durablue adhesive melters model d25, d25h, d50,...

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

DuraBlue�Adhesive Melters

Model D25, D25H, D50, D100

Manual P/N 397056J− English −

Issued 03/11

P/N 397056J � 2011 Nordson CorporationDuraBlue

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.No part of this document may be photocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information contained in this publication is subject to

change without notice.

� 2011 All rights reserved.

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,Excel 2000, 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, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OptiMix, Package ofValues, 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, Seal Sentry, SelectCharge, 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, When you expectmore. are registered trademarks − ® − of Nordson Corporation.

Accubar, 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, Clean Coat, 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, GetGreen 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, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI,Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PurTech, Quad Cure, Ready Coat, RediCoat, RoyalBlue, 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, 2 Rings (Design) are trademarks − � − of Nordson Corporation.

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

Table of Contents I

P/N 397056J� 2011 Nordson Corporation DuraBlue

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. . . . . . . . . . . . . . . . . . . .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 1-4. . . . . . . . . . . . . . . .Intended Use of the Equipment 1-4. . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 1-4. . . . . . . . . . . . . . . . . .Installation Practices 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 1-6. . . . . . . . . . . . . . . . .

Equipment Safety Information 1-7. . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 1-7. . . . . . . . . . . . .De-energizing the System 1-7. . . . . . . . . . . . . . . . . . . . . . .Disabling the Guns 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 1-9. . . . . . . . . . . . .Other Safety Precautions 1-12. . . . . . . . . . . . . . . . . . . . . . . . .First Aid 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Area of Use (EMC) 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Restrictions 2-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use − Examples − 2-1. . . . . . . . . . . . . . . . . . . . .Residual Risks 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Description 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Valve Plate 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Isolation Valve 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Valve 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hopper 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control Valve 2-5. . . . . . . . . . . . . . . . . . . . . . . . .

Material Flow with Two Pumps 2-6. . . . . . . . . . . . . . . . . . . . .Electrical Cabinet 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modes of Operation 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Scan (Normal Mode) 2-8. . . . . . . . . . . . . . . . . .Standby 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ID Plate 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked Melter) 3-2. . . . . . . . . . . . . . . . . . . . . . . . .Installation Requirements 3-2. . . . . . . . . . . . . . . . . . . . . . . . .

Required Space 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching Protective Panels 3-2. . . . . . . . . . . . . . . . . . . . . .

Exhausting Material Vapors 3-3. . . . . . . . . . . . . . . . . . . . . . . .Experience of Installation Personnel 3-3. . . . . . . . . . . . . . . .Pneumatic Connections 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Pressure Control / Bypass Control (Option) 3-4Required Air Quality 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Pressures 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe when Using Residual Current Circuit Breakers 3-5Laying Cable 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Voltage 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Control and Switching Circuits 3-5. . . . . . . . . . . . .Power Supply Connection 3-6. . . . . . . . . . . . . . . . . . . . . . . . .

Mains Filter 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Kit (Accessory) 3-6. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Melter Inputs 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .To wire inputs to the melter 3-7. . . . . . . . . . . . . . . . . . . . . . . .To Set up an Input 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Melter Outputs 3-10. . . . . . . . . . . . . . . . . . . . . . . . . .To connect an output to the melter 3-10. . . . . . . . . . . . . . . . .

Table of Contents III


Setting up Melter Communications 3-12. . . . . . . . . . . . . . . . .Connecting Hose 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Electrically 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second Open-jawed Wrench 3-13. . . . . . . . . . . . . . . . . . . .Disconnecting Hose 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Speed Setpoint 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Up the Melter 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick Setup 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Parameters 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Operating Parameters 3-19. . . . . . . . . . . . . . . . .Reading or Editing Operating Parameters 3-20. . . . . . . . .

Setpoint Temperature of the Tank, Hoses, and Guns 3-22.To Assign a Global Setpoint Temperature 3-23. . . . . . . . .

Save and Restore Melter Settings 3-24. . . . . . . . . . . . . . . . . .To save current settings 3-24. . . . . . . . . . . . . . . . . . . . . . . .To restore saved settings 3-24. . . . . . . . . . . . . . . . . . . . . . .

Review Parameter and Setpoint Temperature Changes 3-25To Review the Change History Log 3-25. . . . . . . . . . . . . . .Change History Log Examples 3-27. . . . . . . . . . . . . . . . . .

Removing Melter 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposing of Melter 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Additional Information 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Startup 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purging Test Material out of Melter 4-2. . . . . . . . . . . . . . . . .Pump 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manually 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Level 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heated Components 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Melter 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .To Start the Melter 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring the Melter 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Confirm that the Melter is Operating Correctly 4-8. . . . . . .Monitor Component Temperatures 4-9. . . . . . . . . . . . . . . . .

To Check Component Temperatures Using the Automatic Scan Mode 4-10. . . . . . . . . . . . . . . . . . . . . . . . . .To Manually Check a Component’s Temperature 4-10. . .

Monitor Melter Faults 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .F1, F2 and F3 Faults 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . .F4 Fault 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resetting Melter 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Log 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Log Examples 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor the Service Interval 4-19. . . . . . . . . . . . . . . . . . . . . . .To Reset the Service LED 4-19. . . . . . . . . . . . . . . . . . . . . . .

Adjusting Component Temperatures 4-20. . . . . . . . . . . . . . . .Recommended Temperatures 4-20. . . . . . . . . . . . . . . . . . . . .

To Adjust the Setpoint Temperature Using the Global Method 4-21. . . . . . . . . . . . . . . . . . . . . . .To Adjust the Setpoint Temperature Using the Global-by-component Method 4-22. . . . . . . . . .To Adjust the Setpoint Temperature of an Individual Component 4-23. . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Password 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .To Enter a Melter Password 4-26. . . . . . . . . . . . . . . . . . . . .

Function keys 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater Key 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Keys 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup Key 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-day Clock Key 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby Key 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the Melter 4-31. . . . . . . . . . . . . . . . . . . . . . . . . .To Shut the Melter Down 4-31. . . . . . . . . . . . . . . . . . . . . . . . . .

