amount of time you want to elapse after all ofzones have reached their set point temperatures before the melterReady\OK status appears.


0 (Zero) minutes 0 (Zero) minutes 60 minutes

NOTE: The ready delay time only functions when the temperature of thereservoir, at the time the melter is turned on, is more than 27 °C (50 °F) fromits set point temperature.

NOTE: The ready delay time begins when all components are within 3 °C (5 °F) of their respective set point temperatures.


Pump 1

Enabled

Adjust Speed

Create/Modify Name

Pump 1

Change Operation

Mode Manual

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home

Done

Cancel

Min. 7 8 9

4 5 6

1 2 3

0

Ready Delay

60 Home


Controls


3. Touch Ready Delay and enter the number of minutes you want to delaythe Ready\OK status.

4. Touch Done.



Defining Standby Settings

There are 3 Standby options:

Standby Option Refer to page

Manual (enter/exit) Standby 5-4

Automatic Standby 6-8

Auto Exit Standby Time 6-10



Automatic Standby

Enables the system to automatically enter Standby mode after a user definedamount of elapsed time of melter inactivity.

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home

ManualDone

Standby Settings

Automatic Standby

Off Off

Auto Exit Standby Time

Auto Standby Start Time

Auto Heaters Off TimeIn Auto Standby Mode

Auto Exit Standby TimeIn Manual Standby Mode

Standby Temp

50�C

60 min.60 min.

60 min.

Home


Controls


3. Touch Standby. Do the following to continue.



Touch Description

Automatic Standby

Standby On

Enables the system the ability to automatically place the melter intostandby mode.

Default: Disabled


60 min.

Define the elapsed time of melter inactivity before the melterautomatically enters Standby mode.

Default is 0 (zero) minutes

Minimum time is 0 (zero) minutes

Maximum time is 60 minutes

Standby Temp

50�C

Define the number of degrees (from the set point temperature) of allenabled zones that you want to decrease while in standby mode.

Default is 50�C (100�F)

Minimum temp is 5�C (10�F)

Maximum temp is 60�C (120�F)

45 min.

Auto Heaters Off Time

In Auto Standby Mode

Define the amount of time that must elapse after the automaticstandby time elapses before the heaters turn off.




4. Touch Done.




If you manually placed the melter into standby mode, you can enable thesystem to automatically exit Standby mode after a user defined amount ofelapsed time.

Done

Temperature

Global Set Point

Temperature Limits

Ready Delay

Standby

Home

ManualDone

Standby Settings

Automatic Standby

Off Off



Auto Heaters Off TimeIn Auto Standby Mode

Auto Exit Standby TimeIn Manual Standby Mode

Standby Temp

50�C

60 min.60 min.

60 min.

Home


Controls


3. Touch Standby. Do the following to continue.

Touch Description


Standby On

Enables the system the ability to automatically exit standby mode.

Default: Disabled

60 min.


In Manual Standby Mode

Define the elapsed time since the melter was manually placed intostandby mode before the melter automatically exits Standby mode.




4. Touch Done.



Advanced Pump SettingsThe following sections detail the following:

� Enabling\Disabling Auto Pump

� Defining Pump Remote Control

� Calibrating Pumps

Accessing Pump Settings

Manual

Done



Settings System

Master Controls

Done

Home

Settings

Temperature

Pump

Inputs/Outputs

Standby: Off



Controls





Enabling and Disabling Auto Pump

Use the Auto Pump option to increase efficiency by allowing you to switch Onthe Master Pump Control, before the melter status indicates Ready\OK.When the melter status indicates Ready\OK, the Master Pump Controlswitches On, and any enabled pump will automatically start.

Otherwise, you will have to wait until the melter status indicates Ready\OKbefore you can switch On the Master Pump Control

Default Available Options

Disabled � Enable

� Disable

Done

Home

Settings

Temperature

Pump

Inputs/Outputs

Done

Home

Pump

Auto Pump

Remote Control

Pump Calibration

Off

0 of 2 set


Controls

2. Touch Settings, then Pump.

3. Touch the Auto Pump button to enable or disable the Auto Pump option.

4. Touch Done.



Defining Pump Remote Control

Use pump remote control to manipulate the pump from a location other thanfrom the melter itself.

NOTE: The default is Disabled for all pumps.

Configuring a pump for remote control is a 3-step process:

Step 1: Run a wire from the pump to the an input connection. Refer to Setting Up Inputs/Outputs for instructions.

Step 2: Configure the input number with Pump (control). Refer to Advanced Input/Output Settings for more information.

Step 3: Select which pump you want to control from a remote location.Refer to the steps below.

Done

Home

Pump

Auto Pump

Remote Control

Pump Calibration

Off

0 of 2 setRemote Control

Done

Home

Pump 1

Pump 2

Pump 3

Pump 4


Controls

2. Touch Settings button, then Pump.

3. Touch Remote Control and select which pump you want to remotelyenable\disable.

4. Touch Done.



Calibrating Pumps

Use Pump Calibration to make sure the displayed pump RPM is accurate.

Done

Home

Pump

Auto Pump

Remote Control

Pump Calibration

Off

0 of 2 set

Cancel

Off

0 of 2 set

CancelPump Calibration

Pump 1

Pump 2

Pump 3

Pump 4

Cancel DonePump

Cancel

7 8 9

4 5 6

1 2 3

0

of full speed, use a tachometer

running at approximately 75%

technicians. While the pump is

only be done by trained

Pump RPM calibration should

to measure actual pump RPM.

Measured RPM:

0

Home

1. Wire a tachometer to the pump.


Controls

3. Touch Settings button, then Pump.

4. Touch Pump Calibration and select which pump you want to calibrate.

Run the pump at approximately 75% of full speed, then enter the RPMdisplayed on the tachometer.

5. Touch Done.



Advanced Input/Output SettingsNOTE: Refer to Hardware Installation and Setup chapter for wiringinstructions.

Done

Home

Settings

Temperature

Pump

Inputs/Outputs

ManualOutput 1

Output 2

Output 3

Inputs/OutputsDone

HomeInput 1

Input 2

Input 3

Input 4

Output 1

Output 2

Output 3

Automatic Standby Ready

Standby Fault

Heater Control Tank Low

Hose / Gun 1


Controls

2. Touch Settings then Inputs/Outputs.

3. Touch the lnput or Output button that you want to modify. Refer to theDefault Input Settings and Default Output Settings for more information.

4. Touch Done.

NOTE: If the optional Input/Output Expansion card is installed, then touch

to configure an additional 6 expansion inputs and an additional 4expansion outputs.



Default Input Settings

By default, all four inputs are pre-configured for you. The following tabledetails the defaults and available input options.

Input # Default Available Options

Input 1 AutomaticStandby

� Disabled

� Heater Control

� Standby

� Pump (Control)

� External Zone# A/B

� Automatic Standby

(only available forInput 1)

Input 2 Standby

Input 3 Heater Control

Input 4 External Zone1A/1B

Expansion Inputs5-10

Disabled

Default Output Settings

By default, all three outputs are pre-configured for you. The following tabledetails the defaults and available output options.

Output # Default Available Options

Output 1 Ready � Disabled

� Ready

� Ready-Pump On

� Fault

� Tank Low

� Alert

� Service Reminder

Output 2 Fault

Output 3 Tank Low

ExpansionOutputs 4-7

Disabled



System SettingsThe following sections detail the following:

� Defining format and units

� Defining the data and time

� Defining service intervals

� Defining language preferences

� Defining display options

Accessing System Settings

Done



Settings System

Master Controls

Standby: Off


Manual

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home Scheduler: On


Controls

2. Touch System button.




Defining Formats and Units

The following table details the default selection for each system-wideformat/unit, as well as its available options.

Item Default Available Options

Date Format mm/dd/yy � yy/mm/dd

� dd/mm/yy

� mm/dd/yy

Time Format 24 � 12

� 24

TemperatureFormat

°C � °C

� °F

Pressure Format PSI � kPa

� Bar

� PSI

NOTE: Pressure units apply only if you have the Flow and Pressure OptionBoard installed.

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Formats/UnitsDone

Date Format

Time Format

Temperature Format

Pressure

yy/mm/dd dd/mm/yy mm/dd/yy

12 24

�C �F

kPa Bar PSI

Home


Controls

2. Touch System, then Formats/Units.

3. Touch the selection you want to use for each format/unit.

4. Touch Done.



Defining the Date and Time

The date and time you define here is used by the system for all time and daterelated functions, such as the Event Log and Service Intervals.

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Administration

Language

English

Done

CancelDate

Time

7 8 9

4 5 6

1 2 3

0

Date/Time Settings

10/8/2012

13:05

Home


Controls

2. Touch System, then Date/Time.

3. Enter the current date and time.

4. Touch Done.



Defining Service Intervals

Service interval refers to the number of hours the heaters have been on.


500 hours 1 hour 8760 hours

NOTE: Refer to Resetting Service Interval Messages for moreinformation.

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Done

Cancel

hours 7 8 9

4 5 6

1 2 3

0

Service Interval

500 Home

500 hours

Clear Service Reminder


Controls

2. Touch System, then Service Interval.

3. Enter the number of heater on hours after which you want the system todisplay a service reminder message.

4. Touch Done.



Resetting Service Interval Messages

When the heaters have been on for more than the defined (default 500)hours, a pop-up message appears and the system status indicatesReady\Service.

There are two ways to reset the service interval value.

� From the Service Reminder pop-up message

� From the Service Interval screen

From the pop-up message

System Status

Ready\Service

Service Reminder

ClearOK

The heaters have been on for more then 500 hours.

Melter is working but maintenance required.

3/20/2012 16:40

Touch Description

OK Closes the pop-up message, but the servicereminder condition still exists.

The System Status indicator continues to displaythe Ready\Service.

Clear Closes the pop-up message, and resets theservice reminder counter back to 0 (zero) hours.

From the Service Interval Screen


Controls

2. Touch System, then Service Interval.

3. Touch Clear Service Reminder to reset the service interval counterback to 0 (zero) hours.

4. Touch Done.



Defining Language Preference

Select the language you want to use.


English � Chinese

� English

� Italian

� German

� French

� Japanese

� Portuguese

� Spanish

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home

Date/Time

Service Interval

Scheduler

03/20/2012 4:40 PM

500 hours

LanguageDone

Home


Controls

2. Touch System, then Language.

3. Touch the flag representing the language you want to use.

4. Touch Done.



Defining Display Settings

The following table details what you can define, along with the default andavailable options.

Setting Default Minimum Maximum

Brightness/Contrast 75% | 75% 30% 100%

Screen Saver Delay 90 minutes 5 minutes 120 minutes

Calibrate Screen -- -- --

Wipe Display 30 seconds -- --

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home

Date/Time

Service Interval

Scheduler

03/20/2012 4:40 PM

500 hours

DoneDisplay

Brightness / Contrast

Screen Saver Delay

Calibrate Screen

Wipe Display

Home

75% | 75%

5 minutes


Controls

2. Touch System, then Display.



3. Do the following to continue.

Touch Description

Brightness/Contrast Enhance the visibility and readability of thetouchscreen displays.

Screen Saver Delay The amount of time (default 5 minutes) of no userinteraction with the touchscreen before the screensaver appears.

The screen saver only displays the melter statusand its corresponding color. To extend the lifespanof the touchscreen itself, the brightness andcontrast are reduced from its current settings to30%

Touch anywhere on the screen to access theOperator Display.

Calibrate Screen Allows you to improve the accuracy of yourinteraction with the touchscreen.

Touch the + symbol to calibrate the touchscreen.

Wipe Display Locks the screen for 30 seconds, allowing you toclear dust from the touchscreen without touching abutton and accidentally changing a setting.

4. Touch Done.



Configuring Password ProtectionBy default, password protection is disabled.

NOTE: Refer to Table 6‐5 for an explanation of each security level.

The following are default password level numeric codes:

Level # Default Code Notes

1 1000 � Cannot start with the number 0 (zero).

� Can be one up to five numbers long.

� The largest 5 digit number is 65535.

� Each level must have a unique numeric code.

2 2000

3 3000

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home

Date/Time

Service Interval

Scheduler

03/20/2012 4:40 PM

500 hours

Done

Help

Password

Create/Modify

Timeout

Set Security Level

5 minutes

Home


Controls

2. Touch System, then Password.

3. Do the following to continue. When finished, touch Done.

Touch Description

Create/Modify Modify the default numeric password code for eachlevel.

Timeout The amount of time (the default is 10 minutes) theselected password protection becomes active afterno user interaction with the touchscreen.

Set Security Level Refer to Table 6‐5 for an explanation of eachsecurity level.



Table 6‐5 Security level details

SecurityLevel

Functions Enabled High Medium Low

3 Application names (temperature channels, pumps, **pressuresensors)Controlled system heating rate temperatureSwitch between °C, °FSwitch between bar, psi, kPaTemperature channel settings (PID control mode)Maximum temperature set pointAssign standard I/O inputs for application groupsSeven-day clock settings: (delete/edit schedule, copy schedule)Motor enables from control panel / control panel AND standard I/OGear-to-line signal: Analog/frequency, voltage/currentSpeed control / Line speed for min./max. pump speed/pressureThreshold switchRestore default settingsMelter configurationConfiguration code input (Local mode / field bus mode)Customer setup (recipes / application names)Service intervalSystem ready-delay setupPassword setup**Pressure alarm monitoring on/off**Over-pressure and under-pressure alarms**Pressure and Flow parameters (PID, threshold, etc.)**pressure control / flow control**Pressure build parameters**Pressure sensors setup**Flow sensors setup

ËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËËË2 Under-temperature/over-temperature warnings/faults

Standby values (setback delta and duration)Automatic enter standbyTemperature channel enabled/disabledChanging pump modes (manual, gear-to-line, **pressure, **flow)**Pressure and Flow alarm bands

1 Temperature set pointIndividual motor enableSpeed set pointMin. and max. pump speed/pressure (in gear-to-line mode)**Pressure set point

NOTE: **Flow and Pressure related tasks apply only if you have the Flowand Pressure Option Board installed.

NOTE: The table indicates the following:

� High Security includes levels 1, 2 and 3

� Medium Security includes levels 2 and 3

� Low Security includes only level 3



Configuring Scheduled EventsUse the scheduler to time daily heater and standby events. Figure x-xillustrates a typical daily schedule.

