Nordson ProBlue P10 Customer Product Manual Download

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Table of Contents

iii

Part 1024496_06

2014

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

4‐7

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

Monitor Component Temperatures

4‐8

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

Monitor Melter Faults

4‐10

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

How F1, F2, and F3 Faults are Handled

4‐14

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

How F4 Faults are Handled

4‐15

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

Monitor the Level of Hot Melt in the Tank

4‐17

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

Monitor and Adjust the Operating Air Pressure

4‐17

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

Monitor the Service Interval

4‐18

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

Adjusting Component Temperatures

4‐19

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

Entering the Melter Password

4‐24

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

Using the Melter Function Keys

4‐25

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

Heater Key

4‐25

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

Pump Key

4‐26

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

Setup Key

4‐26

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

Seven‐day Clock Key

4‐27

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

Standby Key

4‐28

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

Shutting Down the Melter

4‐29

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

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

. .

ProBlue Troubleshooting Flowcharts

6‐21

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

Summary of Contents for ProBlue P10

Page 1: ...Product Manual Part 1024496_06 Issued 3 14 NORDSON CORPORATION DULUTH GEORGIA USA www nordson com This document contains important safety information Be sure to read and follow all safety information...

Page 2: ...Sure Max Sure Wrap Tracking Plus TRAK Trends Tribomatic TrueBlue TrueCoat Ultra UpTime u TAH Vantage VersaBlue Versa Coat VersaDrum VersaPail Versa Screen Versa Spray Watermark and When you expect mor...

Page 3: ...tices 1 4 Maintenance and Repair Practices 1 5 Equipment Safety Information 1 5 Equipment Shutdown 1 6 Relieving System Hydraulic Pressure 1 6 De energizing the System 1 6 Disabling the Applicators 1...

Page 4: ...8 Mounting the Melter 3 10 Configuring the Electrical Service 3 13 Connecting a Compressed Air Supply 3 18 Connecting Hoses and Guns 3 20 Setting Up the Melter 3 24 Quick Setup 3 24 Operating Paramete...

Page 5: ...n the Melter 4 29 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...

Page 6: ...5 1 Low Viscosity Pump Replacement 7 31 6 1 Pump Replacement 7 31 Pump General Service 7 32 Filter 7 32 Pneumatic Panel 7 32 Pressure Discharge Valve 7 33 Manifold Service Kit 7 33 RTD 7 33 Thermostat...

Page 7: ...nts A 1 Operating Parameters B 1 Standard B 2 Temperature Control B 6 Input Setup B 9 Output Setup B 12 Seven day Clock B 14 Example 1 B 15 Example 2 B 15 Example 3 B 15 Melter Communications C 1 Soft...

Page 8: ...move the Magnetic Actuator Assembly D 12 Remove the Valve Spool and Sleeve D 15 Special Reassembly Instructions D 16 Remove the Shifter Fork D 18 Special Reassembly Instructions D 18 Remove the Piston...

Page 9: ...on E 6 Clearances E 6 Installation Kit Components E 7 Prepare the Transformer for Installation E 8 Mount the Transformer to the Parent Machine E 10 Connect the Electrical Service to the Transformer E...

Page 10: ...Table of Contents viii Part 1024496_06 2014 Nordson Corporation...

Page 11: ...t 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 th...

Page 12: ...rning regulations Contact the authority having jurisdiction for information Maintain safety information including the safety labels affixed to the equipment in readable condition Instructions Requirem...

Page 13: ...ction 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 P...

Page 14: ...required installation configuration does not match the installation instructions contact your Nordson representative for assistance Position the equipment for safe operation Observe the requirements f...

Page 15: ...E 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 th...

Page 16: ...e equipment system 2 To prevent the equipment from being accidentally energized lock and tag the disconnect switch es or circuit breaker s that provide input electrical power to the equipment and opti...

Page 17: ...melter read and comply with the material s MSDS Ensure that the material s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling ventilation first aid...

Page 18: ...the solenoid valve s can result in personal injury HM CA PC WARNING Risk of electrocution Even when switched off and electrically isolated at the disconnect switch or circuit breaker the equipment ma...

Page 19: ...ordson melters are specifically designed to process polyurethane reactive PUR hot melt Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and ca...

Page 20: ...ng handguns by their proper suspension point First Aid If molten hot melt comes in contact with your skin 1 Do NOT attempt to remove the molten hot melt from your skin 2 Immediately soak the affected...

Page 21: ...ain 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...

Page 22: ...Safety 1 12 2014 Nordson Corporation Issued 10 11...

Page 23: ...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 al...

Page 24: ...he 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...

Page 25: ...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...

Page 26: ...ire 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 tempe...

Page 27: ...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...

Page 28: ...and the location of key melter components Figure 2 3 Key components 1 Tank 2 Air filter 3 Hose gun modules 4 Chassis 5 Manifold 6 Sub base 7 Pressure adjustment screw 8 Pressure gauge 9 Pump enclosur...

Page 29: ...2014 Nordson Corporation Figure 2 4 Control panel 1 Fault LED 2 Ready LED 3 Component keys LEDs 4 Right display and scroll keys 5 Function keys 6 Serial port 7 Keypad 8 Left display and scroll key 9 S...

Page 30: ...ions 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 t...

Page 31: ...art 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...

Page 32: ...al 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 in...

Page 33: ...es and guns 7 Set up the melter to work with the manufacturing process 8 Optional Install inputs and outputs 9 Install optional equipment 10 Connect a gun driver pattern controller or timer 11 Flush t...

Page 34: ...llation Clearances Item Description Required Clearance A The distance from the outside edge of a 5 16 inch Nordson hose to the front face of the melter when a short 90 degree hose fitting is used to c...

Page 35: ...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 Me...

Page 36: ...en 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 leng...

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Page 38: ...dix 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 require...

Page 39: ...3 Installation kit components 1 Voltage plug 2 2 Voltage plug with neutral 2 3 Input and Output connector 2 4 Cable clamp 5 Electrical connector 6 NPTF to BSPP adapter 7 Air filter 8 45 degree hose f...

Page 40: ...elt 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 infor...

Page 41: ...amp Tighten the cable clamp CAUTION Before setting the melter down onto the sub base ensure that both locking srews on the front chassis of the melter are turned fully counterclockwise until they stop...

Page 42: ...Installation 3 12 Part 1024496_06 2014 Nordson Corporation Mounting the Melter contd Figure 3 4 Mounting the sub base and the melter...

Page 43: ...ards The maximum power draw for each ProBlue shipping configuration operating at 230 volt in both 1 phase and 3 phase are listed in Table 3 2 The values presented in Table 3 2 assume that each hose gu...

Page 44: ...e NOTE If the power cable cannot be routed through the conduit knockout provided in the sub base Refer to Mounting the Melter earlier in this section route the cable through the optional knockout prov...