Settings Record 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual Inspection for External Damage 5-4. . . . . . . . . . . . . .Changing Type of Material 5-4. . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5-5. . . . . . . . . . . . . . . . . . . . . . .Detaching Protective Panels 5-5. . . . . . . . . . . . . . . . . . . . . . .Detaching Insulation Blanket 5-5. . . . . . . . . . . . . . . . . . . . . . .Fan and Air Filter 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for Leakage 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Retighten Gland Bolt 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Pump Shaft Seal 5-7. . . . . . . . . . . . . . . . . . . . . . .Tightening Fixing Screws 5-7. . . . . . . . . . . . . . . . . . . . . . . . .

Motor / Gear Box 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Lubricant 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricant Selection 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Control Valve 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembling and Cleaning 5-9. . . . . . . . . . . . . . . . . . . . . .

Filter Cartridge 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Filter Cartridge 5-10. . . . . . . . . . . . . . . . . . . . . . . . .

Removing Filter Cartridge 5-10. . . . . . . . . . . . . . . . . . . . . . .Installing Filter Cartridge 5-10. . . . . . . . . . . . . . . . . . . . . . . .

Installing Service Kit 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Material 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Tank by Hand 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening Fixing Screws 5-12. . . . . . . . . . . . . . . . . . . . . . . . .

Safety Valve 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Safety Valve (Option) 5-14. . . . . . . . . . . . . . . . . . .

Performance Check 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Record Form 5-15. . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVI


Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Helpful Tips 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter not Functioning 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .One Channel (Heating Zone) does not Heat 6-2. . . . . . . . .Control Panel does not Function 6-2. . . . . . . . . . . . . . . . . . .No Material (Motor does not Rotate) 6-3. . . . . . . . . . . . . . . .No Material (Motor Rotating) 6-4. . . . . . . . . . . . . . . . . . . . . .Too Little Material 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressure too High 6-5. . . . . . . . . . . . . . . . . . . . . . . .Material Pressure too Low 6-5. . . . . . . . . . . . . . . . . . . . . . . .Material Residue in Tank 6-5. . . . . . . . . . . . . . . . . . . . . . . . . .Material Hardens in Tank 6-6. . . . . . . . . . . . . . . . . . . . . . . . . .Others 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LEDs of Motor Controller 6-7. . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe Before Performing Repairs 7-1. . . . . . . . . . . . . . . .Relieving Pressure 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Motor Controller 7-2. . . . . . . . . . . . . . . . . . . . . . . .

Replace Standard I/O Module of Motor Controller 7-2. . . .Pump 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Pump 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tank Isolation Valve 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Detaching Pump 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attaching Pump 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Important Regarding Coupling 7-5. . . . . . . . . . . . . . . . . . .

Replacing Variseal 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly Tool 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Motor 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Filter Cartridge 7-8. . . . . . . . . . . . . . . . . . . . . . . . .Replacing Safety Valve 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . .Tank 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Heater Connection Insulation 7-9. . . . . . . . . . . .Replacing Temperature Sensor 7-10. . . . . . . . . . . . . . . . . . . .

Installing Service Kit 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Thermostat 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fasteners 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Component Designation 8-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents VII


Technical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical Data 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating Parameters B-1. . . . . . . . . . . . . . . . . . . . . . . . .Standard B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input Setup B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output Setup B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-day clock B-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PID Selection B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVIII


O-1Introduction

� 2011 Nordson CorporationAll rights reserved

NI_EN_O-0211-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

� 2011Nordson CorporationAll rights reserved

NI_EN_O-0211-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 EastDED, Germany 49-211-92050 49-211-254 658

Asia / Australia / Latin America

Pacific South Division,USA

1-440-685-4797 −

JapanJapan 81-3-5762 2700 81-3-5762 2701

North AmericaCanada 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

� 2011 Nordson CorporationA1EN−01−[XX−SAFE]−10

Section 1Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation,operation, and maintenance (hereafter referred to as “use”) of the productdescribed in this document (hereafter referred to as “equipment”).Additional safety information, in the form of task-specific safety alertmessages, appears as appropriate throughout this document.

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

Safety Alert Symbols

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

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

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

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

Safety1-2


Responsibilities of the Equipment Owner

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

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

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

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

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

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

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

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

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

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

Safety 1-3


User QualificationsEquipment owners are responsible for ensuring that users:

� Receive safety training appropriate to their job function as directedby governing 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

Safety1-4


Applicable Industry Safety Practices

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

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

specified in this document.

� Do not modify the equipment.

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

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

referenced documents.

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

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

Safety 1-5


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

document and in the documentation provided with auxiliary devices.

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

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

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

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

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

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

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

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

and indicators.

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

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

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

Safety1-6


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

this document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

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

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

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

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

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

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

� Keep equipment safety warning labels clean. Replace worn ordamaged labels.

Safety 1-7


Equipment Safety Information

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

� hot melt and cold adhesive application equipment and all relatedaccessories

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

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

Relieving System Hydraulic PressureCompletely 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 SystemIsolate the system (melter, hoses, guns, and optional devices) from allpower sources before accessing any unprotected high-voltage wiring orconnection point.

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

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

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

Safety1-8


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

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

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

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

Safety 1-9


General Safety Warnings and CautionsTable 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, guns, etc.)

PC = Process control

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

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 acompatible Nordson melter, read and comply with the material’sMSDS. Ensure that the material’s processing temperature andflashpoints will not be exceeded and that all requirements for safehandling, ventilation, first aid, and personal protective equipment aremet. Failure to comply with MSDS requirements can cause personalinjury, including death.

HM

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

HM, CA

WARNING: System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relievethe system hydraulic pressure can result in the uncontrolled release ofhot melt or cold adhesive, causing personal injury.

HM

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

Continued...

Safety1-10


General Safety Warnings and Cautions (contd)

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


HM, PC

WARNING: Equipment starts automatically! Remote triggeringdevices are used to control automatic hot melt guns. Before workingon or near an operating gun, disable the gun’s triggering device andremove the air supply to the gun’s solenoid valve(s). Failure todisable the gun’s triggering device and remove the supply of air to thesolenoid valve(s) can result in personal injury.