Heaters On

Enter Standby - break

Heaters Off

Exit Standby

Enter Standby - shift change

Exit Standby

NOTE: About scheduling events:

� Define up to 12 events per day.

� Each day can have its own unique schedule.

� Copy and paste schedules to other days of the week.

� Scheduled events cannot cross over to the next day.

Creating a Schedule of events is a 3-step process

Step 1: Access the Scheduler and verify that the system date, time and day of week are correct.

Step 2: Define the first work day of the week that you want to start scheduling events.

Step 3: Switch On the Scheduler control.



Step 1: Access the Scheduler and verify that the system date, time andday of week are correct

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home

Display

Administration

Language

English

Scheduler: Data/Time/Day Settings

Select day to edit:

Sun Mon ThuTue FriWed Sat

Sun Mon ThuTue FriWed Sat

Current System Date: 03/20/2012

Current System Time: 16:40

Current System Day: Tuesday

Cancel

Change Date

Home


Controls

2. Touch System, then Scheduler.

3. From the bottom section, make sure the Current System Date, Time andDay are correct.

� If the Date and Time are incorrect, touch Change Date and enter the

correct information.

� If the Day is incorrect, touch the appropriate day of the week button.

4. From the top section, touch the day of the week button that you want toschedule events. It is recommended that you start with the first workingday of the week, for example Monday, and work forward. You can onlycopy/paste schedules from one day to the next, not backwards.

5. Proceed to the step 2.



Step 2: Define the first work day of the week that you want to startscheduling event

Scheduler: Monday

Cancel

Cancel

Next Day

Add Heat Event Add Standby Event

Heat

Standby

6:30

10:00

18:00

10:25

Standby 15:00 15:25

Add Heat Event

Turn Heaters On:

Done

Cancel

Turn Heaters Off:

6:30

18:00

Home

1. Do the following to continue:

Touch Description

Add Heat Event

Enter the time when you want the heaters to switch On and Off.

Typically, you would have only one heat event per day.

Add Standby Event

Enter the time when you want the system to enter, then exit StandbyMode.

You can include multiple Standby events to include lunch breaks, shiftchanges and so on.

To remove the event.



2. Do you want to copy this exact schedule to the other days of the week?

If…. Then

Yes

a. Touch to copy the schedule into memory.

b. Touch Next Day.

c. Touch to paste the schedule to the day you want.

d. Repeat steps b and c until you are done. Proceed to Step 3.

No a. Touch Next Day to configure a different schedule.

b. Touch Done. Proceed to Step 3



Step 3: Switch On the Master Scheduler Control

Hopper

Set Point: 175�C

175�C

Reservoir

Set Point: 175�C

175�C

Zone 1A

Set Point: 175�C

175�C

Zone 1B

Set Point: 175�C

175�C

Zone 2A

Set Point: 175�C

175�C

Zone 2B

Set Point: 175�C

175�C

Zone 3A

Set Point: 175�C

175�C

Zone 3B

Set Point: 175�C

175�C

Zone 4A

Set Point: 175�C

175�C

Zone 4B

Set Point: 175�C

175�C

Zone 5A

Set Point: 175�C

175�C

Zone 5B

Set Point: 175�C

175�C

Zone 6A

Set Point: 175�C

175�C

Zone 6B

Set Point: 175�C

175�C

Zone 7A

Set Point: 175�C

175�C

Zone 7B

Set Point: 175�C

175�C

Pump 1Manual


Pump 1Manual


Pump 1GLT


Pump 1Manual


Melter Status:

Ready\OK

Recipes

SMALL SIZE

Done

Scheduler


Standby

Settings System

Master Controls

Scheduler: Off


Standby: Off

MasterControls

Heaters: On

Pump: On

Password: Disabled


Controls

2. Touch the Scheduler button to switch it On.

3. Touch Done.



Administrative Options and SettingsThe following sections detail the following:

� Managing recipes

� Viewing the event log

� Resetting to System Defaults

� Resetting password level codes

� Viewing firmware version information

� Viewing heaters On hours

� Locking out melter communication

� Changing RTD types

Accessing Administration Settings and Options

SystemDone

Formats/Units

Date/Time

Service Interval

Scheduler

Password

Display

Administration

Language

03/20/2012 4:40 PM

English

500 hours

Home

Date/Time

Service Interval

Scheduler

03/20/2012 4:40 PM

500 hours

Off

AdministrationDone

System Reset

Display/Save Diagnostics

Reset Password

Recipes

RTD Options

Lockout Communications

Hours Heaters On: 770

Firmware Version: 4.40

Motor Board 1 firmware version: 2.2

Motor Board 1 firmware version: -

Off

Home


Controls

2. Touch the System, then Administration.




Upgrading Software and Firmware

Upgrades typically include changes to both the CPU software and MotorControl Board firmware.

Customer SD Card

Internal SD Card

Figure 6-9 Location of the Customer and Internal SD Cards.

1. Switch the melter off, and disconnect the electrical power to the melter atthe local power source. Disassemble the front, to access the CPU board.

2. Remove the Customer SD card, and using a PC, copy the *.dat file to theroot of the SD Card. Refer to Figure 6‐9.

3. Replace the Customer SD Card, close and reassemble the front.Reconnect power and switch On the melter. Refer to Figure 6‐10.



Starting

Entering Flash

Loader Version: 01.05

Found Upgrade File

Updating Firmware

Percent Complete: 40

Figure 6‐10 The upgrade process.

4. Replace the Customer SD Card, close and reassemble the front.Reconnect power and switch On the melter. Refer to Figure 6‐10.

5. The system automatically detects a new *.dat file and does the following:

� A copy of the current *.dat file is copied into the \backup directory on

the SD Card.

� The CPU board is upgraded first, followed by the Motor Control

board(s).

� The entire upgrade process should take approximately 10 minutes.

When done, the software automatically reboots the melter. Theupgrade is complete.

NOTE: It is recommended that you copy and rename the *.dat file,appending the current date in case you want to revert back a differentsoftware\firmware version.

NOTE: It is also recommended that you copy the *.dat files to another backstorage media in case the SD card is damaged.



Reverting back to a Previous Version

As part of the upgrade process, the current *.dat file is automatically copiedinto the \backup directory of the Customer SD Card.

1. Follow the same upgrading steps 1 and 2.

2. Using your PC, do the following:

� Navigate to the \backup directory and copy the *.dat file you want.

� Navigate to the root of the SD Card and paste the *.dat file.

� If you previously renamed the *.dat file, then you must change it back

to its original name.

3. Follow the same upgrading steps 4 and 5.



Managing Recipes

Use recipes to save production settings, such as zones and pump settings,as well as other melter settings including scheduled events, and securitysettings, to a file that you can use, modify and delete.

NOTE:

� You can share recipes with other AltaBlue™ Touch Adhesive Melters.

� Recipes are stored on the Customer SD Card. Refer to Figure 6‐9.

� Refer to table 6‐1 for more information about what is saved to a

recipe.

� The melter retains the settings of the previously loaded recipe, even if

you delete or decide not to make use of a recipe.

Accessing the Recipes Screen

You can access the Recipes screen by doing one of the following:

� From the Operator Display, touch Recipes.

‐ Refer to Figure 6‐11.

� From the Master Controls | System | Administration, touch Recipes.

‐ Refer to Figure 6‐12.

Displays the name of the currently loaded recipe, otherwise displays:

Recipes

Recipes

Nothing Loaded

Touch here to access the Recipes screen

Nothing Loaded

Figure 6‐11 Accessing Recipes from the Operator Display



AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home

RecipesNext

Cancel

Load or Deletea Recipe

Do not use a Recipe

Save Recipe

Home

Figure 6‐12 Accessing Recipes from the Master Controls | Administration screen

1. Access the Recipes screen.

2. Decide what you want to do and touch Next to continue.

Task Touch Description

Load a recipe

Load or Delete aRecipe

Select an existing recipe you want use.

Touch Load to continue.

Delete a recipe Select an existing recipe you no longer want to use.

Touch Delete to continue.

NOTE: The melter retains the settings of the previouslyloaded recipe.

Unload and/or notmake use of anyrecipe

Do not use aRecipe

Unloads the currently loaded recipe.

Select this option when troubleshooting or performingmaintenance on the melter.

NOTE: The melter retains the settings of the previouslyloaded recipe.

Create a newrecipe

Save Recipe

Do the following:

1. Configure and test melter settings until it meets yourmanufacturing requirements.

2. Access the Recipes screen, touch Save Recipe andenter an easily identifiable recipe name.

NOTES:

� To update the settings of the recipe, enter the exact

same recipe name.

� The system unloads the currently loaded recipe, then

saves the new settings and automatically loads it.

Modify an existingrecipe



What's Being Saved in a Recipe

The following highlights what a recipe is saving to a file.

Table 6‐1 Recipe Details

General Information Administration Information

� Software Version

� Language

� Date, Time, Temp and Pressure format

� Under and Over Temperature threshold values

� Configuration settings for standard and expanded

Inputs and Outputs

� Service Alerts (enabled or disabled)

� Service Interval value

� RTD Type value

� Scheduler (enabled or disabled)

Settings and events for each day of the week

� Selected password level

� Numeric password code for each password

level

� Password Timeout value

Temperature Information Zone Information

� Standby Temperature

� Standby (enabled or disabled)

� Auto Exit Standby (enabled or disabled)

� Auto Exit Standby Time value

� Auto Heaters Off Time value

� Auto Standby Time value

� Zone (enabled or disabled)

� Default and user-defined names

� Set Point values

� PID values

Pump Information Flow and Pressure Information

� Pump (enabled or disabled)

� Default and user-defined names

� Auto Pump On (enabled or disabled)

� Number of installed Motor Control Boards

� Remote Pump (enabled or disabled)

� Specific pump operation mode settings

NOTE: Requires additional hardware.

� Pressure and flow channel default and user

defined names

� Specific Pressure and/or Flow configuration

settings

� PID values

� Flow/Pressure Alarm (enabled or disabled)

� Alarm settings

� Pressure Build (enabled or disabled)



Viewing the Event Log - Save Diagnostics

Use the event log to view a list of up to 200 of the most recent fault, alert, andparameter change events. You can save those events from memory to theInternal SD card. Refer to Figure 6‐9. The default file name is EventLog.xml.

Additionally, a Diagnosticsfile.xml, file is also written to the SD card. This filecontains, detailed melter information. The information contained in both filescan help Nordson technical support troubleshoot your issue.

NOTES:

� The system writes the entire event log to the SD card, regardless of

what level of detail you selected.

� The event log can display up to 200 events, after which the oldest

event is overwritten with new events.

� You cannot clear nor change the name of either file.

Recipes

RTD Options


Hours Heaters On

10.0797 770 hours

Display/Save DiagnosticsNext

DoneComplete EventLog

Faults Only

Alerts Only

Parameter/Set PointChanges

Display/Save Diagnostics Back

05/04/12 11:52:20 Event Ready enterDone

Save File

Source: System Status: OK

Zone/Parameter: 0 Zone/Sub-code: 0

05/04/12 11:50:50 Event Ready enter



05/04/12 11:40:03 Event Zone control off

Source: HMI Status: OK


05/04/12 11:34:29 Event Ready enter



Old value: 1 New value: 0

Home


Controls

2. Touch Settings button, then Administration.

3. Touch Display/Save Diagnostics and select which level of detail youwant to view.

4. Touch Next to continue.



5. Decide what you want to do next.

Touch Description

Back Select a different event log option to view.

Done Exit the event log.

Save File Save both the event log and the diagnostic file tothe Internal SD card. Refer to Figure 6‐9.

Touch this button only one-time. Depending on thenumber of events in the log, this can take a fewminutes.

When done, the Attention message appears,indicating The diagnostics file was saved to the SDCard.

The default names are:

EventLog.xml

Diagnosticsfile.xml

6. Touch Done.



Resetting to System Defaults

Use system reset to revert all user definable software settings back to factorydefaults.

NOTES:

� Recipes and event log information are stored on the customer

supplied SD card, and are therefore NOT deleted or changed.

� Use a recipe to restore melter settings.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home

Are you sure you want to revert back to factory settings?

Yes No

Are you sure you want to revert back to factory settings?

Yes No

Confirm


Controls

2. Touch System, then Administration.

3. Touch System Reset. A pop-up message appears.

4. Touch Yes to revert all user definable settings back to factory defaults.

5. Touch Done.



Resetting Password Codes

Use Reset Password to revert all 3 levels of password codes back to theirdefault codes.

The following are the default password level numeric codes:

Level # Default Code Notes

1 1000 � Cannot start with the number 0 (zero).

� Can be one up to five numbers long.

� The largest 5 digit number is 65535.

� Each level must have a unique numeric code.

2 2000

3 3000

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home

Confirm

Are you sure you want to reset all passwords tofactory default?

Yes No


Controls


3. Touch Reset Password. A pop-up message appears.

4. Touch Yes to revert all three password level codes to their default values.

5. Touch Done.



Viewing Software Version and Heater On Hours

Access the Administration screen to view:

� Firmware Version

� Hours Heaters On

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home


Controls


3. Look at the Firmware Version and/or Hours Heaters On button formore information.

4. Touch Done.



Locking Out Communications

Use Lockout Communication to prevent remote access to the melter whileyou are troubleshooting or performing maintenance on the melter.

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home


Controls


3. Touch the Lockout Communication button to toggle it On or Off

4. Touch Done.



Changing RTD Types

You must let the software know when you change RTD types, otherwise thesoftware may display erroneous data and system messages.


NI120 � NI120

� PT100

AdministrationDone

System Reset


Reset Password

Recipes

RTD Options






Off

Home

RTD OptionsDone

NI120

PT100

Home


Controls

2. Touch System button, then Administration.

3. Touch RTD Options and select the appropriate installed RTD type.

4. Touch Done.



Default User Settings and RangesThe following details default settings and ranges for user definable melter,temperature, pump and melter settings.

