Nordson ProBlue 10 Hot Melt Adhesive Dispenser

ProBlueAdhesive Melters Model P4, P7, and P10 Customer Product Manual Part 1024496D02 Issued 2/07

Nordson Corporation • Duluth, Georgia • Usa

Part 1024496D02  2007 Nordson Corporation All rights reserved Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2002. 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, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ETI, e.Stylized, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, Little Squirt, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, Trends, Tribomatic, Ultrasaver, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AquaCure, ATS, Auto-Flo, AutoScan, Blue Series, Check Mate, Classicblue, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, Easy Clean, EasyOn, Eclipse, E-Nordson, Equi=Bead, ESP, Fill Sentry, G−Net, G−Site, HDLV, iON, Iso-Flex, iTrend, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, Minimeter, Multifil, Myritex, OptiStroke, PatternPro, PCI, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners’ rights.

Table of Contents i Part 1024496D02  2007 Nordson Corporation Table of Contents Safety 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Alert Symbols 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibilities of the Equipment Owner 1-2 . . . . . . . . . . . . . . . . . . . . . . Safety Information 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions, Requirements, and Standards 1-2 . . . . . . . . . . . . . . . . . . User Qualifications 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applicable Industry Safety Practices 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use of the Equipment 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions and Safety Messages 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Practices 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Practices 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Repair Practices 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Safety Information 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Shutdown 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving System Hydraulic Pressure 1-6 . . . . . . . . . . . . . . . . . . . . . De-energizing the System 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disabling the Guns 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Warnings and Cautions 1-7 . . . . . . . . . . . . . . . . . . . . . Other Safety Precautions 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Labels and Tags 1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Sources of Information 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Guide 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User’s Guide 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Online Support 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Resource CD 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Description 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limitations of Use 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modes of Operation 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melter Identification 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Components 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Equipment 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents ii Part 1024496D02  2007 Nordson Corporation Installation 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick-Start 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing 400/480 Volt Melters 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Information 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Tasks 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Experience of Installation Personnel 3-2 . . . . . . . . . . . . . . . . . . . . . . . . Installation Requirements 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearances 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Power 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Air 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Considerations 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking the Melter 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents of the Installation Kit 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer-Supplied Materials 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the Melter 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring the Electrical Service 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting a Compressed Air Supply 3-14 . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Hoses and Guns 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up the Melter 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Setup 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Parameters 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Operating Parameters 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . Reading or Editing Operating Parameters 3-22 . . . . . . . . . . . . . . . . . Set-point Temperature of the Tank, Hoses, and Guns 3-26 . . . . . . . . . . Save and Restore Melter Settings 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . Review Parameter and Set-point Temperature Changes 3-29 . . . . . . . Installing Melter Inputs 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Melter Outputs 3-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Optional Equipment 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting a Gun Driver, Pattern Controller, or Timer 3-39 . . . . . . . . . . . . Flushing the Melter 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up Melter Communications 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii Part 1024496D02  2007 Nordson Corporation Operation 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Information 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . More about Heated Components 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling the Tank 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the Melter 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring the Melter 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Confirm that the Melter is Operating Correctly 4-6 . . . . . . . . . . . . . . . Monitor Component Temperatures 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . Monitor Melter Faults 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How F1, F2, and F3 Faults are Handled 4-11 . . . . . . . . . . . . . . . . . . How F4 Faults are Handled 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitor the Level of Hot Melt in the Tank 4-16 . . . . . . . . . . . . . . . . . . . . Monitor and Adjust the Operating Air Pressure 4-16 . . . . . . . . . . . . . . . Monitor the Service Interval 4-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Component Temperatures 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . Enter the Melter Password 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Melter Function Keys 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Key 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Key 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Key 4-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven-day Clock Key 4-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby Key 4-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutting Down the Melter 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relieving System Pressure 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locking Out External Communications 5-2 . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Melter 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Filter 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring the Life of the Filter 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Tank 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Melter from the Sub-base 5-10 . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400/480 Volt Melters 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melter Faults 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Troubleshooting Flowchart 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Quick-checks 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning the Melter Setup to Factory Settings 6-5 . . . . . . . . . . . . . . . Identifying Electrical Components 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Procedures 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DP.1 Isolate a Failed Control Component 6-11 . . . . . . . . . . . . . . . . . . . . DP.2 Check the Tank or Manifold RTD 6-12 . . . . . . . . . . . . . . . . . . . . . . Reheating the Melter During an F1 Fault 6-13 . . . . . . . . . . . . . . . . . . Remove the Tank RTD 6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Manifold RTD 6-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DP.3 Check the Operation of the Power Relay or Thermostats 6-15 . DP.4 Check the Operation of the Tank or Manifold TRIAC 6-16 . . . . . DP.5 Check the Resistance of the Tank and Manifold Heaters 6-17 . .

Table of Contents iv Part 1024496D02  2007 Nordson Corporation Parts 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Illustrated Parts List 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank, Pump, and Manifold Parts List 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Assembly Parts List 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly Parts List 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Components Parts List 7-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Enclosure Parts List 7-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior Panels Parts List 7-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Components Parts List 7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Cable Parts List 7-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kits 7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Replacement 7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump General Service 7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter 7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Panel 7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Discharge Valve 7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Service Kit 7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents v Part 1024496D02  2007 Nordson Corporation Technical Data 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Specifications 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melter Power Requirements 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P4 Melter 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P7 Melter 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P10 Melter 8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub-base 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagrams—200/240 VAC Melter 8-7 . . . . . . . . . . . . . . . . . . . . . . . . Calculating Melter Power Requirements

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Table of Contents vii Part 1024496D02  2007 Nordson Corporation 400/480 Volt ProBlue Adhesive Melters

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Safety 1-1 Part 1024496D02  2007 Nordson Corporation Section 1 Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as “use”) of the product described in this document (hereafter referred to as “equipment”). Additional safety information, in the form of task-specific safety alert messages, appears as appropriate throughout this document. WARNING: Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION: (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property.

Safety 1-2 Part 1024496D02  2007 Nordson Corporation Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information  Research and evaluate safety information from all applicable sources, including the owner-specific safety policy, best industry practices, governing regulations, material manufacturer’s product information, and this document.  Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information.  Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards  Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices.  If applicable, receive approval from your facility’s engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time.  Provide appropriate emergency and first aid equipment.  Conduct safety inspections to ensure required practices are being followed.  Re-evaluate safety practices and procedures whenever changes are made to the process or equipment.

Safety 1-3 Part 1024496D02  2007 Nordson Corporation User Qualifications Equipment owners are responsible for ensuring that users:  Receive safety training appropriate to their job function as directed by governing regulations and best industry practices  Are familiar with the equipment owner’s safety and accident prevention policies and procedures  Receive, equipment- and task-specific training from another qualified individual NOTE: Nordson can provide equipment-specific installation, operation, and maintenance training. Contact your Nordson representative for information  Possess industry- and trade-specific skills and a level of experience appropriate to their job function  Are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment  Use the equipment only for the purposes described and within the limits specified in this document.  Do not modify the equipment.  Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non-standard auxiliary devices. Instructions and Safety Messages  Read and follow the instructions provided in this document and other referenced documents.  Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section.  If you are unsure of how to use the equipment, contact your Nordson representative for assistance.

Safety 1-4 Part 1024496D02  2007 Nordson Corporation 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 and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material.  If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance.  Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects.  Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources.  Properly ground all equipment. Contact your local building code enforcement agency for specific requirements.  Ensure that fuses of the correct type and rating are installed in fused equipment.  Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices  Familiarize yourself with the location and operation of all safety devices and indicators.  Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist.  Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer’s instructions and MSDS for PPE requirements.  Do not use equipment that is malfunctioning or shows signs of a potential malfunction.

Safety 1-5 Part 1024496D02  2007 Nordson Corporation Maintenance and Repair Practices  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 or factory-authorized refurbished replacement parts.  Read and comply with the manufacturer’s instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative.  Confirm the correct operation of all safety devices before placing the equipment back into operation.  Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information.  Keep equipment safety warning labels clean. Replace worn or damaged labels.

Safety 1-6 Part 1024496D02  2007 Nordson Corporation Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment.  Hot melt and cold adhesive application equipment and all related accessories  Pattern controllers, timers, detection and verification systems, and all other optional process control devices Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter-specific product manual for instructions on relieving system hydraulic pressure. De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from all power sources before accessing any unprotected high-voltage wiring or connection point.

Safety 1-7 Part 1024496D02  2007 Nordson Corporation General Safety Warnings and Cautions Table 1-1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1-1 as follows: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns)

Safety 1-8 Part 1024496D02  2007 Nordson Corporation Table 1-1 General Safety Warnings and Cautions Equipment Type Warning or Caution

Hm

Hm

Hm, Ca

Hm

Hm, Pc

Hm, Ca, Pc

Hm, Ca, Pc

Hm, Ca, Pc

Safety 1-9 Part 1024496D02  2007 Nordson Corporation Warning or Caution Equipment Type

Hm

Hm

Hm, Ca

Hm

Safety 1-10 Part 1024496D02  2007 Nordson Corporation Safety Labels and Tags Figure 1-1 illustrates the location of the product safety labels or tags that are affixed to the equipment. Table 1-2 provides the text of any safety message that appears on each tag or the meaning of symbols that appear without any safety message. The installation kit provided with the melter may contain label overlays that are printed in a variety of languages. If required by governing safety regulations, apply the appropriate overlay to the text portion of the labels shown in Figure 1-1. 2 1 5 4 3 Figure 1-1 Location of safety labels and tags Table 1-2 General Safety Warnings and Cautions Item Description 1

Warning

Caution

Warning

Warning

Introduction 2-1 Part 1024496D02  2007 Nordson Corporation Section 2 Introduction This manual describes the installation and use of the ProBlue 4 (P4), ProBlue 7 (P7), and ProBlue 10 (P10) adhesive melter. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties. With the exception of tank capacity, hose/gun capacity, and exterior appearance, all ProBlue melters are functionally identical. To simplify the presentation of information in this manual, depictions of the model P4 are used generically throughout this manual to represent all ProBlue melters.

Introduction 2-2 Part 1024496D02  2007 Nordson Corporation Other Sources of Information Refer to the following additional resources for quick-reference information, technical support, and information about getting the most out of your ProBlue melter. Installation Guide The installation guide shipped with the melter provides a visual quick-reference for installing the melter. User’s Guide The user’s guide shipped with the melter provides a visual quick-reference to the most common operator-level tasks. The guide is appropriately sized and laminated so that it can be kept with the melter on the production floor. Online Support Visit www.enordson/support to download melter firmware updates and software utilities. Visit www.emanuals.nordson.com to download product manuals and instruction sheets. Product Resource CD The resource CD, which is stored in the back of this manual, contains an electronic version of this manual, parts information, and other useful resources that are designed to assist you with using and servicing your melter.

Introduction 2-3 Part 1024496D02  2007 Nordson Corporation Product Description See Figure 2-1. Nordson ProBlue adhesive melters are used in conjunction with Nordson hot melt hoses and guns to create a hot melt application system. The melter liquifies solid-form hot melt and maintains the hot melt at the desired temperature. When the guns are activated, the melter pumps the liquified hot melt through the hoses and out the gun nozzles, where it is commonly applied to the surface of a product or package. Figure 2-1 System components

Introduction 2-4 Part 1024496D02  2007 Nordson Corporation Limitations of Use Use ProBlue melters only for the purpose for which they are designed. ProBlue melters should not be used  to melt or pump polyurethane reactive or polyamid hot melt materials or any other material that creates a health or safety hazard when heated  in environments that will require the melter to be cleaned using a water wash or spray Modes of Operation ProBlue melters operate in the following modes: Automatic scan—The melter automatically checks and displays the current temperature of the tank, hoses, and guns to confirm that they are within their pre-defined temperature range. By default, the melter is always in the automatic scan mode unless it is placed into another operating mode. Standby—The temperatures of the tank, hoses, and guns are reduced down from their operating temperature (hereafter referred to as set-point temperature) by a pre-set number of degrees. Setup—The setup mode is used to configure melter control options and features and to review stored operating data. To prevent unauthorized changes to the melter’s configuration, the melter can be password-protected Fault—The melter alerts the operator when an abnormal event occurs. Melter Identification See Figure 2-2. You will need the model and part number of your melter when requesting service or ordering spare parts and optional equipment. The model and part number are indicated on the equipment identification plate that is located on the front of the melter.