Page 45: ...Installation 3 15 Part 1024496_06 2014 Nordson Corporation EXAMPLE ONLY 3 N PE AC wiring shown TB1 PE G Figure 3 5 Connecting the power cable ground lead and ground jumper...

Page 46: ...0 VAC 3 phase 4 wire service including neutral voltage The 230 VAC 1 phase service 2 wire service including a neutral includes the 240 VAC 1 phase 2 wire service including a neutral voltage To connect...

Page 47: ...Installation 3 17 Part 1024496_06 2014 Nordson Corporation Figure 3 6 Connecting a voltage plug...

Page 48: ...ON Rigidly support the plant air supply before connecting it to the air filter 3 Connect a regulated plant air supply to the inlet of the air filter If required use the 1 4 NPTF to G1 4 BSPP male adap...

Page 49: ...Installation 3 19 Part 1024496_06 2014 Nordson Corporation P N 1034145 1 4 NPTF 1 4 BSPP G Figure 3 7 Connecting the air filter and the plant air supply line...

Page 50: ...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 g...

Page 51: ...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 t...

Page 52: ...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...

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Page 54: ...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...

Page 55: ...abled 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 temp...

Page 56: ...onfigure 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 v...

Page 57: ...go to step 5 5 Press the Enter key The right display flashes 6 Use the keypad to enter the desired numeric set point or control option into the right display Refer to Appendix B for information about...

Page 58: ...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 22 Under Tempe...

Page 59: ...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...

Page 60: ...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...

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Page 62: ...int 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...

Page 63: ...eys turn green 3 Press the Enter key The right display flashes 4 Use the numeric keypad to enter the set point temperature recommended by the manufacturer of the hot melt Refer to the technical data s...

Page 64: ...an 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 save...

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Page 66: ...the left display 2 Press the left display scroll key to change the display to parameter 3 the change history log The following occurs If the last change was to an editable parameter all of the compon...

Page 67: ...hen this LED is on And the Fourth Digit Indicates The change was to And the Method of Change was Tank Key 1 The tank Individual Hose Key 1 6 A single hose Individual Gun Key 1 6 A single gun Individua...

Page 68: ...r and Set point Temperature Changes contd Unused log entries in the change history log are indicated by P _ in the right display To view how many heater hours have elapsed since a specific change disp...

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Page 70: ...or 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 c...

Page 71: ...the installation kit Table 3 8 lists the terminal numbers that correspond to each input NOTE Connector P N 277909 is physically keyed to prevent it from being used in place of connector P N 277908 wh...

Page 72: ...Setting Up the Melter earlier in this section for information about how to select operating parameters and edit parameter control options With the exception of the pump enable disable control option...

Page 73: ...33 Same as parameter 31 Default 4 Optional Inputs 5 11 and 12 34 0 Disabled E 6 13 and 14 35 0 Disabled E 7 15 and 16 36 0 Disabled E 8 17 and 18 37 0 Disabled E 9 19 and 20 38 0 Disabled E 10 9 and 1...

Page 74: ...ductor signal cable from the control equipment to the melter through the PG 16 penetration on the floor of the electrical compartment Use rigid or flexible conduit or a suitable strain relief to prote...

Page 75: ...to the melter Table 3 9 lists the available control options Refer to Setting Up the Melter earlier in this section for information about how to select operating parameters and edit parameter control...

Page 76: ...ts 4 1 and 2 43 0 Disabled D 5 3 and 4 44 0 Disabled 6 5 and 6 45 0 Disabled 7 7 and 8 46 0 Disabled NOTE A When control option condition occurs contacts close Contacts are normally open when power is...

Page 77: ...shing 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 tan...

Page 78: ...Installation 3 48 Part 1024496_06 2014 Nordson Corporation...

Page 79: ...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 con...

Page 80: ...y 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...

Page 81: ...w 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 resu...

Page 82: ...s on the heaters the heaters LED turns green Begins to automatically scan through and display the actual temperature of the tank and each hose and gun that has a set point temperature that is greater...

Page 83: ...ce 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...

Page 84: ...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 Heat...

Page 85: ...for information about melter faults and using the seven day clock and standby functions Refer to Appendix B Parameter 4 for information about the ready delay Heated components with a set point temper...

Page 86: ...he left display until it indicates the position number of the specific component you want to check 3 When the position number of the desired component appears in the left display observe the right dis...

Page 87: ...display To check the actual temperature of the tank simultaneously press the Tank key and the left display scroll key The default unit for temperature display is degrees Celsius C This may be changed...

Page 88: ...ay 2 Scroll the left display to parameter 2 the fault log The right display indicates the last fault that occurred as follows If the last fault was an F1 F2 or F3 fault then the LED on the affected co...

Page 89: ...y 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 heate...

Page 90: ...ition persists Internal clock failure F4 4 Internal clock battery backed RAM Heaters remain on but fault condition persists Battery backed RAM failure F4 5 Internal clock battery Heaters remain on but...

Page 91: ...Section 6 Troubleshooting for information about diagnosing and correcting fault conditions NOTE When a fatal F4 fault exists the control switch will not function Remove power to the melter at the loca...

Page 92: ...t key tank hose or gun turns on to indicate the type of component that has or is failing 3 The right display indicates the type of fault F1 F2 or F3 4 The left display indicates as follows the compone...

Page 93: ...t as being fatal or nonfatal The affect on the melter of each of these two classes of F4 faults is Fatal The fault LED turns on and stays on and the melter stops functioning completely Nonfatal The fa...

Page 94: ...e 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...

Page 95: ...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 oper...

Page 96: ...d 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...

Page 97: ...for information about hose gun modules To adjust set point temperatures using the global method 1 Press and hold the Tank key for three seconds The left display flashes 1 2 Scroll the left display to...

Page 98: ...s 3 Press the Enter key The right display flashes 4 Use the keypad to enter the set point temperature recommended by the manufacturer of the hot melt Refer to the technical data sheet provided by the...

Page 99: ...Use the keypad to enter the set point temperature recommended by the manufacturer of the hot melt Refer to the technical data sheet provided by the manufacturer of the hot melt to determine the optim...

Page 100: ...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 componen...

Page 101: ...o 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 numbe...

Page 102: ...4 Press the Enter key One of the following occurs If the password is correct the left display indicates parameter 1 If the password is incorrect the left display remains at 0 and the right display mom...

Page 103: ...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...

Page 104: ...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 pu...

Page 105: ...e 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 st...

Page 106: ...s 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 ti...

Page 107: ...t be used for an extended period of time To shut the melter down 1 Switch the melter off The automatic pressure discharge APD valve relieves the hydraulic pressure in the manifold back to the tank 2 D...

Page 108: ...Operation 4 30 Part 1024496_06 2014 Nordson Corporation...