Temperature Settings

Setting Default Range/Option

External Zones Set Point 175�C (350�F) Minimum: 40�C (100�F)

Maximum: 230�C (450�F)

Internal Zones Set Point 172�C (341�F) Minimum: 40�C (100�F)


Global Set Point 175�C (350�F) Minimum: 40�C (100�F)


Temperature Limits

Over Temp: 15�C (25�F) Minimum: 5�C (10�F)


Under Temp: 25�C (50�F) Minimum: 5�C (10�F)


Ready Delay 60 minutes Minimum: 0 minutes

Maximum: 60 minutes

Automatic Standby Disabled Enabled

Disabled

Auto Standby Start Time 0 minutes Minimum: 0 minutes

Maximum: 1,440 minutes

Auto Heaters Off Time in AutoStandby Mode

60 minutes Minimum: 0 minutes

Maximum: 1,440 minutes

Auto Exit Standby Time Disabled Enabled

Disabled

Auto Exit Heaters Off Time inAuto Manual Mode

0 minutes Minimum: 0 minutes

Maximum: 180 minutes

Standby Temp 50�C (100�F) Minimum: 5�C (10�F)




Pump Settings


Operation Mode Manual Manual

Gear-to-Line

* Pressure Control

* Flow Control

NOTE: *Requires additionalhardware

Pump RPM 0 Minimum: 0 RPM

Maximum: 94 RPM

Auto Pump Off Pumps 1-4

Remote Control None set Off

On



Melter Settings


Service Interval 500 hours Minimum: 0 hours

Maximum: 8760 hours

Scheduler No events defined Minimum: 2 events per day

Maximum: 12 events per day

Password Protection No Password Protection High

Medium

Low

No Password Protection

Password Level Codes Level 1: 1000

Level 2: 2000

Level 3: 3000

Minimum: 1

Maximum: 65535

NOTE: Code levels must beunique.

Password Timeout 1 minute Minimum: 1

Maximum: 60

Display Brightness/Contrast 75% | 75% Minimum: 30%

Maximum: 100%

Display Screen Saver Delay 1 minute Minimum: 1 minute

Maximum: 120 minutes

RTD Options NI120 NI120

PT100

Lockout Communications Off Off

On

Inputs/Outputs

Inputs Inputs:

#1: Automatic Standby

#2: Standby

#3: Heater Control

#4: External Zone # A/B

Disabled

Standby

Heater Control

Pump (Control)

External Zone # A/B

Automatic Standby (Availableonly for Input #1

Outputs Outputs:

#1: Ready

#2: Fault

#3: Tank Low

Disabled

Ready

Ready-Pump On

Fault

Tank Low

Alert

Service Reminder

Service 7-1


Section 7

Service


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

Relieving System Pressure

WARNING! System and material pressurized. Relieve system of pressurebefore disconnecting hoses, applicators and hot melt handapplicators.Failure to observe can result in serious burns.

Through the Applicators 1. Disable the motor(s).

2. Place a container under the nozzle(s) of the applicator/assemblyhandapplicator.

3. Activate the solenoid valve(s) electrically or manually; or, pull the triggerof the assembly handapplicator. Repeat this procedure until no morematerial flows out.

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

Service7-2


Through the Melter Drain Valves 1. Disable the motor(s).

2. Place a container under the drain valve ports located on the bottom of themanifold.

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 7-1 Location of the melter drain valves

Service 7-3


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 pump temperature

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 15�000 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

Service7-4


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 by

the 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 spray

bottles, 0.5 l each).

Service 7-5


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 the

new material.

� May not be mixed: Thoroughly purge the unit with a cleaning agent

recommended 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 on dustaccumulation.

Refer to Section 9, Parts, for the filter part number.

Service7-6


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 15�000 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 7-7


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 7‐2. 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.

Adjustable

Figure 7-2 Coupling assembly components

1 Motor coupling hub

2 Coupling sleeve

3 Pump coupling hub

Service7-8


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, adjust the motor shaft toalign and tighten the hub set screws.

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 7‐3.

Figure 7-3 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 7-9


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 7‐4. Tighten the screws to 25 N�m (222 in.‐lb).

Figure 7-4 Tightening the pump screws

4. Restore the system to normal operation.

Pump gland bolt

Service7-10


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 7‐5. 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 no longerbe tightened, replace the pump.


Figure 7-5 Tightening the pump gland bolt (clockwise)

Service 7-11


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 7‐6. Close the tank isolation valve.

Figure 7-6 Location of the tank isolation valve

Service7-12


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 7‐7. 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.

Adjustable

Figure 7-7 Coupling assembly components

1 Motor coupling hub

2 Coupling sleeve

3 Pump coupling hub

Service 7-13


8. See Figure 7‐8. Remove the pump screws (3) and then remove the pump(2) and O‐rings (1).

440300046

1

2

3

1 2

3

Figure 7-8 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, adjust the motor shaft to align and tighten the hubset screws.

12. Apply O‐ring lubricant to new pump O‐rings and install them on the pump.

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).

Service7-14


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 7‐9.

Figure 7-9 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 7-15


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 out ofthe hose connection or applicator free of bubbles.

6. Properly dispose of material according to local regulations.

Service7-16


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 7-17


Pressure Control Valve

To replace the pressure control valve

X

Figure 7-10 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.

Service7-18


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 7-19


Cleaning the Tank

Draining Material from the Tank

Pump material out of the melter.

CAUTION! Do not feed charred material though the applicator. Particles canblock the applicator. Instead unscrew hose.

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

Service7-20


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 7‐11. Open the electrical enclosure access panel and locatethe main PCA board.

Figure 7-11 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 7‐12 shows the location ofterminal JP1 on the main PCA board. Figures 7‐13 and 7‐14 show thejumpers installed and not installed, as appropriate for each type of melter.

Service 7-21


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 7-12 Location of the JP1 terminal on the main PCA board

Service7-22


Main PCA Board (contd)

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

a. Go to System>Administration>RTD Options and select Pt100.

NOTE: For 120‐ohm nickel melters, temperature sensor jumpers arenot required in this location, as shown in Figure 7‐14.

b. Locate the JP1 terminal on the replacement board.

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

d. Install the second jumper between terminals 5 and 6. Figure 7‐13shows the jumpers installed.

Figure 7-13 100-ohm platinum melter—jumpers installed

Figure 7-14 120-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 7-23


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

Service7-24


Filter cartridge

Troubleshooting 8-1


Section 8

Troubleshooting


WARNING! Troubleshooting activities may sometimes have to be carried outwhen the melter is energized. Observe all safety instructions and regulationsconcerning energized unit components (active parts). Failure to observe mayresult 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 system

pressure. Refer to Relieving System Pressure in Section 7, Service.

� Refer to the safety information provided with optional equipment.

� If the melter is removed from its sub‐base for diagnostic checks or

service, ensure that the ground lead between the chassis and thesub‐base is re‐attached when the melter is reconnected to the sub‐base.

NOTE: Refer to Administrative Options and Settings located in Chapter 6 ofthis manual.

Troubleshooting8-2


Touch Screen Alerts and Faults The Nordson AltaBlue Touch Adhesive melter diagnoses many alert andfault conditions that may occur during operation. An “alert” condition is asituation in which a potential problem may be occurring with the melter,pump, applicator or hose. The melter will operate under an “alert” conditionunless the problem goes unresolved, at which point the melter will go into a“fault” condition, during which the melter will shut down until the problem isresolved.

Refer to the appropriate table for more information.

About Touch Screen Messages

Pump and Zone Alerts/Faults

Table 8-1 Pump and Zone Alerts/Faults

Screen Message Affect on Melter Cause Corrective Action(s)

Internal or External

Temperature for[ZoneName] hasdropped belowdefined setpointthreshold

Alert condition - anissue has beendetected. Themelter continues tooperate normally.Fault condition - ifthe issue is notresolved within 2minutes of the alertmessage, themaster pump andheaters are switchedoff. Melter stopsfunctioning

The actual temperature of thecomponent has dropped belowthe set temperature limit

Check for conditions that maycause a drop in ambienttemperature or replace thecomponent.


Temperature for[ZoneName] hasrisen above definedsetpoint threshold

The actual temperature of thecomponent has risen above theset temperature limit

Check for conditions that maycause an increase in ambienttemperature or replace thecomponent.


Short RTD on[ZoneName]

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

Check the connections, orreplace the RTD


Open RTD on[ZoneName]

Issue with a pumpThe melter may notcontinue to work.

Refer to Troubleshooting Pumps later in this section for moreinformation

Troubleshooting 8-3


System Alerts

Table 8-2 System Alerts


FieldbusCommunicationsFailure.

The meltercontinues to work,but some functionsmay not beavailable. Melterrequires servicing.

Fieldbus card failure. Replace the Fieldbus card

EightHose/applicatorBoard Failure

Communication failure betweenmain board and hose/applicatorboard.

Replace hose/applicator board

Failed motor boardCommunication failure betweenCPU and the motor board

Replace motor board

NVRAM test failure Internal RAM failure Replace CPU

Communicationswith Optional I/OCard Failure

Communication failure betweenCPU and the optional I/O card

Replace the I/O card or CPU

Troubleshooting8-4


System Faults

Table 8-3 System Faults


Brownout

Master pump andheaters are switchedoff. Melter stopsfunctioning

Plant power dipped and cameback up

Typically nothing to address,unless the system does notoperate properly, or variousmessages appear. ColdStop/Start the melter.

Analog-to-DigitalFailure

RTD analog‐to‐digital converterfailed

Replace main board or CPU

Analog-to-DigitalFailure Calibration

Failed hose or applicator

RTD analog‐to‐digital convertercould not be calibrated(grounded RTD in system)

Replace hose or applicator.Note: Set setpoint to zero toavoid fault.

Replace main board or ribboncable, or CPU

Expansion BoardConnection Failure

Communication failure betweenexpansion board and main board

Check the ribbon cableconnections between theexpansion board and the mainboard.

Expansion BoardFailure

Replace the expansion board.

User Interface Failedto Load

Reload SD card info

Replace SD card

Replace CPU

Main Board Failure Replace the main board

RAM Failure Replace CPU

MotorCommunicationFailure

Refer to “Motor Drive Faults“ laterin this section for moreinformation

Motor ThermostatFailure

Motor thermostat is open Replace thermostat

Manifold orReservoirThermostat Failure

Tank or manifold thermostat isopen

Replace thermostat, J7 harness,or main board

Runaway fault on[ZoneName]

Temperature continues to risebeyond set point.

Replace Hose/applicator cordset

Replace mainboard

Troubleshooting 8-5


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 8‐4 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.

2

1

Figure 8-1 Motor drive power LED and display

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

2. Display

Troubleshooting8-6


Motor Drive Faults (contd)

Table 8-4 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 8-7


Table 8-4 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 and

change as needed. The temperaturesetpoints should be within the rangerecommended by the materialmanufacturer.

� Replace the pump or the drive

assembly.

� 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 the motorinsulation.

OHF

Motor drive overheated

Motor drive temperature too high � Check the motor load, the motor drive

ventilation, and the environment. Waitfor the motor drive to cool downbefore restarting.

� Ensure that the unit ambient

temperature 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 caused

by pressure control valve failure

� Use a material that falls within the

allowable viscosity range. Refer toSection 10, Technical Data, forviscosity ranges.

� Check the motor load. Wait for the

motor drive to cool down beforerestarting.

� If the operating hydraulic pressure

exceeds 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. Refer toSection 10, Technical Data, for allowableinput 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. Refer toSection 10, Technical Data, for allowableinput voltage range.

Troubleshooting8-8


Motor Drive Faults (contd)

1

2

3

4

5

6

7

8

Figure 8-2 Changing a motor drive parameter

1. Graphic display

2. Mode button

3. ESC button

4. RUN button

5. Navigation keys

6. ENTer button

7. STOP button

8. Button for reversing motordirection/rotation

Troubleshooting 8-9


Table 8-5 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

1-0 r2 Relay r2 rUn

CtL Fr1 Configuration Reference 1 AI1

Troubleshooting8-10


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

Troubleshooting 8-11


Troubleshooting Pump

No Material (Pump 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 by foreignmatter, pump too sluggish, materialtoo cold)

Refer to 6.

10. Motor drive defective — Replace

Troubleshooting8-12


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

Troubleshooting 8-13


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

Troubleshooting8-14


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 applicatorduring heatup phase

Safety valve does not open(expansion pressure)

Replace safety valve

Parts 9-1


Section 9

Parts

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, indicatethe relationships between assemblies, subassemblies, and parts.

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

Parts9-2


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

VoltagePump

1Pump

2 3Pump

4Hose/Gun \

FlowControl

Low Motion

A TBox

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−Level I/O

LCDResvd. Comm.

HostPort

ReturnSwitch Sensor Resvd.

Pump

Box1

Cover Resvd.Resvd.

Box Item Code Options Description

1-2 Melter AT — AltaBlue Touch 2 pump platform

AF — AltaBlue Touch 4 pump platform and 100L

3 Hyphen ‐ — —

4-6 Tank capacity 015 15L 15L holding capacity

030 30L 30L holding capacity



7 Voltage 3 240 VAC 3P Delta 240 VAC 3-phase Delta electrical service

4 380-415 VAC Wye 380-415 VAC Wye electrical service

5 400 VAC Delta 400 VAC Delta electrical service

6 480 VAC Delta 480 VAC Delta electrical service

8-11 Pump selection A SN0030, 1.4 kg/hr Single‐stream gear pump

B SN0046, 2.2 kg/hr

C SN0062, 2.9 kg/hr

D SN0093, 4.5 kg/hr

E SN0186, 8.9 kg/hr

F SN0371, 17.8 kg/hr

G SN0773, 37.1 kg/hr

H SN1710, 82.1 kg/hr

9 SH0371, 17.8 kg/hr Stainless‐steel gear pump

Z SH0773, 37.1 kg/hr

2 DN0030, 1.4 kg/hr/stream Dual‐stream gear pump

3 DN0048, 2.2 kg/hr/stream





J SF0016 - 0.8 kg/hr Feinprüf Single stream gear pump

K SF0030 - 1.4 kg/hr

L SF0060 - 2.9 kg/hr

M SF0090 - 4.3 kg/hr

N SF0120 - 5.7 kg/hr

O SF0175 - 8.4 kg/hr

P SF0240 - 11.9 kg/hr

Q SF0300 - 14.4 kg/hr

R SF0450 - 21.6 kg/hr

Continued...

Parts 9-3


DescriptionOptionsCodeItemBox

S DF0016 - 0.8 kg/hr/stream Feinprüf Dual-stream gear pump

T DF0030 - 1.4 kg/hr/stream

U DF0060 - 2.9 kg/hr/stream

V DF0120 - 5.7 kg/hr/stream

W DF0175 - 8.4 kg/hr/stream

Y DF0240 - 11.5 kg/hr/stream

X None No pump at this location.