1/3On/Peac 400/230

V 50Hz 33A

1/3O

Ac 200−240

V 60Hz 35A

R

Introduction 2-5 Part 1024496D02  2007 Nordson Corporation Key Components Figure 2-3 provides the name and the location of key melter components. Figure 2-3 Key components

Introduction 2-6 Part 1024496D02  2007 Nordson Corporation Figure 2-4 Control panel

Introduction 2-7 Part 1024496D02  2007 Nordson Corporation Optional Equipment The following equipment may be ordered to expand the functionality and capacity of ProBlue adhesive melters.  Input/output (I/O) expansion cards that allow you to expand the number of available control inputs.  Communications cards that allow the melter to communicate with other process equipment or a controller that uses standard network protocols.  Hose/Gun modules that allow you to increase the number of hoses/guns that can be connected to the melter.  Automatic Fill Systems that provide automated transfer of dry adhesive materials to your melter. Choose either the FillEasy® or FillMaster® product.  8-Hose/Gun Expansion Base that expands the capacity of a P10 adhesive melter from 6-hoses/guns to 8-hoses/guns.

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Installation 3-1 Part 1024496D02  2007 Nordson Corporation Section 3 Installation WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. Quick-Start If you have already installed the melter using the installation guide (P/N 1024498) that is provided inside the shipping container, and you have no questions concerning the installation, go to Setting Up the Melter later in this section for information about how to prepare the melter to operate with your manufacturing process. Installing 400/480 Volt Melters Refer to Appendix E for information about installing 400/480 volt ProBlue adhesive melters. After completing the procedures described in Appendix E, you will be referred back to this section to set up the melter. Overview ProBlue melters are factory-configured for each order and require only the assembly and set up tasks described in this section. If your melter was ordered as a complete system, the shipping container will also contain one or more hot melt hoses and guns. ProBlue 400/480 volt melters include a transformer assembly that is shipped separately from the melter. The melter is shipped from the factory with an installation kit that contains components that must be assembled onto the melter by the customer. Some additional materials must also be supplied by the customer to complete the installation. If optional equipment was ordered with the melter, refer to the documentation provided with the optional equipment for installation and operating instructions.

Installation 3-2 Part 1024496D02  2007 Nordson Corporation Overview (contd) The illustrations accompanying the procedures in this section depict the P4 melter. Unless otherwise noted, the instructions also apply to the P7 and P10 melter. Additional Information This section presents installation procedures in their most commonly used form. Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross-reference information. Additional information tables are indicated by the symbol shown to the left. Installation Tasks The installation sequence is as follows:

Installation 3-3 Part 1024496D02  2007 Nordson Corporation Installation Requirements Before installing the melter, ensure that the desired installation location provides the required clearances, environmental conditions, and utilities. Clearances Figure 3-1 illustrates the minimum clearances that are required between the melter and surrounding objects. Table 3-1 describes each clearance. NOTE: 400/480 volt melter clearances are provided in Appendix E.

A

B

C

D

A

B

C

D

Installation 3-4 Part 1024496D02  2007 Nordson Corporation Ventilation See Figure 3-2. ProBlue melters are cooled by convection. Air is drawn in through openings in the chassis of the melter and is exhausted out of the ventilation slots at the top of the melter. CAUTION: Do not block the air intake openings and ventilation slots. Figure 3-2 Melter cooling Electrical Power Before installing the melter, ensure that the melter will not be overloaded and that the plant’s electrical service is rated to handle the power required by the melter and the hoses and guns that you plan to use. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the maximum allowable hose lengths and gun wattages that can be used in your manufacturing application. WARNING: Risk of electrocution! Install a lockable power disconnect switch between the electrical service and the melter. Failure to install or properly use the disconnect switch when servicing the melter can result in personal injury, including death.

Installation 3-5 Part 1024496D02  2007 Nordson Corporation Compressed Air To achieve maximum hot melt output, the melter must be connected to an air supply that is capable of providing a maximum of 6.2 Bar (90 psi) of dry, nonlubricated air. The actual pressure required for the melter to support your manufacturing process will depend on such factors as the type of hot melt and gun you are using and the required dimensions of the hot melt bead. NOTE: The minimum operating air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically. Nordson recommends that an isolation valve be installed in the plant air supply line just before the melter. Other Considerations Consider the following additional factors when evaluating where to install the melter.  The maximum distance between the melter and each gun is dictated by the power requirement of each hose. Refer to Appendix A, Calculating Melter Power Requirements for information about how to determine the maximum allowable length.  The operator must be able to safely reach the control panel and accurately monitor the control panel indicators.  The operator must be able to safely observe the level of hot melt inside the tank.  The melter must be installed so that it can be safely removed from its sub-base.  The melter must be installed away from areas with strong drafts or where sudden temperature changes occur.  The melter must be installed where it will be in conformance with the ventilation requirements specified in the Material Safety Data Sheet for the hot melt being used.  The melter should not be exposed to excessive vibration.  P4 and P7 melters provide an auxiliary hose port at the bottom of the manifold. If the auxiliary hose port will be used, the parent machine or other support structure must provide clearance under the melter to connect the hose to the auxiliary hose port.

Installation 3-6 Part 1024496D02  2007 Nordson Corporation Unpacking the Melter Before starting the installation, remove the melter from the pallet, locate the installation kit, and inspect the melter for damaged and missing parts. Report any problems to your Nordson representative. Contents of the Installation Kit The installation kit provided with the melter contains the components shown in Figure 3-3. The quantity and type of hose fittings provided in the kit depends upon the melter’s model number and configuration. NOTE: 400/480 volt transformers are shipped with a separate installation kit. Refer to Appendix E for information about the contents of the transformer installation kit. The installation kit also contains a package of safety label overlays that are printed in a variety of languages. If required by local regulations, the appropriate language overlay should be applied over the English version of the same label. Refer to Section 1, Safety Labels and Tags, for the location of each safety label. NOTE: P10 melters also include a manifold guard kit P/N 1031871. Customer-Supplied Materials The following additional materials are also required to install the melter.  A power cable. If the cable clamp that is provided in the installation kit is not used, rigid or flexible electrical conduit will be required.  Four 8 mm (5/16 in.) machine bolts with locking hardware  A plant air supply with an in-line isolation valve

Installation 3-7 Part 1024496D02  2007 Nordson Corporation Figure 3-3 Installation kit components

Melter sub-base Installation 3-8 Part 1024496D02  2007 Nordson Corporation Mounting the Melter ProBlue melters use a unique mounting sub-base that allows the melter to be easily mounted onto and removed from the parent machine or support structure, without the need to unbolt the melter. Before mounting the melter, ensure that the parent machine or support structure is level with respect to the floor, provides an even mounting surface, is free of excessive vibration, and that it is capable of supporting the combined weight of the melter, a full tank of hot melt, and the hoses and guns. Refer to Section 8, Technical Data, for the dimensions of the sub-base and the weight of the melter. Refer to the technical data provided by the hot melt manufacturer for information about the volumetric weight of the hot melt. To mount the melter See Figure 3-4.

Installation 3-9 Part 1024496D02  2007 Nordson Corporation

Opening the electrical enclosure door Installation 3-10 Part 1024496D02  2007 Nordson Corporation Configuring the Electrical Service ProBlue melters are shipped from the factory without an attached power cable and without an electrical service type specified. To configure the melter to function in your facility, you must connect a power cable and a Nordson-supplied voltage plug to the melter. To connect a power cable to the melter

P4

P7

P10

Electrical connector

(P/N 1022993)

Example Only

Tb1

Pe / G

Voltage plugs with and without the neutral lead Installation 3-12 Part 1024496D02  2007 Nordson Corporation To connect a power cable to the melter (contd) Table 3-3 Electrical Service Information Use Electrical Connector Terminals.. Use Voltage Plug.. If the Electrical Service Type is..

L1

L2

L3

N

3/N/Pe Ac

400/230V

1/N/Pe Ac

200–240V

3/Pe Ac

200–240V

1/Pe Ac

200–240V

Installation 3-13 Part 1024496D02  2007 Nordson Corporation Figure 3-6 Connecting a voltage plug

Pressure regulator and adjustment screw Installation 3-14 Part 1024496D02  2007 Nordson Corporation Connecting a Compressed Air Supply CAUTION: Do not force the air pressure adjustment screw beyond its normal range of adjustment. Forcing the adjustment screw beyond its normal range of adjustment will damage the pneumatic assembly. To connect an air supply

Installation 3-15 Part 1024496D02  2007 Nordson Corporation

P/N 1034145

1/4 Nptf

1/4 Bspp

G

a b Hose/gun module 1 a) Receptacle 1 b) Receptacle 2 1 Hose port 1 (P4/P7 melter manifold shown) Installation 3-16 Part 1024496D02  2007 Nordson Corporation Connecting Hoses and Guns ProBlue melters use standard Nordson hoses and guns. The P4 and P7 melters support the connection of up to four hose/gun pairs. The P10 melter supports the connection of up to six hose/gun pairs. The hose/gun capacity of each melter is determined by the number of hose/gun modules installed on the melter. Each hose/gun module supports the connection of two hose/gun pairs. The hose/gun capacity of melters that were ordered with less than their full hose/gun capacity can be increased by adding additional hose/gun modules. Unused hose/gun module positions are covered by blank modules. WARNING: Risk of fire or equipment damage. Before connecting hoses and guns to the melter, confirm that the power required by each hose/gun pair and each hose/gun module, does not exceed the maximum wattages specified in Appendix A, Table A-2, Maximum Allowable Wattages. To connect hoses See Figure 3-8. Observe the following guidelines:  For information about choosing the correct Nordson hot melt hose for your manufacturing process, refer to the latest edition of Nordson’s hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative.  Refer to the user’s guide provided with each Nordson hose. The guide contains important information about routing and installing the hose.  Always use hose port 1 first. The position of port 1 is stamped on the face of the manifold. The P4 and P7 melters provide four hose ports on the face of the manifold and a fifth hose port at the bottom of the manifold. The P10 melter provides nine ports, six of which can be used at any one time.  If you install an additional hose/gun module, you must restart the melter and enter a set-point temperature for each hose/gun that you connect to the new module in order for the new hoses/guns to be recognized.

P10 6-hose manifold guard Installation 3-17 Part 1024496D02  2007 Nordson Corporation CAUTION: Failure to connect a hose to port 1 may create spaces within the manifold where hot melt will not circulate. The presence of these spaces can result in the build-up of hot melt char, which can lead to an increase in the frequency of melter maintenance.  Use the 6-hose manifold guard that is shipped with all P10 melters. Instructions for installing the guard are provided with the guard.  Coordinate the connection of each hose with the receptacles on each hose/gun module. For example, connect the cordset from the hose that is connected to port 1 (marked) to receptacle 1.  Save all of the port plugs removed from the manifold. A port plug will need to be reinstalled into the manifold if a hose is later removed.  Use the 45- or 90-degree hose fittings provided in the installation kit. NOTE: Only 90-degree fittings are shipped with the P4 and P7 melters. Figure 3-8 Connecting a hose

P10 hose routing options Installation 3-18 Part 1024496D02  2007 Nordson Corporation Connecting Hoses and Guns (contd) P10 Hose Routing Options The unique angled design of the manifold on the P10 melter allows each hose (six hoses maximum) to be routed in the same or different directions without interfering with each other. Use the 45- or 90-degree hose fitting supplied with the melter. Additional 45-degree, 90-degree, and straight fittings may be ordered to customize your hose configuration. To connect guns Observe the following guidelines:  ProBlue melters support all T-style handguns.  For information about choosing the most appropriate Nordson hot melt gun for your manufacturing process, refer to the latest edition of Nordson’s hot melt dispensing equipment Replacement Parts Catalog or contact your Nordson representative. Refer to Appendix A, Calculating Melter Power Requirements, for information about how to calculate the power required by Nordson hot melt guns.  Refer to the user’s guide that is shipped with each gun for information about installing the gun and connecting a hose to the gun. NOTE: ProBlue melters are shipped with a 100-mesh (.15 mm) hot melt filter installed in the pump. Order the appropriate gun nozzle based on this filter mesh size.