HM, CA, PC

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

HM, CA, PC

WARNING: Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and should not be usedwith solvent-based adhesives that can create an explosiveatmosphere when processed. Refer to the MSDS for the adhesive todetermine its processing characteristics and limitations. The use ofincompatible solvent-based adhesives or the improper processing ofsolvent-based adhesives can result in personal injury, including death.

HM, CA, PC

WARNING: 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.

Continued...

Safety 1-11



HM

CAUTION: Hot surfaces! Avoid contact with the hot metal surfacesof guns, hoses, and certain components of the melter. If contact cannot 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.If you are unsure of the equipment’s ability to process PUR, contactyour Nordson representative for assistance.

HM, CA

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

HM

CAUTION: Nordson hot melt equipment is factory tested withNordson Type R fluid that contains polyester adipate plasticizer.Certain hot melt materials can react with Type R fluid and form a solidgum that can clog the equipment. Before using the equipment,confirm that the hot melt is compatible with Type R fluid.

Safety1-12


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

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

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

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

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

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

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

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

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

Introduction 2-1


Section 2Introduction

Intended UseDuraBlue� adhesive melters may be used only to melt and convey suitablematerials, e.g. thermoplastic hot melt adhesives.

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

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

Area of Use (EMC)In regard to electromagnetic compatibility (EMC), the melter is intended foruse in industrial applications.

Operating Restrictions

When operated in residential or commercial areas, the melter may causeinterference in other electrical units, e.g. radios.

Unintended Use − Examples −The melter may not be used under the following conditions:

� In defective condition

� Without insulation blanket and protective panels

� With electrical cabinet door open

� With tank lid open

� In a potentially explosive atmosphere

� When the values stated under Technical Data are not complied with.

The melter may not be used to process the following materials:

� Polyurethane hot melt adhesive (PUR)

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction2-2


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

� Risk of burns from hot material.

� Risk of burns when filling the tank, from the tank lid, and from the tanklid supports.

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

� Risk of burns when attaching and removing heated hoses.

� Material fumes can be hazardous. Avoid inhalation.

� Risk of damage to cables/lines belonging to the customer, if they wereinstalled such that they come into contact with hot or rotating parts.

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

Introduction 2-3


Melter Description

9

16

1415

8

5

12

10

11

2

6

4

17

1

7

13

3

Fig. 2-1 Example D25H

1 Control panel2 Main switch3 ID plate4 Hose receptacles5 Tank lid6 Protective panel, removable

7 Pressure control valve8 Filter cartridge9 Electrical cabinet

10 Hopper11 Tank12 Motor

13 Coupling14 Pump15 Safety valve plate16 Manifold17 Insulation blanket

Introduction2-4


Control Panel

7

1

6

8

2 3

4

5

9

Fig. 2-2 Control panel

1 Fault LED2 Ready LED3 Component keys / LEDs

4 Keypad5 Serial port6 Right display and scroll keys

7 Left display and scroll key8 Function keys9 Service LED

21

1

2

3

1

2

3

Introduction 2-5


Safety Valve Plate

Tank Isolation Valve

The tank isolation valve (1) enables replacement of the pump without firstemptying the tank.

Safety Valve

The safety valve (2) is fixed at

8.5 MPa 85 bar 1235 psi.

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

Fig. 2-3

TankThe tank is divided into grid (low melt) and reservoir (high melt) sections. Aninsulating seal (2) provides a temperature barrier between the two sections.The temperature barrier allows the material in the grid section (1) to begently melted at a low temperature. The material is then melted toprocessing temperature in the reservoir (3).

Hopper

The tank of the model D25H is equipped with a 35 cm high tank extension(hopper); the hopper increases the tank volume from 20 l to 45 l. Thehopper is not heated.

Fig. 2-4

Pressure Control Valve

The pressure control valves (3) can be manually adjusted from

0.5 to 9 MPa 5 to 90 bar 72.5 to 1305 psi

Fig. 2-5

1 Hose connection2 Filter cartridge3 Pressure control valve

Introduction2-6


Material Flow with Two Pumps

The connecting locations on the melter are labeled with numbers.

2.1 on the manifold means motor/pump 2, 1st hose

Motor 1

Motor 2

2.1 2.2 2.3

2

1

1.1 1.2 1.3

Fig. 2-6

Introduction 2-7


Electrical Cabinet

1

452678

32

Fig. 2-7

1 Main board2 Circuit breakers3 Control panel board

4 Fan with filter5 Motor controller6 Terminal blocks speed setpoint

7 Mains terminals8 I/O expansion board

Introduction2-8


Modes of OperationDuraBlue melters operate in the following modes:

Automatic Scan (Normal Mode)The melter automatically checks and displays the current temperature of thetank, hoses, and guns to confirm that they are within their pre-definedtemperature range. By default, the melter is always in the automatic scanmode unless it is placed into another operating mode.

StandbyThe temperatures of the tank, hoses, and guns are reduced down from theiroperating temperature (hereafter referred to as set-point temperature) by apre-set number of degrees.

SetupThe setup mode is used to configure melter control options and featuresand to review stored operating data. To prevent unauthorized changes tothe melter’s configuration, the melter can be password-protected.

Fault

The melter alerts the operator when an abnormal event occurs.

ID Plate

LISTED63U1

USC

ADHESIVEMELTER

Year2003

DuraBlue

Nordson Engineering GmbHLilienthalstr. 6D 21337 Lüneburg − Germanywww.nordson.com

Serial No:

234

5

1

UL

Fig. 2-8

1 Melter designation

2 Order number

3

4 Electrical connection, operating voltage, line voltage frequency, melter fuse protection

5 Serial number

1

2

3

Installation 3-1


Section 3Installation

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

Transport� Refer to section Technical Data for weight. Use only suitable transport

devices.

� If possible, use the pallet (3) that came with the melter and use anglebrackets (2) to fasten the melter.

� Use sturdy cardboard (1) to protect from damage.

� Protect from humidity and dust.

� Avoid jolts and vibrations.

Fig. 3-1 Principle drawing

StorageCAUTION: Do not store melter outside! Protect from humidity, dust andextreme temperature fluctuations (formation of condensation).

Installation3-2


UnpackingUnpack carefully and check for damage caused during transport. Savepallet, angle brackets and box for later use, or dispose of properly accordingto local regulations.