12 Hose/applicatorpairs

2 2 hose/applicator pairs 2 hose/applicator pairs (4 channels) forexternal temperature control (standard)




13 Slash \ — —

Continued...

Parts9-4



14 Flow control A Pneumatic PCV Pneumatic PCVs are installed, allowing thebypass pressure to be adjusted using acustomer‐supplied air pressure regulator.

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.

M Manual Pneumatic PressureControl

Pneumatic PCVs with air regulators areinstalled, allowing the operator to changethe system pressure by adjusting theregulators.

F Flow Control Bypass Pneumatic PCVs with corresponding airregulators and controlling solenoids areinstalled, by customer supplied signalstriggering the solenoids to switch thehydraulic system between pneumaticpressure control mode (by manuallyadjustable air pressure regulators) and thevolumetric mode (which means that nomaterial circulates through the pneumaticpressure control valve).

N Pressure Build Pressure transducer and motor-drivenpressure control function are installed,allowing operator to maintain a presetpressure while the production line isstopped.

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

15 Reserved X — —

16 Low‐levelindication

L Low‐level indication present Provides a signal when the adhesive levelin the tank falls below a specified value.

X None No low‐level indication

17 I/O andindication

Y Optional I/O installed The optional I/O card (digital) is installed

X None No optional I/O expansion card

18 LCD Cover C LCD cover LCD cover is installed

X None —

19 Hostcommunication

E 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 switch

Parts 9-5



22 Sensor type N 120‐ohm nickel sensors Requires Nordson T‐style hose/applicatorconnectors

P 100‐ohm platinum sensors Requires Nordson M‐style hose/applicatorconnectors

23-25 Reserved X — —

Parts9-6


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 9‐1.

Item Part Description Quantity Note

Module, Common,15/30L, 2D, AT

901 � Panel Assembly,Tank Side,15 AND 30 Liter 2

902 � Panel Assembly,Motor Cover,Side 2

903 � Panel Assembly,Motor Cover Front 1

904 � Panel Assembly ,Electrical Cover Front 1

906 � Rivet, Pop, 1/8X.187,BLK,ALUM 8

907 � Plug, Button, M32, Plastic 1

908 � Plate Stamping,160X55 1

913 7403418 � Kit ,Ship with, 2D, ALTA BLUE Touch 1

914 7400868 � Cable Gland, Clamp, M32, 1522mm 1

917 � Plug, Dome, 22.2, Nylon 66, BLK 2

919 � Plug, Button M40, Plastic 1

Parts 9-7


X

Figure 9-1 One/two‐pump melter frame assembly parts

Parts9-8


Three/Four‐Pump Melter Frame Parts

See Figure 9‐2.


Module, Common, 30/50L, 4D, AT

901 � Panel Assembly, Tank Side, 15 and 30 Liter 2

902 � Panel Assembly, Motor Cover Side 2

903 � Panel Assembly, Motor Cover Front 4D 1

904 � Panel Assembly, Electrical Cover, Front 4D 1

906 � Rivet, Pop, 1/8X.187, BLK, ALUM 8

907 � Plug, Button, M32, Plastic 1

908 � Plate Stamping,160X55 1

913 7403419 � Kit, Ship with, 4D, ALTA BLUE Touch 1

914 7400354 � Cable Gland, Glamp, M32,1825mm 1

917 � Plug, Dome, 22.2, Nylon 66, BLK 4

919 � Plug, Button M40,Plastic 1

Parts 9-9


Figure 9-2 Three/four‐pump melter frame assembly parts

Parts9-10


Reservoir/Manifold Assembly The reservoir/manifold assembly parts vary depending on the size of themelter: one/two‐pump, three/four‐pump. Refer to the correct parts list for yourmelter.

One/Two‐Pump Melter Reservoir/Manifold Parts

See Figure 9‐3.

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

101 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Base 1

102 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Manifold assembly 1 A

103 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Spacer, manifold to base 4

104 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Plate, insulator, manifold 1

105 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Support, hydraulics 2

106 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, lock, split, M8 24

107 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, flat, narrow, M8 24

108 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M8 x 45 4

109 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M8 x 25 20

110 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M8 16

111 7400293 � Castor, swivel, 100 mm, 130 kg 2

112 7400294 � Castor, swivel, with lock, 100 mm, 130 kg 2

113 256800 � O‐ring, 26 x 2 2

114 7400132 � O‐ring, Viton, 45 x 2 2

115 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Reservoir, machined 1

116 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M8 x 90 6

117 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Spring washer, 16 mm OD 6

118 7400339 � Plug, M16, O‐ring, Viton 4

119 7400297 � Service kit, heater, 240V, 800W, 1/2 X 13.75 (allmelter manifolds)

3

120 7400569 � Service kit, heater, 240V, 400W, 1/2 X 13.75(one/two pump melter reservoirs)

3

121 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, flat, oversize, M6, 22 OD 12


123 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, pan, recessed, M6 x 10 12


125 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Lock washer, external, M3 2

126 7401366 � Thermoswitch, AltaBlue 1

127 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Deflector, adhesive 1

128 1058990 � Cordstock, 3 mm OD, Viton, 75 D 1

129 900298 � Compound, heat sink, 5 oz tube 1

130 900344 � Lubricant, Never Seez, 8 oz can 1

131 900223 � Lubricant, O‐ring, Parker, 4 oz 1

132 900413 � Sealant, RTV, red, 2.8 oz. tube 1

NOTE A: Refer to Manifold Parts.

Parts 9-11


Figure 9-3 One/two‐pump melter reservoir/manifold assembly parts (30L, 2 SS assembly shown)

Parts9-12


Three/Four‐Pump Melter Reservoir/Manifold Parts

See Figure 9‐4.

Item Part Description Quantity Note— - - - - - - - Assembly, manifold/reservoir, three/four pump —

101 - - - - - - - � Base 1

102 - - - - - - - � Manifold assembly 2 A

103 - - - - - - - � Spacer, manifold/base 8

104 - - - - - - - � Plate, insulator, manifold 2

105 - - - - - - - � Support, manifold 1

106 - - - - - - - � Washer, lock, split, M8 12

107 - - - - - - - � Washer, flat, narrow, M8 12

108 - - - - - - - � Screw,socket, M8 x 45 8

109 - - - - - - - � Screw,socket, M8 x 25 4

110 - - - - - - - � Screw, socket, M10 x 25 16

111 7400478 � Castor, swivel, 100 mm, 280 kg 2

112 7400479 � Castor, swivel, with lock, 100 mm, 280 kg 2

113 256800 � O‐ring, 26 x 2 4

114 7400132 � O‐ring, Viton, 45 x 2 4

115 - - - - - - - � Reservoir, machined 1

116 - - - - - - - � Screw, socket, M8 x 100 12

117 - - - - - - - � Spring washer, 16 mm OD 12

119 7400297 � Service kit, heater, 240V, 800W, 1/2 X 13.75 (allmelter manifolds)

6

120 7400874 � Service kit, heater, 240V, 800W, 1/2 X 27.5(three/four pump melter and 100L melterreservoirs)

3

121 - - - - - - - � Washer, flat, oversize, M6, 22 OD 18

123 - - - - - - - � Screw, pan, recessed, M6 x 10 18

124 - - - - - - - � Screw, pan, recessed, M3 x 8 2

125 - - - - - - - � Lock washer, external, M3 2

126 7401366 � Thermoswitch, AltaBlue 1

127 - - - - - - - � Plate deflector 2

128 1058990 � Cordstock, 3 mm OD, Viton, 75 D 2.4





133 - - - - - - - � Washer, lock, split, M10 16

134 - - - - - - - � Washer, flat, M10 16

136 - - - - - - - � Tag, pump number 2

137 - - - - - - - � Rivet, pop, 1/8 x 0.187 16


Parts 9-13


Figure 9-4 Three/four‐pump melter reservoir/manifold assembly parts (30/50L, 2SS/2SS assembly shown)

Parts9-14


100L Melter Reservoir/Manifold Parts See Figure 9-5.

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

13.75 (all melter manifolds)6

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 9-15


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 9-5 100L melter reservoir/manifold assembly parts (2 DS/2 SS assembly shown)

Parts9-16


Manifold Parts

See Figures 9‐6 through 9‐8.


— ‐ ‐ ‐ ‐ ‐ ‐ ‐ Assembly, manifold/reservoir —

1

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Manifold, 2 Dual Stream, DURA 1

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Manifold, 1 Single Stream, DURA 1

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Manifold, 2 Single Stream, DURA 1

2 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � O-ring 12X2 Viton B 1,2 or 4

3

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Plate, Drain, 2DS 1

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Plate, Drain, 1SS 1

‐ ‐ ‐ ‐ ‐ ‐ ‐ � Plate, Drain, 2SS 1

4 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � SCR, SKT, M6X25,BL 10

5 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, LK, M, SPT, M6, STL, ZN 10

6 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, FLT, M, Narrow, M6, STL, ZN 10

7 973480 � Plug, O-ring, STD THD, M14X1.5 8

8 7400339 � Plug, M16 ,O-ring,Viton 6 or 8

9 7400340 � Plug, M22,O-ring,Viton 3 or 6

10 7400341 � Adapter, M22 TO M16, O-ring Port 2 or 4

11 7400355 � O-ring, Viton,FOR M22 O-ring Plug 2 or 4

12 900223 � Lubricant, O-ring, Parker, 4 OZ, 30122‐5 0.02

13 900344 � Lubricant, Never Seez, 8oz can 0.01

Parts 9-17


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 9-6 Manifold assembly parts—one or two dual stream pump

Parts9-18


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 9-7 Manifold assembly parts - one single stream pump

Parts 9-19


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 9-8 Manifold assembly parts—two single‐stream pumps

Parts9-20


Hopper Assembly The hopper assembly parts vary depending on the size of the melter:one/two‐pump, three/four‐pump. Refer to the correct parts list for your melter.

One/Two‐Pump Melter Hopper Parts

See Figure 9‐9.


— ‐ ‐ ‐ ‐ ‐ ‐ ‐ Assembly, hopper, one/two pump —

201 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Hopper/grid, machined 1


203 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, lock split, M6 40

204 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M6 x 25 20

2057400135 � Gasket, hopper, 30L/50L, one/two pump 1

7400134 � Gasket, hopper, 15L, one/two pump 1



208 7401366 � Thermoswitch, ALTABLUE 1

209

7400298� 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 X 6.38

(two‐pump hopper)4


211 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M6 x 10 8

212 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Frame, tank, paint 2

213 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, flat, regular, M6 12

214 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M6 12



217 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M8 4

218 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, rear, hydraulic 1

219 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, front, hydraulic 1

220 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Bracket, heater terminal 1

221 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, flat, socket, M4 x 12 2

222 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Heater, terminal block assembly 1


224 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Washer, lock split, M5 6

225 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M5 2

226 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, top, hydraulic 1

227 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Lid, outer 1

228 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Lid, inner 1

229 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, pan, slotted, M3 x 6 8

Continued...

Parts 9-21


NoteQuantityDescriptionPartItem



232 7400047 � Hinge, lid 2

233 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, flat, recessed, M5 x 12 8

234 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, button, socket, M5 x 10 12

235 779664 � Handle, lid 1

236 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, pan, M5 x 16 2



239 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Rivet, pop, 1/8 x 0.187 2

240 224905 � Tag, warning, hot 1

241 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, jam, M5 4

242 931074 � Tape, insulation 75

243 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Insulation, foil backed, 600W x 1200L x 25 mm 1

244 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Marker, SAKD 2.5 N 1

245 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Sleeving, insulation, 0.500 ID 1

257 333304 � SENSOR,TEMP,RTD,NI,18FT LEAD 1

NS 162506 � SENSOR,RTD,100 OHM,PLT,18FTLG 1

NS: Not Shown

Parts9-22


One/Two‐Pump Melter Hopper Parts (contd)

Figure 9-9 One/two‐pump melter hopper assembly parts (30L hopper without hose return shown)

Parts 9-23



Parts9-24


Three/Four‐Pump Melter Hopper Parts

See Figure 9‐10.


— ‐ ‐ ‐ ‐ ‐ ‐ ‐ Assembly, hopper, three/four pump —

201 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Hopper, machined 1



204 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M6 x 25 30

205 7400326 � Gasket, hopper, three/four pump, 50L 1

NS 7400327 � Gasket, hopper, three/four pump, 30L 1



208 7401366 � Thermoswitch, ALTABLUE 1

209 7400875 � Service Kit, Heater, 240V, 750W, 1/2 x 11.85(50L�hopper)

9

NS 7400876 � Service Kit, Heater, 240V, 500W, 1/2 X 6.38(30L�hopper)

9


211 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M6 x 10 18

212 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Frame, tank, paint 2


214 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M6 12



217 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M8 x 20 4

218 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, rear, hydraulic 1

219 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, front, hydraulic 1

220 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Bracket, heater terminal 2

221 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, flat, socket, M4 x 12 4

222 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Heater, terminal block, left 1



225 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, M5 4

226 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Panel, top, hydraulic 1

227 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Lid, outer 1

228 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Lid, inner 1

229 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, pan, split, M3 x 6 8



232 7400047 � Hinge, lid 2

233 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, flat, recessed, M5 x 12 8

234 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, button,socket, M5 x 10 12

Parts 9-25



235 779664 � Handle, lid 1

236 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, pan, M5 x 16 2

237 900298 � Compound, heat sink,5 oz tube 1

238 900413 � Sealant, RTV, red, 2.8 oz tube 1

239 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Rivet, pop, 1/8 x 0.187 2

240 224905 � Tag, warning, hot 1

241 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Nut, hex, jam, M5 4

242 931074 � Tape, insulation 200

243 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Insulation, foil backed, 600W x 1200 L x 25 mm 1

245 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Sleeving, insulation, 0.500 ID 1

246 7400540 � O‐ring, Viton, 51.5 x 2.65 1

247 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Plate, machined, hose return 1

248 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M6 x 20 6

249 7400337 � Fitting, hose,45deg, M16x9/16‐18, O‐ring, Viton 1

250 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Heater, terminal block assembly, 400V,three/four‐pump, WYE

1

257 333304 � SENSOR,TEMP,RTD,NI,18FT LEAD 1

NS 162506 � SENSOR,RTD,100 OHM,PLT,18FTLG 1

NS: Not Shown

Parts9-26


Three/Four‐Pump Melter Hopper Parts (contd)

Figure 9-10 Three/four‐pump melter hopper assembly parts (50L hopper with hose return shown)

Parts 9-27



Parts9-28


100L Melter Hopper Parts See Figure 9-11.

