bulk melters versadrum vd200 (p/n 7144289, 7155290...

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

Bulk MeltersVersaDrum� VD200

(P/N 7144289, 7155290, 7177185)with Allen‐Bradley Controller

Manual P/N 7156136_02- English -

Issued 07/12

P/N 7156136_02 � 2012 Nordson CorporationVD200_7155289_DIV

Note

This document is for products with the following P/N:

7155289

7155290

7177185

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2009.

No part of this document may be photocopied, reproduced, or translated to another language without the priorwritten consent of Nordson Corporation. The information contained in this publication is subject to change

without notice.

� 2012 All rights reserved.- Translation of Original Manual -

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve,CleanSpray, Color‐on‐Demand, ColorMax, Control Coat, Coolwave, Cross‐Cut, cScan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,DuraPail, Dura‐Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized, Excel2000, Fibrijet, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Helix,Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March,Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, MicroSet, Millenium, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, Nordson,Optimum, Package of Values, PatternView, PermaFlo, PicoDot, PluraFoam, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus,Prism, ProBlue, Prodigy, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, SealSentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, Spraymelt, Spray Squirt,Super Squirt, SureBead, Sure Clean, Sure Coat, Sure‐Max, Sure Wrap, Tela‐Therm, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra,UniScan, UpTime, u‐TAH, Vantage, Veritec, VersaBlue, Versa‐Coat, VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, Walcom, Watermark, Whenyou expect more. are registered trademarks - ® - of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, Artiste, ATS, Auto‐Flo, AutoScan,Axiom, Best Choice, BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, ContourCoat, Controlled Fiberization, Control Weave, CPX, cSelect, Cyclo‐Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid,DuraCoat, e.dot+, E‐Nordson, Easy Clean, EasyOn, EasyPW, Eclipse, Equalizer, Equi=Bead, Exchange Plus, FillEasy, Fill Sentry, Flow Coat, Fluxplus,G‐Net, G‐Site, Get Green With Blue, Gluie, Ink‐Dot, IntelliJet, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros,MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiMix, OptiStroke, Origin, Partnership+Plus,PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet,PurTech, Quad Cure, Ready Coat, RediCoat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral,Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, Trade Plus,Trlogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Viper, Vista, WebCure, YESTECH, 2 Rings (Design) aretrademarks - � - 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

P/N 7156136_02� 2012 Nordson Corporation VD200_7155289_DIV

Table of Contents

Nordson International O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Europe O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributors in Eastern & Southern Europe O‐1. . . . . . . . . . . . . . . . .Outside Europe / Hors d'Europe / Fuera de Europa O‐2. . . . . . . . . . .

Africa / Middle East O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asia / Australia / Latin America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . .China O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Japan O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .North America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

Table of ContentsII


Introduction 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use - Examples - 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . .Area of Use 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual Risks 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ID Plate 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration Code 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Models 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note on Manual 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Definition of Term(s) 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bulk Melter / Melter 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drum / Pail / Container 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valves 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key‐to‐line 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of the Bulk Melter 2‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VersaDrum 2‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Platen 2‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VersaDrum 2‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Hood 2‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Light Tower 2‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Hose Receptacles 2‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Container Jacket for Cardboard Containers 2‐13. . . . . . . . . . .Swiveling Drip Tray 2‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function / Concepts 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Raising and Lowering Platen 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deaerating Container 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aerating Container 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Platen Position 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Control 2‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overtemperature Shutdown 2‐15. . . . . . . . . . . . . . . . . . . . . . . . . .Undertemperature Interlock 2‐15. . . . . . . . . . . . . . . . . . . . . . . . . . .Standby 2‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heatup Guided by Reference Channel 2‐15. . . . . . . . . . . . . . . . .

Melting Process and Material Flow 2‐16. . . . . . . . . . . . . . . . . . . . . . .Safety Valve 2‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Startup Protection 2‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controlling Material Quantity and Pressure 2‐16. . . . . . . . . . . . . . . .Integrating into a Production System 2‐17. . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Installation 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Personnel's Experience 3‐1. . . . . . . . . . . . . . . . . . . . . . . . .Transport 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked Bulk Melter) 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . .Setup 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhausting Material Vapors 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screwing on Light Tower (Option) 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections - General Information 3‐4. . . . . . . . . . . . . . . . .

Observe when Using Residual Current Circuit Breakers 3‐4. . . . .Laying Cable 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAN Bus: Securing Plug Connections 3‐4. . . . . . . . . . . . . . . . . .Power Supply 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Standard I/O Interface (XS2) 3‐6. . . . . . . . . . . . . . . . . . . .

General Notes 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe for Edge‐controlled Signals 3‐6. . . . . . . . . . . . . . . . . . . . .

Example of Standby 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inputs Pin 4, 5 and 6 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Assignment 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inputs 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outputs 3‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Line Speed Signal for Key‐to‐line (XS5) 3‐9. . . . . . . . . . .General Notes 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Bus Interfaces (XSD) 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Hose 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second Open‐end Wrench 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connection 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting 3‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Compressed Air 3‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Plate 3‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Switch 3‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valves 3‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adapting the Bulk Melter to the Container Used 3‐13. . . . . . . . . . . . . .Platen Position: Adjusting Switches 3‐13. . . . . . . . . . . . . . . . . . . . . .

Dismantling 3‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 3‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Accessories 3‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary Air Relief 3‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Platen Lock 3‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Elements of the Starting Screen 4‐2. . . . . . . . . . . . . . . . . . . . . . . . .Login / Logout Keys 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status Display 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information Line 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Container/Platen, Hose, Gun Keys 4‐3. . . . . . . . . . . . . . . . . . . . .Motor Key 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulk Melter Key 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Elements of the Control Panel 4‐4. . . . . . . . . . . . . . . . . . . . . .Input Window 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Function Keys 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Navigation Keys 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screen Appearance 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Initial Startup 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Conditions for ”Motor Running” 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . .Purging Bulk Melter 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Maintenance 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inserting and Replacing Container 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . .Raising Platen 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Container in the Bulk Melter 4‐8. . . . . . . . . . . . . . . . . . . . . . . .Container in the Bulk Melter 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering Platen 4‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Working Pressure 4‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Values and Parameters 4‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 4‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby 4‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven‐day Clock 4‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information Line: Entering Text 4‐12. . . . . . . . . . . . . . . . . . . . . . . . . .Selecting Control Mode (Unit Operating Mode) 4‐12. . . . . . . . . . . .Enable at Standard I/O Interface (XS2) 4‐13. . . . . . . . . . . . . . . . . . .Communication Mode 4‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key‐to‐line (XS5) 4‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor 4‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Select Control Mode: Manual Mode / Key‐to‐line 4‐14. . . . . . . . .Additional Settings (V14) 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ready Delay 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Interval 4‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Settings (V21) 4‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protected Settings 4‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Temperature Parameters 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . .Setpoints 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommended Setpoints 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Setpoint 4‐17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limits 4‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby Value 4‐18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alarm Values 4‐19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activate Channel, Mode, Control Parameters 4‐20. . . . . . . . . . . . . .Temperature Channel: Select Activated/Deactivated 4‐20. . . . .Mode: Select Display Mode or Control Mode 4‐20. . . . . . . . . . . .Control parameters 4‐21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphic Presentation of Temperature Parameters 4‐22. . . . . . . . . .Key‐to‐line - Settings 4‐23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Line Speed Signal Input 4‐23. . . . . . . . . . . . . . . . . . . . . . . .Calibrating Line Speed Signal at XS5 4‐23. . . . . . . . . . . . . . . . . . .

Line Speed Signal - General Information 4‐24. . . . . . . . . . . . . . . . . .Influence on Speed 4‐24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Threshold Switch 4‐25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Seven‐day Clock 4‐26. . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Bulk Melter ON/OFF 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Startup 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Switchoff 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Off in an Emergency 4‐27. . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel - Overview - 4‐28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screens T1 - T4 4‐28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screens V1 - V4 4‐29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screens V7 - V12 4‐30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screens V14 - V21 4‐31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screens M1 - M4 4‐32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Material Pressure 4‐33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents V


Maintenance 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important when Using Cleaning Agents 5‐2. . . . . . . . . . . . . . . . . . . . .Processing Materials 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Maintenance 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual Inspection for External Damage 5‐5. . . . . . . . . . . . . . . . . . . . . .Changing Type of Material 5‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Melting Plate 5‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan and Air Filter 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing the Buffer Battery 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Pump, Gerotor Pump 5‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for Leakage 5‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor / Gear Box 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Lubricant 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricant Changing Interval 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . .Capacity 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricant Selection 5‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Restrictor Valves (Pneumatics) 5‐10. . . . . . . . . . . . . . . . . . . .

Troubleshooting 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Tips 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alarms 6‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triggering and Resetting Alarms 6‐4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Undertemperature and Overtemperature - Warning - 6‐4. . . . . . .Undertemperature Warning Triggered 6‐4. . . . . . . . . . . . . . . . . .Overtemperature Warning Triggered 6‐4. . . . . . . . . . . . . . . . . . .

Undertemperature and Overtemperature - Fault - 6‐5. . . . . . . . . .Undertemperature Fault Triggered 6‐5. . . . . . . . . . . . . . . . . . . . .Overtemperature Fault Triggered 6‐5. . . . . . . . . . . . . . . . . . . . . .

Overtemperature - Shutdown - 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . .Software‐triggered 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown by Thermostats 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overtemperature Thermostat 6‐6. . . . . . . . . . . . . . . . . . . . . . . . .Transformer Thermostat 6‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sensor - Fault - 6‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Short‐circuit‐triggered 6‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triggered by Broken Sensor or Open Sensor Input 6‐7. . . . . . .

Troubleshooting Tables 6‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bulk Melter does not Function 6‐8. . . . . . . . . . . . . . . . . . . . . . . . . . .One Channel does not Heat 6‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .No Line Speed Signal 6‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel does not Function 6‐9. . . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor Rotating) 6‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . .No Material (Motor does not Rotate) 6‐10. . . . . . . . . . . . . . . . . . . . . .Too Little Material or Irregular Feeding 6‐11. . . . . . . . . . . . . . . . . . . .Material Pressure too High 6‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure too Low 6‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Incorrect Motor Rotation in Key‐to‐line Mode 6‐12. . . . . . . . . . . . . .Others 6‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs 6‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LEDs of Motor Controller 6‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVI


Repair 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe Before Performing Repairs 7‐1. . . . . . . . . . . . . . . . . . . . . . . .

Risk of Burns 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching Control Panel 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Gear Pump 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching Gear Pump 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attaching Gear Pump 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Motor 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Safety Valve 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing O‐rings 7‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Melting Plate 7‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Sealing Ring 7‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VersaPail 7‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VersaDrum 7‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Temperature Sensor or Thermostat 7‐8. . . . . . . . . . . . . . .

Parts 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Use Illustrated Parts List 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fasteners 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Component Designation 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Models 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suitable Containers 9‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Consumption 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Hood (Accessory) 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 9‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated Current / Operating Voltage 9‐3. . . . . . . . . . . . . . . . . . . . . . .Dimensions and Weights 9‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VersaPail 9‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VersaDrum 9‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Password A‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Instructions Regarding Working with Application Materials B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Definition of Terms B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manufacturer Information B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liability B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns B‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vapors and Gases B‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Substrate B‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Processing Temperature B‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents VII


Glossary C‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communication Data List D‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scheduled Read Data D‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scheduled Write Data D‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unscheduled Read Data D‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unscheduled Write Data D‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Diagram E‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVIII


O‐1Introduction

��2012 Nordson CorporationAll rights reserved

NI_EN_P_0612_MX

Nordson International

http://www.nordson.com/Directory

Country Phone Fax

EuropeAustria 43‐1‐707 5521 43‐1‐707 5517

Belgium 31‐13‐511 8700 31‐13‐511 3995

Czech Republic 4205‐4159 2411 4205‐4124 4971

Denmark Hot Melt 45‐43‐66 0123 45‐43‐64 1101

Finishing 45‐43‐200 300 45‐43‐430 359

Finland 358‐9‐530 8080 358‐9‐530 80850

France 33‐1‐6412 1400 33‐1‐6412 1401

Germany Erkrath 49‐211‐92050 49‐211‐254 658

Lüneburg 49‐4131‐8940 49‐4131‐894 149

Nordson UV 49‐211‐9205528 49‐211‐9252148

EFD 49‐6238 920972 49‐6238 920973

Italy 39‐02‐216684‐400 39‐02‐26926699

Netherlands 31‐13‐511 8700 31‐13‐511 3995

Norway Hot Melt 47‐23 03 6160 47‐23 68 3636

Poland 48‐22‐836 4495 48‐22‐836 7042

Portugal 351‐22‐961 9400 351‐22‐961 9409

Russia 7‐812‐718 62 63 7‐812‐718 62 63

Slovak Republic 4205‐4159 2411 4205‐4124 4971

Spain 34‐96‐313 2090 34‐96‐313 2244

Sweden 46‐40-680 1700 46‐40‐932 882

Switzerland 41‐61‐411 3838 41‐61‐411 3818

UnitedKingdom

Hot Melt 44‐1844‐26 4500 44‐1844‐21 5358

IndustrialCoatingSystems

44‐161‐498 1500 44‐161‐498 1501

Distributors in Eastern & Southern Europe

DED, Germany 49‐211‐92050 49‐211‐254 658

O‐2 Introduction

��2012Nordson CorporationAll rights reserved

NI_EN_P_0612_MX

Outside Europe / Hors d'Europe / Fuera de Europa

� For your nearest Nordson office outside Europe, contact the Nordsonoffices below for detailed information.

� Pour toutes informations sur représentations de Nordson dans votrepays, veuillez contacter l'un de bureaux ci‐dessous.

� Para obtener la dirección de la oficina correspondiente, por favordiríjase a unas de las oficinas principales que siguen abajo.

Contact Nordson Phone Fax

Africa / Middle East

DED, Germany 49‐211‐92050 49‐211‐254 658

Asia / Australia / Latin America

Pacific South Division,USA

1‐440‐685‐4797 -

China

China 86-21-3866 9166 86-21-3866 9199

Japan

Japan 81‐3‐5762 2700 81‐3‐5762 2701

North America

Canada 1‐905‐475 6730 1‐905‐475 8821

USA Hot Melt 1‐770‐497 3400 1‐770‐497 3500

Finishing 1‐880‐433 9319 1‐888‐229 4580

Nordson UV 1‐440‐985 4592 1‐440‐985 4593

Safety 1‐1

� 2012 Nordson Corporation Safe_PPA1011LUE_EN

Section 1

Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

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

Safety Alert Symbols

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

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

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

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

Safety1‐2

� 2012 Nordson CorporationSafe_PPA1011LUE_EN

Responsibilities of the Equipment Owner

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

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

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

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

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

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

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

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

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

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

Safety 1‐3


User Qualifications

Equipment owners are responsible for ensuring that users:

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

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

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

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

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

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

Applicable Industry Safety Practices

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

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

specified in this document.

� Do not modify the equipment.

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

Safety1‐4


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

referenced documents.

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

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

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

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create ahazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

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

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

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

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

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

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

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

and indicators.

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

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

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

Safety 1‐5


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

or service the equipment.

� Perform scheduled maintenance activities at the intervals described inthis document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

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

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

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

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

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

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

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

Equipment Safety Information

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

� hot melt and cold adhesive application equipment and all relatedaccessories

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

Safety1‐6


Equipment Shutdown

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

Relieving System Hydraulic Pressure

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

De‐energizing the System

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

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

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

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

Disabling the Applicators

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

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

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

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

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

Safety 1‐7


General Safety Warnings and Cautions

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

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

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

PC = Process control

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

Table 1‐1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

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

HM

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

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

Continued...

Safety1‐8


General Safety Warnings and Cautions (contd.)

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


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

HM, PC

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

HM, CA, PC

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

HM, CA, PC

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

Continued...

Safety 1‐9


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


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

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

HM

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

HM, CA

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

HM

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

Safety1‐10


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

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

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

First Aid

If molten hot melt comes in contact with your skin:

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

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

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

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

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

Safety 1‐11


Safety Labels and TagsFigure 1‐1 illustrates the location of the safety labels and tags affixed to theequipment. Table 1‐3 provides an illustration of the hazard identificationsymbols that appear on the safety labels and tags, the meaning and givesthe complete wording of safety instructions.

1

2

2

3 4 65

Fig. 1‐1 Safety labels and tags

Tab. 1‐3 Safety labels and tags

Position P/N Description

1 290083 ATTENTION: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

2 290082 ATTENTION: Hot surface. Failure to observe can cause burns.

3 421460 ATTENTION: Risk of pinching parts of the body between platenand container. Ensure that, during operation, no one else is nearthe melter.