Page 109: ...Section 6 Troubleshooting for information about diagnosing common problems and performing corrective maintenance Table 5 1 Preventive Maintenance Tasks Task Frequency Reference Relieving system press...

Page 110: ...clockwise three turns 4 Turn the drain valve clockwise until it stops valve closed and then wipe off and raise the drain chute 5 Trigger the guns until hot melt no longer flows from the guns Locking O...

Page 111: ...Maintenance 5 3 Part 1024496_06 2014 Nordson Corporation Figure 5 1 Lowering the drain chute and opening the drain valve...

Page 112: ...rsonal 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...

Page 113: ...1024496_06 2014 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 Figure 5 2 Removing...

Page 114: ...placed 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 o...

Page 115: ...Relieve the system pressure Refer to Relieving System Pressure at the beginning of this section 2 Use a 8 mm hex wrench or an adjustable wrench to loosen counterclockwise and then remove the filter 3...

Page 116: ...chnical data sheet is not available contact the hot melt supplier To clean the tank when changing hot melt 1 Operate the melter normally until the tank is empty 2 Allow the melter to heat or cool to t...

Page 117: ...k See Figure 5 1 2 Lower the drain chute and place a suitable waste container under the drain valve 3 Press the Pump key to start the pump 4 Using a flat tip screwdriver slowly turn the drain valve co...

Page 118: ...melter off 2 Relieve system pressure Refer to Relieving System Pressure earlier in this section 3 Disconnect the hoses See Figure 3 5 4 Disconnect the power cable and ground lead See Figure 3 4 5 Tur...

Page 119: ...hnical 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 48...

Page 120: ...drop in ambient temperature Raise the set point temperature of the component Replace RTD See flowchart T 2 F3 None Over temperature Heaters turn off The actual temperature of the component indicated...

Page 121: ...4 8 Main board feedback Melter stops functioning Communication failure between main board and CPU Replace main board ribbon cable or CPU F4 A Thermostat Melter stops functioning Tank or manifold therm...

Page 122: ...ete 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 opp...

Page 123: ...able 6 2 Main PCA Item Number Type Description Indicators DS1 LED Yellow Control signal for tank heater DS2 Neon Orange Power available for tank and manifold heaters after fuses F1 F2 DS3 LED Yellow C...

Page 124: ...Power Module Item Number Type Description Indicators DS1 LED Yellow Control power present for odd numbered hose DS2 LED Yellow Control power present for odd numbered gun DS3 LED Yellow Control power p...

Page 125: ...Troubleshooting 6 7 Part 1024496_06 2014 Nordson Corporation Figure 6 1 Electrical components...

Page 126: ...Troubleshooting 6 8 Part 1024496_06 2014 Nordson Corporation Figure 6 2 Power and control harness...

Page 127: ...Troubleshooting 6 9 Part 1024496_06 2014 Nordson Corporation Figure 6 3 Location of the return port...

Page 128: ...Troubleshooting 6 10 Part 1024496_06 2014 Nordson Corporation 1 2 3 Figure 6 4 Pneumatic flow diagram 1 Pump air inlet 2 Pressure discharge valve 3 Melter air supply inlet...

Page 129: ...hose gun modules 4 Re energize the melter 5 Check LED DS5 on the main board and then do one of the following If DS5 does not illuminate replace the main board P4 or P7 melters use P N 1028322 P10 melt...

Page 130: ...For the tank RTD refer to Remove the Tank RTD For the manifold RTD refer to Remove the Manifold RTD 4 Allow the RTD to cool to room temperature or use a pyrometer to accurately determine the temperatu...

Page 131: ...h off WARNING Risk of electrocution The control switch will remain in the on position when the melter automatically switches off after 20 minutes Ensure that the control switch is moved back to the of...

Page 132: ...manifold NOTE The face of the pump body contains two M6 threaded holes Bolts can be threaded into these holes to gain leverage when removing the pump 5 Remove the air line from the back of the pump 6...

Page 133: ...S2 does illuminate go to step 6 If indicator DS2 does not illuminate got to step 7 6 Locate a failed hose gun module by individually replacing and checking each module as follows a De energize the mel...

Page 134: ...nent is faulting 3 Re energize the melter and turn the heaters back on 4 Press the Heaters key 5 While watching LEDs DS1 and DS3 on the main board measure the voltage across the heater terminals as fo...

Page 135: ...e shown in Table 6 6 go to step 8 NOTE Refer to Appendix E for 400 480 Volt heater resistance data Table 6 6 Heater Resistance Resistance Model Tank Manifold P4 46 58 ohms 46 58 ohms P7 40 50 ohms P10...

Page 136: ...e is less than 1 Meg ohm for the tank heater replace the tank If the resistance is less than 1 Meg ohm for the manifold replace the manifold heater Refer to Section 7 Parts 8 Remove the front and rear...

Page 137: ...06 2014 Nordson Corporation 250 240 230 220 210 200 190 180 170 160 150 140 130 RESISTANCE IN OHMS 250 240 230 220 210 200 190 180 170 290 280 270 260 RESISTANCE IN OHMS TEMPERATURE TEMPERATURE Figure...

Page 138: ...Troubleshooting 6 20 Part 1024496_06 2014 Nordson Corporation Figure 6 6 Removing the pump...

Page 139: ...hat is connected to terminal J7 on the main board loose or damaged Turn the control switch off secure or replace the harness and then turn the control switch back on Is the fault LED illuminated Has g...

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Page 141: ...ed See Figure 6 1 Are the voltage plugs attached securely to J1 and J2 on the main board See Figure 6 1 Is there power at the disconnect switch Are the wires to the electrical connector into TB1 secur...

Page 142: ...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...

Page 143: ...e Figure 6 1 Is the red CPU warning LED illuminated See Figure 6 1 Replace the CPU board P N 1028325 Replace the main board assembly P4 P7 P N 1028322 P10 P N 1028323 Contact Nordson for technical ass...

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Page 145: ...perature fault indicated in the right display Is an F3 over temperature fault indicated in the right display See Table 6 1 Does replacing the component s listed under the respective fault code and the...

Page 146: ...ning properly J5 to J1 Are all of the gun to hose and hose to melter electrical cordsets securely connected The gun or hose key LED is illuminated Does the fault re occur if you move the faulting hose...

Page 147: ...point temperature Secure or repair the loose cordset then press the Reset key Refer to the hose or gun manual Is the affected gun or hose cordset loose or are the pins bent loose or corroded the gun o...

Page 148: ...e the hose or gun RTD Replace the affected hose gun module P N 1028328 Replace fuse pairs F1 F2 or F3 F4 on the affected hose gun module P N 1028331 See Figure 6 1 Is indicator DS2 on the main board o...

Page 149: ...ure of the faulting component Replace the main board P4 P7 P N 1028322 P10 P N 1028323 Is the tank key LED illuminated Are the tank manifold TRIACs operating properly Refer to DP 4 Replace the tank ma...