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Installation 3-20 Part 1024496D02  2007 Nordson Corporation Setting Up the Melter After physically installing the melter, it must be set up to support your manufacturing process. Melter setup consists of enabling or making changes to factory-set operating parameters that affect the use and function of the melter. The operating temperature (set-point) of the tank and each hose and gun is also established during melter setup. The melter is shipped from the factory with the most commonly used operating parameters already set up. The factory setup can be modified at any time to suit your manufacturing process. Quick Setup Table 3-4 describes the most commonly used operating parameters and their factory settings. Review the table to determine if the factory settings for each parameter will support your manufacturing process. If the default values for each of these operating parameters are appropriate for your manufacturing process, then no melter setup is required. Go directly to Set-point Temperature of the Tank, Hoses, and Guns later in this section to complete the installation process. If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section, Operating Parameters.

Installation 3-21 Part 1024496D02  2007 Nordson Corporation Table 3-4 Common Operating Parameters Parameter Parameter Name Purpose Default Value 4 Ready Delay Time A timer that delays the activation of the ready LED for a pre-defined time period after the tank, hoses, and guns are at the desired set-point temperature. The ready delay timer will only activate if the temperature of the tank, at the time the melter is turned on, is below its assigned set-point temperature by 27 °C (50 °F) or more. 0 minutes 5 Service Interval Time A timer that turns on a service LED when the value set for the timer equals the number of hours that the heaters have been on. The service LED is used to signal the need for maintenance. 500 hours 8 Automatic Pump On Determines whether the pump will turn on automatically when the all components are at their desired set-point temperature (enabled) or whether the pump must be turned on manually (disabled). Enabled 11 Create Password Sets a password that must be entered before any melter operating parameter or set-point temperature can be changed. 5000 20 Temperature Units Sets the units of the temperature display to degrees Celsius (C) or to degrees Fahrenheit

(F).

C

15 °C (25 °F)

25 °C (50 °F)

50 °C (100°F)

Installation 3-22 Part 1024496D02  2007 Nordson Corporation Operating Parameters The melter uses operating parameters to store noneditable and editable values. Noneditable values are those that provide information about the historical performance of the melter. Editable values are either a numeric set-point or a control option setting. Control options settings affect the display of information or the function of the melter. Operating parameters are stored in the melter’s firmware in the form of a sequentially numbered list. The list is organized into the logical groups described in Table 3-5. Table 3-5 Parameter Groups Group Parameter Numbers Group Description Standard 0 to 11 and 14 Noneditable and other frequently used parameters Temperature Control 20 to 26 Control heaters Input Setup 30 to 39 Configure the standard and optional inputs Output Setup 40 to 46 Configure the standard and optional outputs Seven-day Clock 50 to 77 Configure the clock feature In addition to the ability to read and edit parameter values, you can also save and restore the current value of every operating parameter and review a log of the last ten changes that were made to editable parameters. Selecting Operating Parameters Table 3-6 provides a complete list of the operating parameters. Review the list to determine which operating parameters would best support your manufacturing process. Refer to Appendix B, Operating Parameters, for detailed information about each parameter. Appendix B contains a complete description of each parameter, including its affect on the melter, default value, and format. NOTE: Parameters that are used to configure optional equipment or that are otherwise reserved in the firmware are excluded from Table 3-6 and Appendix B. Reading or Editing Operating Parameters Regardless of whether a parameter’s value is editable or not, the procedure for accessing each parameter in order to read or edit its current value is the same.

Melter control switch (On/Off) Setup key Clear/Reset key Enter key Installation 3-23 Part 1024496D02  2007 Nordson Corporation To read or edit a parameter

Installation 3-24 Part 1024496D02  2007 Nordson Corporation Table 3-6 Operating Parameters Parameter Name Range of Values Default Value Standard 0 Enter Password 0 to 9999 4000 1 Total Hours with Heaters On (noneditable) 0−999,999 0 2 Fault Log (noneditable) — _-F0 (empty) 3 Change History Log (noneditable) — P-_ (empty) 4 Ready Delay Time 0 to 60 minutes 0 minutes 5 Service Interval Time 0 to 8736 hours 500 hours 6 Service LED Heater Hours 0 to 9999 hours 0 8 Automatic Pump On 0 (disabled) or 1 (enabled) 1 (enabled) 9 Automatic Pump On Temperature 0 (disabled) or (1 to 230 C) 0 (disabled) 10 Enable or Disable Password 0 (disabled) or 1 (enabled) 0 (disabled) 11 Create Password 0 to 9999 5000 14 External Communications Lock-out 0 or 1 0 (disabled) Temperature Control 20 Temperature Units (degrees C or F) C (degrees Celsius) or F (degrees Fahrenheit) C (degrees Celsius) 21 Over Temperature Delta 5 C (10 F) to 60 C (110 F)

15 C (25 F)

25 C (50 F)

F)

50 C (100 F)

Installation 3-25 Part 1024496D02  2007 Nordson Corporation 45 Optional Output 6 0–6 0 (disabled) 46 Optional Output 7 0–6 0 (disabled) Seven-day Clock 50 Current Day 1 to 7 (1 = Monday) — 51 Current hour 0000 to 2359 — 55 Schedule 1 Heaters On 0000 to 2359 06:00 56 Schedule 1 Heaters Off 0000 to 2359 17:00 57 Schedule 1 Enter Standby 0000 to 2359 —:— 58 Schedule 1 Exit Standby 0000 to 2359 —:— 60 Schedule 2 Heaters On 0000 to 2359 —:— 61 Schedule 2 Heaters Off 0000 to 2359 —:— 62 Schedule 2 Enter Standby 0000 to 2359 —:— 63 Schedule 2 Exit Standby 0000 to 2359 —:— 65 Schedule 3 Heaters On 0000 to 2359 —:— 66 Schedule 3 Heaters Off 0000 to 2359 —:— 67 Schedule 3 Enter Standby 0000 to 2359 —:— 68 Schedule 3 Exit Standby 0000 to 2359 —:— 71 Schedule for Monday 0−7 0 72 Schedule for Tuesday 0−7 0 73 Schedule for Wednesday 0−7 0 74 Schedule for Thursday 0−7 0 75 Schedule for Friday 0−7 0 76 Schedule for Saturday 0−7 0 77 Schedule for Sunday 0−7 0 You can exit the setup mode at any time by pressing the Setup key. Parameter numbers that are not applicable are skipped when you scroll through the operating parameter list in the left display. When the right display is flashing, you can quickly set the value of the current parameter to it’s lowest possible value by simultaneously pressing both of the right-display scroll keys. While in the setup mode, if no key is pressed for two minutes, the melter will return to the automatic scan mode. You can also use the right-display scroll keys to enter or change a parameter’s value or control option. After entering the parameter’s number in the left display, press either of the right-display scroll keys to change the value or control option. If password protection is enabled, the melter will return to the password protected mode whenever you exit the setup mode. Appendix B, Parameter 10

Installation 3-26 Part 1024496D02  2007 Nordson Corporation Set-point Temperature of the Tank, Hoses, and Guns The melter is shipped from the factory with the tank set-point temperature at 175 °C (350 °F) and the hose and gun set-point temperatures at 0 degrees (turned off). Before the melter can be used, a set-point temperature must be assigned to the tank, hoses, and guns. Assign set-point temperatures using any of the following methods:  Global—The tank and all hoses and guns are set to the same set-point temperature.  Global-by-component group—All of the hoses or all of the guns are set to the same set-point temperature.  Individual Component—The set-point temperature of the tank and each hose and gun is set individually. Since most manufacturing processes will require the tank, hoses, and guns to be set to the same temperature, only the global method of assigning set-point temperatures is described in this section. For information about the other two methods of assigning set-point temperatures, refer to Section 4, Adjusting Component Temperatures. As with operating parameters, you can also save and restore set-point temperatures and review past changes that were made to set-point temperatures.

Tank key Left display and scroll key Enter key Ready LED Installation 3-27 Part 1024496D02  2007 Nordson Corporation To assign a global set-point temperature

+ Saving current settings + Restoring saved settings Installation 3-28 Part 1024496D02  2007 Nordson Corporation Save and Restore Melter Settings The current value of all editable operating parameters and the set-point temperature of each component can be saved and, if necessary, restored at a later time. When saved settings are restored, they overwrite the settings that are presently in use. This save-restore feature is useful in instances where the settings that are in use are deliberately or accidentally changed and you need to return the melter to its pre-change setup. To save current settings With the melter in the automatic scan mode, simultaneously press the number 1 key and the Setup key. S-1 appears momentarily in the right display. To restore saved settings CAUTION: All melter settings will be deleted! Before restoring saved settings, ensure that use of the restored settings will not disrupt the current process or create an unsafe operating condition. With the melter in the automatic scan mode, simultaneously press the number 2 key and the Setup key. S-2 appears momentarily in the right display. If you use the restore feature before the save feature is used for the very first time, the factory default set-point temperatures will be restored. This will cause the hoses and guns to stop heating. You can transfer melter settings from one melter to another using the Nordson Configuration Manager software utility. Refer to Appendix C, Melter Communications

Setup key Left display and scroll key Component key LEDs Scrolling through the log Installation 3-29 Part 1024496D02  2007 Nordson Corporation Review Parameter and Set-point Temperature Changes The melter stores in a change history log, a record of the last ten changes that were made to either operating parameters or set-point temperatures. Since the log only stores ten changes, old log entries are overwritten beginning with the first log entry, by the eleventh and following log entries. To review the change history log

Installation 3-30 Part 1024496D02  2007 Nordson Corporation Table 3-7 Change History Log First Digit Second Digit Third and Fourth Digits

P

S

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Opening the electrical enclosure door Connector P/N 277909 Installation 3-32 Part 1024496D02  2007 Nordson Corporation Installing Melter Inputs ProBlue melters are equipped with four standard inputs. Each input is customer-wired to the melter and then set up to provide one of the following control options:  Place the melter into the standby mode  Turn the heaters on and off  Enable or disable a specific hose or gun  Turn the pump on and off Inputs are activated using a constant 10 to 30 VDC signal voltage, which is supplied by the customer’s control equipment. The inputs are not polarity sensitive. WARNING: The operator can override the melter inputs by using the control panel function keys. Ensure that the control logic for any external device that sends an input signal to the melter is programmed to prevent the creation of an unsafe condition in the event that the operator overrides an external input to the melter. To wire inputs to the melter

Installation 3-33 Part 1024496D02  2007 Nordson Corporation 8 9 10 11 12 13 14

Tb2

Installation 3-34 Part 1024496D02  2007 Nordson Corporation Table 3-8 Input Data Input Terminals Operating Parameter Control Option Note Standard Inputs 1 8 and 9 30 0 - Input Disabled 1 - Standby On/Off 2 - Heaters On/Off 3 - Pump Enable/Disable 4 - Hose/Gun 1 Enable/Disable 5 - Hose/Gun 2 Enable/Disable 6 - Hose/Gun 3 Enable/Disable 7 - Hose/Gun 4 Enable/Disable 8 - Hose/Gun 5 Enable/Disable 9 - Hose/Gun 6 Enable/Disable 10 – Automatic standby (Default)

A, B

C

F

D

F

E

E

E

E

E

E

Note

A:

B:

C:

D:

E:

F:

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Opening the electrical enclosure door Connector P/N 277908 Installation 3-36 Part 1024496D02  2007 Nordson Corporation Installing Melter Outputs The melter is equipped with three user-configurable outputs. Outputs are used to communicate with user-supplied production equipment or control hardware, such as a programmable logic controller. Each output is customer-wired and then set up in the melter’s firmware to provide one of the following outputs:  The melter is ready  The melter is ready and the pump is on  A fault has occurred  The hot melt level is low  The service LED is on  A potential fault is detected All outputs contacts are rated at 240 VAC 2 A or 30 VDC 2 A. All contacts are normally open when the melter is turned off. To connect an output to the melter See Figure 3-10.