4, 5, 6 1059866 TAGS, SHEET OF, VERSA/DURABLUE LG,CE LANG

Safety1‐12


Introduction 2‐1


Section 2

Introduction

Intended UseBulk melters of the series VersaPail and VersaDrum - hereafter also referredto as bulk melter - may be used only to melt and convey suitable materials,e.g. thermoplastic hot melt adhesives. When in doubt, seek permission fromNordson.

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

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

Unintended Use - Examples -

The bulk melters may not be used under the following conditions:

� In defective condition� With electrical cabinet door open� In a potentially explosive atmosphere� With unsuitable operating/processing materials� When the values stated under Technical Data are not complied with.

The bulk melters may not be used to process the following materials:

� Explosive and flammable materials� Erosive and corrosive materials� Food products.

Do not use the platen

� As a press� To lift loads� To heat objects.

Area of Use

The bulk melter is designed for use in industrial areas.

When using in industrial areas and in small businesses, the bulk melter maycause interference in other electrical units, e.g. radios.

Introduction2‐2


Residual RisksIn the design of the melter, every measure was taken to protect personnelfrom potential danger. However, some residual risks can not be avoided.Personnel should be aware of the following:

� Risk of burns from hot material

� Risk of burns from hot bulk melter components

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

� Risk of burns when attaching and removing heated hoses

� Material fumes can be hazardous. Avoid inhalation. If necessary, exhaustmaterial vapors and/or provide sufficient ventilation of the location of thebulk melter (Refer to page 3‐3, Exhausting Material Vapors).

� Risk of pinching parts of the body between platen and container. Ensurethat, during operation, no one else is near the bulk melter

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

ID Plate

Operating voltageOperating voltage frequency

Electrical connection

Rated current

Configuration code

Bulk melter designation Order number

Serial number Year of construction

Serial no. Year

Introduction 2‐3


Configuration Code

The series VersaPail and VersaDrum can be configured in various ways. Theconfiguration code offers information on the included features:

An E instead of the ‐ in box 6 means that the equipment differs from theconfiguration code; the respective box contains the # symbol.

Special Models

Also refer to page 8‐2, Special Models.

This manual applies to the following special models:

� P/N 7155289: VD200EPD4K2MP/#FAXXWX#DXX#XXXX

� P/N 7155290: VD200EUD4V2LP/#FAXXWX#DXX#XXXX

15 Included hose connections 8 mm (5/16 in) and 16 mm (5/8 in)

22 EtherNet/IP and ControlNet

26 Divided base plate

Continued...

Introduction2‐4


Other special features of these bulk melters that are not printed in theconfiguration code:

P/N

71

55

28

9

P/N

71

55

29

0

P/N

71

77

18

5

� � �

Controller ControlLogix with control panel PanelView Plus 600 color and motor controllerPowerFlex 40P made by Allen Bradley / Rockwell. Also refer tohttp://www.rockwellautomation.com/support

� � Security system PSSu made by Pilz. Also refer to http://www.pilz.com

� Safety valve 100 bar, lead‐sealed to 85 bar

� Platen sealing ring for low‐viscosity material

� Flap valve with adjustable spring at pump outlet

http://www.rockwellautomation.com/support

http://www.pilz.com

Introduction 2‐5


This page intentionally left blank.

V14 V14.2

Sequence of control panelscreens (example)

Operating side(= front)

Introduction2‐6


Note on Manual

� The position numbers in the illustrations do not correspond to the positionnumbers in the technical drawings and parts lists. Refer to separatedocument Parts List for details.

� Features that the customer may not have purchased - depending on theconfiguration of the bulk melter - are also described in the sectionOperation. In some cases the sequence of the control panel screens maydiffer from the description.

� Some of the illustrations in this manual may deviate from the actualequipment due to ongoing technical development or a differentconfiguration.

� Additional documents:

� For information on components of the controller: Refer tohttp://literature.rockwellautomation.com

� For information on components of the security system: Refer tohttp://www.pilz.com.

NOTE: Refer to the wiring diagram for the type designations of thecomponents.

Definition of Term(s)

Bulk Melter / Melter

The term Bulk melter is used in the manual. The term Bulk unloader is usedon the control panel.

Drum / Pail / Container

The term Container is used regardless of size.

Valves

Depending on their function and use, valves have different designations inNordson documentation, for example:

� Safety valve and Pressure restrictor valve: Valves that limit pressure forsafety reasons. The term Safety valve is usually used in conjunction withmaterial pressure.

� Pressure control valve: A valve used to set or control pressure.Depending on the model, the pressure can be set manually, electrically orpneumatically.

Key‐to‐line

Key‐to‐line is also referred to as Automatic mode in Nordson literature.

http://literature.rockwellautomation.com

http://www.pilz.com

Introduction 2‐7


Symbols

Original state

Configuration Code

If information contained in this manual applies only to certainconfigurations, the respective configuration code is indicated.

Example:

Box 18 = P

Introduction2‐8


Description of the Bulk MelterVersaPail and VersaDrum differ from one another in the size of the container.VersaPail is for 20 liter containers (pails) and VersaDrum for 200 liter containers (drums).

VersaDrum

4

3

2

1

5 6

8

10

7

9

11

Fig. 2‐1

1 Air filter (air inlet)

2 Main switch

3 Selector Raise/lower platen

4 Button Two‐hand control

5 Control panel

6 Light tower

7 Hose holder

8 Motor

9 Pneumatic cylinder

10 Platen

11 Container clamp

Introduction 2‐9


1 10

5

2

6

8

9

3

4

7

Fig. 2‐2

1 Switch Container detection

2 Switch Platen position (3x)

3 Assembly handgun receptacles(interfaces XS18, XS19)

4 Hose receptacles(interfaces XS10, XS11)

5 Pressure control valve Pneumaticcylinder working pressure

6 Interface Field bus (option)

7 Interface Standard I/O (XS2)

8 Interface Line speed signal (XS5)

9 Cable duct Power supply

10 Additional hose receptacles(number according toconfiguration)

Introduction2‐10


Platen

VersaDrum

3 4 5 61 2

Fig. 2‐3

1 Sealing ring

2 Melting plate

3 Automatic aeration valve (option)

4 Pump

5 Air relief valve

6 Pressure control valve (here:option Pneumatically controlled)

Note: Only the lower sealing ring is on the platen with models for cardboard containers (box 16 = F).

Introduction 2‐11


Exhaust Hood

Box 24 = E

If the bulk melter is used to process polyurethane hot melt adhesives (PUR),fumes are created that should be suctioned off directly at the container. Anexhaust hood is attached to the bulk melter for this purpose.

The exhaust hood must be connected to the customer's exhaust device(Refer to page 3‐3, Exhausting Material Vapors and page 9‐1, TechnicalData� ).

Light Tower

Box 20 = W

The light tower shows the bulk melter operating modes.

� : Illuminated

� : Off

X : On or off

White Green Yellow Red Status

Switched on Ready General alarm

�

� � �

X � �General alarm Warning

Refer to page 6‐2, Alarms.

X Flashing �Adhesive level low (containeralmost empty)

X � Flashing Container empty Warning

� � Flashing Container empty Fault

� � � Heatup phase or Standby

� � �General alarm Fault or Shutdown

Refer to page 6‐2, Alarms.

Introduction2‐12


Optional Hose Receptacles

Box 11 = 4, 6 or 8

-XS12

-XS13

-XS14

-XS15

-XS12

-XS13

-XS14

-XS15

-XS16

-XS17

-XS16

-XS17

Ni120 (Box 13 = N)Pt100 (Box 13 = P)

8 gun/hose connections

(Option Hose/Gun Pairs ”8”)





Fig. 2‐4 Maximum equipment (box 11 = 8)

Introduction 2‐13


High Container Jacket for Cardboard Containers

Box 16 = F

CAUTION: Do not use metal containers in this model! The container jacketis intended to be used only with cardboard containers!

NOTE: Only the lower sealing ring is on the platen with models for cardboardcontainers.

Swiveling Drip Tray

Box 23 = D

Air

Deaerating

Compressed air

Aerating

3

2

1

Introduction2‐14


Function / Concepts

Raising and Lowering Platen

The pneumatic cylinders raise and lower the platen. When lowering theplaten, a two‐hand control must be operated for safety reasons until theplaten is in the container.

Deaerating Container

The air relief valve must be opened manually to allow air to escape when theplaten is lowered into the container.

Aerating Container

To prevent a vacuum from forming when the platen is lifted out of thecontainer, the container must be aerated. This is done automatically ormanually, depending on the model.

Platen Position

A switch rod activates the switches (1, 2 and 3) one after the other, triggeringthe following switching functions:

� Switching functions when lowering:

� Switches from two‐hand lowering mode to normal lowering modewhen the platen sealing ring is completely submerged in the container(switch 1)

� Activates the Adhesive level low indication (switch 2)

� Activates the Container empty indication (switch 3).

� Switching functions when raising:

� Switches off automatic container aeration (switch 1).

Time

Temperature

Setpoint Guided channel

10 ° C

Setpoint Reference channel

Time

Temperature

Setpoint Reference channel

2 ° C

Setpoint Guided channel

Introduction 2‐15


Temperature Control

The bulk melter electronically controls the temperature of variouscomponents of the bulk melter itself (platen, pump) as well as connectedcomponents of an entire application system.

Overtemperature Shutdown

The overtemperature shutdown feature protects the bulk melter and thematerial from overheating. For overtemperature shutdown, the heater andmotor are switched off.

Undertemperature Interlock

The undertemperature interlock prevents the bulk melter motor from beingswitched on as long as the material is too cold and thus too thick. This coulddamage the pumps.

Standby

Standby serves to protect the hot melt material and to save energy duringbreaks in production. The temperature setpoints are reduced by a standbyvalue.

Heatup Guided by Reference Channel

After every switchon and after standby is exited, the bulk melter returns toheatup guided by reference channel (status display: Heatup phase).

Heatup guided by reference channel prevents individual temperaturechannels from reaching their setpoint long before the slowest temperaturechannel (pump heater or first hose = reference channel). It prevents hot meltmaterial from charring in hoses/guns and the build‐up of material expansionpressure during heatup. It also helps to save energy.

The actual temperature of the reference channel serves as the currenttemperature setpoint for the guided channels until the reference channel hasreached a temperature of 10 ° C (18 ° F) below its setpoint. Then heatupguided by reference channel ends automatically. This way all channels reachtheir setpoints more or less at the same time.

When the current temperature setpoint of a guided channel (= current valueof reference channel) reaches the guided channel's own setpoint minus 2 ° C(3.6 ° F), it is excluded from heatup guided by reference channel and thenheats to its own setpoint independently.

1 2

Principle drawing

Introduction2‐16


Melting Process and Material Flow

The material is melted only directly below the melting plate. A pump feedsthe melted material to the hose connection.

Safety Valve

A safety valve (2) limits the material pressure generated by the pump (1).

The standard safety valve (2) is fixed at

100 bar 10�000 kPa 1�450 psi

When the pressure is exceeded, the safety valve opens, allowing thematerial to circulate within the adapter plate.

Motor Startup Protection

The motor startup protection prevents the motor from starting up on its ownafter heatup or after a fault. The bulk melter enters startup protection onlyafter the heatup phase ends or there is no longer a fault, and at this time allrequired motor enables have been granted.

Controlling Material Quantity and Pressure

Also refer to page 4‐33, Setting Material Pressure.

Code Pressure Control Function

18 XMechanical control withmanually adjustable pressurecontrol valve

The maximum output pressure rarely needs to beadjusted (requires tool)

Example: Cardboard gluing

XSD

XS2

XS5

Interfaces

Introduction 2‐17


Integrating into a Production System

The bulk melter can exchange control signals with components of aproduction system via various interfaces:

� Interface Standard I/O (XS2):The interface provides various inputs and outputs. Refer to page 3‐6,Connecting Standard I/O Interface.

NOTE: Processing of input signals at interface Standard I/O (XS2) canbe switched off. Refer to page 4‐13, Enable at Standard I/O Interface(XS2)

� Interface Key‐to‐line (XS5):Line speed signal input for key‐to‐line. Refer to page 3‐9, ConnectingLine Speed Signal for Key‐to‐line

� Field bus interface (XSD)

Refer to

� Page 4‐13, Communication Mode

� D‐1, appendix Communication Data List

� Wiring diagram

Introduction2‐18


1Transport protection

2

Eye‐bolt

Installation 3‐1


Section 3

Installation

WARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

Installation Personnel's ExperienceThe instructions contained in this section are intended for personnel withexperience/authorization in the following fields:

� Application methods with hot melt adhesive or similar materials

� Industrial electrical wiring of power and control lines

� Industrial mechanical installation

� General knowledge of process control.

TransportRefer to page 9‐4, Dimensions and Weights for weight.

� If possible, use the pallet on which the bulk melter was delivered, andfasten the bulk melter to the pallet.

� Protect from damage, moisture and dust with suitable packing material.

� Avoid jolts and vibrations.

� Always secure with the transport protection (1) when moving anunpacked bulk melter. Fasten the eye‐bolts (2) to the base plate. Lift witha crane.


2

Eye‐bolt


3

Fastening hole Ø 30 mm

Installation3‐2


UnpackingUnpack carefully and check for damage caused during transport. Save palletand fastening and packing material for later use, or dispose of properlyaccording to local regulations.

Lifting (Unpacked Bulk Melter)

Refer to page 9‐4, Dimensions and Weights for weight.

Always secure with the transport protection (1) when moving an unpackedbulk melter. Fasten the eye‐bolts (2) to the base plate. Lift with a crane.

Setup

� Set up only in an environment that corresponds to the stated Degree ofProtection. Refer to page 9‐1, General Data. Do not set up in a potentiallyexplosive atmosphere!

� Protect from vibration. Remove the transport protection (1).

� Protect the control panel from direct sunlight. The UV rays reduce theservice life of the liquid crystals.

� Ensure that there is sufficient clearance around the bulk melter,especially above it. Refer to page 9‐4, Dimensions and Weights fordimensions.

� Observe the minimum hose bending radius (Refer to the hose manual).

� Screw the bulk melter to the floor.

CAUTION: Risk of damage! Do not operate equipment until it is screwedsecurely to the floor. Otherwise the descending platen would lift the bulkmelter off of the floor.

Installation 3‐3


StorageDo not store the bulk melter outside! Protect from humidity, dust and extremetemperature fluctuations (formation of condensation).

Exhausting Material VaporsEnsure that material vapors do not exceed the prescribed limits. Alwaysobserve the safety data sheet (MSDS) for the material to be processed.

If necessary, exhaust material vapors and/or provide sufficient ventilation ofthe location of the equipment. On bulk melters with exhaust hoods, materialvapors are suctioned off directly at the container.

NOTE: The exhaust hood must be connected to the customer's exhaustdevice. Refer to page 9‐2, Exhaust Hood (Accessories).

Bulk melter without exhaust hood Bulk melter with integrated exhaust hood

Customer's

Fig. 3‐5 Principle drawing

0,6 Nm(5.3 lbin)

1

Installation3‐4


Screwing on Light Tower (Option)The light tower is not attached upon delivery of the bulk melter. Use the twoincluded screws to fasten the light tower to the top of the melter tower.

Electrical Connections - General InformationWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

Observe when Using Residual Current Circuit Breakers

Local regulations in some industrial branches require residual current circuitbreakers.

Then observe the following points:

� Residual current circuit breakers are to be installed only between thepower supply and the bulk melter.

� Use only inverter‐compatible residual current circuit breakers.

Laying Cable

WARNING: Use only temperature resistant cable in warm areas of theequipment. Ensure that cables do not touch rotating and/or hot meltercomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

CAUTION: Lay CAN bus cable with a bending radius > 60 mm (2.4 in).

CAN Bus: Securing Plug Connections

Tighten the hexagon nut (1, if there is one) with 0.6 Nm torque. Nordsonrecommends the torque wrench made by Murr Elektronik, Murr articlenumber 7000-99102-0000000.

Mains terminal (example)

Installation 3‐5


Power SupplyWARNING: Operate only at the operating voltage shown on the ID plate.Permitted deviation from the rated line voltage is �10%.

Box 9 Operating voltageTerminals

L1 L2 L3 N PE

2200 VAC 3‐phase without neutral(Delta)

� � � �


� � � �

4400 VAC 3‐phase with neutral(star - WYE)

� � � � �


� � � �


� � � �


� � � �

CAUTION: The power cable cross‐section must comply with the ratedcurrent (Refer to ID plate).

The bulk melter must be installed securely (permanent power supplyconnection). Refer to wiring diagram for connecting arrangement.