Page 150: ...the fault P N 332182 Is there a DC drive near the melter Stop Is the resistance between the ground leg and earth ground on the power cable greater than zero Is the power cable grounded to the melter...

Page 151: ...the downstream side of fuses F1 F2 or F3 F4 on the main board between 170 and 265 VAC See Figure 6 1 Connect securely Check correct the house voltage Does replacing fuses F1 and F2 on the main board a...

Page 152: ...replacing the malfunctioning tank or manifold RTD solve the problem P N 1028320 Refer to DP 2 Stop Replace the main board P4 P7 P N 1028322 P 10 P N 1028323 Replace the manifold heater tank or the pow...

Page 153: ...ff Is a remote input being used to control the heaters Replace the operator panel P4 P7 P N 1028326 P10 P N 1028327 Does pressing the heater key turn the heaters on Stop Go to T 3 1 Cont on next page...

Page 154: ...y 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 4 Confirm that the tank heater has fai...

Page 155: ...e the heater key to manually turn the heaters on Reprogram the input Is there power across the wires from the parent machine to the inputs on the main board or I O board Is there a signal at the paren...

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Page 157: ...the leak Is hot melt leaking from the system somewhere between the manifold and the guns Adjust the air pressure The pump piston ball valve is stuck open Refer to Appendix D Continued on next page Go...

Page 158: ...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 dis...

Page 159: ...Stop Does replacing the operator s panel and then restarting the melter correct the problem P4 P7 P N 1028326 P10 P N 1028327 Replace the CPU board P N 1028325 Go to T 4 2 Continued on next page Start...

Page 160: ...nated No hot melt output from all guns Pump has stopped T 4 1 Are the inputs properly functioning Refer to table T 3 1 for diagnostic procedures Is the power LED on the I O board illuminated Wait for...

Page 161: ...harness lack continuity Connect securely See Figure 6 2 Replace the J7 wire harness P N 1024600 Connect securely Replace the main board P4 P7 P N 1028322 P10 P N 028323 Is the air supply to the melte...

Page 162: ...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 Does adhesive flow from the drain valve when it is open Cl...

Page 163: ...supply to the gun functioning properly Adjust the set point temperature WARNING Relieve system pressure before continuing Is the gun nozzle or an inline Saturn filter blocked Clean the nozzle or repl...

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Page 165: ...e 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 su...

Page 166: ...Parts 7 2 Part 1024496_06 2014 Nordson Corporation Tank Pump and Manifold Parts List Figure 7 1 Tanks pump and manifold...

Page 167: ...ning RTD 1 9 1017186 Tube cross over tank 1 10 941161 O ring Viton 0 750 x 0 938 x 0 094 in 2 11 1017189 Tube cross over pump 1 12 940133 O ring Viton 0 426 x 0 070 in 2 13 P4 1022747 Screen inlet pum...

Page 168: ...Parts 7 4 Part 1024496_06 2014 Nordson Corporation Manifold Assembly Parts List 3 1 2 4 Figure 7 2 Manifold assembly...

Page 169: ...ANIFOLD 6 H W HTR BLOCK 230V PB 1 A 1064652 SVC KIT MANIFOLD 4 H W HTR BLOCK 480V PB 1 A 1064654 SVC KIT MANIFOLD 6 H W HTR BLOCK 480V PB 1 A 2 942111 O RING VITON 812X1 062X 125 1 3 1019515 ORING VIT...

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Page 171: ...s 3 SEE SECTION D D 40 1 2 5 4 TIGHTEN TO 25 31 IN LBS OF TORQUE 22 40 40 32 TIGHTEN TO SECTION A A SCALE 1 1 14 15 35 39 21 17 18 28 30 20 40 19 40 24 29 41 5 31 39 32 34 39 39 TIGHTEN TO 100 110 IN...

Page 172: ...Parts 7 8 Part 1024496_06 2014 Nordson Corporation 15 1 Pump Assembly Parts contd 38 48 D D A A 36 37 40 16 16 40 Figure 7 4 15 1 double acting pump 2 of 2...

Page 173: ...VALVE ASSY DRAIN 1 22 1022779 CHUTE DRAIN ASSY 1 23 982780 SCR SKT M5X10 ZN 2 24 1021955 ADAPTER FILTER ASSY 1 27 1021919 FILTER ASSEMBLY 100 MESH W O RING 1 NS 945039 O RING VITON 3 4 TUBE 10456 1 D...

Page 174: ...37 O RING VITON 1 TUBE 1 21 276024 VALVE ASSY DRAIN 1 22 1022779 CHUTE DRAIN ASSY 1 23 982780 SCR SKT M5X10 ZN 2 24 1021955 ADAPTER FILTER ASSY 1 27 1021919 FILTER ASSEMBLY 100 MESH W O RING 1 NS 9450...

Page 175: ...15 35 19 17 22 21 28 30 18 20 40 40 24 5 29 5 39 31 34 39 39 100 110 IN LBS OF TORQUE 60 75 IN LBS TIGHTEN TO 25 31 IN LBS OF TORQUE 32 TIGHTEN TO 23 27 16 40 E B C F SCALE 2 1 DETAIL C 10 9 11 SCALE...

Page 176: ...Parts 7 12 Part 1024496_06 2014 Nordson Corporation 15 1 Low Viscosity Pump Assembly Parts contd 38 48 D D A A 36 37 40 16 16 40 Figure 7 6 15 1 low viscosity double acting pump parts 2 of 2...

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Page 178: ...CAGE BALL SIPHON 1 18 900001 BALL 440SSTL 500 50 1 19 1017320 SEAT BALL LOWER 1 20 945037 O RING VITON 1 TUBE 1 21 276024 VALVE ASSY DRAIN 1 22 1022779 CHUTE DRAIN ASSY 1 23 982780 SCR SKT M5X10 ZN 2...

Page 179: ...P N 1028305 E See Figure 7 10 for exploded view AR As Required SEE SECTION D D 40 1 2 4 TIGHTEN TO 25 31 IN LBS OF TORQUE TIGHTEN TO 40 16 40 SCALE 1 1 SECTION A A 32 14 15 27 35 21 42 17 18 28 30 22...

Page 180: ...Parts 7 16 Part 1024496_06 2014 Nordson Corporation 6 1 Pump Assembly Parts contd 38 48 D D A A 36 37 40 16 16 40 Figure 7 8 6 1 double acting pump 2 of 2...

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Page 182: ...Parts 7 18 Part 1024496_06 2014 Nordson Corporation Pump Shifter Assembly Parts Figure 7 9 Pump shifter assembly standard double acting pump...

Page 183: ...VE ASSY SP 1 3 1021998 MANIFOLD AIR G1 8 PORT PUMP 1 4 333560 SPRING WAVE INCONEL SP PUMP 1 5 155057 DETENT UPPER SP 1 6 982059 SCR SKT M4X8 BL 2 7 164606 SERVICE KIT ACTUATOR MAGNETIC ASSY SP 1 A 8 1...