Installation 3-37 Part 1024496D02  2007 Nordson Corporation 1 2 3 4 5 6 7

Tb2

Installation 3-38 Part 1024496D02  2007 Nordson Corporation Table 3-9 Output Data Output Terminals Operating Parameter Control Options Note Standard Outputs 1 1 and 2 40 0 - Output Disabled 1 - Ready (Default) 2 - Ready and the pump is on 3 - Fault 4 - Tank Low Level 5 - Service LED is On 6 - Alert

A

A

A

B

A

C

D

Note

A:

B:

C:

D:

Installation 3-39 Part 1024496D02  2007 Nordson Corporation Installing Optional Equipment Each item of optional equipment is shipped with instructions for installing and operating the equipment. Refer to Section 7, Parts, for equipment part numbers. Connecting a Gun Driver, Pattern Controller, or Timer If applicable, complete the melter installation by connecting the guns to the desired gun driver, pattern control, or timer. Refer to the product manual provided with the device for information about installing and operating the equipment. Flushing the Melter Before using the melter for production, it should be flushed to remove any residue left over from factory-testing. Flushing the melter is accomplished by processing a minimum of one tank volume of hot melt through the melter, hoses, and guns. Refer to Section 4, Operation, for information about filling the tank and operating the melter. Setting Up Melter Communications You can transfer melter settings between melters, and upgrade or downgrade the melters operating firmware by using a personal computer that is connected to your melter’s serial port. Refer to Appendix C, Melter Communications, for information about downloading, installing, and using the software that is required to connect a personal computer to your melter.

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Operation 4-1 Part 1024496D02  2007 Nordson Corporation Section 4 Operation WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. This section provides information about the following operator-level tasks:  Filling the melter tank  Starting the melter  Monitoring melter operation  Adjusting the operating temperature of heated components  Using the melter function keys  Shutting the melter down Most of the controls described in this section are located on the control panel behind the keypad door. Refer to Section 2, Key Components, for the location of the control panel. Additional Information This section presents operating procedures in their most commonly used form. Procedural variations or special considerations are explained in the additional information table that follows most procedures. Where applicable, some table entries also contain cross-reference information. Additional information tables are indicated by the symbol shown to the left.

Component keys (tank, hose, and gun) Operation 4-2 Part 1024496D02  2007 Nordson Corporation More about Heated Components The melter contains three groups of heated components. These are the tank group, which contains the tank and the manifold, the hose group, and the gun group. Component groups are represented on the control panel by the component keys shown to the left. Heated components within each group are identified by their position number. The position of the tank and pump is fixed at 1. Hose and gun position numbers are automatically assigned based on the hose/gun receptacle they are connected to. For example, the position numbers of a hose/gun pair that is connected to the second receptacle would be hose position 2 and gun position 2. The number of hose/gun receptacles available on each melter depends on the configuration in which the melter was ordered. ProBlue adhesive melters may have either two, four, or six hose/gun receptacles. An optional expansion base may be ordered that adds receptacles for two additional hoses/guns.

Low-level LED (yellow) Operation 4-3 Part 1024496D02  2007 Nordson Corporation Filling the Tank Before filling the tank, confirm that the hot melt material is compatible with the melter. Refer to Section 2, Intended Use, for information about hot melt materials that should not be used in ProBlue melters. The tank is equipped with a low-level float switch. When the volume of adhesive in the tank reaches approximately one-half of the tank’s rated capacity, the float switch turns on the low-level LED located on the control panel. To fill the tank WARNING: Hot! Risk of burns! Use a scoop to fill the tank with hot melt Never use your bare hands. Using your bare hands to fill the tank may result in personal injury.

P4

P7

P10

Melter control switch (on/off) Heaters LED Automatic scan sequence Ready LED Air pressure gauge Operation 4-4 Part 1024496D02  2007 Nordson Corporation Starting the Melter Before starting the melter for the first time, confirm that the  melter is fully installed including any required inputs and outputs, gun drivers, pattern controllers, and timers  melter’s operating parameters are set up to support the current manufacturing process Refer to Section 3, Installation, if any of the items listed above are not complete. To start the melter

Operation 4-5 Part 1024496D02  2007 Nordson Corporation If the melter is switched on when the temperature of the tank is 27 C (50 F) or greater below its assigned set-point temperature (cold start condition), the ready LED will not turn on until the ready delay (defined when the melter was set up) has elapsed. Appendix B, Parameter 4 The time remaining on the ready delay (in minutes) appears in right display at the end of every scan cycle. When only one minute remains in the ready delay time, the right display counts down in seconds. Appendix B, Parameter 4 You can by-pass the ready delay time by pressing the Heaters key twice. The appearance of F4 in the right display immediately after the melter is switched on indicates a problem with the melter’s processor or main board. Section 4, Monitor Melter Faults The appearance of F1 in the right display immediately after starting the melter indicates that a hose or gun cordset may be loose or disconnected. Section 6, Troubleshooting If the melter is set up for manual pump activation, the pump LED will not turn on when the melter is ready. Appendix B, Parameter 8 The condition of one or more inputs, may prevent the heaters from turning on. Section 3, Installing Inputs If the seven-day clock feature was set up and turned on when the melter was last switched off, the clock will automatically turn on the next time the melter is switched on. Section 4, Using Melter Function Keys It is normal for the pump to slowly cycle when no hot melt is being dispensed from the guns. If a power failure occurs, the melter will restart in its normal heat-up cycle, even if the heaters were off or the melter was in standby prior to the power failure. If the seven-day clock was on prior to the power failure, the melter will restart in the mode dictated by the clock schedule at the time the melter restarts.

Ready LED Operation 4-6 Part 1024496D02  2007 Nordson Corporation Monitoring the Melter The melter provides indicators that allow you to:  Quickly confirm that the melter is operating correctly  Monitor the actual temperature of the manifold and each hose and gun  Identify melter faults  Identify when the level of hot melt in the tank is low  Check the operating air pressure  Determine when service is required The melter automatically determines the number and location of all hoses and guns that are connected to it. Refer to More About Heated Components, earlier in this section, for information about hose/gun capacity and the identification of heated components. You can also use a personal computer to monitor the melter. Refer to Appendix C, Melter Communications, for information about connecting a personal computer to the melter and installing the required software. Confirm that the Melter is Operating Correctly The ready LED turns on (green) when all of the heated components are within 3 C (5 F) of their set-point temperature. The ready LED will not turn on, or will turn off, if any of the following events occur:  The ready delay is still counting down.  The operator or a remote input places the melter in the standby mode.  The seven-day clock places the melter in the standby mode.  There is a fault (the fault LED will turn on). Refer to Monitoring Melter Faults, and Using Melter Function Keys, later in this section for information about melter faults and using the seven-day clock and standby functions. Refer to Appendix B, Parameter 4, for information about the ready delay.

LEDs on component keys Operation 4-7 Part 1024496D02  2007 Nordson Corporation Heated components with a set-point temperature of zero degrees are skipped during the automatic scan cycle. The set-point temperature of the tank and the manifold cannot be set independently. The time remaining on the ready delay appears in the right display at the end of each scan cycle. Appendix B, Parameter 4 You can override the seven-day clock at any time. If the clock has turned the heaters off, pressing the heaters key will turn the heaters back on. If the clock has placed the melter into the standby mode, pressing the standby key will return the heated components to their assigned set-point temperature. Section 4, Using Melter Function Keys Monitor Component Temperatures You can check the actual temperature of each heated component—the tank and each hose and gun—using the automatic scan mode or by manually selecting and checking each component. By default, the melter remains in the automatic scan mode except when:  The melter is placed into the setup mode  The set-point temperature of all hoses and guns is set to zero degrees  A fault occurs To check component temperatures using the automatic scan mode

Left display and scroll key Component temperature display Operation 4-8 Part 1024496D02  2007 Nordson Corporation Monitor Component Temperatures (contd) To manually check a component’s temperature

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Operation 4-10 Part 1024496D02  2007 Nordson Corporation Monitor Melter Faults The melter alerts the operator to the faults listed in Table 4-2. Faults affect the melter in one of three ways: the heaters turn off; the heaters remain on, but the fault condition persists; or the melter stops functioning. When a fault occurs, you must diagnose and correct the fault condition and then place the melter back into operation. You can use the fault log to determine the type, order, and relative time of the last ten faults. Table 4-2 Melter Faults Display Code/Sub-code Name Affect on Melter Cause F1/None

Rtd

F4/1

F4/2

F4/4

F4/5

F4/6

F4/7

F4/8

F4/A

F4/E

Fault LED (red) Operation 4-11 Part 1024496D02  2007 Nordson Corporation How F1, F2, and F3 Faults are Handled When the melter detects an F1, F2, or an F3 fault:

Clear/Reset key Heater key Operation 4-12 Part 1024496D02  2007 Nordson Corporation Monitor Melter Faults (contd) How F4 Faults are Handled When the melter detects an F4 fault:

Operation 4-13 Part 1024496D02  2007 Nordson Corporation To view the temperature of a heated component when an F2 or F3 fault exists, simultaneously press and hold both of the right-display scroll keys. You can temporarily dismiss an F1 fault (RTD) and return to the automatic scan mode by pressing the Clear/Reset key. The heaters will, however, remain off. If the fault condition still exists two minutes after pressing the clear/reset key, the fault LED will turn back on. When an F1 fault code appears, you can determine whether the fault was caused by an open or a shorted RTD by simultaneously pressing both of the right-display scroll keys. If the right display indicates OP, the RTD is open, if it indicates SH, the RTD has shorted. If, for any reason, a component reaches 235 C (458 F), an immediate F3 fault will occur (no two-minute monitoring period). If F4 appears in the right display when you press the clock key, the internal clock function has failed.

Setup Key Left display and scroll key Scrolling through the fault log Operation 4-14 Part 1024496D02  2007 Nordson Corporation Monitor Melter Faults (contd) To review the fault log

- F

Operation 4-15 Part 1024496D02  2007 Nordson Corporation Fault Log Examples Example 1: An unused log entry. Example 2: If the LED on the tank key were on, this log entry would indicate that the tank is under temperature. If the LED on the hose key were on, this log entry would indicate that hose 1 is under temperature. To view the number of heater hours that have elapsed since a log entry was created, simultaneously press both of the right-display scroll keys. The hours are indicated in the right display. The melter will return to the automatic scan mode if the fault log is left open for a period of two minutes without any key being pressed. When an F1 fault is the result of a hose/gun pair being disconnected from the melter, two fault log entries are created. The first entry is for the gun and the second entry is for the hose.

Low-level LED (yellow) Pressure regulator and adjustment screw Operation 4-16 Part 1024496D02  2007 Nordson Corporation Monitor the Level of Hot Melt in the Tank The tank contains a low-level float switch. When the volume of hot melt in the tank drops below one-half of the tank’s rated capacity, the float switch turns on the low-level LED located inside the tank key. Nordson recommends that the tank be kept at least one-half full while the melter is operating. NOTE: The melter is also equipped with a low-level output that can be connected to a customer-supplied signaling device or process control system. Refer to Section 3, Installing Melter Outputs, for information about using the low-level output. Monitor and Adjust the Operating Air Pressure The air pressure gauge located on the front of the melter indicates the air pressure that is supplied to the melter’s pump. The air pressure must be adjusted to meet the requirements of your manufacturing process. NOTE: The minimum operating air pressure is 0.7 bar (10 psi). Operating the melter with the air pressure set to less than 0.7 bar (10 psi) may cause the pump to function erratically. Use the adjustment screw located to the right of the pressure gauge to adjust the operating air pressure. Typically, adjustments to the operating air pressure are made in order to change the volume of hot melt dispensed by the guns. Other factors such as the temperature of the hot melt, the speed of the manufacturing line, and the type and size of the nozzles used on the guns also impact the volume of hot melt that is dispensed. CAUTION: Do not force the air pressure adjustment screw beyond its normal range of adjustment. Forcing the adjustment screw beyond its normal range of adjustment will damage the pneumatic assembly.