Out

put

s

Inp

uts

Installation3‐6


Connecting Standard I/O Interface (XS2)

General Notes

� To conform with a European standard regarding electro‐magneticcompatibility (EMC), only shielded cable may be connected. The shieldmust be connected to ground in compliance with the standard regardingelectromagnetic compatibility.

� Inductive loads (e.g. solenoid valves) connected to the bulk melter mustbe equipped with a protective device (e.g. recovery diode) that disablesthe inductive voltage generated when an inductive load is switched off.

� The permitted voltage deviation is �10%.

Observe for Edge‐controlled Signals

Example of Standby

If standby is switched on via the interface (rising edge), it can be switched offby the operator on the control panel (Who‐touched‐me‐last�).

If standby is then to be switched on again via the interface, it must first beswitched off (falling edge) then on again via the interface.

Inputs Pin 4, 5 and 6

The Standard I/O interface inputs All motors ON/OFF (collective enable) andEnable motor can be disabled. Refer to page 4‐13, Enable at Standard I/OInterface (XS2).

Installation 3‐7


Interface Assignment

Inputs

NOTE: * optional

Digital inputs

Pin Input Feature Note

1* 24 VDC Internal (bulk melter)

2* 0 VDC External (customer's)

NOTE: Customer connects his reference potential here, if 24 VDC isprovided by customer.

30 V

24 V Rising edge: Heaters ON (main contactor closes)

A

0 V

24 V Falling edge: Heaters OFF (main contactor opens)

4 24 V: All motors ON (collective enable)

0 V: All motors OFF

5 24 V: Enable Motor / Trigger assembly handgun 1

0 V: No enable Motor / Trigger assembly handgun 1

6 24 V: Enable Motor / Trigger assembly handgun 2

0 V: No enable Motor / Trigger assembly handgun 2

Pin 7/8 not assigned

90 V

24 V Rising edge: Enter Standby

A

0 V

24 V Falling edge: Exit Standby

100 V

24 V Rising edge: Key‐to‐line

A

0 V

24 V Falling edge: Manual mode

Pin 11 - 16 not assigned

NOTE A: Refer to page 3‐6, Observe for Edge‐controlled Signals

Installation3‐8


Outputs

NOTE: Contact rating max. 24 VDC/2 A

Digital outputs

Pin Output Feature Note

17 Makecontact

Contact closed: Motor running

Contact open: Motor not running18

Pin 19 - 24 not assigned

25 24 VDC External (customer's; to be connected by customer)

26 Makecontact

24 V: Unit ready

0 V: Unit not ready

27 Makecontact

24 V: No general alarm -warning-

0 V: General alarm -warning-

28 Makecontact

24 V: No general alarm -fault-

0 V: General alarm -fault-

29 Makecontact

24 V: -

0 V: Container is empty

30 Makecontact

24 V: -

0 V: Adhesive level low

Pin 31/32 not assigned

-XS5

Installation 3‐9


Connecting Line Speed Signal for Key‐to‐line (XS5)

General Notes

� To conform with a European standard regarding electro‐magneticcompatibility (EMC), only shielded cable may be connected. The shieldmust be connected to ground in compliance with the standard regardingelectromagnetic compatibility.

� The line speed signal can be:

� A voltage (0 - 10 V)

� For Key‐to‐line, various settings must be made upon initial startup. Referto page 4‐23, Key‐to‐line - Settings.

NOTE: Instead of via XS5, a line speed signal can also be supplied via thefield bus interface (Line speed value). Refer to page 4‐23, Selecting LineSpeed Signal Input, and to D‐1, Appendix Communication Data List.

Field Bus Interfaces (XSD)Refer to

� Refer to page 4‐13, Communication Mode

� D‐1, appendix Communication Data List

� Wiring diagram

1

Example: VersaPail

1 32

Installation3‐10


Connecting HoseWARNING: Hot! Risk of burns. Wear heat‐protective gloves.

WARNING: Verify that the hoses are designed to accommodate the highestmaterial pressure possible! Refer to page 9‐1, General Data and to the hosemanual.

Second Open‐end Wrench

Use a second open‐end wrench when connecting and disconnecting thehose. This prevents the hose connection from turning.

Electrical Connection

Up to two hoses can be attached to the platen. Guide the hoses through thehose holders to the platen and initially connect them electrically to interfacesXS10 and XS11 (1).

Box 11 = 4, 6, or 8: Electrically connect additional hoses (or other

heated components) to interfaces XS12 to XS17.

Connecting

If cold material can be found in the hose connection (1), the components(2, 3) must be heated until the material softens (approx. 70 �C / 158 �F,depending on material).

1. First connect the hose (3) electrically to the unit.

2. Heat the bulk melter and hose to approx. 80 �C / 176 �F.

3. Screw the hose onto the unit.

NOTE: Close unused hose ports with Nordson port plugs.

Installation 3‐11


Disconnecting

WARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns.

Relieving Pressure

1. Switch off motor.

2. Set selector Raise/lower platen to 0/stop.

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

4. Guns: Activate the solenoid valve(s) electrically or manually; or, pull thetrigger of the assembly handgun. Repeat this procedure until no morematerial flows out.

5. Properly dispose of material according to local regulations.

1

2

3

4

Pneumatic plate

Installation3‐12


Connecting Compressed AirConnect dry, clean and nonlubricated compressed air to the compressed airconnection (1). Dirt particles in the air may not exceed 30 �m in size.

Air pressure

Min 3 bar 0,3 MPa 43,5 psi

Max 8 bar 0,8 MPa 116 psi

NOTE: A pressure restrictor valve behind the compressed air connectionlimits the air pressure to 8 bar / 0.8 MPa / 116 psi

Pneumatic Plate

Also refer to E‐1 Appendix Pneumatic Diagram.

Pressure Switch

A pressure switch (3) triggers the fault Air pressure too low when there isinsufficient air pressure.

Pressure Control Valves

CAUTION: Do not change the setting: A lower pressure makes it difficult toraise the platen.

� Raise pneumatic cylinder (2)

VP: 1.6 bar / 0.16 MPa / 23.2 psiVD: 2 bar / 0.2 MPa / 29 psi

� Aerate container (4):

1 bar / 0.1 MPa / 14.5 psi

NOTE: A pressure restrictor valve prevents higher, unpermittedpressure.

3

2

1

2mm

Installation 3‐13


Adapting the Bulk Melter to the Container Used

Platen Position: Adjusting Switches

WARNING: Risk of squash! Ensure that switch 1 is not actuated until theplaten is inside of the container.

A switch rod activates three switches (1, 2 and 3) one after the other,triggering the following switching functions:

� Switching functions when lowering:

� Switches from two‐hand lowering mode to normal lowering modewhen the platen sealing ring is completely submerged in the container(switch 1)

� Activates the Adhesive level low indication (switch 2)

� Activates the Container empty indication (switch 3).

� Switching functions when raising:

� Switches off automatic container aeration (switch 1).

NOTE: The switching state can be displayed on the control panel:

V1 V5 V5.2

Dismantling1. Pump until the bulk melter is empty, then remove the container.

2. When the bulk melter will not be used for longer periods of time, purgewith cleaning agent if necessary. Refer to page 5‐6, Purging withCleaning Agent.

3. Wipe off sealing ring and clean melting plate. Refer to page 5‐6, CleaningMelting Plate.

4. Disconnect all lines to the bulk melter, and allow bulk melter to cool.

DisposalWhen your Nordson product has exhausted its purpose, dispose of itproperly according to local regulations.

CAUTION: The fluorescent light for the control panel background lightingcontains mercury.

1

2

Installation3‐14


Installing AccessoriesThe following components can also be installed later as accessories:

Secondary Air Relief

P/N For Note

7140352 Box 10 =J, K, L,M, U, V,

W, Z

Operation:

1. After changing the container, open the pump airrelief valve (1) with a screwdriver.

2. Feed material into the drip pan (2) at a lowspeed, until it flows out free of bubbles

7140353 Box 10 =1, 2, 3, 4,5, C, D,E, F, G,H, N, P,Q, R, S

1. Relieve system pressure.

2. Extract the plug. In its place, screw in a pump air relief valve with sealingtape (included in delivery). Ensure that the material outlet hole pointsdown.

Platen Lock

P/N For Note

7140350 VD

Fasten the platen lock to the piston rod of a pneumatic cylinder.

CAUTION: Remove the platen lock before setting the selector to Lower.Otherwise the bulk melter could be damaged.

Operation 4‐1


Section 4

Operation


Control Panel

The control panel is a touch screen that graphically displays systemcomponents (e.g. container, hose, gun) and operating elements (e.g. keys,input fields). Touch the icons to operate. This will lead to other Screens of thecontrol panel.

Fig. 4‐1 Starting screen

NOTE: In this manual control panel screens are designated withabbreviations, e.g. V1 or M3. Refer to page 4‐28, Control Panel - Overview - for the screen structure.

V2 (Alarm log)

Operation4‐2


Elements of the Starting Screen

Login / Logout Keys

To be able to make settings on the control panel, the operator must Login.

Touch the LOGIN key in the starting screen, then enter the user name andrespective password.

Refer to A‐1, Appendix Password.

Level Functions enabled

Level 1

Operation

Normal operation for alloperators

All functions of the first operating level.

No parameters can be changed.

Level 2

Parameters

Settings for trained personnel

All functions of all operating levels

Status Display

The current bulk melter mode is shown. Examples:

� System ready

� Standby.

The system moves directly to screen V2 (Alarm log) when the line Statusdisplay is touched.

Meaning of Colors in the Status Display

Red: Fault

Yellow: Warning

Green: Ready

Any text

Operation 4‐3


Information Line

Text can be determined by the customer, e.g. adhesive type used in theproduction line.

Refer to page 4‐12, Information Line: Entering Text.

Container/Platen, Hose, Gun Keys

Lead to control panel screens T.., . Examples:

� T1: Temperature setpoints

� T4: Controller characteristics.

Meaning of Container Colors

Gray: Platen outside of container

Turquoise: Platen in container

Yellow: Adhesive level low (container almost empty)

Red: Container is empty

White: No container

Motor Key

Leads to control panel screens (M..), which directly or indirectly influence themotor's behavior. Examples:

� M1: Enable / switch on/off motor.

� M 6: Threshold switch enabled.

Bulk Melter Key

Initially leads to the control panel screen V1 with the following keys:

Entering/exiting standby for all activated temperature channels.Also refer to page 4‐11, Standby.

Enable / switch on/off motor. Also refer to page 4‐12, SelectingControl Mode.

Switching on/off heater for all activated temperature channels.

Switching on/off seven‐day clock. Also refer to page 4‐26,Programming Seven‐day Clock.

Operation4‐4


Other Elements of the Control Panel

Input Window

� When a field for entering a name is touched, this input window appears.

� When a field for entering a numerical value is touched, this input windowappears.

Function Keys

Keys with Indication Lamp

The indication lamp indicates the status (illuminated = switched on). In thiscase: Heaters are switched on.

Keys without Indication Lamp

The label indicates the status. In this case: The temperature channel is incontrol mode.

Navigation Keys

Call up a help text

General information

Return to previous level. Cancel and close when in input windows

To next/previous screen

Access other settings of the current screen

Select an item from a list

V11

Operation 4‐5


Screen Appearance

Some settings (e.g. contrast and brightness) can be made via a menu in thehardware (Panel Setup):

V1 V11V7

If YES is confirmed, the control panel restarts the operating program. Thistakes approx. three to five minutes.

Starting screen

Operation4‐6


Initial Startup

1. Set selector Raise/lower platen to 0.

2. Set the main switch to I/ON.

3. Switch on heaters.

4. Insert container. Refer to page 4‐8, Inserting and Replacing Container.

5. Wait until the starting screen appears on the control panel.

6. Set values and parameters. Refer to page 4‐11, Setting Values andParameters.

7. Wait for Ready indication.

8. Enable and start motor/pump. Refer to page 4‐6, Conditions for ”MotorRunning.”

NOTE: Refer to page 4‐27, Switching Bulk Melter ON/OFF for information ondaily operation.

Conditions for ”Motor Running”

V18

Refer topage 4‐12

M2

Refer topage 4‐14

V1 M1

XS2, pin 4

Collective enable

XS2, pin 6

Enable Motor

XS2, pin 5

Enable Motor

V1 M1

Field BusMelter control Motor ON/OFF

Field BusMelter control

Enable motor

Operation 4‐7


Purging Bulk Melter

All features were tested before the bulk melter left the factory. Special testmaterial was used. There may be residue from this material on the meltingplate, in the pump, etc. To remove such residue, melt and feed severalkilograms of material before starting production.

Initial Maintenance

Heating and cooling that occur during daily operation can cause screwedparts to loosen, resulting in leakage. Thus initial maintenance should beperformed after the first day. Refer to page 5‐4, Initial Maintenance.

1

Operation4‐8


Inserting and Replacing ContainerCAUTION: Place only undamaged, suitable containers in the bulk melter;otherwise the platen sealing ring will be damaged. Refer to page 9‐1,Suitable Containers. Always keep the base plate of the bulk melter clean sothat the container is positioned straight.

WARNING: Risk of pinching parts of the body between platen andcontainer. Ensure that, during operation, no one else is near the bulk melter.

1. Raise platen (See below).

2. Set selector Raise/lower platen to 0/Stop.

3. Move the container under the platen using a drum trolley (1). Fasten withthe container clamp (when available).

4. Lubricate sealing ring. Refer to page 5‐2, Processing Materials.

5. Lower platen (See below).

6. Properly dispose of empty container according to local regulations.

Raising Platen

WARNING: Risk of burns! Hot material can splash out when the platen exitsthe container. Hot material may flow out of the air relief valve. Wear gogglesand heat‐protective gloves.

No Container in the Bulk Melter

1. Set selector Raise/lower platen to Raise.

2. Press both buttons on the two‐hand control at the same time (within 0.5 seconds).

Setpoint

Undertemp.fault

�

Overtemp.fault

�

Setpoint temperature range

Operation 4‐9


Container in the Bulk Melter

Platen Lift‐up Protection

The platen can not be raised until it is within the setpoint temperature range.The indication Platen lift‐up protection appears. This protects the sealingrings from being damaged by charred material. To acknowledge theindication:

� Press both buttons on the two‐hand control at the same time (within 0.5 seconds)

or

� Set selector Raise/lower platen to 0, then move it back to Raise.

Aerating Container

If the platen is inside of the container, the container must be aerated tosupport raising. Aerating means that compressed air is forced under theplaten.

The air pressure in the container is limited to 1 bar (0.1 MPa / 14.5 psi) by apressure restrictor valve.

Box 17 = A (Automatic aeration):

The bulk melter is equipped with a valve (1) for automatic aeration:

1

1. Set selector Raise/lower platen to Raise.

Operation4‐10


Lowering Platen

The container must always be deaerated when the platen is moved into thecontainer. When the container is deaerated, the air that is under the platenescapes.

1. Set selector Raise/lower platen (1) to Lower.

2. Place a drip pan under the air relief valve (3).

3. Unscrew the rod (2) somewhat to open the air relief valve.

4. Press both buttons on the two‐hand control at the same time (within 0.5 seconds) until the platen is inside of the container. The downwardmotion continues on its own now.

5. Close air relief valve when material flows out free of bubbles: Screw therod back into place.


1

2 3

Setting Working Pressure

6 bar / 0.6 MPa / 87 psi

The setting can be modified on the pressure control valve:

� Increase pressure for high‐viscosity (ropy) materials

� Decrease pressure for low‐viscosity (liquid) materials

V9

Operation 4‐11


Setting Values and ParametersNOTE: To be able to make settings on the control panel, the operator mustLogin. Refer to page 4‐2, Login / Logout Keys.

Temperatures

Refer to page 4‐17, Setting Temperature Parameters.

Standby

V1 V9V7

NOTE: Set the standby value (value by which the setpoint temperature isreduced) on the control panel screen T2. Refer to page 4‐18, Limits.

NOTE: Standby can be entered and exited at any time:

� By the operator on the control panel

� Via the field bus

� Via the Standard I/O interface,

Automatic Enter Standby After Motor Stop

Enabled:

Standby is entered as soon as the motor has been stopped for a certaintime.

Disabled (60 min if enabled)

Manual Standby Duration

Enabled:

Standby is exited automatically. After the set time has expired, the bulkmelter automatically returns to heatup guided by reference channel.

Disabled (60 min if enabled)

V18

Operation4‐12


Seven‐day Clock

Heaters can be switched on via the seven‐day clock. A starting time for everyday of the week must then be entered.

V1 V8V7

Refer to page 4‐26, Programming Seven‐day Clock.

NOTE: The seven‐day clock can be switched on/off in control panel screen

V1 with .

Information Line: Entering Text

Text can be determined by the customer, e.g. adhesive type used in theproduction line. Appears in the information line of the starting screen. Referto page 4‐3, Information Line.