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 1

Parts 9-29


NoteQuantityDescriptionPartItem247 - - - - - - - � Plate, machined, hose return 1248 - - - - - - - � 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

257 333304 � SlENSOR,TEMP,RTD,NI,18FT LEAD 1

NS 162506 � lSENSOR,RTD,100 OHM,PLT,18FTLG 1

NS: Not Shown

Figure 9-11 100L melter hopper assembly parts (100L hopper with hose return shown)

Parts9-30


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 9‐12.


— ‐ ‐ ‐ ‐ ‐ ‐ 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 4

305 ‐ ‐ ‐ ‐ ‐ ‐ � Screw, socket, M8 x 110 4

306‐ ‐ ‐ ‐ ‐ ‐ � Gear pump, single‐stream 1 C

‐ ‐ ‐ ‐ ‐ ‐ � Gear pump, dual‐stream 1 D



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 9-31


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 9-12 Pump module parts

Parts9-32


Single‐Stream Pump Adapter Parts

See Figure 9‐13.


7402910 Kit, Service, Adapter, SSN

7402911 Kit, Service, Adapter, SSN,

7402914 Kit, Service, Adapter, SSF

01 Adapter, pump, singlestream 1

02 Valve, rotary 1

03 Plate, stop 1

04 Screw, socket, M5 x 12 4

05 Washer, flat, narrow, M5 4

06 Washer, lock, split, M5 4

07 207932 Valve, safety 1 A

08 973480 Plug, Oring, straightthread, M14 x 1.5 4

09 900223 Lubricant, Oring, Parker, 4 oz 1

10 900341 Lubricant, NeverSeez, 16 oz cans 1

12 250267 Oring, 32 x 2 1

13 985022 Pin, dowel, M6 x 20 long, hose and applicator 1

NOTE A: Refer to Safety Valve Parts.

08 10

1007

10040605

01

1209

08 10

03

13

02

Figure 9-13 Single‐stream pump adapter parts

Parts 9-33


Dual‐Stream Pump Adapter Parts

See Figure 9‐14.


7402909 Kit, Service, Adapter, DSN

7402913 Kit, Service, Adapter, DSF

01 � Adapter, pump, dualstream 1

02 � Valve, rotary 1

03 � Plate, stop 1

04 � Screw, socket, M5 x 12 4

05 � Washer, flat, narrow, M5 4

06 � Washer, lock, split, M5 4

07 207932 � Valve, safety 2 A

08 973480 � Plug, Oring, straightthread, M14 x 1.5 5

09 900223 � Lubricant, Oring, Parker, 4 oz 1

10 900341 � Lubricant, NeverSeez, 16 oz cans 1

11 973459 � Plug, Oring, straightthread, M22 x 1.5 1

12 250267 � Oring, 32 x 2 1

13 985022 � Pin, dowel, M6 x 20 long, hose and applicator 1

01

02

03

05 06 04

13

09 12

11 10

0810

10

07 10

08 10

08 10

0810

Figure 9-14 Dual‐stream pump adapter parts

Parts9-34


Single‐Stream Gear Pumps

See Figure 9‐15.

Item GlandSeal Part

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 9‐1

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



Parts 9-35


Table 9-1 Variseal Pump Service Kits (Except SN1710)


NS 7136920 Sealing Kit,PUMP F.Shaft D12,7(pump seal service kit)

—

NS ‐ ‐ ‐ ‐ ‐ ‐ � O-ring 22X3 Viton 70 Shore a Black 2

NS ‐ ‐ ‐ ‐ ‐ ‐ � Ring ID 12, 7 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Turcon-Roto-Variseal D12, 7 Inside Seal 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Allen Head Cap Screw M5X16 DIN912 A2‐70 3

NS ‐ ‐ ‐ ‐ ‐ ‐ � High-Temp. Grease GLS 595/N2 CAN:10G 1

NS 7146229 � In‐Assembly Tools 7136915, 7136918, EN/GE 1 A

NS 7136915 Assembly Tool F.Shaft Sealing D12,7(assembly tool service kit)

—

NS ‐ ‐ ‐ ‐ ‐ ‐ � Assembly Mandrel F.Shaft Sealing D12, 7 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Assembly Bushing F.Shaft Sealing D12, 7 1


NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordsonrepresentative.

NS: Not Shown

Parts9-36


Single‐Stream Gear Pumps (contd)

Table 9-2 Variseal Pump SN1710 Service Kit


— 7136921 Sealing Kit, Pump F.Shaft D16(pump seal service kit)

—

NS ‐ ‐ ‐ ‐ ‐ ‐ � O-ring 28X3 Viton 70 Shore A Schwarz 2

NS ‐ ‐ ‐ ‐ ‐ ‐ � Buffer Ring ID 16 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Turcon‐Roto-Variseal D16 Inside Seal 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Allen Head Cap Screw M6X20 DIN912 SST 4

NS ‐ ‐ ‐ ‐ ‐ ‐ � High-Temp. Grease GLS 595/N2 CAN:10G 1

— 7136918 Assembly Tool F.Shaft Sealing D16(assembly tool service kit)

— —

NS ‐ ‐ ‐ ‐ ‐ ‐ � Assembly Mandrel F.Shaft Sealing D16 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Assembly Bushing F.Shaft Sealing D16 1


NOTE A: This is instruction may be obtained from http://emanuals.nordson.com, or contact your Nordsonrepresentative.

NS: Not Shown

Figure 9-15 Single‐stream gland seal (left) and Variseal (right) gear pumps

Parts 9-37


Dual‐Stream Gear Pumps

See Figure 9‐16.

Item GlandSeal Part

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 9-16 Dual‐stream gland seal gear pump

Parts9-38


Safety Valve Parts

See Figure 9‐17.


— 207932 Valve, safety, 85 bar 1

— 394592 Service kit 1

1 ‐‐‐‐‐‐ � O‐ring 11 x 2 1

2 ‐‐‐‐‐‐ � O‐ring 9 x 2 1

— ‐‐‐‐‐‐ � High‐temp. Grease, GLS 595/N2, 10g 1

1

2

Figure 9-17 Safety valve parts

Parts 9-39



Parts9-40


Control Valve Assemblies The control valve assemblies vary depending on the type of pressure controlvalve: pressure control valve, pneumatic pressure control valve, circulationcontrol valve, or blank. Refer to the correct parts lists for your melter.

Control Valve Module Parts

See Figure 9‐18.


Assembly,control valve module

401 7104265 � Filter cartridge MW0,2 VB reinf. compl. 1 A

401 � Plug M56x1,5 L35 1

402 203059 � Pressure ctrl valve 590 bar VB/DB 1 B

207300 � Pressure ctrl valve 590 bar VB/DB pneum 1 C

1070961 � Valve, Circulation Control, AltaBlue 1 D

� Plug, pressure regulator valve VB/DB 1

403 � Valve, Ball, 8 MM, SS 316 1

404 � Screw, Drain Valve 1

405 � Retaining Ring,INT,51,Basic 1

NOTE A: Refer to Filter Cartridge Parts.

B: Refer to Pressure Control Valve Parts OR Pressure Build Control.

C: Refer to Pneumatic Pressure Control Valve Parts OR Manual Pneumatic Pressure ControlOR Flow Control Bypass.

D: Refer to Circulation Control Valve Parts.

Parts 9-41


Figure 9-18 Pressure control module parts

Parts9-42


Filter Cartridge Parts

See Figure 9‐19.


— 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 9-19 Filter cartridge parts

Parts 9-43


Pressure Control Valve Parts

See Figure 9‐20.


— 203059 Valve, pressure control, adjustable, 90 bar 1

1 ‐ ‐ ‐ ‐ ‐ � Body, valve 1

2 ‐ ‐ ‐ ‐ ‐ � Piston, valve, supporting ring 1

3 ‐ ‐ ‐ ‐ ‐ � Set screw, black, 90 bar 1

4 ‐ ‐ ‐ ‐ ‐ � Compression spring, 2.2 x 7.4 x 34.4 1

5 ‐ ‐ ‐ ‐ ‐ � O‐ring, 6 x 2 1

6 ‐ ‐ ‐ ‐ ‐ � O‐ring, 11 x 2 1

7 ‐ ‐ ‐ ‐ ‐ � O‐ring, 9 x 2 1

8 ‐ ‐ ‐ ‐ ‐ � Supporting ring, Da10, Di6.7, spiral 1

— 394600 Service Kit Pressure control valve 1

6 ‐ ‐ ‐ ‐ ‐ � O‐ring 11 x 2 1

7 ‐ ‐ ‐ ‐ ‐ � O‐ring 9 x 2 1

— ‐ ‐ ‐ ‐ ‐ � High‐temp. grease, GLS 595/N2, 10 g 1

7

3

4

2

8

5

6

1

Figure 9-20 Pressure control valve parts

Parts9-44


Pneumatic Pressure Control Valve Parts

See Figure 9‐21.


207300 Pressure ctrl valve 590 bar VB/DB pneum —

1 � Piston, pressure control valve 1

2 � Valve body, bypass 300 degree 1

3 � Cylinder, bypass pneu., Da19.3 1

4 � Valve, body, bypass pneumatic, 50bar (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 1

� Fitting, quick thread-in, -W-d08-R1/8-TURN 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, 10g 1

Parts 9-45


9

6

7

5

1

118

2

4

3

10

Figure 9-21 Pneumatic pressure control valve parts

Parts9-46


Pneumatic Pressure Control Valve Interface Parts

See Figure 9‐23.

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 9-22 Pneumatic pressure control valve interface parts

Parts 9-47



Parts9-48


Manual Pneumatic Pressure Control Valve Parts

See Figure 9‐23.


Manual Pneumatic PCV Assembly,4 Path , Touch

1 � Cabinet, Assembly ,Manual Pneumatic PCV,Touch

1

2 � Air Inlet, with Safety Valve, FCB/AOPCV, Touch 1

3 7403318 � Service Kit, pressure regulator, ARM10 4

4 � Pneumatic Connector,3XD042XD6 2

5 � Fitting, Plug, D06 2


8 � Multi Plug Connector,4 Fitting 1

9 � Tubing, Polyurethane, 0.6


11 � AIE Hose, D4.0,d2.5,PU,BLUE 0.8



16 � Rivet, #8X11#Nylon 4

17 207300 � Pressure ctrl valve 590 bar VB/DB pneum 4

18 � Heat-Resistant Tube D4 7

19 � Clamp,Wire Routing, D04 8

20 � SCR, SKT, M8X1.25X25,BL 4

21 � Washer, LK, M, EXT,M10, ZN 4

22 � Nut, HEX, Serrated, M8, STL,(8.8)M ZP 4

NOTE: this part list is 4 path option for Manual Pneumatic Pressure Control

Parts 9-49


Figure 9-23 Manual pneumatic pressure control valve parts

Parts9-50


Flow Control Bypass Control Valve Parts

See Figure 9‐24.


FCB Assembly,4 Path , Touch

1 � Cabinet, Assembly,Flow Control Bypass, Touch 1

2 � Air Inlet, with Safety Valve, FCB/AOPCV, Touch 1

3 7403318 � Service Kit, pressure regulator, ARM10 4

4 � 2/3 Valve,Assembly,14 Unit, FCB, Touch 1

5 � Pneumatic Connector,3XD042XD6 2



8 � Multi Plug Connector,4 Fitting 1






14 � AIE Hose, D4.0,d2.5,PU,BLUE 4

18 � Heat-Resistant Tube D4 7

19 � Clamp,Wire Routing, D04 8

20 � Rivet, #8X11#Nylon 4

21 207300 � Pressure ctrl valve 590 bar VB/DB pneum 4

22 � SCR, SKT, M8X1.25X25,BL 4

23 � Washer, LK, M, EXT,M10, ZN 4

24 � Nut, HEX, Serrated, M8, STL,(8.8)M ZP 4

26 � Nut, HEX with EXT TOOTH Washer, M4 4

27 � Wire,0.75SQMM, 24/ 0.20,PVC,RED 4

28 � Wire,0.75SQMM, 24/ 0.20,PVC,BLK 4

NOTE: this part list is 4 path option for Flow Control Bypass

Parts 9-51


Figure 9-24 Flow control bypass control valve parts

Parts9-52


Manual Pneumatic Pressure Control Valve Cabinet

See Figure 9‐25.


Cabinet, Assembly,Manual Pneumatic PCV, Touch

1 � Cabinet, Manual Pneumatic, FCB, Touch 1

2 � Cover, GUGUE Mounting, FCB, Touch 1

3 � Panel, with Shutter, FCB, Touch 1

4 � Dust Guard Cover 1

7 � SCR, SKT, Low, M4X10, ZN 16

8 � Washer, FLT, M, Narrow, M4, STL, ZN 16

9 � Washer, LK, M, SPT,M4, STL, ZN 16

09�08

08��09

08 09

03

07

01

07

02

04

07

Figure 9-25 Manual pneumatic pressure control valve cabinet parts

Parts 9-53



Parts9-54


Flow Control Bypass Control Valve Cabinet

See Figure 9‐26.


Cabinet, Assembly,Flow Control Bypass, Touch —

1 � Cabinet, Manual Pneumatic, FCB, Touch 1

2 � Cover, GUGUE Mounting, FCB, Touch 1

3 � Panel, with Shutter, FCB, Touch 1

4 � Dust Guard Cover 1

5 � Heavy Connector,Housing, with Cover 1

6 � Heavy Connector,Insert, Female,16 PIN 1

7 � Scr, skt, Low,M4X10, ZN 16

8 � Washer, flt, M, Narrow, M4, STL, ZN 16

9 � Washer, lk, M, SPT,M4, STL, ZN 16

10 � Allen Head Cap Screw M3X10 DIN912 SST 4

11 � Washer, flt, M, REG, M3, Zinc Plate 4

12 � Washer, lk, M, SPT,M3, STL, ZN 4

Parts 9-55


08

09 08

09

11

09

06

08

12

01

07

10

07

03

07

02

04

05

13

Figure 9-26 Flow control bypass control valve cabinet parts

Parts9-56


Manual Pneumatic Pressure & Flow Control Bypass Control ValveInterface Parts

See Figure 9‐27.