Service LED (yellow) Clear/Reset key Operation 4-17 Part 1024496D02  2007 Nordson Corporation Monitor the Service Interval The melter can be set up so that the service LED located on the left side of the control panel turns on after a customer-defined time period elapses. The service LED may be used to signal the need to change the hot melt filter or to complete any other customer-specified maintenance activity. Once the specified maintenance is performed, the service LED must be reset. To reset the service LED With the melter in the scan mode, press the Clear/Reset key to turn off the service LED and reset the service interval time. The default setting for the service interval time is 500 hours. Appendix B, Parameter 5

Tank key Left display and scroll key Enter key Ready LED Operation 4-18 Part 1024496D02  2007 Nordson Corporation Adjusting Component Temperatures You can adjust the the set-point temperature of heated components using the following methods:  Global—The tank and all hoses and guns are set to the same set-point temperature.  Global-by-component group—All of the hoses or all of the guns are set to the same set-point temperature.  Individual Component—The set-point temperature of the tank and each hose and gun is adjusted independently. Before adjusting set-point temperatures, confirm that each hose/gun pair is connected to the correct hose/gun module. For example, hose/gun pair 1 should be connected to the first receptacle (lowest) on hose/gun module 1 (lowest module). Refer to More About Heated Components, earlier in this section for information about hose/gun modules. To adjust set-point temperatures using the global method

Tank, hose, and gun keys Operation 4-19 Part 1024496D02  2007 Nordson Corporation To adjust the set-point temperature using the global-by-component method

Operation 4-20 Part 1024496D02  2007 Nordson Corporation To adjust the set-point temperature of an individual component (contd)

Operation 4-21 Part 1024496D02  2007 Nordson Corporation If you enter a valid set-point temperature for a hose/gun that is not connected to the melter or if you enter a set-point temperature that is out of range, the right display will indicate dashes (----) for three seconds and then change back to the original set-point temperature. When the right display is flashing, you can quickly change the current set-point temperature to 0 degrees (off) by simultaneously pressing both of right-display scroll keys. After removing a hose or a gun, use the individual component method of set-point temperature adjustment to set the component’s temperature to zero degrees (off). This will avoid causing an F1 fault when a hose or gun is added. The factory set-point temperature of the tank is 175 C (350 F). The factory set-point temperature of all others components is zero degrees (off). When the units of temperature is set to degrees Celsius, the minimum and maximum set-point temperatures are 40 C and 230 C. When the units of temperature are set to degrees Fahrenheit, the minimum and maximum set-point temperatures are 100 F and 450 F. When using the right-display scroll keys to adjust a set-point temperature, the right display automatically increments between 0, 175, and 230 C or between 0, 350, and 450 F. If you make a mistake while you are changing a set-point temperature, but you have not yet pressed the enter key, press the Clear/Reset key to reset the right display to the original temperature. The melter will exit the setup mode and return to the automatic scan mode two minutes after the last key is pressed. A global set-point temperature of zero degrees (Celsius or Fahrenheit) turns all components off. When scrolling through component numbers in the left display, component numbers that are associated with unused hose/gun receptacles are skipped. The melter stores a record of the last ten changes made to the set-point temperatures (and operating parameters) in the change history log. Section 3, Installation, Review Parameter and Set-point Temperature Changes You can save set-point temperature changes by simultaneously pressing the 1 key and the Setup key. Section 3, Operation, Save and Restore Melter Setting

Operation 4-22 Part 1024496D02  2007 Nordson Corporation Enter the Melter Password If the melter is password protected, a valid password must be entered before any set-point temperature or melter parameter can be changed. To enter a melter password

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Heater key Pump key Operation 4-24 Part 1024496D02  2007 Nordson Corporation Using Melter Function Keys The control panel provides the following standard and special function keys. Standard function keys  Heater  Pump  Setup Special function keys  Seven-day clock  Standby CAUTION: Unintentionally activating function keys can, under the correct circumstances, have undesirable effects on the melter or the manufacturing process. Only personnel who are familiar with the melter’s setup and its connection with the manufacturing process should use the function keys. Improper use of the function keys can result in erratic process behavior or personal injury. Heater Key Use the heater key to manually turn the component heaters on and off. Pressing the heater key overrides the control (on or off) of the heaters by either the seven-day clock feature or a remote input. The LED on the heater key turns on when the heaters are on. When a fault occurs (Refer to Monitor Melter Faults, earlier in this section) the heaters automatically turn off. The heater key is used to turn the heaters back on after correcting a fault condition. Pump Key Use the pump key to start or stop the pump. The LED on the pump key turns on (green) when the pump is running. If the automatic pump on feature (parameter 8) is disabled, then the pump key must be used to start the pump when the melter is ready. If any of the inputs are set up to use the pump enable/disable control option (option 3), the pump will not start until the pump key is pressed (LED on) and the correct voltage is applied to the input contacts. If the pump is enabled, but the input voltage is not present, the pump LED will flash green.

Setup key Seven-day clock key Operation 4-25 Part 1024496D02  2007 Nordson Corporation Setup Key Use the setup key to place the melter into and take the melter out of the setup mode. When the melter is placed into the setup mode, the automatic scan stops and the left and right displays are used to select and read or edit operating parameters. Seven-day Clock Key Use the seven-day clock key to turn the melter’s clock feature on and off. When the clock is on, the temperature of each heated component is automatically regulated based on a set of user-defined schedules. To accommodate daily shift work and non-working days, four clock schedules are available. Schedules 1, 2, and 3 are used to specify when the heaters should turn on and off or when the melter should enter and exit the standby mode. Schedule 0 is used to keep the melter in the last condition dictated by the clock (heaters on or off, or standby). When a clock schedule calls for the heaters to be on, the heaters are regulated at their pre-assigned set-point temperatures. When the clock activates the standby mode, the set-point temperature of each component is temporarily reduced by a pre-set standby delta. Refer to Appendix B, Operating Parameters, Seven-day Clock, for information about setting up the seven-day clock and the standby delta. If the melter is switched off while the clock is on, the clock will automatically turn back on the next time the melter is switched back on. If the heaters are manually turned off at the time that a clock schedule calls for the heaters to be on, the heaters will not turn back on until the next clock schedule calls for them to be on. The clock will still operate when the melter is faulting or is in the setup mode. If F4 appears in the right display when you press the clock key, the internal clock function has failed. Section 7, Troubleshooting

Standby key Operation 4-26 Part 1024496D02  2007 Nordson Corporation Using Melter Function Keys (contd) Standby Key Use the standby key to manually place the melter into, and take it out of, the standby mode. Using the standby mode during periods of time when the melter is inactive helps to conserve energy and allows heated components to quickly return to their set-point temperatures when the melter is once again needed. When the melter is placed into the standby mode, the temperatures of all components are reduced down from their set-point temperature by a pre-set standby delta. The melter will remain in the standby mode until the standby key is pressed or the function of one of the operating parameters takes the melter out of the standby mode. If the melter was set up to use the manual standby timer (parameter 26), pressing the standby key will place the melter in the standby mode for the period of time specified by the timer. After the manual standby time has elapsed, the melter will once again begin heating all of the components to their assigned set-point temperature. Using the standby key overrides the control of the melter (on or off) by the seven-day clock or a remote input. Refer to Section 3, Operation Setting Up the Melter, and to Appendix B, Operating Parameters, for information about setting the standby delta and the standby timer. The melter may also be set up to enter the standby mode using a variety of operating parameters. Appendix B, Parameters 23, 24, 25, 26, 30–33, 57, 62, and 67 Whenever manual standby is enabled, the standby LED blinks. Appendix B, Parameter 26

Melter control switch (on/off) Operation 4-27 Part 1024496D02  2007 Nordson Corporation Shutting Down the Melter Shut down the melter when it will not be used for an extended period of time. To shut the melter down

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Maintenance 5-1 Part 1024496D02  2007 Nordson Corporation Section 5 Maintenance WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. Table 5-1 describes the preventive maintenance tasks required to keep ProBlue melters operating within their specified limits and to prevent equipment malfunctions. For information about maintaining optional equipment that was supplied by Nordson, refer to the instructions provided with the equipment. If the melter stops operating or is operating incorrectly, refer to Section 6, Troubleshooting, for information about diagnosing common problems and performing corrective maintenance. Table 5-1 Preventive Maintenance Tasks Task Frequency Reference Relieving system pressure Before performing any maintenance task that requires opening a hydraulic connection or port Relieving System Pressure Lockout external communications Before performing any maintenance task Locking Out External Communications Cleaning the exterior of the melter, hoses, and guns Daily Cleaning the Melter Replacing the filter  As needed  When changing the type or grade of hot melt Replacing the Filter Cleaning the tank  When changing the type or grade of hot melt  When excessive charring occurs Cleaning the Tank Removing the melter from the sub-base  As needed Removing the Melter from the Sub-base

Melter control switch (on/off) Maintenance 5-2 Part 1024496D02  2007 Nordson Corporation Relieving System Pressure Before disconnecting any hydraulic fitting or opening any pressurized port, always complete the following procedure to safely relieve hydraulic pressure that may be trapped inside the melter, hoses, and guns. To relieve system pressure

Maintenance 5-3 Part 1024496D02  2007 Nordson Corporation Figure 5-1 Lowering the drain chute and opening the drain valve

Maintenance 5-4 Part 1024496D02  2007 Nordson Corporation Cleaning the Melter To prevent components from overheating due to heat build-up or loss of air circulation, regularly remove any hot melt that collects on the exterior of the melter, hoses, and guns. If hot melt inadvertently spills inside the pump compartment or other interior spaces, the exterior panels can be removed in order to clean out the spilled hot melt. WARNING: Risk of electricution and fire! Do not clean the melter with a direct stream of water or steam. Use only water or an appropriate, non-flammable cleaning solution that is applied using a clean cloth. Cleaning the melter using a direct stream of water or steam or a flammable solvent can result in property damage and personal injury, including death. To clean the exterior of the melter  Use citrus-based or other cleaning compounds that are compatible with polyester.  Apply cleaning compounds using a soft cloth.  Do not use pointed or sharp tools to clean the exterior surface. To remove and replace the exterior panels See Figure 5-2.

Maintenance 5-5 Part 1024496D02  2007 Nordson Corporation NOTE: When re-installing panel P4, ensure that the metal hooks on P4 engage the hinge pin before rotating the panel back into position.

P1

P2

P3

P4

Filter location Hot melt flow path Maintenance 5-6 Part 1024496D02  2007 Nordson Corporation Replacing the Filter ProBlue melters are equipped with a 100-mesh (.15 mm) disposable hot melt filter. The filter removes debris and char from the hot melt as it flows from the tank. Hot melt flows from the inside to the outside of the filter, trapping contaminants inside the filter. There is no need to back-flush or clean the filter. When the filter reaches the end of its service life, it should be replaced. The factors that determine the service life of the filter are:  the type, grade, and purity of the solid-form hot melt  the set point temperature of the tank  the period of time that the hot melt remains in the tank The filter should also be replaced when making the change to a different type or grade of hot melt. To determine the optimal service life for the filter, monitor and compare the total number of hours that the heaters are on with observations of:  the purity of the dispensed hot melt  increases in operating pressure  the frequency of gun nozzle replacement or cleaning Monitoring the Life of the Filter As an aid to ensuring that the filter is replaced at the end of its service life, the melter is equipped with a service LED that turns on at the end of a customer-defined time period. You can use this feature to alert you when it is time to change the filter. Refer to Section 3, Setting Up the Melter, for information about the service interval time. When the service LED turns on, replace the filter, and then press the Clear/Reset key to reset the timer and turn off the service LED. NOTE: The melter must be in the automatic scan mode when you press the Clear/Reset key.

Pump key Loosening the filter Maintenance 5-7 Part 1024496D02  2007 Nordson Corporation To replace the filter NOTE: Instructions for replacing the filter are also provided on the inside of the pump enclosure door.

Pump key Maintenance 5-8 Part 1024496D02  2007 Nordson Corporation Cleaning the Tank To avoid the problems that can occur when different hot melt materials are mixed or when hot melt char forms in the tank, clean the tank when:  changing to a different type of hot melt  excessive char builds up inside the tank NOTE: The tank cleaning procedures provided in this section require that an appropriate hot melt cleaning fluid be used to soften or dissolve residual hot melt. Each type of hot melt should be supplied with a technical data sheet that names the appropriate cleaning fluid. If the technical data sheet is not available, contact the hot melt supplier. To clean the tank when changing hot melt

Pump key Maintenance 5-9 Part 1024496D02  2007 Nordson Corporation To clean the tank of excessive char

Maintenance 5-10 Part 1024496D02  2007 Nordson Corporation Removing the Melter from the Sub-base NOTE: For 400/480 VAC melters, refer to Appendix E.