V1 V12V7

Selecting Control Mode (Unit Operating Mode)

V1 V14V7 V18

� Field bus mode

All screens can still be viewed, but the bulk melter can no longer beoperated via the control panel.

NOTE: The bulk melters on the field bus each require a node address forcommunication; each address may be assigned only once in the entirefield bus. The node address may be changed with the software RS Logix5000 only by personnel with PLC training.

� Local mode

The bulk melter can be operated via the control panel.

V18

Operation 4‐13


Enable at Standard I/O Interface (XS2)

NOTE: Applicable only with control mode Standalone. Refer to page 4‐12,Selecting Control Mode.

If the motor is also to be enabled via the Standard I/O interface:

Change from Control panel to Control panel AND standard I/O:

M2M1

Exchange of the remaining signals is not affected by the setting.

Also refer to page 3‐6, Connecting Standard I/O Interface.

Communication Mode

V1 V14V7 V18

This key is used to select the type of communication between the customer'sPLC and the bulk melter.

PLC 5: The customer's PLC 5 control unit communicates with the bulk melterin PLC 5 format (example: N20:0).

CLX: The customer's ControlLogix control unit communicates with the bulkmelter in tag address format (example: CS_READ_SD[0]).

Key‐to‐line (XS5)

Refer to page 4‐23, Key‐to‐line - Settings.

Refer to page 3‐9, Connecting Line Speed Signal for Key‐to‐line.

M1 (Speed control)

Operation4‐14


Motor

For information on starting the motor, refer to page 4‐6, Conditions for”Motor Running.”

Select Control Mode: Manual Mode / Key‐to‐line

M1

Touch to switch between Manual mode and Key‐to‐line

Indication lamp not illuminated: Manual mode

Indication lamp illuminated: Key‐to‐line

Manual mode (Indication lamp not illuminated).

Manual Mode

In manual mode the motor turns at the set speed.

To adjust, touch the display and enter the setpoint.

NOTE: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1 (rpm).

Speed setpoint: 5 min‐1

Key‐to‐line

The speed depends on the line speed signal and the respective settings.Refer to page 4‐23, Key‐to‐line - Settings.

V14 V15

V14 V17

V14 V16

Operation 4‐15


Additional Settings (V14)

V1 V14V7 Feature

Units

� Temperature: °Select °C or ° F.

� Pressure: Select bar, psi or kPa.

° C, bar

Ready Delay

The system ready delay time is the time after which all components havereached their setpoint temperatures (A) and before the system indicatesreadiness (B). This additional time allows the material to reach a thermallyhomogenous state.

System readydelay time

Time

Temperature

(A) (B)

The system ready delay time, if activated, runs after every Heatup phase(status display).

0 min

Service Interval

When the Service interval time defined by the customer has expired, theservice symbol (open‐end wrench) lights up on the starting screen.

500 h (total hours with heaters on)

V21

Operation4‐16


Additional Settings (V21)

V1 V14V7 FeatureV19

Protected Settings

Only for Nordson employees with the Nordson password.

T1

Operation 4‐17


Setting Temperature Parameters

T1 Setpoints

T1 T2 Limits

T2 Others

Component

Also refer to page 2‐15, Temperature Control and page 4‐22, GraphicPresentation of Temperature Parameters.

CAUTION: The temperature setting is determined by the processingtemperature prescribed by the material supplier. The maximum operatingtemperature for the bulk melter and heated components described here maynot be exceeded.

Nordson will grant no warranty and assume no liability for damage resultingfrom incorrect temperature settings.

Setpoints

T1

Display

Left temperature column (yellow): Actual valuesRight temperature column (green): Setpoints

NOTE: A value of 0 (zero) indicates that the channel is deactivated. Alsorefer to page 4‐20, Activate Channel, Mode, Control Parameters

Recommended Setpoints

Platen and pump(only some models have apump heater)

Prescribed processing temperature

(Material quantity used <50 g/min: up to 10 ° C / 18 ° F below prescribedprocessing temperature)

Gun (accessory) Prescribed processing temperature

Hose (accessory) Prescribed processing temperature

Adjusting Setpoint

1. Touch the green field in the right temperature column (setpoints)

2. Enter the value in the input window and confirm with .

T2

T2 T2.1

T2.1

Operation4‐18


Limits

T1 T2Component

NOTE:

� A different component can be selected in screen T2 on the control panel.

� Values can be entered in two ways:

� To apply to single temperature channels: in screen T2

� To apply to all temperature channels: in screen T2.1

� The value Overtemperature shutdown cannot be modified

� The temperatures in control panel screens T2 and T2.1 are differentialvalues

Standby Value

Standby temperature =Temperature setpoint - Standby value 50 °C (90 ° F)

The minimum standby temperature is 40 ° C (100 ° F), even if the selectedsettings would (mathematically) permit it to be lower.

NOTE: Refer to page 4‐11, Standby for more standby settings.

Operation 4‐19


Alarm Values

Warning and Fault

Warning Undertemperature =Temperature setpoint - Undertemperature warning 5 °C (9 ° F)

Fault Undertemperature =Temperature setpoint - Undertemperature fault 10 °C (18 ° F)

Warning Overtemperature =Temperature setpoint + Overtemperature warning 5 °C (9 ° F)

Fault Overtemperature =Temperature setpoint + Overtemperature fault 10 °C (18 ° F)

NOTE: If the heated platen is lowered onto the cold material, it will cool off,the degree of which is a factor of the processing temperature and material.This may trigger the fault or warning Undertemperature. If this happens,increase the alarm value. Observe the following:

� A Warning value can not be greater than the respective Fault value. Thusthe Fault value should be increased first.

Shutdown

Overtemperature shutdown =Temperature setpoint + Overtemperature fault + 10° C / 20° F, at the latestwhen maximum value is reached

Maximum value 245 °C (475° F)

Example:� Temperature setpoint = 170 ° C (338 ° F)� Overtemperature fault = 60 ° C (108 ° F)

This results in� Fault Overtemperature at 230 ° C (446 ° F)� Overtemperature shutdown at 240 ° C (464 ° F)

During operation the operator increases the setpoint to 190 ° C (374 ° F);the value Overtemperature fault delta is left unchanged. Mathematically,an overtemperature fault indication would then occur at 250 ° C (482 ° F).However, shutdown occurs at a fixed value of 245 ° C (475 ° F).

T3

Operation4‐20


Activate Channel, Mode, Control Parameters

T1 T2Component T3

Temperature Channel: Select Activated/Deactivated

NOTE: Temperature channels for platen and pump can not be deactivated.

Deactivated

A deactivated channel is not heated. Temperature control and monitoring forfaults do not take place. Exception: Overtemperature shutdown at fixedtemperature.

Activated

Normal state of a channel during operation. Activated channels can beswitched to display or control mode.

Mode: Select Display Mode or Control Mode

Display Mode (Monitoring)

In Display mode only the measured temperature is displayed. Temperaturecontrol and monitoring for faults do not take place. Exception:Overtemperature shutdown at fixed temperature.

NOTE: Temperature channels for platen and pump cannot be switched todisplay mode.

Control Mode

A PID control algorithm is used for the selected control parameters in controlmode.

T4T3

T4

T4.1T4

T4.1

Operation 4‐21


Control parameters

The PID control parameters can be selected as desired in this screen.

CAUTION: Should be adjusted only by personnel with experience inmetrology and control technology.

NOTE:

� The I‐component can be deactivated with the value 0

� Values can be entered in two ways:

� To apply to single temperature channels: in screen T4

� To apply to all temperature channels: in screen T4.1

Operation4‐22


Graphic Presentation of Temperature Parameters

Overtemperature shutdown by software

Fault Undertemperature

Overtemperature shutdown by thermostat

Fixed max. temperature valuefor overtemperature shutdownand fixed max. temperaturevalue for fault Overtemperature

Fixed max. temperature valuefor warning Overtemperature

Min. temperature for setpoint

Min. temperature forfault Undertemperature

Overtemperature fault

Undertemperature fault

Overtemperaturewarning

Undertemperaturewarning

Fault Overtemperature

WarningUndertemperature

WarningOvertemperature

10 ° C20 ° F

Standby value

Standby temperature

} Fixedvalue

Setpoint

M2

Operation 4‐23


Key‐to‐line - SettingsFor information on selecting Key‐to‐line mode, refer to page 4‐14, SelectControl Mode: Manual / Key‐to‐line..

Selecting Line Speed Signal Input

M1 M2

If Field bus is selected as the control mode, the following can be chosen asthe source of the line speed signal:

� Field Bus

� Interface Key‐to‐line (XS5).

For information on selecting the control mode, refer to page 4‐12, SelectingControl Mode.

Calibrating Line Speed Signal at XS5

Example:

The parent machine runs at maximum speed. An input signal of 9.8 V(Actual line speed) is displayed.

Then set Max. line speed to 9.8.

M1 M3Pump

M3 (speed)

Operation4‐24


Line Speed Signal - General Information

Influence on Speed

NOTE: The graph does not change to adapt to the entered values.

NOTE: rpm = min‐1 = revolutions per minute

Min. Pump Speed

Pump speed setpoint when the external line speed signal lies below theentered value Line speed for min. pump speed.

0.0 min‐1 / 0 bar (0 kPa / 0 psi)

Max. Pump Speed

Pump speed setpoint when the external line speed signal exceeds theentered value Line speed for max. pump speed.

80.0 min‐1 / 80 bar (8000 kPa / 1160 psi)

Line Speed for Min./max. Pump Speed

Line speed signal value in %, below or above which the pumps begin torotate at the set min./max. speed.

Max: 100.0 %

Min: 0.0 %

M3 M4

M4

Operation 4‐25


Threshold Switch

Threshold switch enabled: The motor is started and stopped dependent onthe line speed signal.

Motor

100 %Start at:Stop at:0

Off

On

(lower threshold value) (upper threshold value)Line speedsignal value

When the upper threshold value is exceeded, the motor starts; when thevalue falls below the lower value, the motor stops.

Start at: 10.0 %

Stop at: 5.0 %

V8

Operation4‐26


Programming Seven‐day Clock

V1 V8V7

Heaters can be switched on via the seven‐day clock. A starting time for everyday of the week must then be entered.

If 0:00 is entered as the starting time, the seven‐day clock is deactivated forthat day.

NOTE: The switching times are entered in 24‐hour format.

Set Date / Time

The current date and time are set before the bulk melter is delivered.However, both can be changed in the Panel setup. Refer to page 4‐5,Screen Appearance.

NOTE: The time is not automatically changed to and from daylight savingstime.

Operation 4‐27


Switching Bulk Melter ON/OFFNOTE: Before initial startup, read and observe the instructions in InitialStartup. Start up only as described under Initial Startup.

Daily Startup

NOTE: Do not operate Nordson pumps without material. Before switching onthe motor, ensure that a container that is not empty is in the bulk melter andthat the platen has contact with the material.

1. Set the main switch to I/ON.

2. Set selector Raise/lower platen to Lower.

3. Wait until the bulk melter is ready.

4. Enable and start motor. Refer to page 4‐6, Conditions for ”MotorRunning.”

Daily Switchoff

NOTE: The main switch must remain set to I/ON (switched on) when usingthe seven‐day clock.


2. Perform daily maintenance.

3. Switch off the heaters or set the main switch to 0/OFF and protect fromunauthorized access with padlocks if necessary.

Switching Off in an Emergency

WARNING: Immediately switch off the bulk melter in any emergencysituation.

1. Set the main switch to 0/OFF.


3. After standstill and before switching the bulk melter back on, have thefault remedied by qualified personnel.

Operation4‐28


Control Panel - Overview -NOTE: Some screens may differ from the illustrations, depending on thesoftware version used.

Screens T1 - T4

T1

T2

T3

Starting screen

T4

HOSE1

T2.1

T4.1

Operation 4‐29


Screens V1 - V4

V3

V1

V2

Starting screen

V7

V4

Operation4‐30


Screens V7 - V12

V1

V7V14

V9

V8

V11

V12

Operation 4‐31


Screens V14 - V21

V14

V7

V15

V16

V17

V18

V19

Only for Nordson employees with theNordson password.

V21

Operation4‐32


Screens M1 - M4

Starting screen

M4

M3

M2

M1

Operation 4‐33


Setting Material Pressure

Code Pressure Control Actuator

18 X

Mechanical control withmanually adjustable pressurecontrol valve (1)

1Example: VersaPail

+-

Hose

Manually adjustablepressure control valve

MotorPump

Platen / adapterplate

Safety valve (100bar)

1M

NozzleControl module

Gun

Operation4‐34


Maintenance 5‐1


Section 5

Maintenance


NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the service life of the unit. It should not beneglected under any circumstances.

Risk of BurnsSome maintenance work can only be done when the bulk melter is heatedup.

WARNING: Hot! Risk of burns. Wear safety goggles and heat‐protectivegloves.

Relieving PressureWARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns.


2. Set selector Raise/lower platen to 0.



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

Maintenance5‐2


Important when Using Cleaning Agents

� Use only a cleaning agent recommended by the hot melt materialmanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

� Properly dispose of cleaning agent according to local regulations.

Processing MaterialsBefore using, read the included EU safety data sheet.

Designation Order number Use

High temperature grease To be applied to O‐rings andthreads

NOTE: The grease may not bemixed with other lubricants.Oily/greasy parts must be cleanedbefore application.

� Can 10 g P/N 394769

� Tube 250 g P/N 783959

� Cartridge 400 g P/N 402238

Grease Centoplex H0

� 1 kg P/N 285600

Lubricating platen sealing ring

Sealing paste Stucarit 203 Applied to sealing surfaces

� Tube 100 ml P/N 255369

Temperature‐resistantadhesive Loctite 640

Secures screw connections

� 50 ml P/N 230359

Heat transfer compound To improve heat conducting oftemperature sensors

� 500 g P/N 257326

Maintenance 5‐3


Preventive MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the operating environment, production conditions and hours ofoperation, other scheduled maintenance tasks may prove necessary.

Interval Bulk melter part Activity Page

After initial startup Various Initial maintenance 5‐4

Every time the container ischanged

Melting plate Check melting plate for charredmaterial, clean if necessary. Do notuse sharp tools

-

Lubricate sealing ring

Refer to page 5‐2, ProcessingMaterials for the type of grease tobe used.

-

Base plate Check base plate for materialresidue or other impurities, clean ifnecessary

-

Daily Complete bulk melter External cleaning 5‐5

Inspect for external damage 5‐5

Power cable Inspect for damage -

Air hoses

Daily, if dust accumulation issevere

Electrical cabinetventilation

Clean fan screens, clean or replacefilter

5‐7

Motor / gear box Clean fan cover -

Depending on hours ofoperation, pump speed andpump temperature

Recommendation: Monthly

Various Like initial maintenance 5‐4

Every six months Pressure restrictorvalve (pneumatics)

Performance check 5‐10

Every 15�000 hours of operationor every 2 to 3 years

Motor / gear box Change lubricant 5‐9

Every 3 years

At the latest when the BATTstatus display is illuminated

Processor board Replace the buffer battery 5‐7

Maintenance5‐4


Initial Maintenance

Heating and cooling that occur during daily operation can cause screwedparts to loosen, resulting in leakage.

Retighten the following components with a torque wrench.

Component TorqueNote

Example Pos. Designation [Nm] [lbin]

541 2

1 Plug 20 176 A

2 Hose fitting 25 220 A

5 Safety valve 15 133 A

4 Pump: Fixing screws 25 220 A, B

NOTE A: Retighten while the material is still soft (approx. 70 ° C/158 ° F, depending on the material)

B: Retighten crosswise

Maintenance 5‐5


External CleaningExternal cleaning prevents pollution created by production from causing bulkmelter malfunctions.

CAUTION: Observe the unit's Degree of Protection when cleaning. Refer topage 9‐1, Technical Data.

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

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

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

Control Panel

CAUTION: Switch off the unit before cleaning the control panel. Thisensures that no functions are unintentionally triggered by touching thescreen.

CAUTION: Abrasive cleaning agents or solvents can damage the controlpanel. Do not scratch the control panel or use cleaning brushes.

NOTE: Paint splatters and grease can be removed with a 70 % isopropanolsolution.

1. Use a soft sponge or cloth and mild soap to clean the control panel.

2. Dry the control panel e.g. with a chamois to prevent water spots.

Visual Inspection for External DamageWARNING: When damaged parts endanger the operating safety and/or thesafety of personnel, switch off the bulk melter and have the damaged partsreplaced by qualified personnel. Use only original Nordson spare parts.

Maintenance5‐6


Changing Type of MaterialNOTE: Before changing the material type, determine whether the old andnew material can be mixed.

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

� May not be mixed: Purge thoroughly and clean melting plate with acleaning agent recommended by the material manufacturer. Refer topage 5‐6, Cleaning Melting Plate.