Page 184: ...mbly 15 1 and 6 1 double acting pumps Item Part Description Quantity Note 1022658 PISTON ASSY HYDRAULIC PROBLUE 1 1017229 PISTON PUMP 15 1 1 2 985302 PIN ROLL 125X 500 STL ZN 1 3 900000 BALL 440SSTL 3...

Page 185: ...5 1 low viscosity double acting pump Item Part Description Quantity Note 1073918 PISTON ASSY HYDRAULIC LV PROBLUE 1 1017229 PISTON PUMP 15 1 1 2 985302 PIN ROLL 125X 500 STL ZN 1 3 900000 BALL 440SSTL...

Page 186: ...Parts 7 22 Part 1024496_06 2014 Nordson Corporation Pneumatic Components Parts List 2 3 4 5 6 7 8 1 Figure 7 12 Pneumatic components...

Page 187: ...55 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...

Page 188: ...Parts 7 24 Part 1024496_06 2014 Nordson Corporation Electrical Enclosure Parts List Figure 7 13 Electrical enclosure...

Page 189: ...9649 Frame machined upper keyed 1 7 P4 P7 1020572 Panel divider P4 P7 1 P10 1025470 Panel divider P10 1 8 1017896 Hinge assembly 2 9 Printed circuit assembly display CPU 1 B 10 P4 P7 Panel assembly fr...

Page 190: ...Parts 7 26 Part 1024496_06 2014 Nordson Corporation Exterior Panels Parts List Figure 7 14 Exterior panels...

Page 191: ...mbly end P4 1 P7 1025591 Panel assembly end P7 1 P10 1028495 Panel assembly end P10 1 5 P4 1022948 Panel assembly front P4 1 P7 1025594 Panel assembly front P7 1 P10 1028494 Panel assembly front P10 1...

Page 192: ...Parts 7 28 Part 1024496_06 2014 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 Figure 7 15 Chassis components...

Page 193: ...1 P7 1025642 Bracket panel rear P7 1 P10 1028525 Bracket panel rear P10 1 9 1017603 Spacer bottom tank 4 10 P4 1021660 Chassis P4 1 P7 P10 1018822 Chassis P7 P10 1 11 1024525 Tray drip manifold 1 12...

Page 194: ...ion Ribbon Cable Parts List Figure 7 16 Ribbon cables Item Used Part Description Quantity Note 1 1018283 Cable assembly ribbon main 1 2 1018284 Cable assembly serial port 1 A NOTE A Included in servic...

Page 195: ...4 50 1 15 1 Low Viscosity Pump Replacement Part Description Quantity 1073930 KIT SERVICE PUMP ASSY LOW VISCOSITY 15 1 PUMP ASSY LOW VISCOSITY 1 ORING VITON 50 X 75 X 125 1 O RING VITON 812X1 062X 125...

Page 196: ...aining ring internal 100 push on 1 1064157 NUT HEX LOCK TORQUE M6X1 DIN 980V V3 1 982147 Screw hex cap M6 x 120 4 982237 Screw hex cap M6 x 35 4 983410 Washer flat M6 8 940172 O ring Viton 0 676 x 0 0...

Page 197: ...Viton 0 625 x 0 875 in 1 942111 O ring Viton 0 812 x 0 062 x 0 125 in 1 O ring Viton 0 750 x 0 938 x 0 094 in 2 Lubricant Parker 1 2 oz 1 RTD Part Description Quantity 1028320 Kit service RTD P4 P7 P1...

Page 198: ...art Description Quantity P4 P7 1028326 Kit service operator s panel enclosure P4 P7 P10 1028327 Kit service operator s panel enclosure P10 Panel assembly front electrical enclosure 1 Hose Gun Module P...

Page 199: ...board P4 P7 P10 1 1028331 Kit service fuse hose gun module P4 P7 P10 1 Expanded Spare Parts Part Description Quantity 1028333 Kit basic expanded parts P4 P7 P10 1028305 Filter Saturn melter 100 mesh...

Page 200: ...Screw socket head M5 x 20 3 Vent Guard P10 Part Description Quantity 1048884 Guard kit assembly vent screen P10 Guard screen pump cover P10 1 Reference drawing guard kit vent screen P10 1 Replacement...

Page 201: ...LK M SPT M5 STL ZN 5 ORING VITON 50 X 75 X 125 2 O RING VITON 812X1 062X 125 1 O RING VITON 50 DURO 116 750X 938X 094 2 O RING VITON 426ID X 070W BR 10413 2 INST MANIFOLD HEATER SERVICE KIT 1 Heater B...

Page 202: ...Quantity 1036607 Kit I O expansion card PCA optional I O 1 Terminal block connector 10 position 1 10 1 Terminal block connector 10 position 11 20 1 Screw machine pan head M3 x 6 8 Fill Master Part De...

Page 203: ...YBUS S DEVICENET 17MM PINS 1 MACH SCRM PAN REC M3X6 SEMS 3 Profibus Card Part Description Quantity 1053300 KIT PROFIBUS CARD PCA ANYBUS S PROFIBUS 17MM PINS 1 MACH SCRM PAN REC M3X6 SEMS 3 P10 8 H G E...

Page 204: ...9 Screw socket M5 x 10 F10 Nut hex 10 32 F11 Washer flat 10 F12 Washer flat M5 F13 Washer flat oversized M5 F14 Screw socket M5 x 50 F15 Nut hex M6 F16 Screw socket M4 x 10 F17 Nut hex M8 F18 Washer l...

Page 205: ...ght of 1 5 kva transformer 400 480 VAC melters only 18 kg 40 lb Hose ports 4 to 6 A Melt rate P4 4 3 kg hr 9 5 lb hr P7 8 2 kg hr 18 lb hr P10 11 kg hr 24 lb hr Noise 64dB A at maximum pump speed B Wo...

Page 206: ...int at RTD Pump Specifications Item Data Air pressure while running 70 to 689 kPa 10 to 100 psi Minimum air pressure 0 7 bar 10 psi Viscosity range 800 to 10 000 cps Maximum hydraulic pressure 15 1 pu...

Page 207: ...Technical Data 8 3 Part 1024496_06 2014 Nordson Corporation Dimensions P4 Melter Figure 8 1 P4 Melter dimensions...

Page 208: ...Technical Data 8 4 Part 1024496_06 2014 Nordson Corporation P7 Melter Figure 8 2 P7 Melter dimensions...

Page 209: ...Technical Data 8 5 Part 1024496_06 2014 Nordson Corporation P10 Melter Figure 8 3 P10 Melter dimensions...

Page 210: ...8 6 Part 1024496_06 2014 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 Figure 8 4 Sub b...