Air Inlet, with Safety Valve, FCB/AOPCV, Touch

1 � quick threadin fitting Gd06G1/40000 1

2 � airoperated hose D8,0 d6,0 PU blue 2

3 � female air coupling d6 NW7,2 L60 1

4 � male air coupling KS41/4A 1

5 � Sealing Ring R1/4 Type:PDR14 2

6 � Bulkhead Connection IG1/4 1

7 � Double Nipple AR1/4AR1/4 1

8 � TPiece 3XIRP1/4 1

9 � Pipeftg,hyd,elbow90street,1/4bsp,brass,n 1

10 � Pneumatic Connector, Type T,Rc1/42XD6 1

11 � Safety Valve 6BAR G1/4 SW20 1

12 � Sign "MAX. 6 BAR" Self Adhesive 1

Figure 9-27 Manual pneumatic pressure & flow control bypass control valve interface parts

Parts 9-57


Flow Control Bypass Control Valve Solenoid Parts

See Figure 9‐28.


2/3 Valve,Assembly,14 Unit, FCB, Touch

1 � Fixing Plate,2/3 Valve, AOPCV&FCB 1

2 7403314 � Service kit, Solenoid Valve,2/3,1 Unit 1

� Solenoid Valve,2/3,2 Unit 1



3 � Connector,Type I,M5D04 4

4 � Pneumatic Connector,Rc1/84 4

5 � Connector, Male, 6MM 1/8" Thread, BR

Figure 9-28 Flow control bypass control valve solenoid parts

Parts9-58


Manual Pneumatic Pressure & Flow Control Bypass Control Valve MultiConnector Parts

See Figure 9‐29.


Multi Plug Connector —

1 Multi Plug Connector Socket 1

2 Multi Plug Connector Plug 1

3 BARB Fitting Socket

4 BARB Fitting Plug

5 SCR, SKT, Low,M4X10, ZN 4

6 Washer, FLT, M, Narrow, M4, STL, ZN 4

7 Washer, LK, M, SPT,M4, STL, ZN 4

Figure 9-29 Manual pneumatic pressure & flow control bypass control valve multi connector parts

Parts 9-59



Parts9-60


Pressure Build Control Parts

Table 9‐3 Internal transducer parts list

Item Part Description Quantity

401 7403137 KIT,FLOW/PRESSURE CONTROL BOARD 1

402 SCR,PAN,SLT,M3X6,ZN 4

403 WASHER,LK,M,INT,M3,STL,ZN 4

1001 TRANSDUCER,PRESSURE,M14X1.5, 0-1500PSI 1

1002 CABLE,PRESSURE,6 PIN,MELTER SIDE,TOUCH 1

1003 CLAMP,D26.5,TRANSDUCER,PRESSURE,ALUM 1

1004 SCR,SKT,M5X16,BL 1

1005 WASHER,LK,M,SPT,M5,STL,ZN 1

1006 MOUNT,SADDLE TIE, DIA.6 2

1007 NUT,HEX,M5,STL,ZN 2

1008 WASHER,FLT,M,REG,M5,STL,ZN 2

Parts 9-61


1006, 1007 and 1008

401, 402 and 403

1006, 1007 and 1008

1005

1004

10031001

1002

Figure 9‐25 Internal transducer parts

Parts9-62


Circulation Control Valve Parts

See Figure 9‐30.


— 1070961 Valve, circulation control 1

1 ‐ ‐ ‐ ‐ ‐ � Body, circulation valve 1

2 ‐ ‐ ‐ ‐ ‐ � Spool, circulation valve 1

3 ‐ ‐ ‐ ‐ ‐ � Nut, hex, M12 1

4 ‐ ‐ ‐ ‐ ‐ � O‐ring, 9 x 2 1

5 ‐ ‐ ‐ ‐ ‐ � O‐ring, 11 x 2 1

6 ‐ ‐ ‐ ‐ ‐ � O‐ring, Viton, 0.239 ID x 0.070 W 1

7 ‐ ‐ ‐ ‐ ‐ � Screw, set, cup, M4 x 4, stainless‐steel 1

— 394600 Service Kit Circulation control valve 1

4 ‐ ‐ ‐ ‐ ‐ � O‐ring 9 x 2 1

5 ‐ ‐ ‐ ‐ ‐ � O‐ring 11 x 2 1

— ‐ ‐ ‐ ‐ ‐ � High‐temp. grease, GLS 595/N2, 10g 1

1 2

3

4

5

5

7

Figure 9-30 Circulation control valve parts

Parts 9-63


Flow Control Bypass

This option contains:

a. Pneumatically actuated pressure control valve (1x per stream)

b. Fast switching 3-way solenoid (1x per stream)

c. Pressure gauge (1x per stream – for single stream pumps only)

d. Pressure regulator + gauge (1x per stream)

Set up:

Available line pressure (approx. 6 bar) is being put on the pressure regulatorand into the solenoid input. The outlet pressure of the regulator is adjustedaccording to the desired recirculation flow setting. The pressure gauge isinstalled after the pump into the stream that goes to the hose connectorfitting. The actuation signal for the solenoid is being supplied externally viaconnector and in accordance to the trigger signal of the gun.

Function:

When the gun is open the system is run in volumetric mode, which meansthat no material does circulate through the pneumatic pressure control valve.In this mode the flow is determined by the motor rpm setting, respectively thekey to line signal. To achieve this a trigger signal (e.g. the trigger signal forthe gun) is send to the solenoid for the pneumatic pressure control valve,which does close with maximum air pressure (e.g. available line pressure of6 bar). In cases of overpressure the safety pressure valve would operate.When the gun is closed, a trigger signal (e.g. the trigger signal for the gun)does operate the solenoid for the bypass valve. This allows the regulated(reduced) air flow to open the pneumatic pressure control valve and to adjustrecirculation pressure according to the air pressure setting. The major goal isto reduce/ eliminate the burn-through (hammerhead) effect by adjusting thepressure during gun closed. The gun or nozzle pressure in this mode isusually the same as during gun open.

Parts9-64


Schematics

Figure 9-31 Flow control bypass control valve schematic

Parts 9-65


Figure 9-32 Manual pneumatic pressure control valve schematic

Parts9-66


Manual Pneumatic Pressure

This option contains:

a. Pneumatically actuated pressure control valve (1x per stream)

b. Manually operated pressure regulator + guage (1x per stream)

Set up:

Available line pressure is supplied to the manually activated pressureregulator. Air conditioning units to be provided separately. The output of theregulator supplies the pneumatically actuated pressure control valve withregulated air.

Function:

It provides the same functionality as the standard manual pressure controlvalve but allows the operator to change the system pressure without tools.However, in addition it provides a possibility to remotely control the setting, ifcustomer provides additional pressure regulator.

Bottom View Front

Port #3

Port #4

Port #2

Port #1

Parts 9-67


Motor Assembly See Figure 9‐33.


— ‐ ‐ ‐ ‐ ‐ ‐ Assembly, motor, standard —

501 7402299 � Coupling,m24,dan/Normal 1

7402293 � Coupling,M24,DAN/SN1710(SN1710 pumpsonly)

1

502 7402295 � Service Kit,Motor,BG06-31/D06LA4TOF 1

503, 531, 532 7403719 � KIT,MOTOR BRACKET,ADJUST,ALTA 1

504 ‐ ‐ ‐ ‐ ‐ ‐ � Washer,flat,regular,M8 8

505 ‐ ‐ ‐ ‐ ‐ ‐ � Washer,lock,split,M8 8

506 ‐ ‐ ‐ ‐ ‐ ‐ � Screw,socket,M8 X 25 3

507 ‐ ‐ ‐ ‐ ‐ ‐ � SCR,SKT,M8X30,BL 3

NS ‐ ‐ ‐ ‐ ‐ ‐ � Cable assembly, motor 1

NS ‐ ‐ ‐ ‐ ‐ ‐ � Harness, internal 1

NS: Not Shown

Figure 9-33 Motor assembly parts (four‐pump melter shown)

Parts9-68


Electrical Enclosure Panel Assemblies The electrical enclosure panel assembly parts vary depending on the size ofthe melter: one/two‐pump, three/four‐pump. Refer to the correct parts lists foryour melter.

400V Melter Left Panel

See Figure 9‐34.


Panel Assembly,LH, with LK,400V, Touch —

1 � Panel, Left, Outside, Electrical Cabinet, with LK 1

2 � Panel, Left, Inside, Electrical Cabinet, Touch 1

3 � Stock WireWay 45X65 ALTABLUE 0.33


5 � WireWay,25X65X180,ALTABLUE 1


7 � Washer, FLT, M, REG, M3, Zinc Plate 10

8 � Washer, LK, M, SPT,M3, STL, ZN 10

9 � Nut, Acorn, M3, STL, ZN 10

10 � DIN Rail, 280 LG 1

11 � Hex nut, Flanged, Serrated, M5 8

12 7400378 � Main switch, 100 A, 3 pole 1

13 7401321 � Service Kit, Filter, Fan, Electrical Cabinet 1

14 7403435 � Main Contactor DILM40C 1

15 7400482 � RC suppressor, 110−250 VAC 1

16 318248 � Circuit breaker 63A 3pole FAZB63/3 1

17 7403519 � Terminal Block, Power Distribute, 400V, AT 1

18 � End Stop, Terminal Block 4

19 � Spacer Sleeve, ALTABLUE 5

20 � Hex nut, Flanged, Serrated, M6 5

21 � Panel, Cover, Filter 1

22 7400369 � Lockout Switch 63A 3POLE 600V 1

NOTE A: Present only on melters with the optional lockout switch.

Parts 9-69


Figure 9-34 Left panel assembly parts (400V melter shown)

Parts9-70


One/Two‐Pump Melter 2 Hose/Gun (400V) Back Panel Parts (15, 30L)

See Figure 9‐35.

Item Part Description Quantity Note Panel assy, back, 2H/G, 2D, 15/30L, 400V, touch

1 � Panel, back, inner, elect cab, 2D, touch 1

2 � Wireway, 50 x 50 x 570, Alta 2

3 � Wireway, 25 x 50 x 300, Alta 3

4 � Washer, flt, M, reg, M3, zinc plate 17

5 � Washer, lk, M, spt, M3, stl, zn 17

6 � Nut, acorn, M3, stl, zn 17

7 � Rail, din, 300 lg, Alta 2

8 � Hex nut, flanged, serrated, M5 4

9 1078624 � Svce kit, DuraBlue, main, PCA 1

10 � Scr, pan, rec, w/washer, M4 x 10, zn 4

11 1031201 � Svce kit, DuraBlue, expansion PCA 1

12 � Scr, pan, rec, M3 x 8, zn DIN 7985H 7

13 � Lockwshr M, ext, M3, stl, zn 7

14 � Jumper 3/N/PE, AC 400230V 1

15 � This item number is reserved

16 � terminal block,end plate ZAP/TW3 1

17 256227 � Circuit breaker, 2A 1pole 1





22 � Terminal block ZDU 2,5/4AN 2

23 � End stop, terminal block 6

24 777404 � REALY,DC24V,MY2NJ 1

25 777630 � BASE, RELAY (OMRON) 1

26 7400010 � Clip, relay 1

27 207396 � Solidstate relay G3PE 100260V MAX. 15A 2

28 7400070 � Solid state relay, 100260VAC, 35A, DC TRIG 1

32 � Spacer sleeve, AltaBlue 4

33 7403060 � Hexnut, flanged, serrated, M6 4

34 7402290 � Panel, back, outer, elect cab, 2D 1

35 7403476 � Marker, terminal block, DEK 5/5+MC, touch 1

Parts 9-71


Figure 9-35 One/two-pump melter 2 Hose/Applicator (400V) back panel parts (15L, 30L)

Parts9-72


One/Two‐Pump Melter 2 Hose/Gun (400V) Back Panel Parts (50L)

See Figure 9‐36.

Item Part Description Quantity Note Panel assy, back, 2H/G, 2D, 50L, 400V


2 � Wireway, 50 x 50 x 570, Alta 2

3 � Wireway, 25 x 50 x 300, Alta 3




7 � Rail, din, 300 lg, Alta 2



10 � Scr, pan, rec, w/washer, M4 x 10, zn 4


12 � Scr, pan, rec, M3 x8 ,zn DIN 7985H 7

13 � Lockwshrm, ext, M3, stl, zn 7

14 � Jumper 3/N/PE,AC 400230V 1


16 � terminal block,end plate ZAP/TW3 1

17 256227 � Circuit breaker,2A 1pole 1





22 � terminal block ZDU 2,5/4AN 2


24 777404 � REALY,DC24V,MY2NJ 1


26 7400010 � Clip, relay 1


28 7400070 � Solid state relay,100260VAC,35A,DC TRIG 2


33 7403060 � Hex nut, flanged, serrated, M6 4

34 7402290 � Panel, back, outer, elect cab, 2D 1

35 7403476 � Marker, terminal block, DEK 5/5+MC, touch 1

NOTE A: See Figure 9‐37 for the location of this part on the main board.

Parts 9-73


Figure 9-36 One/two‐pump melter 2 Hose/Gun (400V) back panel parts (50L)

Parts9-74


One/Two‐Pump Melter 2 Back Panel Parts

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 9-37 Location of the shunt on the main board

Parts 9-75



Parts9-76


One/Two-pump Melter 4/6 Hose/Gun (400V) Back Panel Parts (15L, 30L)

See Figure 9‐38.


Panel assy, back, 4/6H/G, 2D, 15&30L, 400V,touch

1 Panel, back, inner, elect cab, 2D, touch

2 Wireway, 50 x 50 x 570, Alta 2


4 Washer, flt, M, reg, M3, zinc plate 17

5 Washer, lk, M, spt, M3, stl, zn 17

6 Nut, acorn, M3, stl, zn 17

7 Rail, din, 300 lg, Alta 2

8 Hex nut, flanged, serrated, M5 6

9 1078624 Svce kit, DuraBlue, main, PCA 1

10 Scr, pan, rec, w/washer, M4 x 10, zn 4

11 1031201 Svce kit, DuraBlue, expansion PCA 1

12 Scr, pan, rec, M3 x 8, zn DIN 7985H 7

13 Lockwshr, ext ,M3, stl, zn 7

14 Jumper 3/N/PE, AC 400230V 1

15 This item number is reserved

16 terminal block,end plate ZAP/TW3 1

17 256227 Circuit breaker, 2A 1pole 1

18 256141 Circuit breaker 16A 3pole FAZB16/3 1


20 7400071 Circuit breaker,32A 1pole 1


22 Terminal block ZDU 2,5/4AN 2

23 End stop, terminal block 6

24 777404 REALY,DC24V,MY2NJ 1

25 777630 BASE, RELAY (OMRON) 1

26 7400010 Clip, relay 1

27 207396 Solidstate relay G3PE 100260V max. 15A 6

28 7400070 Solid state relay, 100260VAC, 35A, DC TRIG 1

32 Spacer sleeve, AltaBlue 4

33 7403060 Hex nut, flanged, serrated, M6 4

34 7402290 Panel, back, outer, elect cab, 2D 1

35 7403476 Marker, terminal block, DEK 5/5+MC, touch 1


Parts 9-77


Figure 9-38 One/two-pump melter 4/6 Hose/Gun (400V) back panel parts (15L, 30L)

Parts9-78


One/Twopump Melter 4/6 Hose/Gun (400V) Back Panel Parts (50L)

See Figure 9‐39.