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

Purging with Cleaning AgentPlace a container of cleaning agent in the bulk melter to purge. Then feed thecleaning agent until it comes out free of material residue.

CAUTION: Use only a cleaning agent recommended by the hot meltmaterial manufacturer. Observe the Material Safety Data Sheet for thecleaning agent.

Before starting production again, flush out residue of the cleaning agentusing the new material.

NOTE: Properly dispose of cleaning agent according to local regulations.

Cleaning Melting PlateThe melting plate is standardly release‐coated. This makes it easy to clean.Cooled material can usually be pulled off of the melting plate; if necessary,first heat to approx. 60 ° C / 140 ° F.

CAUTION: Do not use hard or metallic tools to clean. Do not use wirebrushes! This could damage the release coating. Use only soft aids (woodenor PTFE spatula or soft brush).

Maintenance 5‐7


Fan and Air FilterDepending on dust accumulation, the air filters in the fan and for the air outletmust be cleaned (knocked out) or replaced.

Refer to separate document Parts for filter order numbers.

1

2

3

4

1 Air filter, top air inlet

2 Fan

3 Air filter, bottom air inlet 4 Air filter, air outlet

Replacing the Buffer BatteryNOTE: To prevent the program from being lost, the processor must remainon when the buffer battery is removed.

The battery should be replaced when the BATT status display on theprocessor is illuminated, but at the latest every three years.

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

NOTE: Make a note of the date on which the battery was changed on thebattery compartment cover.

Properly dispose of the old battery.

3

Maintenance5‐8


Gear Pump, Gerotor Pump

Checking for Leakage

If material escapes along the shaft, the pump shaft seal must be replaced.

NOTE: A special assembly tool is needed for replacement. Refer to theseparate document Parts List. However, Nordson recommends replacing thepump and sending the old one in to be repaired. Refer to page 7‐3,Replacing Gear Pump.

Maintenance 5‐9


Motor / Gear Box

Changing Lubricant

Observe when changing lubricant:

� Drain lubricant when warm

� Use only the stated lubricant or one that has proven to be equivalent.Using any other lubricant can result in premature wear and/or damage tothe gear box

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

Remove gear box from the motor to change lubricant. Wash out casing withsuitable cleaning agent and remove lubricant residue.

Lubricant Changing Interval

When lubricant temperature is below 100° C / 212° F: Every 15�000 hours of operation or at least every 2 to 3 years.

Capacity

The lubricant quantity is indicated on the ID plate.

NOTE: Never mix different types of lubricants.

Lubricant Selection

Lubricant manufacturer Mineral oil CLP 220

AGIP Blasia 220

ARAL Degol BMB 220 or Degol BG 220

BP Energol GR‐XP 220

DEA Falcon CLP 220

ESSO Spartan EP 220 or GP 90

KLÜBER Klüberoil GEM 1‐220

OPTIMOL Optigear 220

SHELL Omala Oil 220

TEXACO Geartex EP‐A SAE 85 W‐90

Maintenance5‐10


Pressure Restrictor Valves (Pneumatics)The factory‐set, lead‐sealed pressure restrictor valves prevent unpermissiblyhigh pressurization of subsequent pneumatic components. When the factorysettings are exceeded, compressed air audibly escapes.

Box 1-5 = VersaDrum and Box 17 = A (Automatic aeration)

Functioning of the pressure restrictor valve Aerate container (1) should bechecked approx. every six months. Do this by turning the knurled screw untilthe compressed air is audibly released. When functioning is not correct, thepressure restrictor valve should be cleaned. If it still does not function, it mustbe replaced.

Impurities that have penetrated seat surfaces and conical nipples can beremoved by unscrewing the entire top piece - without changing the minimumoperating pressure. Use a sickle wrench to unscrew.

1

Checking Cleaning

Troubleshooting 6‐1


Section 6

Troubleshooting


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

Helpful TipsBefore starting systematic troubleshooting, check the following:

� Is the seven‐day clock set correctly?

� Are all parameters set correctly?

� Is the interface wired correctly?

� In key‐to‐line mode: Is there a line speed signal provided?

� Do all plug connections have sufficient contact?

� Have circuit breakers been activated?

� Could the fault have been caused by an external PLC?

� Are external, inductive loads (e.g. solenoid valves) equipped withrecovery diodes?

Troubleshooting6‐2


AlarmsThe light tower indicates the melter status. The colors represent variousalarms, described below.

The status line of the control panel indicates only Warning, Fault orShutdown The special alarm text is displayed when the line Status display istouched.

Light tower colors

Status Green Yellow Red

Heatup phase �

(Motor) startup protection active� � �

System ready �

Standby active �

Heaters off

Motor running �


Warning

The operator must decide whether the situation is critical for theapplication and action is required.

� �

Service interval is expired � �

Channel: Overtemperature warning � �

Channel: Undertemperature warning � �

Underpressure: Motor #, sensor # � �



Light tower colors


Fault

A fault switches off the motors. As soon as the fault is corrected, themotor startup protection is automatically activated.

�

Channel: Overtemperature fault �

Channel: Undertemperature fault �

Channel: Sensor input open or sensor broken(Sensor = temperature sensor)

�

Channel: Sensor short‐circuit(Sensor = temperature sensor)

�

Motor or motor controller overtemperature(longer than 5 sec)

�


Shutdown

Shutdown turns the bulk melter off

(Main contactor opens).

�

Main contactor / tank thermostat fault� Main contactor defective or open� Temperature exceeded

�

(Motor) controller fault:� Controller defective� Overload� Motor short‐circuit

(At least one fault longer than 5 sec.)

�

Channel: Overtemperature shutdown �

Motor coupling blocked or phase missing(motor current exceeds limit longer than 5 sec)

�

Setpoint

Undertemp.warning

Undertemperature warning

2 ° C

�

Setpoint

Overtemp.warning

Overtemperature warning [1]

2 ° C

Setpoint

Overtemperature warning [2]X1

2 ° C

�



Triggering and Resetting AlarmsFaults can trigger different alarms with various consequences. If severalalarms are triggered at once, the most severe takes priority: Shutdownbefore Fault before Warning.

Undertemperature and Overtemperature - Warning -

Also refer to page 4‐22, Graphic Presentation of Temperature Parameters.

� Alarm Triggered� Alarm Reset

Undertemperature Warning Triggered

The temperature has fallen below the setpoint by more than the differentialvalue (�) Undertemperature warning delta for longer than 5 seconds.

Automatic Reset

The warning goes away when the temperature has increased to 2 ° C (3.6 ° F)below the setpoint.

Overtemperature Warning Triggered

[1] The temperature has exceeded the setpoint by more than the differentialvalue (�) Overtemperature warning delta for longer than 5 seconds.

or

[2] The value X1 (fixed max. temperature value for Overtemperature warning)was exceeded for longer than 5 seconds.

Automatic Reset

The warning goes away when the temperature has fallen to 2 ° C (3.6 ° F)above the setpoint.

Setpoint

Undertemp.fault

Undertemperature fault

2 ° C

�

Setpoint

Overtemp.fault

Overtemperature fault [1]

2 ° C

Setpoint

Overtemperature fault [2]

Y1

2 ° C

�



Undertemperature and Overtemperature - Fault -


� Alarm Triggered� Alarm Reset

Undertemperature Fault Triggered

The temperature has fallen below the setpoint by more than the differentialvalue (�) Undertemperature fault delta for longer than 5 seconds.

Automatic ResetThe fault no longer exists as soon as the actual value exceeds the setpointminus differential value (�) Undertemperature fault delta by 2 ° C (3.6 ° F).

Overtemperature Fault Triggered

[1] The temperature has exceeded the setpoint by more than the differentialvalue (�) Overtemperature fault delta for longer than 5 seconds.

or

[2] The value Y1 (fixed max. temperature value for Overtemperature fault)was exceeded for longer than 5 seconds.

Automatic Reset[1] The fault no longer exists as soon as the temperature has fallen below thesetpoint plus differential value (�) Overtemperature fault delta by 2 ° C(3.6 ° F).

or

[2] The fault no longer exists as soon as the temperature has fallen below thevalue Y1 by 2 ° C (3.6 ° F).

Setpoint

Overtemp.fault

Overtemperatureshutdown [1]

10 ° C

Setpoint

Y1'

Overtemperatureshutdown [2]

�

1

Example: VersaPail



Overtemperature - Shutdown -


� Alarm Triggered

Software‐triggered

[1] The temperature has exceeded the setpoint by more than the differentialvalue (�) Overtemperature fault delta plus 10 ° C (18 ° F) for longerthan 5 seconds.

or

[2] The value Y1' (fixed max. temperature value for overtemperatureshutdown) was exceeded for longer than 5 seconds.

NOTE: Channels in display mode trigger shutdown only when they havereached the maximum Y1'.

Reset

Switch bulk melter off/on with main switch.

Shutdown by Thermostats

NOTE: The Main contactor / thermostat fault indicates that either theovertemperature thermostat or the transformer thermostat has switched offthe bulk melter.

Overtemperature Thermostat

The thermostat is located behind the electrical equipment cover (1) of theplaten. The shutdown value depends on the thermostats installed:

Box 12 = L Box 12 = M Box 12 = H

Thermostat 180 °C (350° F) 210 °C (410° F) 260 °C (500° F)

Reset


Transformer Thermostat

Shutdown value: 155�5 ° C / 311�9 ° F.

Reset




Temperature Sensor - Fault -

Every temperature sensor is monitored.

Short‐circuit‐triggered

The sensor has supplied the fixed value - 10 ° C (14 ° F) for more than 5 seconds.

Triggered by Broken Sensor or Open Sensor Input

The sensor has supplied the fixed value 305 ° C (581 ° F) for more than 5 seconds.

Automatic ResetThe fault no longer exists when the sensor has supplied a value between- 10 ° C (14 ° F) and 305 ° C (581 ° F) for more than 5 seconds.

NOTE: If reset does not occur automatically, the temperature sensor isprobably defective and may need to be replaced.



Troubleshooting Tables

Bulk Melter does not Function

Possible Cause Possible Fault / Troubleshooting Corrective Action

1. No line voltage - Connect line voltage

2. Main switch notswitched on

- Switch on main switch

3. Main switch defective - Replace main switch

4. Main circuit breakeractivated

- Switch on main circuit breaker

5. Main circuit breakeractivated again

Check for short circuit in bulkmelter or accessories

-

6. 24 VDC power supplydefective

- Replace

One Channel does not Heat


1. Channel isdeactivated

- Activate the temperature channel onthe control panel (or via the optionalfield bus)

2. Channel is in displaymode

- Switch to control mode. Refer to page4‐20, Mode: Select Display Mode orControl Mode

No Line Speed Signal

Refer to page 3‐9, Connecting Line Speed Signal for Key‐to‐line.


1. Parent machine notoperating

- Start up parent machine

2. Polarity of line speedvoltage input isreversed

- Reverse polarity

3. Encoder defective - Replace



Control Panel does not Function

Problem Possible Cause Corrective Action

1. Control panel dark orbright

Background lighting / contrastmisadjusted

Refer to page 4‐5, ScreenAppearance

2. Control panel doesnot function/react

Hardware defective Refer to page 7‐2, Control Panel.

Refer to separate document Parts forpart numbers.

Control panel dirty Clean

Refer to page 5‐5, External Cleaning

No Material (Motor Rotating)


1. Material supply holeto pump or pumpsuction hole clogged

Blocked by foreignobjects/particles

Detach pump and clean supply holeor suction hole

2. Pressure controlvalve malfunctioneddue to hardened orcharred material

- Replace

3. Hose or gun is cold Hose/gun not connectedelectrically

Insert plug into the correspondingreceptacle (Refer to wiring diagramfor assignment)

Hose/gun temperature channel notactivated

Activate on control panel

Hose/gun heater defective Replace hose

Replace heater cartridge(s) in gun



No Material (Motor does not Rotate)


1. System not yet readyfor operation (heatupphase)

- Wait until the system has heated upand when appropriate until Systemready delay time has expired

Refer to page 4‐15, Ready Delay

2. Motor not switchedon

- Switch on motor

Refer to page 4‐6, Conditions for”Motor Running.”

3. Motor startupprotection activated

Standby entered Switch on motor again

Undertemperature during operation

4. Speed (rpm) not set The parameter Max. pump speedin key‐to‐line is on 1 min‐1

Set speed (RPM)

Refer to page 4‐14, Select ControlMode: Manual Mode / Key‐to‐line

5. Key‐to‐line modeselected, howeverbulk melter should bein manual mode

- Switch to manual mode

Refer to page 4‐14, Select ControlMode: Manual Mode / Key‐to‐line

6. No external motorenabling via interfaceStandard I/O

- Activate the corresponding contactsof the interface

Refer to page 4‐13, Enable atStandard I/O Interface (XS2)

7. Key‐to‐line selectedbut no line speedsignal present

- Provide line speed signal

Refer to page 3‐9, Connecting LineSpeed Signal for Key‐to‐line

8. Threshold switch notproperly set

- Check and set values on controlpanel

Refer to page 4‐25, Threshold Switch

9. Standby entered - Exit or wait until standby period hasexpired

10. Motor defective - Replace

11. Motor not suppliedwith voltage

- Technical inspection

12. Motor controller fault ⇒ Switch the bulk melter off and onagain with the main switch

Short circuit Check motor cable

13. Motor controllerdefective

- Replace



Too Little Material or Irregular Feeding


1. Material supply holeto pump or pumpsuction hole partiallyclogged

- Detach pump and clean supply holeor suction hole

2. Pump block of thegear pump worn

- Replace pump

3. Processingtemperature set toolow

- Correct temperature setting

4. Pressure controlvalve malfunctioneddue to hardened orcharred material

- Replace

Material Pressure too High


1. Safety valve orpressure controlvalve dirty and thusblocked

- Replace

2. Safety valve orpressure controlvalve defective

- Replace

3. Pressure controlvalve set incorrectly

- Set



Material Pressure too Low


1. Gear pump is worn - Replace pump. Refer to page 7‐3,Replacing Gear Pump

2. Safety valve does notclose any more

- Replace safety valve. Refer to page 7‐4, Replacing Safety Valve

3. Pressure controlvalve defective

- Replace pressure control valve

4. Pressure controlvalve set incorrectly

- Refer to page 4‐33, Setting MaterialPressure

Incorrect Motor Rotation in Key‐to‐line Mode


1. Line speed signalfluctuates duringconstant machinespeed

Encoder defective or loose contact Replace encoder

Drive element (e.g. belt) slips Eliminate slip

Electromagnetic compatibilitydisruptions

Use shielded cable



Others


1. Leakage at pumpshaft seal

Pump shaft seal is worn Replace seal. Refer to page 5‐8,Replacing Gear Pump, Gerotor Pump

- Replace pump. Refer to page 7‐3,Replacing Gear Pump

2. Gear pump blocked Processed material too cold Correct temperature setting (observedata sheet of material manufacturer)

Foreign material in gear pump Replace pump. Refer to page 7‐3,Replacing Gear Pump

3. Leakage at gunduring heatup phase

Safety valve does not open(expansion pressure)

Replace safety valve. Refer to page7‐4, Replacing Safety Valve

4. Platen can not beraised (container inbulk melter)

Platen lift‐up protection is activated Refer to page 4‐9, Platen Lift‐upProtection.

Container is not aerated Refer to page 4‐9, Aerating Container

5. Platen can not belowered (container inbulk melter)

Container is not relieved of air Refer to page 4‐10, Lowering Platen



LEDsWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

LEDs of Motor Controller

Basic display group (only display)Indicates the most common operating modes.

Extended display group (only display)Indicates the extended operating modes.

FaultA list of codes for certain fault situations. Appears only when a fault hasoccurred.

DescriptionMenu

No. LED State Description

1 Operating status

RUN

Constantly red MC running.

Flashing red The motor controller has received a command to reversedirection.

Direction status

REV

Constantly red Motor controller running and motor turning in changeddirection

Flashing red The motor controller has received a command to reversedirection. The motor decelerates to standstill.

Fault status

FAULT

Flashing red Indicates a motor controller fault.

No. Key Name Description

2 Arrow up Scroll:

Press and release to show the various parameters.

Refer to the manual PowerFlex 40P for more information.

Reset:

Press for three seconds to reset active faults.

Repair 7‐1


Section 7

Repair


Observe Before Performing RepairsWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

Risk of Burns

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

Some components can be detached only when the bulk melter is heated up.

Relieving Pressure

WARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns.






Repair7‐2


Control Panel

2

3

5 46

1

1 Interface for communicationboard

2 Power supply

3 Slot for memory board

4 EtherNet port

5 RS 232 port

6 USB port

Detaching Control Panel

1. Lift one side of the control panel and press in a spring clip (Refer to Fig. 61, arrows) on the other side. Then the control panel can be liftedhigh enough that the connections are exposed.