Page 211: ...Technical Data 8 7 Part 1024496_06 2014 Nordson Corporation Wiring Diagrams 200 240 VAC Melter See next eight pages NOTE For 400 480 Volt melters refer to Appendix E...

Page 212: ...Technical Data 8 8 Part 1024496_06 2014 Nordson Corporation...

Page 213: ...Technical Data 8 9 Part 1024496_06 2014 Nordson Corporation...

Page 214: ...Technical Data 8 10 Part 1024496_06 2014 Nordson Corporation...

Page 215: ...Technical Data 8 11 Part 1024496_06 2014 Nordson Corporation...

Page 216: ...Technical Data 8 12 Part 1024496_06 2014 Nordson Corporation...

Page 217: ...Technical Data 8 13 Part 1024496_06 2014 Nordson Corporation...

Page 218: ...Technical Data 8 14 Part 1024496_06 2014 Nordson Corporation...

Page 219: ...Technical Data 8 15 Part 1024496_06 2014 Nordson Corporation...

Page 220: ...Technical Data 8 16 Part 1024496_06 2014 Nordson Corporation...

Page 221: ...lowing three maximum wattages must be considered when calculating the power required by the hoses and guns Single component maximum The wattage of any single hose or gun Hose gun pair maximum The watt...

Page 222: ...tal wattage for each hose gun module 4 Compare the wattages tabulated in Table A 1 with the associated maximum allowable wattages listed in Table A 2 5 Do one of the following If each of the wattages...

Page 223: ...wattage of hose gun module 1 Hose Gun Module 2 Hose 3 Gun 3 Hose 4 Gun 4 Total wattage of hose gun module 2 Hose Gun Module 3 Hose 5 Gun 5 Hose 6 Gun 6 Total wattage of hose gun module 3 Table A 2 Ma...

Page 224: ...Calculating Melter Power Requirements A 4 Part 1024496_06 2014 Nordson Corporation...

Page 225: ...tion 3 Installation Setting Up the Melter NOTE Parameter numbers that are reserved or that are not used do not appear in this appendix Table B 1 Parameter Groups Group Parameter s Description Standard...

Page 226: ...hat the heaters have been on Value 999 999 using abbreviated convention described below Resolution 1 hour Default Value 0 Format Use The right display indicates up to 9999 hours of heater operation Wh...

Page 227: ...e begins when all components are within 3 C 5 F of their respective set point temperature Value 0 to 60 minutes Resolution 1 minute Default Value 0 minutes Format Left display rd Right display minutes...

Page 228: ...rmat Use If Automatic Pump On is disabled you must press the pump key to turn the pump on 9 Automatic Pump On Temperature Description Sets the temperature at which the pump will automatically turn on...

Page 229: ...anges to operating parameters or set point temperatures Value 0 to 9999 Resolution 1 Default Value 5000 Format Use Refer to Section 4 Operation Enter the Melter Password NOTE When the password is crea...

Page 230: ...of degrees that the temperature of any component can increase over its assigned set point temperature before an over temperature fault F3 will occur Value 5 C 10 F to 60 C 110 F Resolution 1 C 1 F Def...

Page 231: ...nction Keys NOTE The standby delta does not affect the under temperature delta parameter 22 24 Automatic Standby Timeout Description The amount of time that must elapse after the last signal gun drive...

Page 232: ...ime Description The amount of time that the melter will remain in the standby mode after the standby key is pressed Value 0 to 180 minutes Resolution 1 minute Default Value 0 Format Use Set the standb...

Page 233: ...nsidered inactive off until all of the inputs with the same input value are de energized Multiple inputs set to the same input value are logical ORed 31 Standard Input 2 Description Control options th...

Page 234: ...d inactive off until all of the inputs with the same input value are de energized Multiple inputs set to the same input value are logical ORed 33 Standard Input 4 Description Control options that dete...

Page 235: ...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...

Page 236: ...ation Monitor Melter Faults for information about fault monitoring 43 46 Optional Outputs 4 5 6 and 7 Description Control options that determine the function of the four optional outputs provided when...

Page 237: ...Operating Parameters B 13 Part 1024496_06 2014 Nordson Corporation This page intentionally left blank...

Page 238: ...e standby mode 4 Using parameters 60 through 68 create schedules 2 and 3 by repeating step 3 5 Use parameters 71 through 77 to assign which of the four schedules should be used on each day of the week...

Page 239: ...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...

Page 240: ...once for all daily schedules 55 Schedule 1 Heaters On Description Used to set the time that the clock will turn on the heaters during schedule 1 Value 0000 to 2359 Resolution 1 minute Default Value 0...

Page 241: ...the time that the melter will exit the standby mode during schedule 1 Value 0000 to 2359 Resolution 1 minute Default Value Format Hour Hour Minute Minute Use Set the time that the melter will exit the...

Page 242: ...dby mode during schedule 2 To disable this parameter set the parameter s value to by simultaneously pressing both of the right display scroll keys Note Do not set an enter standby time that is outside...

Page 243: ...Value Format Hours Hour Minute Minute Use Set the desired time for the heaters to turn off To disable this parameter set the parameter s value to by simultaneously pressing both of the right display s...

Page 244: ...eys Note Do not set an exit standby time that is outside of the time period defined by the schedule s heater on and off time The melter cannot enter the standby mode when the heaters are off 71 Schedu...

Page 245: ...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...

Page 246: ...schedule s for the day NOTES If the 0 schedule option is used the heaters will not turn on again until the next scheduled heaters on time arrives 75 Schedules for Friday Description Used to select wh...

Page 247: ...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 schedul...

Page 248: ...Operating Parameters B 24 Part 1024496_06 2014 Nordson Corporation...

Page 249: ...ad it from the internet by navigating to www enordson com support If you do not have a connection to the internet you can request a software CD from your Nordson representative System Requirements The...

Page 250: ...on com onto a PC that can not be connected to the melter but the PC does have a CD RW and the PC that is connected to the melter does have a CD drive OR You have a CD with the software and you have a...

Page 251: ...and then locate and double click on the file Setup exe The Blue Series Software Setup wizard appears 2 Click Next and then follow the on screen instructions If you are installing from the span disk se...

Page 252: ...settings files that you have saved using the NCM Settings files ncm extension are stored in your Windows My Documents folder NOTE Windows XP 2000 and NT users must have administrator rights in order...

Page 253: ...rt Melter Communications C 5 Part 1024496_06 2014 Nordson Corporation Connecting the PC and the Melter Connect a serial cable between the PC COM port selected during the software installation routine...

Page 254: ...estoring settings or upgrading the melter s firmware The first time you download and install Configuration Manager the latest version of the melter s firmware is also downloaded Saving and Restoring M...

Page 255: ...group of settings you are saving and then click Save The save settings progress bar indicates the status of the save When the save is complete the melter automatically returns to the scan mode NOTE I...