Panel assy, back, 4/6H/G, 2D, 50L, 400V, touch

1 Panel, back, inner, elect cab, 2D, touch






7 Rail, din, 300 lg, Alta 2






13 Lockwshrm, ext, M3, stl, zn 7



16 Terminal block, end plate ZAP/TW3 1










26 7400010 Clip, relay 1

27 207396 Solidstate relay G3PE 100260V MAX. 15A 6



33 7403060 Hex nut, flanged, serrated, M6 4

34 7402290 Panel, back, outer, elect cab, 2D 1

35 7403476 Marker, terminal block, DEK 5/5+MC, touch 1


Parts 9-79


Figure 9-39 One/twopump melter 4/6 Hose/Gun (400V) back panel parts (50L)

Parts9-80


Three/Fourpump 4/6 Hose/Gun (400V) Melter Back Panel Parts(30,50L)

See Figure 9‐40.


Panel assy, back, 4/6H/G, 4D, 30&50L, 400V,touch

1 Panel, back, inner, elect cab, 4D, touch 1

2 Wireway 45 x 65 x 590 AltaBlue 2

3 Wireway 25 x 65 x 690 AltaBlue 4




7 Rail, din 35 x 7.5 x 690 AltaBlue 2






13 Lockwshrm, ext, M3, stl, zn 7



16 Terminal block, end plate ZAP/TW3 2





21 This item number is reserved 1




25 7400010 Clip, relay 1

26 207396 Solidstate relay G3PE 100260V MAX. 15A 7



35 Marker, terminal block, DEK 5/5+MC, touch 1

37 Panel, back outer elect cab 4D 1



Parts 9-81


Figure 9-40 Three/fourpump 4/6 Hose/Gun (400V) melter back panel parts (30,50L)

Parts9-82


Three/Four‐Pump Eight Hose/Gun (400V) Melter Back Panel Parts(30,50L)

See Figure 9‐41.

Item Part Description Quantity Note Panel assy, back, 8H/G, 4D, 30&50L, 400V, touch


2 � Wireway 45 x 65 x 590 AltaBlue 2

3 � Wireway 25 x 65 x 690 AltaBlue 4




7 � Rail, DIN 35 X 7.5 X 690 AltaBlue 2

8 � Hexnut, flanged, serrated, M5 10


10 � Scr, pan, rec, w/washer, M4 X 10, ZN 4


12 � Scr, pan, rec, M3X8, zn DIN 7985H 7

13 � Lockwshrm, ext, M3, stl, zn 7

14 � Jumper 3/N/PE, AC 400230V 1 A


16 � Terminal block,end plate ZAP/TW3 2





21 � This item number is reserved 6

22 � Terminal block ZDU 2,5/4AN 2


24 777404 � REALY,DC24V,MY2NJ 1

25 7400010 � Clip, relay 1


27 7400070 � Solid state relay, 100260VAC, 35A, DC TRIG 2

28 � End stop,terminal block 7

29 1061712 � Board, assy, 8 H/G exp. base,PB II 1

35 � Marker, terminal block, DEK 5/5+MC, touch 1

37 � Panel, back outer elect cab 4D 1

38 � Spacer sleeve, ALTABLUE 4



Parts 9-83


Figure 9-41 Three/fourpump 8 Hose/Gun (400V) melter back panel parts (30, 50L)

Parts9-84


Two Hose/Gun (400V) Melter Right Panel Parts

See Figure 9‐42.

Item Part Description Quantity Note Panel assy, RH, 2H/G, 400V, touch

1 � Panel,right inside,elect cab,touch 1

2 � Wireway, 25x50x490 1

3 � Wireway 25x50x290 3

4 � Stock, wireway, 25x50, pearl 0.19




8 � Terminal block, RH, 400V, AT 1

9 � Terminal block, ground, AT 1



16 7401320 � Service kit, fan, 240VAC, 170 CFM 1

17 7401321 � Service kit, filter, fan, elect. cab 1

18 � Screw, shcs M4 X 45 GD 8.8 ZP 2

19 � Panel, cover, filter 1



22 � Panel, right, outside, elect cab


24 � Insert, female, 16 pin, 116, cage clamp 1

25 � Insert, female, 16 pin,17132, cage clamp 1

26 � Connector housing, base, 32 pin, w/cover 1

27 � Scr, pan, rec, M4X16 4

28 � Washer, flt, M, narrow, M4, stl, zn 4


30 � End stop, terminal block

31 7403256 � 24VDC power supply, 150W 1

32 � Rail, din, 280lg, AltaBlue 1

Parts 9-85


Figure 9-42 Two Hose/Gun(400V) melter right panel parts

Parts9-86


Four Hose/Gun(400V) Melter Right Panel Parts

See Figure 9‐43.


1 � Panel, right inside, elect cab, touch 1

2 � Wireway, 25x50x490 1

3 � Wireway, 25x50x290 3


5 � Washer ,flt, M, reg, M3, zinc plate 15






15 � Board, breakout, DuraBlue, expand, tb, 20POS 1







22 � Panel, right, outside, elect cab 1





27 � SCR,PAN,REC,M4X16 4






Parts 9-87


Figure 9-43 Four Hose/Gun(400V) melter right panel parts

Parts9-88


Six Hose/Gun (400V) Melter Right Panel Parts

See Figure 9‐44.


1 � Panel, right inside,elect cab, touch 1

2 � Wireway, 25x50x490 1

3 � Wireway, 25x50x290 3








11 1031202 � Svce kit, DuraBlue, PCA pwr mod 4ch 1

12 � Scr, pan, rec, M4x10, zn 4

13 � Washer, lk, M, ext, M4, stl, zn 4

15 � Board, breakout, DuraBlue, expand, tb, 20pos 1



18 � Screw, shcs M4 x 45 gd 8.8 zp 2









27 � Scr, pan, rec, M4x16 4





32 � Rail, din, 280 lg, AltaBlue 1

Parts 9-89


Figure 9-44 Six Hose/Gun (400V) melter right panel parts

Parts9-90


Eight Hose/Gun (400V) Melter Right Panel Parts

See Figure 9‐45.



2 � Wireway, 25x50x490 1

3 � Wireway, 25x50x290 3


























Parts 9-91


Figure 9-45 Eight Hose/Gun (400V) melter right panel parts

Parts9-92


Two Hose/Gun (240V) Melter Right Panel Parts

See Figure 9‐42.

Item Part Description Quantity Note PANEL ASSY,RH,2H/G,240V DELTA,TOUCH


2 � Wireway, 25x50x490 1

3 � Wireway 25x50x290 3















22 � Panel,right, outside, elect cab, touch













Parts 9-93


Figure 9-46 Two Hose/Gun(240V) melter right panel parts for 2H/G, 15/30L and 2H/G, 50L

Parts9-94


Two Hose/Gun (240V) Melter Right Panel Parts (contd)

Figure 9-47 Two Hose/Gun(240V) melter right panel parts for 2H/G, 100L

Parts 9-95



Parts9-96


Four Hose/Gun(240V) Melter Right Panel Parts

See Figure 9‐43.

Item Part Description Quantity Note PANEL ASSY,RH,4H/G,240V DELTA,TOUCH


2 � Wireway, 25x50x490 1

3 � Wireway 25x50x290 3















22 � Panel,right, outside, elect cab, touch












34 � Ref dwg, panel assy, rh, 240v delta, touch 1

Parts 9-97


Figure 9-48 Four Hose/Gun(240V) melter right panel parts for 4/6H/G, 15/30/50L

Parts9-98


Four Hose/Gun(240V) Melter Right Panel Parts (contd)

Figure 9-49 Four Hose/Gun(240V) melter right panel parts 4/6H/G, 100L

Parts 9-99



Parts9-100


Six Hose/Gun (240V) Melter Right Panel Parts

See Figure 9‐44.

Item Part Description Quantity Note Panel assy, RH, 6H/G, 240V, delta, touch

1 � Panel, right inside,elect cab, touch 1

2 � Wireway, 25x50x490 1

3 � Wireway, 25x50x290 3








11 � Pca, pwr mod, 4ch, 240v, ms/us/as 1

12 � Scr, pan, rec, M4x10, zn 4

13 � Washer, lk, M, ext, M4, stl, zn 4


















32 � Rail, din, 280 lg, AltaBlue 1

33 � Board, breakout, durable, expand, tb, 20pos 1


Parts 9-101


Figure 9-50 Six Hose/Gun(240V) melter right panel parts for 4/6H/G, 15/30/50L

Parts9-102


Six Hose/Gun (240V) Melter Right Panel Parts (contd)

Figure 9-51 Six Hose/Gun(240V) melter right panel parts 4/6H/G, 100L

Parts 9-103



Parts9-104


Eight Hose/Gun (240V) Melter Right Panel Parts

See Figure 9‐45.

Item Part Description Quantity Note Panel assy, RH, 8H/G, 240V delta, touch


2 � Wireway, 25x50x490 1

3 � Wireway, 25x50x290 3


























33 � Board, breakout, durablue, expand, tb, 20pos 1


Parts 9-105


Figure 9-52 Eight Hose/Gun (240V) melter right panel parts for 8 H/G, 4D/100L

Parts9-106


One/Two‐Pump Melter Bottom Panel Parts

See Figure 9‐53.


Panel Assembly, Bottom, 400V Y,2D, Touch

1 � Panel, Bottom, Electrical Cabinet,2D, Touch 1

2 � EMI Filter, 500VAC, 60A, 3P+N+PE 1

3 � Terminal Block, Ground, Touch 1

4 � Grommet Rubber ID32 5

5 � SCR, SKT, M8X20, ZN 4

6 � Washer, FLT, M, REG, 8, STL, ZN 4

7 � LockWasher, M8 4

8 � Hexnut, Flanged, Serrated, M5 2

9 � Mount, Saddle Tie, DIA.6 1

10 � Nut, HEX, M5, STL, ZN 1

11 � Washer, FLT, M, REG, M5, STL, ZN 1

Figure 9-53 One/two‐pump melter bottom panel assembly parts

Parts 9-107


Three/Four‐Pump Melter Bottom Panel Parts

See Figure 9‐54.


Panel Assembly, Bottom, 400V Y,4D, Touch

1 � Panel, Bottom, Electrical Cabinet, 4D/100L,Touch

1

2 � EMI Filter,500VAC,60A,3P+N+PE 1

3 � Terminal Block, Ground, Touch 1


5 � Grommet Rubber ID32 8

6 � SCR, SKT, M8X20, ZN 4

7 � Washer, FLT, M, REG, 8, STL, ZN 4

8 � LockWasher, M8 4




Figure 9-54 Three/four‐pump and 100L melter bottom panel assembly parts (400V melter shown)

Parts9-108


Control Panel Assembly See Figure 9‐55.


Control Assembly, ELEC, 1/2D, Touch

0001 � Panel, Assembly, Control, 2D, Touch 1

0002 1108174 � Tag, Display, ALTABLUE Touch 1

0003 7403311 � Service Kit, LCD MODULE 1

0004 7403315 � Service Kit,PCA Motor Control, Touch 1

0005 � THRDSPCRMM, Male/Female ss, hex, M3,8MMLG

6

0006 � Washer, LK, M, INT,M3, STL, ZN 6

0007 � Clamp, Ribbon Cable 1

0008 � SCR, PAN, REC, M3X8, ZN 2


0010 � Harness, COMM, CPUMotor Control, 6", Touch 1




Figure 9-55 Control panel assembly parts (twopump melter shown)

Parts 9-109



Parts9-110


Sensor Assembly See Figure 9‐56. The sensors on your melter may be one of two types:120‐ohm nickel or 100‐ohm platinum.


Module, Sensor, NI, 2H/G, 400V,100L, Touch

0801 7403503 Hose Connect Assembly,NI,2H/G,2D, Touch 1

7403504 Hose Connect Assembly,NI,4H/G,2D, Touch 1

7403505 Hose Connect Assembly,NI,6H/G,2D, Touch 1

7403506 Hose Connect Assembly,NI,2H/G,100L, Touch 1

7403507 Hose Connect Assembly,NI,4H/G,4D/100L, Touch 1



7403510 Hose Connect Assembly,PT,2H/G,2D, Touch 1



7403513 Hose Connect Assembly,PT,2H/G,100L, Touch 1

7403514 Hose Connect Assembly,PT,4H/G,4D/100L, Touch 1



0802 7401367 RTD,Assembly,NI120, Grid, ALTABLUE 1

7400280 RTD Assembly, PT100, Grid, ALTABLUE 1

0803 7401368 RTD, Assembly, NI120, Reservoir, ALTABLUE 1

7400281 RTD Assembly, PT100, Reservoir, ALTABLUE 1

0804 Washer, FLT, M, REG, M6, STL, ZN 8

0805 Washer, LK, M, SPT, M6, STL, ZN 8

0806 Nut, HEX, M6, STL, ZN 8

0807 Panel Cover Manifold 4D 2

0808 Washer, FLT, M, REG, M3, Zinc Plate 8

0809 Washer, LK, M, SPT,M3, STL, ZN 8

0810 SCR, PAN, SLT,M3X6, ZN 8

0811 7403496 Harness,INL1/2,28 H/G,4D/100L, Touch 1

0812 7403501 Harness,INH3/4,400V,4D/100L, Touch 1

0813 7403498 Harness,INL5/6,8 H/G,4D/100L, Touch 1

0814 7403499 Harness,INH7/8,8 H/G,400V,4D/100L, Touch 1

0815 171856 Shunt,.1IN,2POS 2

0802 7401368 RTD, Assembly, NI120, Reservoir, ALTABLUE 1

7400281 RTD Assembly, PT100, Reservoir, ALTABLUE 1

0803 333304 SENSOR,TEMP,RTD,NI,18FT LEAD 1

162506 SENSOR,RTD,100 OHM,PLT,18FTLG 1

Parts 9-111


Figure 9-56 Sensor assembly parts (four‐pump 100‐ohm platinum melter shown)

Parts9-112


Low Level Assembly See Figure 9‐57.