2. Press control panel back into place.

1

Repair 7‐3


Replacing Gear PumpWARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns. Refer to page 7‐1,Relieving Pressure.

WARNING: Hot! Risk of burns. Wear heat‐protective gloves.

Detaching Gear Pump

NOTE: Detach the gear pump only when the material is soft (approx. 70 ° C/158 ° F, depending on material).

1. Remove the cover and detach the Cardan joint (1) from the pump shaft.

2. Detach pump.

3. Allow the bulk melter to cool to room temperature.

31 2

Attaching Gear Pump

1. Clean the sealing surfaces on the plate and pump. If necessary, heatmaterial residue with a hot air fan, then remove.

2. Put the pump in place. Ensure that the suction hole (2) is positionedproperly.

3. Screw the pump into place:

a. Apply high temperature grease (Refer to page 5‐2, ProcessingMaterials) and tighten by hand, such that the pump and plate havethermal contact.

b. Wait until the pump and plate are at the same temperature.

c. Tighten the fixing screws crosswise using a torque wrench. Torque: 25 Nm / 220 lbin.

4. Attach Cardan joint. Ensure that the marks (3) line up.

5. Put the cover into place.

Repair7‐4


Replacing MotorObserve when replacing:

� Verify that the electrical connection effects the desired direction ofrotation (see arrow).

Replacing Safety ValveWARNING: For safety reasons, the safety valve may not be disassembled.The complete valve must be replaced every time.

WARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns. Refer to page 7‐1,Relieving Pressure.


Observe when replacing:

� Replace the valve only when the bulk melter is heated. Otherwise thesealing rings could be damaged by charred material.

� Apply high temperature grease to all threads and O‐rings (Refer to page 5‐2, Processing Materials).

� Tighten valve with a torque wrench. Torque: 15 Nm (133 lbin).

SW 19

Repair 7‐5


Replacing O‐ringsWARNING: System and material pressurized. Relieve bulk melter pressurebefore disconnecting pressurized components (e.g. hoses, pressuresensors). Failure to observe can result in serious burns. Refer to page 7‐1,Relieving Pressure.


When leakage occurs, e.g. at the hose connections, the O‐rings must bereplaced. Observe the following:

� Clean and lubricate O‐ring groove. Nordson recommends special hightemperature grease; refer to page 5‐2, Processing Materials

� Also lubricate O‐ring.

� Do not use removed O‐rings again

� Tighten hose connection and blind covers with a torque wrench to 9.5 Nm.

43

1

4

Repair7‐6


Replacing Melting PlateWARNING: Hot! Risk of burns. Wear heat‐protective gloves.

1. Heat the platen until the material softens (approx. 70 ° C / 158 ° F,depending on the material).

2. Place a clean, hard, heat‐resistant resting surface (e.g. metal plate) onthe container and lower the platen onto the surface.

3. Release all of the fixing screws (1).

4. Raise the platen approx. 10 cm. The melting plate remains on the restingsurface.

5. Shut down the bulk melter.

6. Carefully extract the temperature sensor from the bore (4).

7. Replace the O‐rings (3). Clean and grease the grooves. Refer to page5‐2, Processing Materials for the type of grease to be used.

8. Apply heat transfer compound (Refer to page 5‐2, Processing Materials)to the temperature sensor and insert it into the bore (4).

9. Screw the melting plate into place:

a. Grease the fixing screws and screw in loosely such that the platenand melting plate have thermal contact

b. Wait until the platen and melting plate are at the same temperature

c. Tighten the fixing screws with a torque of 15 Nm

NOTE: The next time the platen is cold (e.g. weekend, factory vacation)tighten the fixing screws again with the torque 15 Nm.

Repair 7‐7


Replacing Sealing RingWARNING: Hot! Risk of burns. Wear heat‐protective gloves.

VersaPail

Proceed as described under Replacing Melting Plate. Refer to page 7‐6.

VersaDrum

1. Heat the platen to operating temperature.

2. Place a clean, hard, heat‐resistant resting surface (e.g. metal plate) onthe container and lower the platen onto the surface.

3. Cut old sealing rings with a knife and dispose of properly.

CAUTION: Do not dame the nonstick coating.

4. Clean and grease the grooves. Refer to page 5‐2, Processing Materialsfor the type of grease to be used.

5. Put the sealing rings on the heated platen; this will require two persons. Ifnecessary, heat the new sealing rings in a heating furnace (180 ‐ 200 °C /356 ‐ 392 °F).

180 ‐ 200 °C356 ‐ 392 °F

Box 16 = F: Only the lower sealing ring is on the platen with models for

cardboard containers

Blade terminals (example)

1

1

VersaDrum

VersaPail

Repair7‐8


Replacing Temperature Sensor or ThermostatWARNING: Hot! Risk of burns. Wear heat‐protective gloves.

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

CAUTION: Tighten the nuts on the blade terminals with max. 1 Nm and holdthe lower nut to brace. Otherwise the ceramic bases or the heating elementscould be damaged.

1. Disconnect the bulk melter from the line voltage.

2. Remove the cover (1).

2 3

3.

Thermostat (2)

1. Apply heat transfer compound (Refer to page 5‐2, ProcessingMaterials) to the new thermostat and replace.

Temperature sensor (3)

1. Carefully pull the temperature sensor out of the melting plate by theconnecting cable. If it cannot be pulled out easily, the melting platemust be removed. Refer to page 7‐6, Replacing Melting Plate.

2. Apply heat transfer compound (Refer to page 5‐2, ProcessingMaterials) to the temperature sensor and insert/fasten.

4. Re‐attach the cover.

5. Start up the bulk melter again.

Parts 8‐1


Section 8

Parts

How to Use Illustrated Parts ListThe parts lists in the separate document Parts List are divided into thefollowing columns:

Item Identifies parts that can be obtained from Nordson.

Part Nordson part number for each spare part shown in the illustration. Arow of hyphens in the column Part (‐ ‐ ‐ ‐ ‐) indicates that this part can notbe ordered separately.

Description This column contains the name of the part and, whenappropriate, its dimensions and other properties. The points in thecolumn Description show the relationship between assemblies,subassemblies and single parts.

Quantity The quantity needed per unit, assembly or subassembly. Theabbreviation AR (as required) is used when this item is a bulk item orwhen the quantity per assembly depends on the product version ormodel.

NOTE: Refer to separate document Parts List.

Fasteners

Fasteners are shown as Fx in every illustration, whereby ”x” indicates thenumber of the fastener in the list Schedule of Fasteners at the end of theseparate document Parts List.

Component Designation

The electrical components are labeled in accordance with DIN 40719, part 2.

Parts8‐2


Special Models

An E instead of the ‐ in box 6 of the configuration code indicates a specialmodel. When appropriate, a so‐called Delta Parts List is added to thedocument Parts List. Then parts that differ from the standard spare partsoffering are indicated as followed:

� Note Example

#M Mechanicalcomponent

Refer to additionaldrawing

#E‐ Electrical component

Refer to wiringdiagram

Technical Data 9‐1


Section 9

Technical Data

General Data

Storage temperature - 45 °C to + 75 °C - 49 °F to + 167 °F

Min. ambient temperature - 5 ° 23 °F

Max. ambient temperature 40 °C 104 °F

Humidity 10 to 95 %, not condensing

Max. operating height 3,000 m 9840 ft

Max. material pressure 100 bar 10�000 kPa 1�450 psi

Degree of protection IP 54

Noise emission 1 m away 62 dB(A)

Motor/pump speed settingrange

1.0 to 100 min‐1

To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1 (rpm).

Suitable Containers

Code Container diameter (interior) Max. container height (exterior)

8

K 280 mm 475 mm

N 286 mm 486 mm

J 567 mm 960 mm

D 571 mm 960 mm

Technical Data9‐2


TemperaturesCAUTION: The temperature setting is determined by the processingtemperature prescribed by the material supplier. The maximum operatingtemperature for the bulk melter and heated components described here maynot be exceeded.

Box 12 = L Box 12 = M Box 12 = H

Min. operating temperature(setpoint)

40 °C 100 °F 40 °C 100 °F 40 °C 100 °F

Max. operating temperature

150 °C 300 °F 180 °C 350 °F 230 °C 450 °F

Overtemperature shutdownby thermostat

180 °C 356 °F 210 °C 410 °F 260 °C 500 °F

Air Consumption

VersaPail VersaDrum

Per cycle (platen up anddown)

Approx. 400 standard liters Approx. 600 standard liters

Exhaust Hood (Accessory)

VersaPail VersaDrum

Nominal air quantity(recommendation)

205 m3/h 510 m3/h

Pressure loss at nominal airquantity

Approx. 50 Pa Approx. 180 Pa

Connecting sleeve ∅ 100 mm ∅ 150 mm



Electrical DataWARNING: The unit is designed for only one operating voltage. Operateonly at the operating voltage shown on the ID plate.

Permitted deviation fromoperating voltage

� 10%

Operating voltagefrequency

50/60 Hz

Max. power output perheating channel

2�000 W, but also max. 2000 W per receptacle Hose/gun

(Each receptacle supplies two heating channels)

Permitted voltage deviationat interface Standard I/O

� 10%

Rated Current / Operating Voltage

Receptacles Hose/gun

Box 11

2 4 6 2 4 6 8

VersaPail VersaDrum

Op

era

tin

g v

olt

ag

e

Bo

x 9

2200 V

3 Ph �43 A 52 A 57 A 76 A 93 A 100 A 100 A

3230 V

3 Ph �38 A 45 A 53 A 67 A 81 A 96 A 97 A

4400 V

3 Ph Y22 A 30 A 31 A 38 A 47 A 55 A 56 A

5400 V

3 Ph �22 A 30 A 31 A 38 A 47 A 55 A 56 A

6480 V

3 Ph �19 A 25 A 26 A 32 A 39 A 46 A 47 A

7575 V

3 Ph �- - - 27 A 33 A 39 A 39 A

Technical Data9‐4


Dimensions and Weights

VersaPail

Note

Weight Approx. 332 kgRefer to consignment note forexact weightLoad on floor (when melter is

completely filled)Approx. 0.94 N/mm2

380

540

87

276

1920

1190



VersaDrum

Note

Weight Approx. 672 kgRefer to consignment note forexact weightLoad on floor (when melter is

completely filled)Approx. 0.41 N/mm2

580

740

87

276

3010

1520 (1905)

(800)

Box 26 = # (divided base plate): The values in parentheses apply

Technical Data9‐6


Password A‐1


Appendix A

Password

Level Functions enabled

Level 1

Operation

Normal operation for alloperators

All functions of the first operating level.

No parameters can be changed.

Level 2

Parameters

Settings for trained personnel

All functions of all operating levels

Level Nordson

Only for Nordson personnel

NORDSON setup

PasswordA‐2


This page intentionally left blank.

Password A‐3


If appropriate, remove this page and store in a safe location.

Level User name Password

1: Operator u 747

2: Trained personnel e 757

PasswordA‐4


General Instructions Regarding Working with Application Materials B‐1


Appendix B

General Instructions Regarding Working withApplication Materials

Definition of TermsApplication materials can be e.g. thermoplastic hot melt materials,adhesives, sealants, liquid adhesives and similar application materials. Theyare referred to as materials.

NOTE: The materials that may be processed with your Nordson product aredescribed in the manual under Intended Use and Unintended Use. When indoubt, please contact your Nordson representative.

Manufacturer InformationMaterials may be processed only when the manufacturer's productdescriptions and Safety Data Sheets (MSDS) are observed.

They provide information, amongst other things, on correct processing of theproduct, transport, storage and disposal. Information regarding reactivity andpotentially hazardous decomposition products, toxic properties, flash points,etc. can also be found there.

LiabilityNordson is not be liable for danger or damage resulting from the materials.

Risk of BurnsThere is a risk of burns when handling heated materials. Work carefully andwear appropriate protective clothing/equipment.

General Instructions Regarding Working with Application MaterialsB‐2


Vapors and GasesEnsure that vapors and gases do not exceed the prescribed limits. Ifnecessary, exhaust vapors and gases and/or provide sufficient ventilation ofthe work space.

SubstrateThe substrate should be free of dust, grease and moisture. The suitablematerial, optimum working conditions, and possible pre‐treatment of thesubstrate must be determined by testing.

Processing TemperatureWhen materials require heating, adherence to the prescribed processingtemperature is imperative to ensure the quality of the application. It may notbe exceeded! Overheating can cause material coking or cracking, resulting inmalfunctioning or unit failure.

Material should always be melted gently. Extended, unnecessarytemperature load should be avoided. The temperature should be reducedduring breaks in work. The temperature in the tank should be attuned to thematerial consumption. Thus it is close to the prescribed processingtemperature for high material consumption and lower for lower consumption.

When materials are processed cold, take into consideration the shear heatand the ambient temperature; cool if necessary.

Glossary C‐1


Appendix C

Glossary

Advance DistanceDistance between initiator and gun/application head.

Angel HairFine threads of adhesive that are created when adhesive is incorrectlytransferred from the nozzle to the substrate. This could be caused e.g. bypoor shaving of high viscosity material at the nozzle.

Application HeadRefer to Gun.

Application System, Hot Melt

An arrangement of units and components that melt, feed, meter and applyhot melt adhesive, e.g. bulk melter, melter, gear metering pump station, gun,coating stand and heated hoses.

Application WeightThe weight (grammage) of the application material applied to a surface unitof the substrate.

Determining the application weight: A circle cutter is used to cut several 100 mm2 sized circles from the uncoated substrate. The cut out sectionsshould be evenly distributed on the substrate. The samples are eachweighed to exactly 0.01 g, and the average weight is calculated. The same isdone with the coated substrate. The number of samples taken depends onhow much the weights of the samples differ. The application weight is thedifference between the coated and uncoated substrate. The applicationweight is usually stated in g/m2.

Assembly HandgunManually operated system component used to apply material as a bead, dot,surface or spray application.

barLegal unit for pressure. The SI unit is Pascal (Pa). The unit commonly used inthe USA is psi. Refer to Conversions.

GlossaryC‐2


Bd (Baud)

Rate of data transfer: Bit/s.

Bead Size

The width of a bead of material applied to a substrate. The size refers to thebead before it is compressed by the two parts.

CAN Bus

The Controller Area Network is an internationally standardized serial bussystem. With Nordson melters, control components such as temperaturecontrollers, motor controllers (frequency converters) and pressure sensorsexchange data with the industrial PC via the CAN bus. The CAN bus is usedas an internal network for Nordson unit control and is not intended to be aninterface for the customer's control units.

Cast‐in Heater

A resistance heating element that is cast into a tank or melting plate. Thisfixed connection provides optimal heat conducting.

Charring

Decomposition of a synthetic material, particularly through heat influence.Can occur when processing temperature is too high.

Class of protection

Protective measures are required to ensure electrical safety of the units. Themeasures prevent accessible metal parts from conducting voltage when afault occurs. Assignment of classes of protection indicates the protectivemeasures.

Class ofprotection

Symbol Precaution

1 All accessible metal parts are conductively connected to one another andare linked to the mains ground conductor.

2 The unit is insulated such that there are no accessible metal parts thatcould conduct voltage in the event of a fault. There is no ground conductor.

3 The unit is operated with extra‐low voltage up to 42 V from a safetyisolating transformer or a battery.

Glossary C‐3


Component1. System component:

This term designates a single unit (e.g. melter) that is part of an application system.

2. Unit component:This term designates a single part (e.g. coupling, EMERGENCY OFFbutton) or a group of parts that forms a functional unit (e.g. inert gasequipment).

Controller

Used to control proportional valves (pressure control unit) or solenoid valvesand guns/application heads (pattern controller) dependent on the speed ofthe parent machine.

ControlNet

Internationally standardized serial field bus with scanner and adaptersubscribers. Nordson melters (adapter) with a ControlNet interface can becontrolled remotely by the customer's control unit (scanner).

Control Voltage

Electrical cabinet internal voltage for electrical components such astemperature controllers, PLC, etc. The control voltage in Nordson electricalcabinets is usually 230 VAC or 24 VDC.

Conversions

In mesh In mm In mesh In mm

2,5 8.0 50 0.30

3 6.73 60 0.25

5 4.0 80 0.18

8 2.38 100 0.149

10 2.0 140 0.105

14 1.41 170 0.088

18 1.0 200 0.074

20 0.84 270 0.053

30 0.59 325 0.044

40 0.42 400 0.037

Table: U.S. Bureau of Standards

GlossaryC‐4


Conversions (contd.)