Page 256: ...an use the NCM to restore the pre upgrade settings CAUTION The upgrade process returns the melter s settings to factory configuration with the exception that current heater hours data is saved Data in...

Page 257: ...appears The upgrade can take as long as 12 minutes When the upgrade is complete the Success dialog box appears and the melter restarts CAUTION Once the uprade progress bar appears do not interrupt th...

Page 258: ...ick Connect The Select COM Port dialog box appears 3 Select the COM port you are using to connect to the melter and then click Ok The PC and melter establish communications and a picture of the melter...

Page 259: ...Ad Cycle power to the melter at the local power disconnect switch CAUTION Ensure that the firmware update process is not running before taking power off of the melter UPLOAd does not appear on the mel...

Page 260: ...Melter Communications C 12 Part 1024496_06 2014 Nordson Corporation...

Page 261: ...se be mistaken for a failure of the pump Refer to Section 6 Troubleshooting NOTE The procedures and illustrations in this section are specific to 15 1 pumps but can be used for 6 1 pumps as well Refer...

Page 262: ...magnet at the end of the actuator which shifts the position of the air valve When the valve shifts air is redirected to the opposite side of the air cylinder which forces the piston downwards On the p...

Page 263: ...SP Pump Diagnostics and Repair D 3 Part 1024496_06 2014 Nordson Corporation This page intentionally left blank...

Page 264: ...fully disassemble the pump To assist you in determining the appropriate level of disassembly Table D 1 provides a logical breakdown of the three types of pump failures the potential conditions that co...

Page 265: ...k Magnets on actuator assembly loose Remove the Magnetic Actuator Assembly Piston damaged or has char buildup Remove the Lower Ball Seat Assembly and the Piston 2 Pump Leaking Adhesive O ring and or p...

Page 266: ...bers Melter Preparation The melter must be brought up to operating temperature before the pump can be removed and disassembled Once the pump is removed the molten material within the pump will remain...

Page 267: ...lists in Section 7 Parts for a complete listing of pump related parts Supplies The following table described the lubricants and other compounds that are required during the re assembly of the pump Lub...

Page 268: ...face of the pump body contains two M6 threaded holes Bolts can be threaded into these holes to gain leverage when removing the pump 5 Remove the air line from the back of the pump 6 Lift the pump clea...

Page 269: ...SP Pump Diagnostics and Repair D 9 Part 1024496_06 2014 Nordson Corporation Figure D 1 Removing the pump...

Page 270: ...hifter fork assembly 6 3 Remove the two O rings 8 Check Repair O rings P N 940332 Inspect for nicks gouging or swelling Apply Parker lubricant during reassembly Special Reassembly Instructions Slide t...

Page 271: ...Repair D 11 Part 1024496_06 2014 Nordson Corporation 1 2 3 4 5 6 7 5 6 N m 45 55 in lb 8 Figure D 2 1 M6 screw 4 2 M6 washer 4 3 Cylinder head 4 Cylinder 5 Can 6 Shifter fork assembly 7 Piston cup se...

Page 272: ...ilar tool into the tool hole to prevent the actuator from rotating 4 With the actuator assembly held in position with the 1 8 in steel rod tool remove the valve spool nut 1 and then remove the bumper...

Page 273: ...ir D 13 Part 1024496_06 2014 Nordson Corporation 1 2 3 3 4 N m 28 36 in lb Figure D 3 1 Actuator assembly 2 Can 3 M5 screw 2 1 2 3 4 9 11 N m 81 99 in lb Figure D 4 1 Valve spool nut 2 Bumper assembly...

Page 274: ...SP Pump Diagnostics and Repair D 14 Part 1024496_06 2014 Nordson Corporation Remove the Magnetic Actuator Assembly contd 1 2 9 11 N m 81 99 in lb Figure D 5 1 Wrench flats 2 Actuator assembly...

Page 275: ...e exchanged with parts from another air valve assembly If either the spool or sleeve is damaged they must be replaced with a new valve assembly CAUTION Do not scrape the valve spool or sleeve Clean th...

Page 276: ...orporation Special Reassembly Instructions Use the flange to press the sleeve back into the air manifold Apply only one drop of lubricating oil to each spool land Ensure that the valve spool slides fr...

Page 277: ...7 Part 1024496_06 2014 Nordson Corporation 1 2 3 4 5 6 3 2 4 1 N m 28 36 in lb 1 82 2 27 N m 16 20 in lb Figure D 7 1 Flange 2 M5 screws 2 3 Air manifold 4 Spring 5 M4 screws 6 Upper detent 1 2 Figure...

Page 278: ...the shifter fork 3 2 Remove the shifter fork from the piston by sliding the fork up to the narrowest point on the piston Check Repair Shifter fork assembly P N 166880 Word UP is facing upwards Secure...

Page 279: ...SP Pump Diagnostics and Repair D 19 Part 1024496_06 2014 Nordson Corporation 1 2 3 4 7 8 5 N m 60 70 in lb Figure D 9 1 Washer 2 Hex head screw 3 Shifter fork assembly 4 Piston shoulder...

Page 280: ...epair Piston cups P N 163039 Not torn or deteriorated Pliable Apply Parker lubricant during reassembly Special Reassembly Instructions To prevent damage to the upper piston cup when reinstalling the c...

Page 281: ...SP Pump Diagnostics and Repair D 21 Part 1024496_06 2014 Nordson Corporation 1 2 3 2 4 11 3 13 6 N m 100 120 in lb Figure D 10 1 Torque nut 2 Piston cup washer 2 3 Piston seal washer 4 Piston cup 2...

Page 282: ...Repair Pump insulator P N 1017307 Cracked or warped U cup piston seal P N 952100 Nicked cut or deteriorated Apply Parker lubricant during reassembly Special Reassembly Instructions Before reinstallin...

Page 283: ...SP Pump Diagnostics and Repair D 23 Part 1024496_06 2014 Nordson Corporation 1 2 3 4 3 3 5 N m 25 31 in lb Figure D 11 1 Hex head screw 4 2 Pump frame 3 Insulator 4 Washers 4...

Page 284: ...SP Pump Diagnostics and Repair D 24 Part 1024496_06 2014 Nordson Corporation Remove the Pump Frame and the Insulator contd 1 2 Figure D 12 1 Retaining ring 2 U cup...

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Page 286: ...13 1 Unscrew the lower ball seat assembly 2 from the pump body 2 Pull the piston 1 out of the bottom of the pump body Check Repair Pump body P N 1016863 Remove solidified adhesive before reassembly Pi...

Page 287: ...SP Pump Diagnostics and Repair D 27 Part 1024496_06 2014 Nordson Corporation 1 2 Figure D 13 1 Piston 2 Lower ball seat assembly...

Page 288: ...all 2 Check Repair Siphon ball P N 900001 Pressure ball P N 900000 Char buildup Ball seats P N 1017320 Char buildup or damage Apply Never seez during reassembly Siphon ball cage P N 503696 Char buildu...