Fig. 3-2

Lifting (Unpacked Melter)Refer to the section Technical Data for weight. Lift melter only at the chassisusing suitable lifting equipment or a forklift.

Installation RequirementsSet up only in an environment that corresponds to the stated Degree ofProtection (Refer to section Technical Data). Do not mount in a potentiallyexplosive atmosphere! Protect from vibration.

Required SpaceRefer to section Technical Data, Dimensions

Detaching Protective Panels

Open the protective panels with a 4 mm Allan key.

On the inside

Installation 3-3


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

If necessary, exhaust material vapors and/or provide sufficient ventilation ofthe location of the system.

Fig. 3-3

Experience of Installation PersonnelThe instructions provided in this section are intended to be used bypersonnel who have experience in the following subjects:

� Hot melt application processes

� Industrial power and control wiring

� Industrial mechanical installation practices

� Basic process control and instrumentation

1

2

5

43

Installation3-4


Pneumatic Connections

Pneumatic Pressure Control / Bypass Control (Option)

Required Air Quality

The compressed air must be dry and non-lubricated. Dirt particles in the airmay not exceed 30 �m in size.

Setting Pressures

The pneumatic safety valve limits the inlet pressure to 6 bar (600 kPa /87 psi).

The pneumatic pressure control valve has a transmission ratio operating airpressure / material pressure of 1:15.

1: Pressure display Pump 1 (with options Manual pneumatic pressurecontrol and Bypass control )2: Pressure display Pump 2 (with options Manual pneumatic pressurecontrol and Bypass control )3: Pneumatic safety valve4: Interface Pneumatic pressure control / bypass control (XS4)5: Connection Compressed air

The arrows point to the handwheels of the individual pressure controllers.They are available only with options Manual pneumatic pressure control andBypass control.

Fig. 3-4 Melter tower

ON4 − 20 mA

ON0 − 10 V

12

34

56

78

ONOFF

ON

ON

ON

OFF

OFF

OFF

ONOFF

ON

ON

ON

OFF

OFF

OFF

Installation 3-5


Pneumatic Pressure Control / Bypass Control (Option) (Forts.)

Interface Assignment Pneumatic Pressure Control

PIN Input Function

1 − 4 − 20 mA

0 − 10 V

Proportional valve pump 1

2 +

3 − 4 − 20 mA

0 − 10 V

Proportional valve pump 2

4 +

Fig. 3-5 Proportional valve

The proportional valves for pneumatic pressure control are located in themelter tower.

DIP switch SW1 to switch between 0 − 10 V and 4 − 20 mA.

0 − 10 V

Fig. 3-6 SW1

Compressed air

Proportional valve

NozzleGun

Hose

Pneumatic pressurecontrol valve

MotorPump

Filter

Tank

M

0−10 V or4−20 mA

Fig. 3-7 Option Automatic pneumatic pressure control (1 pump)

Installation3-6


Electrical ConnectionsWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or melter damage.

Observe when Using Residual Current Circuit Breakers

Local regulations in some geographic areas or industrial branches mayrequire residual current circuit breakers.

Then observe the following points:

� Permanent installation is required (fixed line voltage connection)

� The residual current circuit breaker is to be installed only between thepower supply and the melter.

� Only residual current circuit breakers sensitive to pulsating current oruniversal current (> 30 mA) may be used.

Laying CableWARNING: Use only temperature resistant cable in the heating part of themelter. Ensure that cables do not touch rotating and/or hot meltercomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

Operating VoltageWARNING: Operate only at the operating voltage shown on the ID plate.

NOTE: Permitted deviation from the rated line voltage is �10%.

NOTE: The power cable cross-section must comply with the maximumpower consumption (refer to section Technical Data).

External Control and Switching CircuitsWARNING: Connect external control and switching circuits using suitableNEC class I cables. In order not to cause short circuits lay cables such thatthey do not touch any printed circuit boards.

1

2

Installation 3-7


Power Supply ConnectionNOTE: The melter must be installed securely (permanent power supplyconnection).

Line voltage Terminals Mains terminals inelectrical cabinetL1 L2 L3 N PE

200 VAC 3-phase without neutral(Delta)

� � � �


� � � �

400 VAC 3-phase with neutral (star − WYE)

� � � � �


� � � �


� � � �

Refer to wiring diagram for connecting arrangement.

Mains Filter

Installing Kit (Accessory)

WARNING: Disconnect the unit from the line voltage.

1. Disconnect the customer’s power supply from the mains terminals in theelectrical cabinet. Extract power cable.

2. Replace the cable gland on the electrical cabinet with the EMC cablegland on the shielded cable (1).

3. Screw on mains filter on electrical cabinet.

4. Connect shielded cable (1) to mains terminals in electrical cabinet.

5. Connect customer’s power cable (2) to the terminals in the mains filtercasing.

6. Fasten casing cover again.

Fig. 3-8

Connector P/N 277909

Installation3-8


Installing Melter Inputs

DuraBlue melters are equipped with four inputs. Each input iscustomer-wired to the melter and then set up to provide one of the followingcontrol options:

� Place the melter into the standby mode

� Turn the heaters on and off

� Enable or disable a specific hose or gun

� Turn the motor(s) on and off

Inputs are activated using a constant 10 to 30 VDC signal voltage, which issupplied by the customer’s control equipment. The inputs are not polaritysensitive.

WARNING: The operator can override the melter inputs by using thecontrol panel function keys. Ensure that the control logic for any externaldevice that sends an input signal to the melter is programmed to prevent thecreation of an unsafe condition in the event that the operator overrides anexternal input to the melter.

To wire inputs to the melter

1. Route a 2-, 4-, 6-, or 8-conductor signal cable from the controlequipment to the melter, through the smaller of the two PG-penetrationson the back of the electrical compartment. Use rigid or flexible conduit ora suitable strain relief to protect the cable from the sharp edge of theconduit penetration.

NOTE: To reduce the possibility of electrical shorting, route the cable sothat it does not touch nearby circuit boards.

See Figure 3-9.

2. Connect each pair of input wires to the appropriate terminals (8 through14) on connector P/N 277909. If input number four is used, terminal 7 onconnector P/N 227908 must also be used. Both connectors are providedin the installation kit. Table 3-1 lists the terminal numbers thatcorrespond to each input.