Unit Multiplied by Result

Density SI unit: [kg/m3]

Kilograms per cubic meter kg/m3 1.0 x 10-3 Kilograms per liter kg/l

Kilograms per cubic meter kg/m3 8.35 x 10-3 Pounds per gallon (US) lb/gal

Kilograms per liter kg/l 8.35 Pounds per gallon (US) lb/gal

Pounds per gallon (US) lb/gal 0.12 Kilograms per liter kg/l

Starting torque SI unit: [Nm]

Newtonmeter Nm 8.85 Pound inch (US) lbin

Newtonmeter Nm 0.74 Pound foot (US) lbft

Pound inch (US) lbin 0.113 Newtonmeter Nm

Pound foot (US) lbft 1.36 Newtonmeter Nm

Pressure SI unit: Pascal [Pa = N/m2]

Pascal Pa 1.0 x 10-5 Bar bar

Pascal Pa 0.69 x 10-6 Pounds per square inch (US) psi

Bar bar 14.5 Pounds per square inch (US) psi

Pounds per square inch (US) psi 0.069 Bar bar

Speed SI unit: [m/s]

Meters per second m/s 196.89 Feet per minute ft/min

Feet per minute ft/min 5.1 x 10-3 Meters per second m/s

Length SI basic unit: Meter [m]

Meter m 3.2808 Foot ft

Foot ft 0.3048 Meter m

Centimeter cm 0.3937 Inch in

Inch in 2.54 Centimeter cm

Glossary C‐5


Conversions (contd.)

Unit Multiplied by Result

Mass SI basic unit: Kilogram [kg]

Kilogram kg 2.2046 Pound (US) lb

Pound (US) lb 0.4536 Kilogram kg

Gram g 0.0353 Ounce oz

Ounce oz 28.35 Gram g

Temperature SI basic unit: Kelvin [K]

Degrees Celsius ° C (° C x 1.8) + 32 Degrees Fahrenheit ° F

Degrees Fahrenheit ° F (° F - 32) � 1.8 Degrees Celsius ° C

Viscosity, dynamic SI unit: Pascal second [Pas]

Pascal second Pas 1.0 x 103 CentipioseA cP

CentipioseA cP 1.0 x 10-3 Pascal second Pas

Viscosity, kinematic SI unit: [m2/s]

Square meters per second m2/s 1.0 x 10-6 CentistokeA cSt

CentistokeA cSt 1.0 x 106 Square meters per second m2/s

Volume SI unit: [m3]

Cubic meter m3 1. 0 x 103 Liter l

Cubic meter m3 264.2 Gallon (US) gal

Liter l 0.2642 Gallon (US) gal

Gallon (US) gal 3.7853 Liter l

NOTE: A: Has not been a legal unit since 1986.

GlossaryC‐6


dB (A)

Unit for the sound intensity level, measured according to the internationallystandardized evaluation curve A, which measures sound in a way similar tohow it is perceived by the human ear.

Degree of Protection

According to IEC 529/DIN 40 050.

The degrees of protection of electrical components through metal protectionare stated as an abbreviation such as IP 54. The first numeral stands for thecontact and impurity protection, and the second numeral indicates waterprotection. The third numeral, which indicates impact protection, is usuallynot stated.

1. numeral 2. numeral 3. numeral

IP Contact and impurityprotection

Water protection Impact protection

Protection from... Protection from... Protection from impact strengthup to...

0 - - -

1 Foreign object > 50 mm Water dripping vertically 0,225 J = Impact of 150 g from aheight of 15 cm

2 Foreign object > 12 mm Water dripping diagonally 0,375 J = Impact of 250 g from aheight of 15 cm

3 Foreign object > 2.5 mm Spray water 0,5 J = Impact of 250 g from a heightof 20 cm

4 Foreign object > 1 mm Splash water -

5 Dust accumulation Water stream 2,0 J = Impact of 500 g from a heightof 40 cm

6 Dust penetration Upon flooding -

7 - When dipped 6,0 J = Impact of 1.5 kg from aheight of 40 cm

8 - When submerged -

9 - - 20 J = Impact of 5 kg from a heightof 40 cm

Drop‐off Delay1. The time between the signal to switch off the gun/application head and

the end of material application.

2. The time that a delay relay remains engaged after it has been switchedoff.

Glossary C‐7


Encoder

The encoder compiles the line speed of the parent machine. It supplies acertain number of electrical pulses per revolution. The frequency is ameasure of line speed. Refer to Line Speed Signal.

Firmware

Internal software that cannot be changed by and that is not accessible to thecustomer.

Flap Valve

A valve through which material can only flow in one direction. The valvecloses automatically when the flow direction changes.

Free‐wheeling Diode

Electronic component that protects electronic assemblies from power surgesthat occur when relays or solenoid valves are switched off.

Grammage

Refer to Application Weight.

Gun, Hot Melt

System component used to apply material as a bead, dot, surface or sprayapplication.

Heater Cartridge

A replaceable, cylindrical resistance heating element. It is inserted into a holein the component to be heated.

Hopper

Unheated tank extension, used to increase tank volume.

Host

Higher‐order control unit.

GlossaryC‐8


Hot Melt

Synonym for hot melt adhesive.

Hot Melt Adhesive

Hot melt adhesives are thermoplastic synthetic materials. They areprocessed in a liquid state. They bond by solidifying.

Inert gas

Gas (e.g. nitrogen) used to protect the adhesive from contact with humidityand therefore from undesired reactions. Inert gas is also referred to asprotective gas.

Initiator

Component that generates a signal when an object is in a certain area of itssurroundings. Possible models are e.g. proximity initiators and light beamphoto cells.

Intermittent Mode

Mode of operation for guns/application heads. Instead of material applicationbeing continuous, it occurs with pauses to create the desired applicationpattern.

LED

Light Emitting Diode.

Line Speed Signal

A signal generated by the parent machine (voltage, current or frequency) tocontrol the melter.

Line Voltage

Voltage in the customer's network. It may need to be converted to operatingvoltage by a transformer.

Glossary C‐9


Machine Enable

A control unit is enabled by a signal from the parent machine. In Nordsonliterature the enable feature is also referred to as Parent Machine Interlock orSecurity.

Master‐Slave

The setup of two or more units in which one assumes control of one or moreslaves.

Example: Nordson melters on the PROFIBUS are slaves that are controlledby the customer's master.

Material

General Nordson term for application materials such as thermoplastic hotmelt adhesives, adhesives, sealants, cold glue, etc.

Melter

Melts and feeds hot melt adhesives or similar materials.

Menu

Branched program structure from which the operator selects the desiredfunctions/features.

min-1

min-1 = 1/min. Revolutions per minute (rpm).

MSDS

Material Safety Data Sheet.

Ni 120

Abbreviation for a nickle based resistance temperature sensor. At atemperature of 0° C (32° F), it has an electrical resistance of 120 �.

Nm

Newtonmeter, SI unit for energy and starting torque. Refer to Conversions.

GlossaryC‐10


Noise Emission

Noise level that a unit produces in the immediate vicinity. The noise emissionis stated in dB (A).

Nominal Air Quantity

States suction volume of exhaust hoods. The pressure drop from the exhausthood to the customer's fan must also be taken into consideration.

Nozzle

The component through which the material leaves the gun/application head.The nozzle determines the volume, shape and direction of the material outlet.

Open Time

The maximum time in which bonding can occur between application of thematerial to the substrate and pressing on the second part. Factors such asapplication temperature, substrate, adhesive properties and amount ofadhesive are relevant to open time.

Operating Air Pressure

The customer's compressed air supply is usually reduced by pressurecontrollers in the units. The operating air pressure is the reduced pressure atwhich pneumatic components are operated.

Operating Voltage

The voltage used to operate the unit. The operating voltage is stated on theID plate. A transformer may be necessary to adapt the melter to thecustomer's line voltage.

Output Quantity

The material volume fed by the pump. Stated e.g. in cm3/min.

Pa

Pascal, SI unit for pressure. Refer to Conversions.

Parameters

Variably adjusted values that must be entered into a control unit, a PLCcontrol or the control system.

Glossary C‐11


Parent Machine

The user's machine that generates the line speed signal for key‐to‐line mode.Refer to Line Speed Signal.

Pas

Pascal second, SI unit for dynamic viscosity.

PID Controller

A type of controller that combines different control characteristics ofproportional, integral and differential aspects.

The controller should be calibrated such that the controlled variable (outputvariable) and the manipulating variable (input variable) fluctuate as little aspossible and the time needed for the manipulating variable to stabilize is asshort as possible.

PLC

Programmable Logic Controller.

Polyamide

A term used by Nordson to describe polyamide‐based hot melt adhesives.Other common designations are polyamide resin and polyamide hot meltadhesive.

Polyurethane Hot Melt Adhesive

Moisture interlaced hot melt adhesive. Common abbreviations are PU andPUR. When processing polyurethane adhesives, additional safetyinstructions must be observed.

Power Consumption P

The electrical power consumption (wattage) of the unit (motor, heater and theelectrical components in the electrical cabinet).

Power Consumption Pmax

The maximum electrical power consumption (wattage) of the unit and theconnected accessories. It is calculated as the product of the connectedvoltage and the maximum current protected by fuse.

GlossaryC‐12


Processing Temperature

The processing temperature is prescribed or recommended by the materialmanufacturer. It can be found in the product information and/or in theMaterial Safety Data Sheet (MSDS�)

PROFIBUS

Internationally standardized serial field bus with master‐slave subscribers.Nordson melters (slave) with a PROFIBUS DP interface can be controlledremotely by one of the customer's control units (master).

Proper Disposal

Disposal of all types of waste in compliance with all local regulations.

Proportional Pressure Control Valve

Electropneumatic component that enables control of pneumatic pressurewith an electrical variable (usually control voltage).

Protective Gas

Refer to Inert Gas.

Pt 100

Abbreviation for a platinum based resistance temperature sensor. At atemperature of 0° C (32° F), it has an electrical resistance of 100 �.

Pull‐in Delay1. The time between the signal to switch on the gun/application head and

the beginning of material application.

2. The time between when the voltage is turned on and when the delayrelay is actually engaged.

PUR

Refer to Polyurethane Hot Melt Adhesive.

Rated Current

The setpoint for current to a unit, determined by standards or as agreed uponby the manufacturer and the customer.

Glossary C‐13


Release Coating

Largely prevents hot melt adhesive from burning onto the surface and makesit easier to clean the application system parts coming into contact with theadhesive.

Residual Risks

Hazards that can pose a danger to the user, even when all safety regulationsfor manufacturing a product are followed and when the unit is used only asintended. Residual risks are noted ‐ as extensively as the manufacturer isaware of them ‐ in the manual and/or with waning signs on the unit.

Resistance Temperature Sensor

Component with an electrical resistance, the value of which changes as afactor of the temperature. Nordson units use the models Pt 100 and Ni 120.

Reverse Mode

A pump motor operates counter to the direction of material feeding. Preventsmaterial from dripping.

RPM

Revolutions per minute, same as min-1 = 1/min.

Safety Valve

A valve that prevents the material pressure from exceeding a preset value.

Safety Valve Plate

A component in which material circulates when the installed safety valve isopen.

Set Time

The amount of time that the adhesive needs from application to completehardening.

SI

Système International d' Unités (international standardization system).

GlossaryC‐14


Solenoid Valve

Usually part of the gun/application head. A control valve that is activated byan electromagnetic coil.

Solid State Relay

Electronic assembly without mechanical parts but with the function of anelectromechanical relay.

Solvent

Solvents are liquid, organic materials and their compounds, used to cleanadhesive off of surfaces. Solvents are slightly volatile. Special regulationsmust be followed when using solvents.

In Nordson literature, the solvent is always the substance prescribed by thehot melt manufacturer.

Substrate

The product - fabric, foil, etc. - to which a material is applied.

Tach Generator

A component that generates electrical voltage (pilot voltage). The voltage isproportional to the speed at which the tach generator is driven.

Temperature Sensor

A part of a temperature control system that compiles the temperature andtransmits it to the control system. Resistance temperature sensor are used inNordson units.

Thermostat

Component that regulates temperature. It is usually an electrical switch thatswitches at a certain or set temperature. The difference between thetemperatures at which the unit switches on and off is called hysteresis.

Transformer

Voltage converter.Used in Nordson units to convert the customer's line voltage to the operatingvoltage.

Glossary C‐15


VAC

Abbreviation for Alternating Current. AC voltage.

VDC

Abbreviation for Direct Current. DC voltage.

Viscosity

Strength; an indication of the force that must be generated to move a liquid:

1. Viscosity (also called dynamic viscosity). Unit: Pas (Refer to Conversions).

2. Kinematic viscosity (dynamic viscosity divided by material density). Unit: m2/s (Refer to Conversions).

GlossaryC‐16


Communication Data List D‐1


Appendix D

Communication Data List

� The data is transmitted in four tags:

� Scheduled Read Data

� Scheduled Write Data

� Unscheduled Read Data

� Unscheduled Write Data

Communication Data ListD‐2


Scheduled Read Data

Data designation Channelnumber

Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Melter mode 0 CS_READ_SD[0] N20:0 0 / 1

0: Local mode

1: Field bus mode

Melter status 1 0 CS_READ_SD[1] N20:1 Bit field

Bit 0 Value: 1 System ready

0 System not ready

Bit 1 Value: 1 Startup protection

0 No startup protection

Bit 2 Value: 1 Warning

0 No warning

Bit 3 Value: 1 Fault

0 No fault

Bit 4 Value: 1 Shutdown

0 No shutdown

Bit 5 Value: 1 Heatup phase

0 No heatup

Bit 6 Value: 1 Start standby

0 Stop standby

Bit 7 Value: 1 Motor 1 running

0 Motor 1 not running










Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Melter status 2 0 CS_READ_SD[2] N20:2 0 - 13

0: Reserved

1: Heatup phase

2: Startup protection

3: System ready

4: Motor running

5: Warning

6: Fault

7: Shutdown

8: Standby

9: Heaters off

10: Reserved

11: Motor circuit switch open

12: Enable all motors for key‐to‐line mode

13: Pressure build‐up completed

14: Plate outside of drum

16: Container is empty

17: No container

18: Plate startup protection

20: Material level low




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Melter status and alarms 0 CS_READ_SD[3] N20:3 Bit field

Bit 0 Value: 1 Alarm: Main contactor

0 No alarm

Bit 1 Value: 1 Alarm: Field buscommunication failure

0 No alarm

Bit 2 Value: 1 Alarm: PLC battery voltagelow

0 No alarm

Bit 3 Value: 1 Service interval expired

0 Service interval is notexpired

Bit4-8

Reserved

Bit 9 Value: 1

0

Tank is being filled

Tank is not being filled

Bit 10 Value: 1 Alarm: Tank overfilled

0 No alarm

Bit 11 Value: 1 Alarm: Tank level low

0 No alarm

Bit 12 Value: 1 Warning: Tank is empty

0 No alarm

Bit 13 Value: Reserved

Bit 14 Value: 1 Pressure build‐upcompleted

0 Pressure build‐up notcompleted

Bit 15 Value: 1 Motor circuit switch open

0 Motor circuit switch closed




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Reserved 0 CS_READ_SD[4] N20:4 Bit field

Alarm: Pressure sensor A 0 CS_READ_SD[5] N20:5 Bit field

Bit 0 Value: 1 Pressure sensor A channel 1 failure

0 No failure

. . .

Bit 11 Value: 1 Pressure sensor A channel 12 failure

0 No failure

Alarm: Pressure sensor B 0 CS_READ_SD[6] N20:6 Bit field

Bit 0 Value: 1 Pressure sensor B channel 1 failure

0 No failure

. . .

Bit 11 Value: 1 Pressure sensor B channel 12 failure

0 No failure

Alarm: Pressure sensor C 0 CS_READ_SD[7] N20:7 Bit field

Bit 0 Value: 1 Pressure sensor C channel 1 failure

0 No failure

. . .


0 No failure

Alarm: Pressure sensor C 0 CS_READ_SD[8] N20:8 Bit field


0 No failure

. . .


0 No failure

Reserved 0 CS_READ_SD[9] N20:9 Bit field

Actual speed 1 - 12 CS_READ_SD[10]

- CS_READ_SD[21]

N20:10

- N20:21

0.0 - 100.0min‐1




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Motor status and alarms 1 - 12 CS_READ_SD[22] N20:22 Bit field

Bit 0 Value:

1 Motor running - CS_READ_SD[33] - N20:33

0 Motor not running

Bit 1 Value:

1 Alarm: Motor couplingblocked

0 No alarm

Bit 2 Value:

1 Alarm: Phase missing

0 No alarm

Bit 3 Value:

1 Alarm: Motorovertemperature

0 No alarm

Reserved 0 CS_READ_SD[34]

- CS_READ_SD[46]

N20:34

- N20:46

Bit field



Scheduled Write Data


Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

General control data 2 0 CS_WRITE_SD[0] N21:0 Bit field

Bit 0 Value: 1 Heaters ON

0 Heaters OFF

Bit 1 Value: 1 All motors ON

0 All motors OFF

Bit 2 Value: 1 Enable motor 1

0 Motor 1 not enabled







Bit 6 Value: 1 Start standby

0 Stop standby

Bit 7 Value: 1 Key‐to‐line mode (allmotors)

0 Manual mode (all motors)




















Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Motor mode 0 CS_WRITE_SD[1] N21:1 Bit field

Bit 0 Value: 0 Speed control motor #1

1 Pressure control motor #1

. . .