— 1079477 Low level indication, 15/30L, one/two pump —

— 1079478 Low level indication, 50L, one/two pump —

— 1079476 Low level indication, 30/50L, three/four pump —

— 1079973 Low level indication, 100L —

1201 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Wire harness, low level 1

1202 ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Low level assembly, 169 mm 1

NS ‐ ‐ ‐ ‐ ‐ ‐ ‐ � Cable tie, 4 in., 302 degrees F 5

NS: Not Shown

12021201

GASCKETROUTE WIRE FROM SWITCHASSEMBLY BETWEEN THEHOPPER GASKET AND TOP COVER.

Figure 9-57 Low level assembly parts

Parts 9-113


Optional Accessories To optimize the use of your system, Nordson Corporation recommends theseoptional accessories.

Pressure Indication

Part Description Note

1030537 Kit, gauge, analog pressure, 1500 psi

Pneumatic Pressure Control Valve


1079939 Kit, pressure control valve, pneumatic

NOTE: Refer to Pneumatic Pressure Control Valve Parts earlier in this section for a parts list andillustration.

Parts9-114


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.


119560 Generator, 0-10 VDC, with bracket and cable

Optional Fittings

See Figure 9‐58. These fittings can be used at the melter end of a hose.

Hose SizeFitting

Part�NumberFitting Type

Fitting Size,Melter Side

Fitting 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

12

3

Figure 9-58 Typical non‐swivel fittings

1. Straight fitting 2. 45� fitting 3. 90� fitting

Parts 9-115


Recommended Spare Parts

Table 9-4 Recommended Spare Parts

P/N Description

All 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 hoppers andthree/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 melterreservoirs)

7401366 Thermoswitch Assembly, ALTABLUE

7403137 KIT,FLOW/PRESSURE CONTROL BOARD

7403138 KIT,FLOW/PRESSURE CONTROL BOARD

777404 REALY,DC24V,MY2NJ

777630 BASE, RELAY (OMRON)

7401321 Service Kit, Filter, Fan, Electrical Cabinet

7401320 Service Kit, Fan, 240VAC, 170 CFM

7400318 Service Kit, Motor Control, ALTABLUE

7140101 Interference Filter 230VAC/2X6A B

1078624 Service Kit, DURABLUE, Main, PCA

1031201 Service Kit, DURABLUE, Expansion PCA

1031175 Service Kit, DURABLUE, 2H TO 4H Conversion

207396 Solid State Relay, 100-260VAC, 15A, DC Trigger

7400070 Solid State Relay, 100-260VAC, 35A, DC Trigger

207932 Safety valve, 85 bar, VB/DB

7400299 Service Kit, O-ring, Viton, 45 X 2

7400300 Service Kit, O-ring, Viton, 26 X 2

1058990 CordStock, 3 MM OD, Viton, 75D

7400134 Gasket, Hopper, 15L (one/two pump melters)

7400135 Gasket, Hopper, 30/50L, ALTA

7400326 Gasket, 50L, Hopper, 4D

7400327 Gasket, 30L, Hopper, 4D

7402295 Service Kit, Motor, BG06‐31/D06LA4TOF

7403311 Service kit, LCD module

Continued...

1107260 BATTERY,COIN CELL,3.0V,24MM,LITHIUM

Parts9-116


7403314 Service kit, solenoid valve, 2/3, 1 unit

7403315 Service kit, PCA motor control, touch

Parts 9-117


Recommended Spare Parts (contd)

P/N Description

All Melters

7403317 Kit, LCD cover

7403318 Service kit, pressure regulator, ARM10

7403274 Service kit, insulation, hopper, 15L, 2D





7403279 Service kit, insulation, hopper, 100L

7403280 Service kit, insulation, reservoir, 100L

7403281 Service kit, insulation, hopper, 15L, W/R, 2D





7403286 Service kit, insulation, hopper, 100L, W/R

7402919 Service kit, lid, AB2D15L/4D30L

7402920 Service kit, lid, AB2D30&50L/4D50L

7402921 Service kit, lid, AB100L

7402922 Service kit, hinge, lid, AltaBlue

7402923 Service kit, hinge, support, lid, AB100L

7403095 Kit, change normal pump to SN1710

7403096 Kit, change SN1710 to notmal pump

7403139 Kit, transducer, applicator, 4-20mA

7403140 Kit, transducer, applicator, 0-10 VDC

7403141 Kit, cable, 0-10V, 16 ft, pressure



7403146 Kit, Truflow, T-style, 12mm, Trueflow, melter

7403147 Kit, Truflow, M-style, 12mm, Trueflow, melter

7403148 Kit, cable, Truflow, L-16 ft w/ 6 pin conn



7403151 Kit, RVS 1 melter, 24 ft, touch

7403152 Kit, RVS 1-5 melter, 50 ft, touch

Continued...

Parts9-118


P/N Description

All Melters

7403153 Kit, RVS 1-5 melter, 100 ft, touch

7403154 Kit, cable, 4-20 mA, 16 ft, pressure



Parts 9-119


Table 9-5 Recommended Pump Spare Parts

P/N Description

Pumps

394589 Service Kit, PUMP O-ring, Single-Stream, PUMP SIZE SN0030-SN0773

394596 Service Kit, PUMP O-ring, Single-Stream, PUMP SIZE SN1710

7104645 Service Kit, PUMP O-ring, DUAL‐STREAM

Select Based on Specific Melter Configuration

One/Two‐Pump Melters, 240 VAC

7403435 MAIN CONTACTER DILM50C

318248 circuit breaker, 63 A, 3‐pole

7400320 Circuit breaker, 32 A, 2‐pole




256141 Circuit breaker, 16 A, 3‐pole, inductive load

One/Two‐Pump Melters, 400 and 480 VAC

7403435 MAIN CONTACTOR, DILM50C





256227 Circuit breaker, 2 A, 1-pole

256141 Circuit breaker, 16 A, 3‐pole inductive load

Continued...

Parts9-120


Recommended Spare Parts (contd)

Three/Four‐Pump and 100L Melters, 240 VAC

7403071 Main Contactor, DILM80C

7104855 Circuit breaker, 90 A, 3‐pole, UL489






Three/Four‐Pump and 100L Melters, 400 and 480 VAC

7403435 Main Contactor, DILM50C





256227 Circuit breaker, 2 A, 1-pole


Pt100 Melters

7400281 RTD assembly, reservoir, PT100

7400280 RTD assembly, tank, PT100

Ni120 Melters

7401367 RTD assembly, reservoir, Ni120

7401368 RTD assembly, tank, Ni120

Technical Data 10-1


Section 10

Technical Data

General Data Storage temperature - 45° C to + 75 ° C

- 49 ° F to + 167 ° F

Type of heating Cartridge‐type resistance heating elements

Temperature sensor Ni120 and PT100 � 1 ° C

— Measuring precisionMaterial pressure 5 to 85 bar 0.5 to 8.5 MPa 72.5 to 1�233 psi

Melting capacity 1 tank‐full per hour

Degree of protection IP 33

Noise emission <70 dB

Motor type 3 ph AC motor

Gear box type Helical gear

Motor/pump speeds 94 rpm

Heatup time <45 min

Temperatures Min. ambient temperature - 5 °C 23 °F

Max. ambient temperature 40 ° C 104 °F

Humidity 10 to 95 %, not condensing

Min. operating temperature(setpoint)

40 ° C 100 °F

Max. operatingtemperatures

230 ° C 450 °F

Overtemperature shutdownby thermostat

260 ° C 500 °F

Technical Data10-2


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 melterpower requirements

400 VAC Delta480 VAC Delta400 VAC Star WYE

One/two-pump melter Two hose/applicator 15L:8380W30L:9482W50L:12420W

Four hose/applicator 15L:12053W30L:13155W50L:16094W

Six hose/applicator 15L:13890W30L:14992W50L:17931W

Two-pump melter Eight hose/applicator 30L:23166W50L:25232W

Three/four-pump melter

Four hose/applicator 30L:18684W50L:20750W

Six hose/applicator 30L:20521W50L:22587W

Eight hose/applicator 30L:24194W50L:26161W

100L Two hose/applicator 100L:21347WFour hose/applicator 100L:25021WSix hose/applicator 100L:26858WEight hose/applicator 100L:30531W

Technical Data 10-3


Maximum melterpower requirements

230 VAC Delta

One/two-pump melter Two hose/applicator 15L:9124W

30L:10324W50L:13524W

Four hose/applicator 15L:13124W30L:14324W50L:17524W

Six hose/applicator 15L:15124W

30L:16324W50L:19524W

Two-pump melter Eight hose/applicator 30L:25224W50L:27474W

Three/four-pump melter

Four hose/applicator 30L:20344W50L:22594W

Six hose/applicator 30L:22344W

50L:24594WEight hose/applicator 30L:26344W

50L:28594W100L Two hose/applicator 100L:23244W

Four hose/applicator 100L:27244WSix hose/applicator 100L:29244WEight hose/applicator 100L:33244W

Max. load per hosereceptacle (2 chan-nels), two/four/six/eight hose/applicatormelters

1000 W, any single hose or applicator

1200 W, any hose/applicator pair2000 W, sum of hose/applicator pairs 1 and 22000 W, sum of hose/applicator pairs 5 and 62000 W, any single hose, or applicator 3 or 42000 W, any single hose, or applicator 7 or 82000 W, hose/applicator pair 3 or 42000 W, hose/applicator pair 7 or 84000 W, sum of hose/applicator pairs 3 and 44000 W, sum of hose/applicator pairs 7 and 8NOTE: Total external wattage must not exceed 12,000 W.

Technical Data10-4


Mechanical Data

One/Two and Three/Four Pump Melters

Item 15L 30L 50L 100L Note

Weight 200 kg (441 lb) One/two pump:225�kg (496 lb)

Three/fourpump:440 kg (970 lb)

One/two pump:250 kg (551 lb)

Three/fourpump:472 kg (1,041 lb)

590 kg (1,301 lb)

Tank opening(length and width)

145 x 270 mm 270 x 270 mm 270 x 270 mm 270 x 635 mm

Approximate tankvolume

15 L 30 L 50 L 100 L

Number of pumps(one/two‐pumpmelter)

1-2single‐stream

1-2 dual‐stream

1-2single‐stream

1-2 dual‐stream

1-2single‐stream

1-2 dual‐streamNot applicable

Number of pumps(one/two‐pumpmelter)

Not applicable 2 single‐stream

2 dual‐stream

2 single‐stream

2 dual‐stream

Not applicable A

Number of pumps(three/four‐pumpmelter)

3-4single‐stream ordual-streampumps

3-4single‐stream ordual-streampumps

Up to foursingle-stream ordual-streampumps

Number of hoseconnections

One single‐stream manifold: 7 connections

Two single‐stream manifolds: 3 connections per pump stream

Dual‐stream manifold: 2 connections per pump stream

NOTE A: Only for 2 pumps with 8 hose/applicator.

Technical Data 10-5


Electrical Schematics Refer to the electrical schematics provided with the melter.

Technical Data10-6


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 10-1 Hydraulic system schematic

Calculating Melter Power Requirements (Including Heater Specifications) A-1


Appendix A

Calculating Melter Power Requirements(Including Heater Specifications)

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 when calculatingmelter power requirements.

� Single‐component maximum—The wattage of any single hose or

gun

� Hose/gun pair maximum—The combined wattage of any hose and

gun (hose/gun pair)

� Two hose/gun pair maximum—The combined wattage of hose/gun

pairs 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 not beexceeded, 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 the

original wattage evaluation

� replace an existing hose with a longer hose or an existing gun with a

larger gun

Calculating Melter Power Requirements (Including Heater Specifications)A-2


Table A-1 Maximum Allowable Hose/Gun Wattages(Eight Hose/Gun Melters)

Component Maximum Wattage

Any single hose or gun 1000W

Any hose/gun pair 1200W

Sum of hose/gun pairs 1 and 2 2000W


Any single hose, or gun 3 or 4 2000W

Any single hose, or gun 7 or 8

Hose/gun pair 3 or 4 2000W

Hose/gun pair 7 or 8


Sum of hose/gun pairs 7 and 8

NOTE: Total external wattage must not exceed 12,000 W.



Table A-2 Power Calculations (400V WYE)

SIZE H/G PUMP MOTOR POWER STAMPING

15L 2 H/G 2D 2 motor 8380 3Ø N/PE AC 400/230 V 50/60 Hz 22A

1 motor 7865 3Ø N/PE AC 400/230 V 50/60 Hz 20A

30L 2 motor 9482 3Ø N/PE AC 400/230 V 50/60 Hz 27A




100L 100L 4 motor 21347 3Ø N/PE AC 400/230 V 50/60 Hz 35A










30L 4D 4 motor 18684 3Ø N/PE AC 400/230 V 50/60 Hz 33A
























Table A-3 Power Calculations (400V WYE) contd.

SIZE H/G PUMP MOTOR POWER STAMPING













Table A-4 Heater Specifications

2 Pump Platform P/N Description QTY. RESISTANCE/EACH(OHMS)

MIN. MAX.

15L Hopper 7402319 HEATER, 240V 500W,.50DIA X 6.38LG

4 98 115

Reservoir 7400481 HEATER CARTRIDGE, 240V400W, .50DIA X 13.75LG

3 123 144

Manifold 7400051 HEATER CARTRIDGE, 240V800W, .50DIA X 13.75 LG

3 61 72


4 61 72


3 123 144


3 61 72


8 61 72


3 123 144


3 61 72

4 Pump Platform


9 98 115

Reservoir 7400480 HEATER CARTIDGE, 240V800W, .50DIA X 27.5LG

3 61 72


6 61 72

50L Hopper 7402318 HEATER, 240V 750W, .50DIA X 11.85LG

9 65 77


3 61 72


6 61 72


9 49.25 57.45


6 61 72


6 61 72

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______________________________________

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