Fig. 3-9 Wiring inputs

NOTE: Connector P/N 277909 is physically keyed to prevent it frombeing used in place of connector P/N 277908, which has terminalsnumbered 1 through 7.

Installation 3-9


To wire inputs to the melter (contd.)

3. Plug the connector (P/N 277909) into the bottom receptacle (1, Fig.3-10) of terminal XT7, which is located on the expansion board. If inputnumber four is used, plug connector P/N 277908 into the top receptacleon terminal XT7.

1

Fig. 3-10

To Set up an Input

Set up the parameter control option for each input that you connected to themelter. Table 3-1 lists the available control options. Refer to Setting Up theMelter, for information about how to select operating parameters and editparameter control options.

With the exception of the pumpenable/disable control option (Table 3-1,Input Data), All inputs aretransition-based.

Input Setup in Appendix B

The input capacity of the melter may beincreased from four inputs to a total often inputs by adding an optional I/Oexpansion card that is available fromNordson Corporation.

Parts

Installation3-10


Tab. 3-1 Input Data

Input Terminals Operating Parameter Control Option Note

1 8 and 9 30

0 - Input Disabled

1 - Standby On/Off

2 - Heaters On/Off

3 - Pump 1 Enable/Disable

4 - Hose/Gun 1 Enable/Disable






10 – Automatic standby (Default)


A, B

C

D

2 10 and 11 31

0 - Input Disabled

1 - Standby On/Off (Default)

2 - Heaters On/Off









3 12 and 13 32 Same as parameter 31 (Default=2)


Optional Inputs

5 11 and 12 34 0 E

6 13 and 14 35 0 E

7 15 and 16 36 0 E

8 17 and 18 37 0 E

9 19 and 20 38 0 E

10 9 and 10 39 0 E

NOTE A: Parameter 30 has 11 control options. Parameters 31, 32 and 33 each have only 10 control options.

B: Parameters 34 through 39 are reserved for the six inputs created when the optional I/O expansion card is installed.The six optional inputs have the same control options as parameter 31.

C: If control option 3 is selected, the motor will not turn on—even if you press the pump key—if voltage is not present onthe input’s contacts.

D: If control option 10 is selected for input 1, a time must be set in parameter 24.

E: Refer to the instruction sheet provided with the optional I/O expansion card for wiring information.

Connector P/N 277908

Installation 3-11


Installing Melter Outputs

The melter is equipped with three user-configurable outputs. Outputs areused to communicate with user-supplied production equipment or controlhardware, such as a programmable logic controller.

The output capacity of the melter may beincreased from three outputs to seven outputsby adding an optional I/O expansion card thatis available from Nordson Corporation. Meltersthat have an Ethernet card can not beequipped with the optional I/O expansionboard.

The customer wires each output and then configures it in the melter’sfirmware for one of the following control options:

� The melter is ready

� The melter is ready and the motor is on

� A fault has occurred

� The service LED is on

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

To connect an output to the melterRefer to figure 3-11.

1. Route a 2-, 4-, or 6-conductor signal cable from the control equipment tothe melter, through the PG-16 penetration on the floor of the electricalcompartment. Use rigid or flexible conduit or a suitable strain relief toprotect the cable from the sharp edge of the conduit penetration.

NOTE: To reduce the possibility of electrical shorting, route the cable sothat it does not touch nearby circuit boards.

2. Connect each pair of output wires to the appropriate terminals(1 through 7) on connector P/N 277908. The connector is provided inthe installation kit. Table 3-2 lists the terminal numbers that correspondto each output.

NOTE: Terminal number 7 on connector P/N 277908 is reserved forinput number four. Connector P/N 277908 is physically keyed to preventit from being used as connector P/N 277909, which has terminalsnumbered 8 through 14.

Fig. 3-11 Outputs

Installation3-12


To connect an output to the melter (contd.)

3. Plug connector P/N 277908 into the top receptacle (1, Fig. 3-12) onterminal XT7, which is located on the expansion board.

1

Fig. 3-12

To set up an output

Set up the parameter control option for each output that you connected tothe melter. Table 3-2 lists the available control options. Refer to Setting Upthe Melter, for information about how to select operating parameters andedit parameter control options.

1

Installation 3-13


Tab. 3-2 Output Data

Output Terminals OperatingParameter Control Options Note

1 1 and 2 40 0 - Output Disabled

1 - Ready (Default)

2 - Ready and the Motor is On

3 - Fault

4 - Tank Low Level (not available)

5 - Service LED is On

6 - Alert

A

A

B

A

A

C



Optional outputs

4 1 and 2 43 0

D5 3 and 4 44 0

6 5 and 6 45 0

7 7 and 8 46 0

NOTE A: When control option condition occurs, contacts close. Contacts are normally open when power is off.

B: When control option condition occurs, contacts open. Contacts are normally open when power is off.

C: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6are both used, then both a fault output and an alert output signal will be present when the fault LEDturns on.

D: Refer to instruction sheet included with the optional expansion card for information on wiring.

Setting up Melter Communications

You can view and change all melter settings, transfer settings betweenmelters, and upgrade or downgrade the melters operating firmware by usinga personal computer that is connected to your melter’s serial port (1).

MXHH002S033A0295

Installation3-14


Connecting HoseAlso refer to the hose manual.

Connecting Electrically1. First connect the hose (1) electrically to the unit.

Use the hose receptacles XS10 to XS15 (2b) for the plugs (2a) of thehoses. The connections are protected with a clamp.

NOTE: For more than one hose: Every hose connection is allocated to acorresponding receptacle. Do not mistakenly exchange!

Refer to wiring diagram for connecting arrangement.

2a

1

2b

2a

Fig. 3-13 Electrical connection

Connecting

Second Open-jawed Wrench

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

Fig. 3-14

2 13

Installation 3-15


Connecting (contd.)

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

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

Fig. 3-15 Connecting

2. Heat the melter and hose to approx. 70 ° C (176 ° F).

3. Connect the hoses in the order of the numbers on the manifold. Thisprevents the creation of dead space that would otherwise result fromunused connections.

NOTE: Close unused hose connections with Nordson port plugs.

Disconnecting HoseWARNING: System and material pressurized. Relieve system pressurebefore disconnecting hoses. Failure to observe can result in serious burns.