Bit 12 Value: 0 Speed control motor #12

1 Pressure control motor #12

Switch motor to manual mode / key‐to‐line 0 CS_WRITE_SD[2] N21:2 Bit field

Bit 0 Value: 0 Manual mode motor 1

1 Key‐to‐line mode motor #1

. . .

Bit 11 Value: 0 Manual mode motor 12

1 Key‐to‐line mode motor #12

General control data 2 0 CS_WRITE_SD[3] N21:3 Bit field

Bit 4 Value: 1 Line start signal

0 Line stop signal

Bit 9 Value: 1 Enable flow control mode

0 Do not enable flow controlmode

Pressure setpoint, in manual mode 1 - 12 CS_WRITE_SD[4]

- CS_WRITE_SD[15]

N21:4

- N21:15

1 -70% ofmeasuring‐

range

Pressure build‐up enabled CS_WRITE_SD[16] N21:16 Bit field

Bit 0 Value: 0 Pressure build‐up motor #1 enabled

1 Pressure build‐up motor #1 not enabled

. . .

Bit 11 Value: 0 Pressure build‐up motor #12 enabled

1 Pressure build‐up motor #12 not enabled

Line speed signal for motor 1 - 12 1 - 12 CS_WRITE_SD[17]

- CS_WRITE_SD[28]

N21:17

N21:28

0.0 -100.0%

Factor 10

Speed setpoint, in manual mode 1 - 12 CS_WRITE_SD[29]

- CS_WRITE_SD[40]

N21:29

N21:40

1.0 - 100.0min‐1



Unscheduled Read Data


Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Manufacturer 0 CS_READ_UD[0]-CS_READ_UD[3]

N22:0 -N22:3

Nordson

Software version PLC 0 CS_READ_UD[4] N22:4 1.000 -9.999

Factor:1000

Software version HMI 0 CS_READ_UD[5] N22:5 1.000 -9.999

Factor:1000

Total hours with heaters on 0 CS_READ_UD[6] N22:6 0 - 32�767

Hours with heaters on (longer than 32767 h)(Multiply the displayed value by 32767 and thenadd the value shown under the tag addressCS_READ_UD[6] to determine the correctnumber of hours of heater operation)

0 CS_READ_UD[7] N22:7 0 - 32�767

Reserved 0 CS_READ_UD[8]

- CS_READ_UD[12]

N22:8

- N22:12

Bit field

Motor OFF delay 1 - 12 CS_READ_UD[13]

- CS_READ_UD[24]

N22:13

- N22:24

0 -30 s

Status: Motor OFF delay 0 CS_READ_UD[25] N22:25 Bit field

Bit 0 Value: 1 Motor 1 Motor OFF delayoperating

0 Motor 1 Motor OFF delay not operating

. . .

Bit 11 Value: 1 Motor 12 Motor OFF delayoperating

0 Motor 12 Motor OFF delaynot operating

Pressure unit for all values 0 CS_READ_UD[26] N22:26 0 / 1

0: bar

1: psi

Temperature unit 0 CS_READ_UD[27] N22:27 0 / 1

0: ° Celsius

1: ° Fahrenheit




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Status: Temperature channel 3 - 54 CS_READ_UD[28] N22:28 0 - 4

0: Switched off - CS_READ_UD[79] - N22:79

1: Deactivated

2: Display mode

3: Control mode

4: Standby

Reserved CS_READ_UD[80]

- CS_READ_UD[83]

N22:80

- N22:83

Bit field

Actual temperature 1 - 54 CS_READ_UD[84]

- CS_READ_UD[137]

N22:84

- N22:137

-10 - 250° C

(32 - 480° F)

Value for overtemperature shutdown 1 - 54 CS_READ_UD[138]

- CS_READ_UD[191]

N22:138

- N22:191

Overtemp.fault

+10 °C(20 ° F)

Temperature status and alarms 1 - 54 CS_READ_UD[192] N22:192 Bit field

Bit 0 Value: 1 Heater switched on - CS_READ_UD[245] -

0 Heater switched off N22:254

Bit 1 Value: 1 Alarm: Undertemperaturewarning

0 No alarm

Bit 2 Value: 1 Alarm: Undertemperaturefault

0 No alarm

Bit 3 Value: 1 Alarm: Overtemperaturewarning

0 No alarm

Bit 4 Value: 1 Alarm: Overtemperaturefault

0 No alarm

Bit 5 Value: 1 Alarm: Overtemperatureshutdown

0 No alarm

Bit 6 Value: 1 Alarm: Sensor short‐circuit(fault)

0 No alarm

Bit 7 Value: 1 Alarm: Sensor input openor sensor broken (fault)

0 No alarm

Reserved CS_READ_UD[246]

- CS_READ_UD[257]

N22:246

- N22:257

Bit field




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Actual level 1 - 2 CS_READ_UD[258]

- CS_READ_UD[259]

N22:258

- N22:259

0 - 100 %

Actual pressure value (sensor A) 1 - 12 CS_READ_SD[260]

- CS_READ_SD[271]

N20:260

-N20:271

0 -400 bar

0-5�800 psi

Actual pressure value (sensor B) 1 - 12 CS_READ_SD[272]

- CS_READ_SD[283]

N20:272

-N20:283

0 -400 bar

0-5�800 psi

Actual pressure value (sensor C) 1 - 24 CS_READ_SD[284]

- CS_READ_SD[307]

N20:284

-N20:307

0 -400 bar

0-5�800 psi

Pressure status and alarms 1 - 24 CS_READ_SD[308] N20:308 Bit field

Bit 0 Value: 1 Alarm: Pressure sensor A,underpressure warning

- CS_READ_SD[331] -N20:331

0 No alarm

Bit 1 Value: 1 Alarm: Pressure sensor A,overpressure warning

0 No alarm

Bit 2 Value: 1 Alarm: Pressure sensor A,overpressure fault

0 No alarm

Bit 3 Value: 1 Alarm: Pressure sensor B,underpressure warning

0 No alarm

Bit 4 Value: 1 Alarm: Pressure sensor B,overpressure warning

0 No alarm

Bit 5 Value: 1 Alarm: Pressure sensor B,overpressure fault

0 No alarm

Bit 6 Value: 1 Alarm: Pressure sensor C,underpressure warning

0 No alarm

Bit 7 Value: 1 Alarm: Pressure sensor C,overpressure warning

0 No alarm

Bit 8 Value: 1 Alarm: Pressure sensor C,overpressure fault

0 No alarm



Unscheduled Write Data


Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Service interval 0 CS_WRITE_UD[0] N23:0 1 - 8736 h(1 year)

Reset service symbol 0 CS_WRITE_UD[1] N23:1 0 / 1

0: No reset

1: Reset

Reserved 1 - 12 CS_WRITE_UD[2]

- CS_WRITE_UD[13]

N23:2

- N23:13

Bit field

Key‐to‐line

Max line speed at n % of the value at which thepumps begin to turn at the speed set in Max.speed.

1 - 12 CS_WRITE_UD[14]

- CS_WRITE_UD[25]

N23:14

- N23:25

0.0 - 100.0%

Key‐to‐line

Max. speed


- CS_WRITE_UD[37]

N23:26

- N23:37

1.0 - 100.0min‐1

Key‐to‐line

Min. speed


- CS_WRITE_UD[49]

N23:38

- N23:49

0.0 - 100.0min‐1

Key‐to‐line

Min line speed at n % of the value at which thepumps begin to turn at the speed set in Min.speed.


- CS_WRITE_UD[61]

N23:50

- N23:61

0.0 - 100.0%

Motor OFF delay 1 - 12 CS_WRITE_UD[62]

- CS_WRITE_UD[73]

N23:62

- N23:73

0 -30 s

Reserved 0 CS_WRITE_UD[74]

- CS_WRITE_UD[98]

N23:74

- N23:98

Bit field

Activate/deactivate threshold switch 0 CS_READ_UD[99] N22:99 Bit field

Bit 0 Value: 0 Deactivate motor #1

1 Activate motor #1

. . .

Bit 11 Value: 0 Deactivate motor #12

1 Activate motor #12

Upper threshold value 1 - 12 CS_WRITE_UD[100]

- CS_WRITE_UD[111]

N23:100

- N23:111

1.0 - 100.0%

Lower threshold value 1 - 12 CS_WRITE_UD[112]

- CS_WRITE_UD[123]

N23:112

- N23:123

1.0 - 100.0%

Reserved 0 CS_WRITE_UD[124]

- CS_WRITE_UD[148]

N23:124

- N23:148

Bit field




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

PID pressure control parameter Xp 1 - 12 CS_WRITE_UD[149]

- CS_WRITE_UD[160]

N23:149

- N23:160

0.00 -300.00

PID pressure control parameter Tn 1 - 12 CS_WRITE_UD[161]

- CS_WRITE_UD[172]

N23:161

- N23:172

10 - 32�000ms

PID pressure control parameter Td 1 - 12 CS_WRITE_UD[173]

- CS_WRITE_UD[184]

N23:173

- N23:184

0.0 - 50.0

Activate pressure alarm monitoring 0 CS_WRITE_UD[185] N22:185 0 / 1

0: Deactivate

1: Activate

Pressure sensor A, underpressure value(warning)

1 - 12 CS_WRITE_UD[186]

- CS_WRITE_UD[197]

N23:186

- N23:197

Pressure sensor B, underpressure value(warning)

1 - 12 CS_WRITE_UD[198]

- CS_WRITE_UD[209]

N23:198

- N23:209

Pressure sensor C, underpressure value(warning)

1 - 24 CS_WRITE_UD[210]

- CS_WRITE_UD[233]

N23:210

- N23:233

Pressure sensor A, overpressure value(warning)

1 - 12 CS_WRITE_UD[234]

- CS_WRITE_UD[245]

N23:234

- N23:245

Pressure sensor B, overpressure value(warning)

1 - 12 CS_WRITE_UD[246]

- CS_WRITE_UD[257]

N23:246

- N23:257

Pressure sensor C, overpressure value(warning)

1 - 24 CS_WRITE_UD[258]

- CS_WRITE_UD[281]

N23:258

- N23:281

Pressure sensor A, overpressure value(fault)

1 - 12 CS_WRITE_UD[282]

- CS_WRITE_UD[293]

N23:282

- N23:293

Pressure sensor B, overpressure value(fault)

1 - 12 CS_WRITE_UD[294]

- CS_WRITE_UD[305]

N23:294

- N23:305

Pressure sensor C, overpressure value(fault)

1 - 24 CS_WRITE_UD[306]

- CS_WRITE_UD[329]

N23:306

- N23:329

Key‐to‐line

Max. pressure

1 - 12 CS_WRITE_UD[330]

- CS_WRITE_UD[341]

N23:330

- N23:341

1% to endof

measuringrange




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Key‐to‐line

Min. pressure

1 - 12 CS_WRITE_UD[342]

- CS_WRITE_UD[353]

N23:342

- N23:353

1% to endof

measuringrange

Line speed at which pressure build‐upbegins

1 - 12 CS_WRITE_UD[354]

- CS_WRITE_UD[365]

N23:354

- N23:365

0.0 -100.0%

Pressure setpoint for pressure build‐upwhen the parent machine stops

1 - 12 CS_WRITE_UD[366]

- CS_WRITE_UD[377]

N23:366

- N23:377

1% to endof

measuringrange

Activate/deactivate temperature channel 0 CS_WRITE_UD[378] N23:378 Bit field

Bit 0 Value: 0 Deactivate channel #1

1 Activate channel #1

. . .






. . .






. . .






. . .



Switch application group 0 CS_WRITE_UD[382] N23:382 Bit field

Falling edge: Switch application group tostandby or

Falling edge: Deactivate application group

Rising edge: Switch application group to controlmode

Bit 0 Application group A

. . .

Bit 7 Application group H




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Temperature channel control mode / display mode

0 CS_WRITE_UD[383] N23:383 Bit field

Bit 0 Value: 0 Display mode channel #1

1 Control mode channel #1

. . .







. . .







. . .







. . .



Temperature setpoint 1 - 54 CS_WRITE_UD[387]

- CS_WRITE_UD[440]

N23:387

- N23:440

40 - 230 °C

(100 - 450°F)

Reserved CS_WRITE_UD[441]

- CS_WRITE_UD[444]

N23:441

- N23:444

Bit field

PID temperature control parameter Xp 1 - 54 CS_WRITE_UD[445]

- CS_WRITE_UD[498]

N23:445

- N23:498

0.00 -300.00

PID temperature control parameter Tn 1 - 54 CS_WRITE_UD[499]

- CS_WRITE_UD[552]

N23:499

- N23:552

10 - 32�000ms

PID temperature control parameter Td 1 - 54 CS_WRITE_UD[553]

- CS_WRITE_UD[606]

N23:553

- N23:606

0.0 - 50.0




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution


- CS_WRITE_UD[609]

N23:607

- N23:609

Bit field

Standby value 1 - 54 CS_WRITE_UD[610]

- CS_WRITE_UD[663]

N23:610

- N23:663

25 - 190 ° C

(50 - 350° F)


- CS_WRITE_UD[667]

N23:664

- N23:667

Bit field

Manual Standby Duration 0 CS_WRITE_UD[668] N23:668 1 - 1�440min

Automatic enter standby after motor stop 0 CS_WRITE_UD[669] N23:669 0 / 1

0: Not enabled

1: Enabled

Automatic enter standby after motor stop 0 CS_WRITE_UD[670] N23:670 1 - 1�440min

Value for undertemperature warning 1 - 54 CS_WRITE_UD[671]

- CS_WRITE_UD[724]

N23:671

- N23:724

5 -30 ° C

(10 -55 ° F)


- CS_WRITE_UD[728]

N23:725

- N23:728

Bit field

Value for undertemperature fault 1 - 54 CS_WRITE_UD[729]

- CS_WRITE_UD[782]

N23:729

- N23:782

5 -60 ° C

(10 -110° F)


- CS_WRITE_UD[786]

N23:783

- N23:786

Bit field

Value for overtemperature warning 1 - 54 CS_WRITE_UD[787]

- CS_WRITE_UD[840]

N23:787

- N23:840

5 -30 ° C

(10 -55 ° F)


- CS_WRITE_UD[844]

N23:841

- N23:844

Bit field

Value for overtemperature fault 1 - 54 CS_WRITE_UD[845]

- CS_WRITE_UD[898]

N23:845

- N23:898

5 -60 ° C

(10 -110° F)


- CS_WRITE_UD[917]

N23:899

- N23:917

Bit field




Tag address

(DINT)

AddressPLC 5format

(INT)

Settingrange,

resolution

Switch on/off inert gas injection (manual) 0 CS_WRITE_UD[918] N23:918 0 / 1

0: Switch off

1: Switch on

Gas on duration 0 CS_WRITE_UD[919] N23:919 2 - 120 s

Gas off duration 0 CS_WRITE_UD[920] N23:920 2 -120 min

Gas on duration after closing lid 0 CS_WRITE_UD[921] N23:921 2 -240 s

Air exhaust duration after closing lid 0 CS_WRITE_UD[922] N23:922 2 -240 s

Level: Start (filling) at 2 CS_WRITE_UD[923]

- CS_WRITE_UD[924]

N23:923

- N23:924

5 - 98 %

Level: Stop (filling) at 2 CS_WRITE_UD[925]

- CS_WRITE_UD[926]

N23:925

- N23:926

5 - 98 %

Warning Tank Level Low 2 CS_WRITE_UD[927]

- CS_WRITE_UD[928]

N23:927

- N23:928

5 - 90 %

Enable/disable level control 2 CS_WRITE_UD[929] N23:929 0 / 1

0: Deactivate

Now the tank can be emptied formaintenance or repair work without thefault Tank empty occurring.

- CS_WRITE_UD[930] - N23:930

1: Activate

Pneumatic Diagram E‐1


Appendix E

Pneumatic Diagram

Continued...

Pneumatic DiagramE‐2


X

3 2

1

135

42

12

3

312

2 13

X

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312

312

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plu

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option automatic

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p:

VP

: 1,6

bar

VP

: 1,6

bar

VP

: 1,6

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VP

: 1,6

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VD

: 2,0

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VD

: 2,0

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F

bulk melters versadrum vd200 (p/n 7144289, 7155290...

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