Troubleshooting 6-1 Part 1024496D02  2007 Nordson Corporation Section 6 Troubleshooting WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. This section provides quick-reference information for diagnosing melter faults indications as well as comprehensive melter diagnostic information that is provided in flowchart format. When required, the troubleshooting flowchart will refer you to diagnostic procedures provided later in this section. If you cannot resolve the problem using the troubleshooting flowchart, contact your Nordson representative for technical assistance. 400/480 Volt Melters Refer to Appendix E for information about troubleshooting the transformer, 400/480 volt heater information, and information about parts that are specific to 400/480 volt melters. NOTE: With the exception of power supply and heater failure problems, the information provided in this section applies to all ProBlue adhesive melters. Safety  Never disconnect cables from, or reconnect cables to, the main board while the melter is energized.  Before breaking any hydraulic connection, always relieve system pressure. Refer to Section 5, Relieving System Pressure.  Refer to the safety information provided with optional equipment.  If the melter is removed from its sub-base for diagnostic checks or service, ensure that the ground lead between the chassis and the sub-base is re-attached when the melter is reconnected to the sub-base.

Troubleshooting 6-2 Part 1024496D02  2007 Nordson Corporation Melter Faults Table 6-1 lists the four types of melter faults, potential causes, and expected corrective actions. Table 6-1 Melter Faults Display Code/Sub-code Name Affect on Melter Cause Corrective Action F1/None

Rtd

F4/1

F4/2

F4/4

Ram

F4/5

F4/6

Cpu

F4/7

F4/8

Troubleshooting 6-3 Part 1024496D02  2007 Nordson Corporation Corrective Action Cause Affect on Melter Name Display Code/Sub-code

F4/A

Cpu

F4/E

a b Troubleshooting question and action blocks a) Question b) Action Troubleshooting 6-4 Part 1024496D02  2007 Nordson Corporation Using the Troubleshooting Flowchart The flowchart, which is provided at the end of this section, is designed to assist you in diagnosing and correcting a complete or partial stop in hot melt output from the guns. The chart is organized in a simple question-action block format. If your response to a question is yes (Y), continue downward in the chart to the next question or action block. If you response is no (N), continue to the right to the next question or action block. All diagnostic paths within the chart end with an action block that specifies one of the following three courses of action:  Refer to information provided elsewhere in this manual  Replace a component  Complete a diagnostic procedure (DP.x) To return your melter to service as quickly as possible, the chart is designed under the assumption that it is preferable to immediately replace a faulty assembly as opposed to conducting detailed diagnostics and repair of the assembly while the melter is out of service. Use of the chart assumes that the melter is installed correctly and that it is set up to support the current manufacturing process. Refer to Section 3, Installation, for information about installing and setting up the melter. Troubleshooting Quick-checks Before using the troubleshooting charts confirm:  whether or not service was recently performed on the melter or the melter’s settings were recently adjusted.  the correct voltage plug is installed on terminal J1. Refer to Section 4, Installation, for information about selecting the correct voltage plug.  external inputs (if used) are functioning properly.  the standby or clock functions are not turned on (if not required or expected at the current time).

Troubleshooting 6-5 Part 1024496D02  2007 Nordson Corporation Returning the Melter Setup to Factory Settings By returning the melter to its factory setting many common melter problems can be isolated to either a problem with the melter settings or the melter hardware. To return the melter to its factory settings, simultaneously press and hold the Setup key and the right-display UP arrow key, and then, while holding down these keys, cycle the melter control switch off and on. When the melter restarts, release the two keys. Identifying Electrical Components Tables 6-2 through 6-5 describe the circuit board indicators, connection points, and test points that are referred to in the troubleshooting flowchart. Figure 6-1 illustrates the location of each of these circuit board components. Table 6-2 Main PCA Item Number Type Description Indicators

Ds1

Ds2

F1/F2

Ds3

Ds4

Ds5

F1/F2

F3/F4

J1/J2

Tb1

Tb2

J5

J6

J7

J8

J9

J10

Troubleshooting 6-6 Part 1024496D02  2007 Nordson Corporation Table 6-3 CPU board Item Number Type Description Indicators Red LED — Indicates that CPU board has failed Green LED — + 5 VDC control voltage is present at the CPU board Connection Points

J1

J5

Tp2/Tp4

Ds1

Ds2

Ds3

Ds4

Ds5

Ds6

J1

J2

J10

Troubleshooting 6-7 Part 1024496D02  2007 Nordson Corporation Figure 6-1 Electrical components

Troubleshooting 6-8 Part 1024496D02  2007 Nordson Corporation Figure 6-2 Power and control harness

Troubleshooting 6-9 Part 1024496D02  2007 Nordson Corporation Figure 6-3 Location of the return port

Troubleshooting 6-10 Part 1024496D02  2007 Nordson Corporation 1 2 3 Figure 6-4 Pneumatic flow diagram

Troubleshooting 6-11 Part 1024496D02  2007 Nordson Corporation Diagnostic Procedures Use these diagnostic procedures when directed by the troubleshooting flowchart. If a diagnostic procedure fails to identify or correct the problem, return to the troubleshooting flowchart or contact your Nordson representative for technical assistance. DP.1 Isolate a Failed Control Component

Troubleshooting 6-12 Part 1024496D02  2007 Nordson Corporation DP.2 Check the Tank or Manifold RTD

Rtd).

Removing the tank RTD Troubleshooting 6-13 Part 1024496D02  2007 Nordson Corporation Reheating the Melter During an F1 Fault

Troubleshooting 6-14 Part 1024496D02  2007 Nordson Corporation Remove the Manifold RTD

Removing a hose/gun module Troubleshooting 6-15 Part 1024496D02  2007 Nordson Corporation DP.3 Check the Operation of the Power Relay or Thermostats The pre-conditions for this diagnostic procedure are as follows:  The heater LED is illuminated.  Indicator DS2 on the main board is not illuminated.  Indicators DS5 and DS6 on all hose/gun modules are not illuminated.

Troubleshooting 6-16 Part 1024496D02  2007 Nordson Corporation DP.4 Check the Operation of the Tank or Manifold TRIAC See Figure 6-1. WARNING: Risk of electrocution! Ensure that disconnect switch that serves the melter is in the off position and locked.

P/N 1038323).

Troubleshooting 6-17 Part 1024496D02  2007 Nordson Corporation DP.5 Check the Resistance of the Tank and Manifold Heaters WARNING: Risk of electrocution! Ensure that disconnect switch that serves the melter is in the off position and locked.

P4

P7

P10

Troubleshooting 6-18 Part 1024496D02  2007 Nordson Corporation DP.5 Check the Resistance of the Tank and Manifold Heaters (contd)

Troubleshooting 6-19 Part 1024496D02  2007 Nordson Corporation 250 240 230 220 210 200 190 180 170 160 150 140 130

Resistance In Ohms

Resistance In Ohms

Temperature

Temperature

Troubleshooting 6-20 Part 1024496D02  2007 Nordson Corporation Figure 6-6 Removing the pump

Troubleshooting 6-21 Part 1024496D02  2007 Nordson Corporation Start ProBlue Troubleshooting Flowcharts Go to

T.3

T.1

T.4

T.2

T.5

P/N 1017947.

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Troubleshooting 6-23 Part 1024496D02  2007 Nordson Corporation Quick Check: Verify that the voltage plug is correct Starting Condition: Control panel is not illuminated

T.1

Troubleshooting 6-24 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... + − Is there voltage on the downstream side of fuses F3 and F4 on the main board? See Figure 6-1. + − Is there voltage across the wires in the power cable from the disconnect switch to TB1? Replace the main board assembly.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

P/N 1028329.

T.1

Troubleshooting 6-25 Part 1024496D02  2007 Nordson Corporation + − Starting conditions: Control panel is not illuminated > Disconnect switch is on > DS4 is illuminated

T.1.1

P/N 1028325.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

P/N 1018283.

P/N 1028325.

Troubleshooting 6-26 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank

Troubleshooting 6-27 Part 1024496D02  2007 Nordson Corporation + − Starting Condition: Fault LED is illuminated

T.2

Troubleshooting 6-28 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... Confirm that the RTD has failed. Refer to DP.2.

P/N 1028320.

T.2

Troubleshooting 6-29 Part 1024496D02  2007 Nordson Corporation Reset the melter and turn the heaters back on. Allow the unit to come to temperature. Starting Conditions: Fault LED is illuminated > F2 fault exists

T.2.1

T.2.3

P/N 1017723.

Troubleshooting 6-30 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... + − + − Are the hose and gun RTD functioning correctly? + − Are the indicators DS5 or DS6 on the affected hose/gun module illuminated? See Figure 6-1. Does the fault re-occur if you replace the affected hose/gun module with a known good module? Replace the main board.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

P/N 1028328.

P/N 1028331.

T.2.1

Troubleshooting 6-31 Part 1024496D02  2007 Nordson Corporation Reset the melter and turn the heaters back on. Allow the unit to come to temperature. Starting conditions: Fault LED is illuminated > F3 fault exists

T.2.2

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

P/N 1028320.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

P/N 1028328.

Troubleshooting 6-32 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... Starting conditions: Fault LED is illuminated > F3 fault exists

T.2.2

P/N 332182.

P/N 332182.

Troubleshooting 6-33 Part 1024496D02  2007 Nordson Corporation Starting conditions: Fault LED is illuminated > F2 fault exists > Tank key LED is illuminated > Hot melt has not been added

T.2.3

P/N 1028329.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Dp.3

Troubleshooting 6-34 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... + − + − Are the tank and the manifold TRIACs functioning properly? Refer to DP.4. + − Is the resistance correct for the tank and the manifold heaters? Refer to DP.5. Does replacing the malfunctioning tank or manifold RTD solve the problem?

P/N 1028320.

P4/P7 − P/N 1028322.

P/10 − P/N 1028323

T.2.3

Troubleshooting 6-35 Part 1024496D02  2007 Nordson Corporation Starting conditions: No faults > Ready LED is not illuminated

T.3

P4/P7 − P/N 1028326.

P10 − P/N 1028327.

T.3.1

Troubleshooting 6-36 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... The melter is in the standby mode. Refer to Section 4, Standby Key. + − Is the standby LED on? + − Is the ready delay counting down? Wait for the ready delay to count down. Refer to Appendix B, parameter

T.3

Troubleshooting 6-37 Part 1024496D02  2007 Nordson Corporation Starting conditions: No faults > Ready LED is not illuminated > Remote input is being used

T.3.1

P/N 1036607.

P4/P7 − P/N 1028322.

P10 − P/N 1028323.

Troubleshooting 6-38 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank

Troubleshooting 6-39 Part 1024496D02  2007 Nordson Corporation Starting conditions: No faults > Ready LED is illuminated > No hot melt output from all guns

T.4

Troubleshooting 6-40 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... + − Is the tank empty? Turn off the pump. Fill the tank. Wait for the unit to heat the adhesive to operating temperature. + − Is the isolation valve (shut off valve) closed? See Figure 6-6. Open the valve. + − Is hot melt returning to the tank through the return port located behind the tank screen? See Figure 6-3. Replace the pressure discharge valve.

P/N 1028308.

T.4

Troubleshooting 6-41 Part 1024496D02  2007 Nordson Corporation + − + − Is the pump LED illuminated? Is the pump LED flashing? + − Are you using an optional input (parameters 5 thru 10) to enable/disable the pump? Stop. + − Does pressing the pump key turn the pump on? Stop. + − Does replacing the operator’s panel and then restarting the melter correct the problem?

P4/P7 − P/N 1028326.

P10 − P/N 1028327.

P/N 1028325.

T.4.2

T.4.1

Troubleshooting 6-42 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... Starting conditions: No faults > Ready LED is illuminated > No hot melt output from all guns > Pump has stopped

T.4.1

P/N 1036607.

Troubleshooting 6-43 Part 1024496D02  2007 Nordson Corporation Problem Turn on or adjust the plant air pressure. + − + − Is air being supplied to the top of the pump? Is 24 VDC being supplied to the solenoid valve (wire harness leads 9 and 10)? Replace the pneumatic assembly.

P/N 1028307.

P/N 1024600.

P4/P7 − P/N 1028322.

P10 − P/N 028323.

T.4.2

Troubleshooting 6-44 Part 1024496D02  2007 Nordson Corporation Continued from previous page.... Starting conditions: No faults > Ready LED is illuminated > No hot melt output from all guns > Pump has stopped > Pump LED is illuminated > Tank set-point temperature is OK > Pump is not controlled by a remote input

T.4.2

P/N 1022727.

P/N 1028305.