Relieving Pressure1. Switch off the motor(s) (Refer to section Operation).

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

3. Activate the solenoid valve(s) electrically or manually; or, pull the triggerof the assembly handgun. Repeat this procedure until no more materialflows out.

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

Installation3-16


Setting Speed SetpointWARNING: Disconnect melter from line voltage before opening theelectrical cabinet.

The speed is set with the terminal blocks (1) in the electrical cabinet.

1 1

Fig. 3-16

Terminal 1 Terminal 3 Speed Output capacity per pump

D25 / D25H / D50 D100

in out 50 min−1 35 kg/h 77 lb / hr 50 kg/h 110 lb / hr

out in 65 min−1 45 kg/h 99 lb / hr 65 kg/h 143 lb / hr

in in 129 min−1 90 kg/h 198 lb / hr 130 kg/h 286 lb / hr

out out 0 min−1 0 kg/h 0 lb / hr 0 kg/h 0 lb / hr

NOTE: The setting 0 min−1 is not meant to shut down the melter. To shutdown the melter set the main switch to 0/OFF.

Installation 3-17


Setting Up the Melter

After physically installing the melter, it must be set up to support yourmanufacturing process. Melter setup consists of enabling or makingchanges to factory-set operating parameters that affect the use and functionof the melter. The operating temperature (set-point) of the tank and eachhose and gun is also established during melter setup.

The melter is shipped from the factory with the most commonly usedoperating parameters already set up. The factory setup can be modified atany time to suit your manufacturing process.

Quick Setup

Table 3-3 describes the most commonly used operating parameters andtheir factory settings. Review the table to determine if the factory settings foreach parameter will support your manufacturing process. If the defaultvalues for each of these operating parameters are appropriate for yourmanufacturing process, then no melter setup is required. Go directly toSet-point Temperature of the Tank, Hoses, and Guns later in this section tocomplete the installation process.

If you need to make changes to the factory setup or if you want to learnabout other operating parameters, go to the next part in this section,Operating Parameters.

Installation3-18


Tab. 3-3 Common Operating Parameters

Parameter Parameter Name Purpose Default Value

4 Ready Delay Time

A timer that delays the activation of the ready LED for apre-defined time period after the tank, hoses, and gunsare at the desired set-point temperature. The readydelay timer will only activate if the temperature of thetank, at the time the melter is turned on, is below itsassigned set-point temperature by 27 °C (50 °F) ormore.

0 minutes

5 Service Interval Time

A timer that turns on a service LED when the value setfor the timer equals the number of hours that theheaters have been on. The service LED is used tosignal the need for maintenance.

500 hours

7 Motor Off Delay Not being used, only displayed. −

8 Automatic Pump OnAllows the pump to start automatically when systemready is reached, provided that the pump has beenenabled by pressing the pump key.

Enabled

11 Create PasswordSets a password that must be entered before anymelter operating parameter or set-point temperaturecan be changed.

5000

14ExternalCommunicationInterlock

Before beginning maintenance work to the melter, setthe parameter to 1 (activated). External control of themelter is completely disabled until the parameter is setto 0 (deactivated) again.

0 (disabled)

15 Pressure SetpointUsed to set a percentage value of the maximumoutput pressure (from 0 − 100 %). 0 (disabled)

16OverpressureSetpoint

If the pressure in the system exceeds this setting, anoverpressure alarm is triggered. 0

17UnderpressureSetpoint

If the pressure in the system falls below this setting,an underpressure alarm is triggered. 0

20 Temperature UnitsSets the units of the temperature display to degreesCelsius (C) or to degrees Fahrenheit (F). C

21Over TemperatureDelta

Sets the number of degrees that any heatedcomponent can exceed its assigned set-pointtemperature before an over temperature fault occurs.

15 °C (25 °F)

Installation 3-19


Parameter Parameter Name Purpose Default Value

22Under TemperatureDelta

Sets the number of degrees that any heatedcomponent can drop below its assigned set-pointtemperature before an under temperature fault occurs.

25 °C (50 °F)

23 Standby DeltaSets the number of degrees that the temperature of allheated components will be decreased when the melteris placed into the standby mode.

50 °C (100°F)

26 Manual Standby TimeSets the amount of time the melter will remain in thestandby mode after the standby key is pressed. Disabled

50 to 77 Seven-day ClockA group of parameters that control the melter’s clock.The clock is used to automatically turn the heaters onand off and to place the melter into the standby mode.

Disabled

Installation3-20


Operating Parameters

The melter uses operating parameters to store noneditable and editablevalues. Noneditable values are those that provide information about thehistorical performance of the melter. Editable values are either a numericset-point or a control option setting. Control options settings affect thedisplay of information or the function of the melter.

Operating parameters are stored in the melter’s firmware in the form of asequentially numbered list. The list is organized into the logical groupsdescribed in Table 3-4.

Tab. 3-4 Parameter Groups

GroupParameternumbers Description

Standard0 to 8 and 10 to 14 Frequently used parameters

Pressure control 15 to 17 Configure the pressure settings

Temperature control 20 to 26 Control heater function

Input setup 30 to 39 Configure the inputs

Output setup 40 to 46 Configure the outputs

Seven-day clock 50 to 77 Configure the clock function

Automatic fill timer 78Configures the external motor controlswitch

PID selection 80 to 91 Change the default PID settings

In addition to the ability to read and edit parameter values, you can alsosave and restore the current value of every operating parameter and reviewa log of the last ten changes that were made to editable parameters.

Selecting Operating ParametersRefer to Appendix B, Operating Parameters, for detailed information abouteach parameter. Appendix B contains a complete description of eachparameter, including its affect on the melter, default value, and format.

NOTE: Parameters that are used to configure optional equipment or thatare otherwise reserved in the firmware are excluded from Appendix B.

Setup key

Clear/Reset key

Enter key

Installation 3-21


Reading or Editing Operating ParametersRegardless of whether a parameter’s value is editable or not, the procedurefor accessing each parameter in order to read or edit its current value is thesame.

To read or edit a parameter

1. Switch the melter on.

The melter performs a start-up check.

2. Press the Setup key.

The left display flashes parameter 1.

3. Use the numeric keypad to enter the number of the desired parameter.Refer to Appendix B for a complete list of parameters.