Page 289: ...Repair D 29 Part 1024496_06 2014 Nordson Corporation 1 2 3 4 Figure D 14 1 Siphon ball cage 2 Siphon ball 3 O ring 4 Lower ball seat 1 2 3 5 6 6 78 N m 50 60 in lb Figure D 15 1 Piston 2 Pressure bal...

Page 290: ...Apply Parker lubricant during reassembly Pump Seal P N 273139 Nicked cut deteriorated or deformed Apply Parker lubricant during reassembly Special Reassembly Instructions The O ring and the pump seal...

Page 291: ...SP Pump Diagnostics and Repair D 31 Part 1024496_06 2014 Nordson Corporation This page intentionally left blank...

Page 292: ...and Repair D 32 Part 1024496_06 2014 Nordson Corporation Pump Assembly Parts List 1 2 3 4 5 6 7 8 9 11 24 12 10 13 14 16 19 17 18 21 20 36 37 35 33 34 32 30 29 28 15 31 27 26 25 23 22 F6 F1 F2 F4 F2...

Page 293: ...al 100 push on 1 14 952100 Cup U Viton 1 15 166880 Service kit fork magnetic 1 16 1017320 Seat ball lower 1 17 900001 Ball 440 stainless steel 0 500 in 1 18 503696 Cage ball siphon 1 19 945037 O ring...

Page 294: ...1 984092 Nut hex lock torque M6 1 982147 Screw hex cap M6 x 120 4 982237 Screw hex cap M6 x 35 4 983410 Washer flat M6 8 940172 O ring Viton 0 676 x 0 070 1 Lubrication Parker 1 2 oz 1 940261 O ring V...

Page 295: ...the equipment This appendix provides information about the 400 480 volt versions of the ProBlue adhesive melter Key information provided in this appendix which does not appear in the body of this man...

Page 296: ...mation provided in Section 1 Safety Intended Use The 1 5 kVA and 3 0 kVA transformers can only be used with ProBlue adhesive melters that are specifically designed for 400 480 volt electrical service...

Page 297: ...E 1 lists the wattages of common hoses and guns that are sold by Nordson Corporation If your hose or gun is not listed in Table E 1 refer to the identification tag that is affixed to the hose gun 2 C...

Page 298: ...uto hose 3 m 10 ft 287 Auto hose 3 6 m 12 ft 345 Auto hose 4 8 m 16 ft 463 Auto hose 7 2 m 24 ft 698 Manual hose 2 4 m 8 ft 228 Manual hose 4 8 m 16 ft 463 Guns H 201 or 401 T or T L 140 H 202 or 402...

Page 299: ...e harness The melter s CPU controls the duty cycle of the heaters No change in melter programming is required in order for the transformer to operate The transformer s reduces the input electrical ser...

Page 300: ...and front views shown Table E 2 Installation Clearances Item Description Required Clearance A The distance from the outside edge of a 5 16 inch Nordson hose to the front face of the melter when a shor...

Page 301: ...llowing components are shipped with the transformer NOTE These components are in addition to the components that are provided in the melter installation kit Figure E 2 Installation Kit 1 Voltage plug...

Page 302: ...isconnect the ground lead from the sub base 3 Turn both locking screws counter clockwise until they stop 4 Remove the transformer from the sub base by pulling the transformer forward approximately 1 2...

Page 303: ...400 480 Volt ProBlue Adhesive Melters E 9 Part 1024496_06 2014 Nordson Corporation Figure E 4 Installing the voltage plug...

Page 304: ...dy configured for mounting either a model 3100V or a model 3400V adhesive melter To mount the transformer See Figure E 5 1 Attach the sub base to the parent machine using four 8 mm 5 16 inch bolts wit...

Page 305: ...400 480 Volt ProBlue Adhesive Melters E 11 Part 1024496_06 2014 Nordson Corporation Figure E 5 Mounting the sub base and the transformer...

Page 306: ...er source Failure to de energize the melter when required can result in personal injury including death WARNING Risk of electrical shock or short circuit Use rigid or flexible conduit or an appropriat...

Page 307: ...400 480 Volt ProBlue Adhesive Melters E 13 Part 1024496_06 2014 Nordson Corporation Figure E 6 Connecting the electrical service 1 Terminal block 2 Ground lug 3 Sub base ground post...

Page 308: ...rmer wire harnesses are not pinched between the transformer and the melter 2 Set the melter down onto the transformer so that the four tabs on the transformer enter the slots in the base of the melter...

Page 309: ...400 480 Volt ProBlue Adhesive Melters E 15 Part 1024496_06 2014 Nordson Corporation Figure E 8 Connecting the melter ground lead to the transformer chassis...

Page 310: ...ain board 3 Connect the control harness to terminal J9 on the melter main board 4 Connect the heater power harness from the transformer to the heater power harness plug that enters the bottom of the m...

Page 311: ...480 Volt ProBlue Adhesive Melters E 17 Part 1024496_06 2014 Nordson Corporation J9 J1 Figure E 9 Connecting the transformer electrical harnesses 1 Control harness 2 Power harness 3 Heater power harne...

Page 312: ...400 480 Volt ProBlue Adhesive Melters E 18 Part 1024496_06 2014 Nordson Corporation Connect the Transformer to the Melter contd Figure E 10 Covering the service entrance...

Page 313: ...melter Programming control issue Loose disconnected cables Problem in heater Blown fuse Power problem Problem with power distribution module Turn heaters on check that tank set point is correct not 0...

Page 314: ...w socket M4 x 25 2 11 Nut hex M5 4 8 A 12 Washer lock spit M5 14 13 Terminal lug ground 6 14 AWG 1 15 1040002 Shield assembly water transformer ProBlue 1 17 Power transformer automatic 1 5 kVA 1 2 A B...

Page 315: ...400 480 Volt ProBlue Adhesive Melters E 21 Part 1024496_06 2014 Nordson Corporation...

Page 316: ...400 480 Volt ProBlue Adhesive Melters E 22 Part 1024496_06 2014 Nordson Corporation Transformer Assembly contd...

Page 317: ...480 V 1 NS 1037490 Weldment tank machined P4 480 V 1 NS 1037491 Weldment tank machined P7 480 V 1 NS 1037492 Weldment tank machined P10 480 V 1 NS 1033838 Harness heater transformer P4 P7 P10 1 Servic...

Page 318: ...400 480 Volt ProBlue Adhesive Melters E 24 Part 1024496_06 2014 Nordson Corporation...

Page 319: ...s MiniPUR Melters ProBlue Melters Models P4 P7 P10 P15 P30 and P50 ProBlue Fulfill Models P4F P7F P10F PURBlue Melters Series 3000V Melters SureFoam Foam Dispensing System APPLICABLE DIRECTIVES Machin...

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