Troubleshooting 6-45 Part 1024496D02  2007 Nordson Corporation Starting conditions: No faults > Ready LED is illuminated > Hot melt output from some guns

T.5

Troubleshooting 6-46 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank

Parts 7-1 Part 1024496D02  2007 Nordson Corporation Section 7 Parts NOTE: Refer to Appendix E for information about 400/480 Volt melter parts. Using the Illustrated Parts List The parts lists provided in this section are organized into the following columns: Item—Identifies illustrated parts that are available from Nordson Corporation. Used—Identifies the melters in which the part is used. A blank entry indicates that the part is used in all ProBlue melters. Part—Provides the Nordson Corporation part number for each saleable part shown in the illustration. A series of dashes in the parts column (- - - - - -) means the part cannot be ordered separately. Description—Provides the part name, as well as its dimensions and other characteristics when appropriate. Bullets in the description, indicate the relationships between assemblies, subassemblies, and parts. Quantity—The quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. NOTE: Illustrations of the model P4 are used throughout this section to represent all ProBlue melters. Refer to the Used column to determine the part number associated with your melter. Fasteners Fasteners are called out in each illustration using the convention Fx, where “x” is the fastener number used in the Schedule of Fasteners, which is located at the end of this section.

Parts 7-2 Part 1024496D02  2007 Nordson Corporation Tank, Pump, and Manifold Parts List Figure 7-1 Tanks, pump and manifold

Parts 7-3 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1

A, B

P4, P7

C

P10

C

P4, P7

C

P10

C

P4

F

P7

F

P10

F

F, G

D

P4

P7

P10

E

Ns

P4

P7

P10

Note

A:

B:

C:

D:

E:

F:

Parts 7-4 Part 1024496D02  2007 Nordson Corporation Manifold Assembly Parts List Figure 7-2 Manifold assembly

Parts 7-5 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note —

P4, P7

P10

P4, P7

P10

A

B

C

C

C

Note

A:

B:

C:

Parts 7-6 Part 1024496D02  2007 Nordson Corporation Pump Assembly Parts List Figure 7-3 Standard Double-Acting pump (Part 1)

Parts 7-7 Part 1024496D02  2007 Nordson Corporation Figure 7-4 Standard Double-Acting pump (Part 2)

Parts 7-8 Part 1024496D02  2007 Nordson Corporation Item Part Description Quantity Note 1 1016863

Body,Pump−Filter

Frame,Pump,Machine

Head,Cylinder,Sp,Machin

Scr,Hex,Cap,M6X120,Zn

Washer,Flt,M,Narrow,M6,Stl,Zn

Tube,Crossover,Pump

O Ring,Viton,.426Id X .070W,Br,10413

Back−Up Ring,Single,7/16X9/16

Cup,Piston,Sp

Washer,Piston Seal,Sp

Washer,Piston Cup,Sp

O Ring,Viton,.676Id X .070W,Br

Seal,Pump.

Shifter Assembly,G1/8

B

Service Kit, Fork,Magnetic,Assy

A

Plug,O Ring,Str Thd,7/16−20

Cage,Ball,Siphon

Ball,440Sstl,.500, 50

Seat,Ball,Lower

O Ring,Viton,1 Tub

Valve Assy,Drain

Chute,Drain,Assy

Scr,Skt,M5X10,Zn

Adapter,Filter,Assy

Filter,Saturn,Melter,100 Mesh,W/ O−Ring

A

D

Insulator,Pump

Scr,Hex,Cap,M6X35,Zn

Piston Assy,Hydraulic,Problue

C

Scr,Hex,Cap,M6X30,Zn

O Ring,Viton, 2X2.125X.063

Cup,U,Viton

Retaining Ring,Int,100,Pushon

Nut,Hex,Lock,Torque,M6,Class10

Scr,Skt,M5X12,Bl

Plate,Filter,Anti Rotate

Pin,Roll,.188X1,Stl,Zn

Lubricant,Parker Hi−Temp,11208

Lubricant,Never Seez,8Oz Can

Note

Parts 7-9 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

Parts 7-10 Part 1024496D02  2007 Nordson Corporation Figure 7-5 Shifter assembly/Standard Double-Acting pump

Parts 7-11 Part 1024496D02  2007 Nordson Corporation Item Part Description Quantity Note 1 982028

Scr,Skt,M5X20,Bl

Service Kit, Valve Assy Sp

Manifold,Air,G1/8 Port,Pump

Spring,Wave,Inconel,Sp Pump

Detent,Upper,Sp

Scr,Skt,M4X8,Bl

Service Kit, Actuator,Magnetic,Assy,Sp

A

Can,Sp

Detent,Lower ,Sp

Retaining Ring,Int,156,Bowed

Lubricant,Parker Hi−Temp,11208

Note

Parts 7-12 Part 1024496D02  2007 Nordson Corporation Figure 7-6 Piston assembly/Standard Double-Acting pump Item Part Description Quantity Note 1 −−−−−−

Piston,Pump,15:1

Pin,Roll,.125X .500,Stl,Zn

Ball,440Sstl,.375, 50

Seat,Ball,Pressure

Adhesive,Loctite 272,Red,Hi Temp,50Ml

Parts 7-13 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

Parts 7-14 Part 1024496D02  2007 Nordson Corporation Pneumatic Components Parts List 2 3 4 5 6 7 8 1 Figure 7-7 Pneumatic components

Parts 7-15 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1 1023307 Elbow, male, 6 mm tube x G1/8 1 2 1023855 Tubing, PDV-to-pump, 6 mm tube 1 3 1019511 Tee, run, 6 mm tube, G1/8 1 4 1023853 Tubing, regulator-to-PDV, 6 mm tube (yellow) 1 5 1023290 Fitting, bulkhead, 90-degree, 6 mm tube 1 6 1023267 Filter assembly, air, 6 mm BSPP 1 7 1023854 Tubing, filter-to-regulator, 6 mm tube (blue) 1 8

A

Note

A:

Parts 7-16 Part 1024496D02  2007 Nordson Corporation Electrical Enclosure Parts List Figure 7-8 Electrical enclosure

Parts 7-17 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1

Ar

A

Ar

P4, P7

P10

P4, P7

P10

P4, P7

P10

P4, P7

P10

B

P4, P7

C

P10

D

P4, P7

E

P10

F, G

Note

A:

B:

C:

D:

E:

F:

G:

Parts 7-18 Part 1024496D02  2007 Nordson Corporation Exterior Panels Parts List Figure 7-9 Exterior panels

Parts 7-19 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1

P4, P7

P10

P4

A

P7, P10

A

P4

P7

P10

P4

P7

P10

P4

P7

P10

P4, P7

P10

P4, P7

P10

P4

P7

P10

Note

A:

Parts 7-20 Part 1024496D02  2007 Nordson Corporation Chassis Components Parts List 9 10 12 11 13 14 16 15 1 3 2 4 7 6 5 8

F24

F7

F3

F6

F16

F3

F17

F18

F3

F8

F15

F16

F3

Parts 7-21 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1

A

P4, P7

B

P10

C

P4

P7, P10

P4

P7/P10

E

P4

P7

P10

P4

P7, P10

P4

P7, P10

D

P4

P7

P10

Note

A:

B:

C:

D:

E:

Parts 7-22 Part 1024496D02  2007 Nordson Corporation Ribbon Cable Parts List Figure 7-11 Ribbon cables

Parts 7-23 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note 1 1018283 Cable assembly, ribbon, main 1 2 1018284 Cable assembly, serial port 1

A

Note

A:

Parts 7-24 Part 1024496D02  2007 Nordson Corporation Service Kits Pump Replacement Part Description Quantity 1028303 Kit, service, pump assembly, P4/P7/P10 —

Parts 7-25 Part 1024496D02  2007 Nordson Corporation Filter Part Description Quantity 1028305 Filter, Saturn, 100-mesh —

Parts 7-26 Part 1024496D02  2007 Nordson Corporation

Rtd

P4, P7

P10

P4, P7

P10

Parts 7-27 Part 1024496D02  2007 Nordson Corporation Hose/Gun Module Part Description Quantity 1028328 Kit, service, hose/gun module, P4/P7/P10 —

Note

A:

Note

A:

Parts 7-28 Part 1024496D02  2007 Nordson Corporation Expanded Spare Parts Part Description Quantity 1028333 Kit, basic expanded parts, P4/P7/P10 — 1028305  Filter, Saturn, melter, 100-mesh 5 1028320  Kit, service, RTD, P4/P7/P10 1 1028321  Kit, service, thermostat, melter 1 1028328  Kit, service, hose/gun module, P4/P7/P10 1 1028329  Kit, service, fuse, main circuit board, P4/P7/P10 1 1028331  Kit, service, fuse, hose/gun module, P4/P7/P10 1 1028304  Kit, service, pump, P4/P7/P10 1 1028309  Kit, service, manifold, P4/P7/P10 1 1023267  Filter assembly, air, 6 mm BSPP 1 Level Switch Used Part Description Quantity

P4, P7

P10

Parts 7-29 Part 1024496D02  2007 Nordson Corporation Vent Guard (P10) Part Description Quantity 1048884 Guard kit assembly, vent , screen, P10 —

Svc Kit,Heater Block,230V,Problue

Heater Block,Problue,230V

Scr,Skt,M5X25,Bl

Washer,Lk,M,Spt,M5,Stl,Zn

Compound,Heatsink,10Cc Syringe

Parts 7-30 Part 1024496D02  2007 Nordson Corporation Manifold 4 or 6-hose/230V or 480V Part Description Quantity 1064651

Svc Kit,Manifold 4−H,W/Htr Block,230V,Pb

Svc Kit,Manifold 4−H,W/Htr Block,480V,Pb

Svc Kit,Manifold 6−H,W/Htr Block,230V,Pb

Svc Kit,Manifold 6−H,W/Htr Block,480V,Pb

Heater Block,Problue,480V

Manifold Assy, 6 Hose

Scr,Skt,M5X25,Bl

Washer,Lk,M,Spt,M5,Stl,Zn

O Ring, Viton, .50 X .75 X .125

O Ring,Viton, .812X1.062X.125

O Ring,Viton, .750X .938X.094

O Ring,Viton,.426Id X .070W,Br,10413

Grease,Hi−Temp,.50Oz,Slube 884−.50

Compound,Heatsink,10Cc Syringe

Parts 7-31 Part 1024496D02  2007 Nordson Corporation Option Kits 6-Hose Extension Part Description Quantity 1028324 Kit, 6-hose extension, board, P10 —

A, B

B

B

Note

A:

B:

Parts 7-32 Part 1024496D02  2007 Nordson Corporation Ethernet Card Part Description Quantity 1053289

Kit,Ethernet Card

Pca,Anybus−S,Ethernet,17Mm Pins,Programm

Mach Scrm,Pan,Rec,M3X6,Sems

Kit,Devicenet Card

Pca,Anybus−S,Devicenet,17Mm Pins

Mach Scrm,Pan,Rec,M3X6,Sems

Kit, Profibus Card

Pca,Anybus−S,Profibus,17Mm Pins

Mach Scrm,Pan,Rec,M3X6,Sems

8 H/G, Base,Expansion

Base,Expansion,8 H/G,P10

Kit,Ship With,2 H/G Base,P10

Parts 7-33 Part 1024496D02  2007 Nordson Corporation Schedule of Fasteners Number Description

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F29

Parts 7-34 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

Technical Data 8-1 Part 1024496D02  2007 Nordson Corporation Section 8 Technical Data General Specifications Item Data Note Weight of empty melter

P4

P7

P10

P4

P7

P10

A

P4

P7

P10

B

P4

P7

P10

Note

A:

B:

Technical Data 8-2 Part 1024496D02  2007 Nordson Corporation Electrical Specifications Item Data Note Hose/gun heating capacity 2, 4, or 6 hose/gun pairs

A

1 °C

B

Ip54

Note

A:

B:

Technical Data 8-3 Part 1024496D02  2007 Nordson Corporation Melter Power Requirements Melter Number of Hose/Guns 1-Phase Power Draw (Amps) 3-Phase Power (Amps) Without Neutral With Neutral

P4

P7

P10

Technical Data 8-4 Part 1024496D02  2007 Nordson Corporation P7 Melter Figure 8-2 P7 Melter dimensions

Technical Data 8-5 Part 1024496D02  2007 Nordson Corporation P10 Melter Figure 8-3 P10 Melter dimensions

Technical Data 8-6 Part 1024496D02  2007 Nordson Corporation Sub-base 8.7 mm (.343 in.) 8.0 mm (.314 in.) 381mm (15.00 in.) 436 mm (17.16 in.) 249 mm (9.8 in.) 249 mm (9.8 in.) 8.7 mm (.343 in.)