NOTE: If you incorrectly enter the parameter number, press theClear/Reset key to return to parameter 1 and then re-enter the correctparameter number.

When you have finished entering the one- or two-digit parameternumber, the right display indicates the parameter’s current value.

4. Do one of the following:

� If the value is noneditable, refer to Monitor the Melter in Section 4,Operation.

� If the value is editable go to step 5.

5. Press the Enter key.

The right display flashes.

6. Use the keypad to enter the desired numeric set-point or control optioninto the right display. Refer to Appendix B, Operation Parameters, forinformation about the numeric value or control option choices for eachparameter.

NOTE: If the keypad has no affect on the right display, the melter ispassword protected. You must enter a valid password before you canedit parameters. Refer to Enter the Melter Password in Section 4,Operation.

Installation3-22



The melter checks that the new value or control option is acceptable.

� If the numeric set-point or control option is accepted, the left andright displays index to the next sequential parameter number andvalue.

� If the numeric set-point or control option is not accepted, the rightdisplay will indicate dashes (----) for three seconds and then it willchange back to the original value.

8. Repeat step 5 through step 7 to read or change the next sequentialparameter number or press the Setup key to exit the setup mode.

You can exit the setup mode at any timeby pressing the Setup key.

Parameter numbers that are notapplicable are skipped when you scrollthrough the operating parameter list inthe left display.

When the right display is flashing, youcan quickly set the value of the currentparameter to it’s lowest possible value bysimultaneously pressing both of theright-display scroll keys.

While in the setup mode, if no key ispressed for two minutes, the melter willreturn to the automatic scan mode.

You can also use the right-display scrollkeys to enter or change a parameter’svalue or control option. After entering theparameter’s number in the left display,press either of the right-display scrollkeys to change the value or controloption.

If password protection is enabled, themelter will return to the passwordprotected mode whenever you exit thesetup mode.

Installation 3-23


Setpoint Temperature of the Tank, Hoses, and Guns

The melter is shipped from the factory with the tank set-point temperature at175 °C (350 °F) and the hose and gun set-point temperatures at 0 degrees(turned off).

Before the melter can be used, a set-point temperature must be assigned tothe tank, hoses, and guns. Assign set-point temperatures using any of thefollowing methods:

� Global—The tank and all hoses and guns are set to the same set-pointtemperature.

� Global-by-component group—All of the hoses or all of the guns areset to the same set-point temperature.

� Individual Component—The set-point temperature of the tank andeach hose and gun is set individually.

Since most manufacturing processes will require the tank, hoses, and gunsto be set to the same temperature, only the global method of assigningset-point temperatures is described in this section. For information about theother two methods of assigning set-point temperatures, refer to Section 4,Adjusting Component Temperatures.

As with operating parameters, you can also save and restore set-pointtemperatures and review past changes that were made to set-pointtemperatures.

Tank key

Left display andscroll key

Enter key

Ready LED

Installation3-24


To Assign a Global Setpoint Temperature

1. Press and hold the Tank key for three seconds.

The left display flashes 1.

2. Scroll the left display to 0.

The right display indicates all dashes (----) and the LEDs on the tank,hose, and gun keys turn green.



4. Use the numeric keypad to enter the set-point temperaturerecommended by the manufacturer of the hot melt.

Refer to the technical data sheet provided by the manufacturer of thehot melt to determine the optimal set-point temperature.

5. Press the Tank key.

Each component begins to heat or cool to the new global set-pointtemperature and the melter returns to the automatic scan mode.

When all of the components reach the global set-point temperature, theready LED turns on (green).

+

Saving current settings

+

Restoring saved settings

Installation 3-25


Save and Restore Melter Settings

The current value of all editable operating parameters and the set-pointtemperature of each component can be saved and, if necessary, restored ata later time. When saved settings are restored, they overwrite the settingsthat are presently in use.

This save-restore feature is useful in instances where the settings that arein use are deliberately or accidentally changed and you need to return themelter to its pre-change setup.

To save current settings

With the melter in the automatic scan mode, simultaneously press thenumber 1 key and the Setup key.

S-1 appears momentarily in the right display.

To restore saved settings

CAUTION: All melter settings will be deleted! Before restoring savedsettings, ensure that use of the restored settings will not disrupt the currentprocess or create an unsafe operating condition.

With the melter in the automatic scan mode, simultaneously press thenumber 2 key and the Setup key.

S-2 appears momentarily in the right display.

If you use the restore feature before thesave feature is used for the very firsttime, the factory default set-pointtemperatures will be restored. This willcause the hoses and guns to stopheating.

Setup key


Component key LEDs

Scrolling through the log

Installation3-26


Review Parameter and Setpoint Temperature Changes

The melter stores in a change history log, a record of the last ten changesthat were made to either operating parameters or set-point temperatures.Since the log only stores ten changes, old log entries are overwrittenbeginning with the first log entry, by the eleventh and following log entries.

To Review the Change History Log


Operating parameter 1 flashes in the left display.

2. Press the left-display scroll key to change the display to parameter 3(the change history log).

The following occurs:

� If the last change was to an editable parameter, all of the componentkey LEDs remain off.

or

� If the last change was to a set-point temperature, the LED on theassociated component key(s) turns on.

and

� The right display indicates the four-digit log entry associated with thelast change that was made.

Table 3-5 provides the meaning, from left to right, of each digit in thelog entry. Following the table are two example log entries.

3. Press a right-display scroll key to review each of the remaining nine logentries. Each press of a scroll key displays a progressively older logentry.

4. Press the Setup key to return to the automatic scan mode.

Installation 3-27


Tab. 3-5 Change history log

First digit Seconddigit Third and fourth digit

P(Parameter)

−

Indicates the number of the parameter that was changed

S (Set-point)

Are used in conjunction with the LEDs on the component keys to indicate thelocation and method of a set-point temperature change.

When this LED ison..

And the FourthDigit Indicates..

The change wasto..

And the Methodof Change was..

Tank Key 1 The tank Individual

Hose Key 1– 6 A single hose Individual

Gun Key 1– 6 A single gun Individual

All Keys 0 All components Global

Hose Key 0 All hosesGlobal-by-component

Gun Key 0 All gunsGlobal-by-component

Installation3-28


Change History Log Examples

Example 1:

Parameter 4 (ready delay) was changed.