Pg−16

Pg−21

1” Npt

P7/P10

P4

Technical Data 8-7 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-8 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-9 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-10 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-11 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-12 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-13 Part 1024496D02  2007 Nordson Corporation

Technical Data 8-14 Part 1024496D02  2007 Nordson Corporation

Calculating Melter Power Requirements

A-1

Calculating Melter Power Requirements

A-2

Calculating Melter Power Requirements

A-3

200 Vac

220 Vac

230 Vac

240 Vac

870 W

957 W

1000 W

1043 W

1071 W

1179 W

1233 W

1286 W

1740 W

1913 W

2000 W

2086 W

Calculating Melter Power Requirements

A-4

Operating Parameters

B-1

Operating Parameters

B-2

Operating Parameters

B-3

Operating Parameters

B-4

Or

Operating Parameters

B-5

Operating Parameters

B-6

C

1C

1F

15 C (25 F)

1C

1F

25 C (50 F)

Operating Parameters

B-7

1C

1F

50 C (100 F)

Operating Parameters

B-8

Operating Parameters

B-9

Operating Parameters

B-10

Operating Parameters B-11 Part 1024496D02  2007 Nordson Corporation 34 – 39 Optional Inputs 5, 6, 7, 8, 9, and 10 Description: Control options that determine the function of the six optional inputs provided when the optional I/O expansion card is installed on the CPU board. Value: 0 – Input Disabled 1 – Standby On/Off 2 – Heaters On/Off 3 – Pump Enable/Disable 4 – Hose/Gun 1 Enable/Disable 5 – Hose/Gun 2 Enable/Disable 6 – Hose/Gun 3 Enable/Disable 7 – Hose/Gun 4 Enable/Disable 8 – Hose/Gun 5 Enable/Disable 9 – Hose/Gun 6 Enable/Disable 11 – Motor 2 Enable/Disable (DuraBlue adhesive melters only) Resolution: 1 Default Value: 0 (disabled) Format: — Use: Multiple inputs can be set to the same input value. After one or more inputs that have the same input value are energized, the input functionality will not be considered inactive (off) until all of the inputs with the same input value are de-energized (Multiple inputs set to the same input value are logical ORed.).

Operating Parameters

B-12

Operating Parameters B-13 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

Seven-day clock key Operating Parameters

B-14

Operating Parameters B-15 Part 1024496D02  2007 Nordson Corporation Example 1 To turn the heaters on at 0600 and turn them off at 0015 every day of the week: Par 55 = 0600 Par 56 = 0015 Par 60 = - - - - Par 61 = - - - - Par 71 through 77 = 1 Example 2 To turn the heaters on at 0700 and off at 1700 Monday through Friday, and turn the heaters off Saturday and Sunday: Par 55 = 0700 Par 56 = 1700 Par 57 = - - - - Par 58 = - - - - Par 71 through 75 = 1 Par 76 and 77 = 0 Example 3 To turn the heaters on at 0600 each morning, go into standby for lunch at 1130, come out of standby after lunch at 1230, and turn the heaters off at 1600 at the end of the day, every day of the week: Par 50 = 1 Par 51 = current time Par 55 = 0600 Par 56 = 1600 Par 57 = 1130 Par 58 = 1230 Par 71 through 75 = 1 Par 76 and 77 = 1

Operating Parameters

B-16

Operating Parameters B-17 Part 1024496D02  2007 Nordson Corporation 57 Schedule 1 Enter Standby Description: Used to set the time that the melter will enter the standby mode during schedule 1. Value: 0000 to 2359, - - - - Resolution: 1 minute Default Value:

Operating Parameters

B-18

Operating Parameters B-19 Part 1024496D02  2007 Nordson Corporation 65 Schedule 3 Heaters On Description: Used to set the time that the clock will turn on the heaters during schedule 3. Value: 0000 to 2359, - - - - Resolution: 1 minute Default Value:

Operating Parameters

B-20

Operating Parameters B-21 Part 1024496D02  2007 Nordson Corporation 72 Schedules for Tuesday Description: Used to select which schedule(s) should be used on Tuesday. Value: 0 – Remain at last clock transition 1 – Use just schedule 1 2 – Use just schedule 2 3 – Use just schedule 3 4 – Use schedule 1 and 2 5 – Use schedule 2 and 3 6 – Use schedule 1 and 3 7 – Use schedule 1, 2, and 3 Resolution: 1 Default Value: 0 Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. 73 Schedules for Wednesday Description: Used to select which schedule(s) should be used on Wednesday. Value: 0 – Remain at last clock transition 1 – Use just schedule 1 2 – Use just schedule 2 3 – Use just schedule 3 4 – Use schedule 1 and 2 5 – Use schedule 2 and 3 6 – Use schedule 1 and 3 7 – Use schedule 1, 2, and 3 Resolution: 1 Default Value: 0 Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

Operating Parameters

B-22

Operating Parameters B-23 Part 1024496D02  2007 Nordson Corporation 76 Schedules for Saturday Description: Used to select which schedule(s) should be used on Saturday. Value: 0 – Remain at last clock transition 1 – Use just schedule 1 2 – Use just schedule 2 3 – Use just schedule 3 4 – Use schedule 1 and 2 5 – Use schedule 2 and 3 6 – Use schedule 1 and 3 7 – Use schedule 1, 2, and 3 Resolution: 1 Default Value: 0 Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives. 77 Schedules for Sunday Description: Used to select which schedule(s) should be used on Sunday. Value: 0 – Remain at last clock transition 1 – Use just schedule 1 2 – Use just schedule 2 3 – Use just schedule 3 4 – Use schedule 1 and 2 5 – Use schedule 2 and 3 6 – Use schedule 1 and 3 7 – Use schedule 1, 2, and 3 Resolution: 1 Default Value: 0 Format: — Use: Selects the active schedule(s) for the day. NOTES: If the 0 schedule option is used, the heaters will not turn on again until the next scheduled heaters on time arrives.

Operating Parameters

B-24

Melter Communications

C-1

Melter Communications

C-2

Or

Or

Melter Communications

C-3

Melter Communications

C-4

ProBlue serial port 11 22 00 44 55 33 66 99 DuraBlue serial port Melter Communications

C-5

Configuration Manager desktop icon Melter Communications

C-6

Melter Communications

C-7

Melter Communications

C-8

Melter Communications

C-9

Melter Communications

C-10

Or

SP Pump Diagnostics and Repair

D-1

SP Pump Diagnostics and Repair

D-2

SP Pump Diagnostics and Repair

D-3

SP Pump Diagnostics and Repair

D-4

SP Pump Diagnostics and Repair

D-5

SP Pump Diagnostics and Repair

D-6

(475 F).

SP Pump Diagnostics and Repair

D-7

SP Pump Diagnostics and Repair

D-8

P/N 1019515

P/N 942111

P/N 940133 (2)

P/N 954013

SP Pump Diagnostics and Repair

D-9

SP Pump Diagnostics and Repair

D-10

P/N 940332

SP Pump Diagnostics and Repair D-11 Part 1024496D02  2007 Nordson Corporation 1 2 3 4 5 6 7 5–6 Nm (45–55 in.-lb) 8 Figure D-2

SP Pump Diagnostics and Repair

D-12

P/N 164606

P/N 1014650

SP Pump Diagnostics and Repair D-13 Part 1024496D02  2007 Nordson Corporation 1 2 3 3–4 Nm (28–36 in.-lb) Figure D-3

SP Pump Diagnostics and Repair

D-14

SP Pump Diagnostics and Repair D-15 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

SP Pump Diagnostics and Repair

D-16

P/N 940181

SP Pump Diagnostics and Repair D-17 Part 1024496D02  2007 Nordson Corporation 1 2 Figure D-6

SP Pump Diagnostics and Repair

D-18

SP Pump Diagnostics and Repair D-19 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

SP Pump Diagnostics and Repair

D-20

P/N 166880

SP Pump Diagnostics and Repair D-21 Part 1024496D02  2007 Nordson Corporation 1 2 3 4 7–8.5 Nm (60–70 in.-lb) Figure D-9

SP Pump Diagnostics and Repair

D-22

P/N 163039

SP Pump Diagnostics and Repair D-23 Part 1024496D02  2007 Nordson Corporation 1 2 3 2 4 11.3–13.6 Nm (100–120 in.-lb) Figure D-10

SP Pump Diagnostics and Repair

D-24

P/N 1017307

P/N 952100

SP Pump Diagnostics and Repair D-25 Part 1024496D02  2007 Nordson Corporation 1 2 3 4 3–3.5 Nm (25–31 in.- lb) Figure D-11

SP Pump Diagnostics and Repair

D-26

P/N 1016863

P/N 1022658

SP Pump Diagnostics and Repair D-27 Part 1024496D02  2007 Nordson Corporation 1 2 Figure D-13

SP Pump Diagnostics and Repair

D-28

P/N 900001

P/N 900000

P/N 1017320

P/N 503696

P/N 945037

SP Pump Diagnostics and Repair D-29 Part 1024496D02  2007 Nordson Corporation 1 2 3 4 Figure D-14

SP Pump Diagnostics and Repair

D-30

P/N 940172

P/N 273139

SP Pump Diagnostics and Repair D-31 Part 1024496D02  2007 Nordson Corporation This page intentionally left blank.

SP Pump Diagnostics and Repair

D-32

F6

F1

F2

F4

F2

F19

F25

4401005A

F6

SP Pump Diagnostics and Repair D-33 Part 1024496D02  2007 Nordson Corporation Item Used Part Description Quantity Note —

A

B

Note

A:

B:

SP Pump Diagnostics and Repair

D-34

F1

F2

F4

F6

F19

400/480 Volt ProBlue Adhesive Melters

E-1

400/480 Volt ProBlue Adhesive Melters

E-2

400/480 Volt ProBlue Adhesive Melters

E-3

400/480 Volt ProBlue Adhesive Melters

E-4

C

D

A

B

A

B

C

D

400/480 Volt ProBlue Adhesive Melters

E-5

400/480 Volt ProBlue Adhesive Melters

E-6

400/480 Volt ProBlue Adhesive Melters

E-7

Sub-base 400/480 Volt ProBlue Adhesive Melters

E-8

400/480 Volt ProBlue Adhesive Melters

E-9

400/480 Volt ProBlue Adhesive Melters

E-10

8 A

11 A

400/480 Volt ProBlue Adhesive Melters E-11 Part 1024496D02  2007 Nordson Corporation Figure E-6 Connecting the electrical service

400/480 Volt ProBlue Adhesive Melters

E-12

400/480 Volt ProBlue Adhesive Melters E-13 Part 1024496D02  2007 Nordson Corporation Figure E-8 Connecting the melter ground lead to the transformer chassis

400/480 Volt ProBlue Adhesive Melters

E-14

400/480 Volt ProBlue Adhesive Melters E-15 Part 1024496D02  2007 Nordson Corporation

J9

J1

400/480 Volt ProBlue Adhesive Melters

E-16

400/480 Volt ProBlue Adhesive Melters E-17 Part 1024496D02  2007 Nordson Corporation Troubleshooting The following table provides transformer-specific troubleshooting guidance. Refer to the Section 6, Troubleshooting for general melter troubleshooting information. Problem Possible Cause Corrective Action

400/480 Volt ProBlue Adhesive Melters

E-18

B

A

A/B

A

Ns

Ns

Ns

Ns

Note

400/480 Volt ProBlue Adhesive Melters E-19 Part 1024496D02  2007 Nordson Corporation

400/480 Volt ProBlue Adhesive Melters

E-20

400/480 Volt ProBlue Adhesive Melters E-21 Part 1024496D02  2007 Nordson Corporation 400/480-Volt Melter-Specific Components The following table lists melter components that are specific to 400/480 volt melters. Refer to the ProBlue product manual, Section 7, Parts for information about melter components that are common to both standard and 400/480 volt melters. Item Part Description Quantity Note

Ns

Ns

Ns

Ns

Ns

400/480 Volt ProBlue Adhesive Melters

E-22