Example 2:

If the LED on the gun key is on, then this display wouldindicate that the global-by-component method was used to change thetemperature of the guns.

Unused log entries in the change history logare indicated by “P-_” in the right display.

To view how many heater hours haveelapsed since a specific change (displayed)was made, simultaneously press both of theright-display scroll keys.

Removing MelterRun the melter until empty, separate all connections from the melter, andallow the melter to cool down.

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

Operation 4-1


Section 4Operation


This section provides information about the following operator-level tasks:

� Filling the melter tank

� Starting the melter

� Monitoring melter operation

� Adjusting the operating temperature of heated components

� Using the melter function keys

� Shutting the melter down

Most of the controls described in this section are located on thecontrol panel. Refer to Melter Description in Section 2, Introduction, forthe location of the controls and indicators described in this section.

Additional InformationThis section presents operating procedures in their most commonly usedform. Procedural variations or special considerations are explained in theadditional information table that follows most procedures. Where applicable,some table entries also contain cross-reference information. Additionalinformation tables are indicated by the symbol shown to the left.

X

Operation4-2


Initial StartupAfter the melter has been properly installed, initial startup can take place.

Purging Test Material out of MelterThe melter was subjected to extensive testing prior to shipment. In doing so,the tank was filled with a special test material. Material residue may still bepresent in the melter. To remove the residue, melt and feed severalkilograms of material before starting production.

WARNING: Risk of burns! The test liquid may splash if it comes out at highpressure. Before purging the melter, set the pressure control valve to lowpressure.

PumpAfter initial startup check the pump for leakage; tighten the gland bolt ifnecessary.

Before retightening for the first time, the space between the gland and thefront block (dimension X, Fig. 4-1) should be 8 − 9 mm on a PR100/SN1710gear pump. The distance must be 4 mm for all other pumps used inDuraBlue.

Fig. 4-1

Operation 4-3


Filling the Tank

ManuallyWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Tank and tank lid are hot. When filling, hot material maysplash out of the tank. Use caution when filling tank with material.

WARNING: Do not operate melter with open tank. When the tank is open,hot material vapors can escape; vapors may contain potentially hazardoussubstances.

CAUTION: Before filling the tank, ensure that tank and material are cleanand free of foreign substances. Foreign substances can hinder functioningor even cause damage to the melter or accessories.

Fig. 4-2

CAUTION: Cease operation before the tank is completely empty. If there istoo little material in the tank, the material can overheat. Overheated materialcan char, collect on surfaces and cause malfunctioning.

25 m

m

Component keys(tank, hose, and gun)

Operation4-4


Maximum Level

The maximum level should not exceed 25 mm (1 inch) under the rim of thetank.

Fig. 4-3 Cross-section oftank

Heated Components

The melter contains three groups of heated components. These are thetank group, which contains the tank and the pump, the hose group, and thegun group. Component groups are represented on the control panel by thecomponent keys shown to the left.

Heated components within each group are identified by their positionnumber. The position of the tank and pump is fixed at 1. Hose and gunposition numbers are automatically assigned based on the hose/gunreceptacle they are connected to. For example, the position numbers of ahose/gun pair that is connected to the second receptacle would be hoseposition 2 and gun position 2.

NOTE: In some installations, auxiliary devices (such as a heated airmanifold) may be connected to a hose/gun receptacle. In such cases, youshould label (or otherwise identify) the auxiliary device as to the hose or gunposition number that represents the device. The control panel will identifysuch devices as a hose or gun, regardless of what the device actually is.

Heaters LED

Automatic scan sequence

Ready LED

Operation 4-5


Starting the MelterBefore starting the melter for the first time, confirm that the

� melter is fully installed including any required inputs and outputs,gun drivers, pattern controllers, or timers.

� melter’s operating parameters are set up to support thecurrent manufacturing process.

Refer to Section 3, Installation, if any of the items listed above arenot complete.

To Start the Melter

1. Switch the melter on.

The melter:

� Tests the control panel LEDs

� Turns on the heaters (the heaters LED turns green)

� Begins to automatically scan through and display theactual temperature of the tank and each hose and gun that has aset-point temperature that is greater than zero degrees. Thesequence of the automatic scan is: tank, each hose and gun pair,and then back to the tank.

� Turns on the ready LED (green) when the tank and all of thehoses and guns are within 3 �C (5 �F) of their assignedset-point temperature.

1

2Pump keys

Operation4-6


To Start the Melter (contd.)

CAUTION: Do not operate Nordson pumps without material. Beforeswitching on the motor, ensure that the tank is filled.

2. Press one of the two pump keys (1 or 2) to enable the pump.

� If the system has not reached the system-ready state at the time thatthe pump key is pressed, the LED on the pump key will turn yellow,indicating that the pump is enabled, but not started. The pump willstart automatically when the system-ready state is reached.

� If the system has reached the system-ready state at the time that thepump key is pressed, the pump will start and the LED on the pumpkey will turn green, indicating that the pump is running.

� If the melter is set up for manual pump activation, the pump LED willnot turn on and the pump will not start until the pump is manuallystarted using the switching device.

NOTE: You can change the way the pump key operates by changingparameter 8 (automatic pump on). Refer to Appendix B, OperatingParameters.

If the melter is switched on when thetemperature of the tank is 27 �C (50 �F) or greater below its assignedset-point temperature (cold startcondition), the ready LED will notturn on until the ready delay (definedwhen the melter was set up) haselapsed.

Appendix B, parameter 4

The time remaining on the readydelay (in minutes) appears in theright display at the end of every scancycle. When only one minuteremains in the ready delay time, theright display counts down inseconds.


You can by-pass the ready delaytime by pressing the Heaters keytwice.

Operation 4-7


To Start the Melter (contd.)

The appearance of F4 in the rightdisplay immediately after the melteris switched on indicates a problemwith the melter’s processor or mainboard.

Monitor Melter Faults

The appearance of F1 in the rightdisplay immediately after starting themelter indicates that a hose or guncordset may be loose ordisconnected.

Section 6, Troubleshooting

The condition of one or more inputs,may prevent the heaters from turningon.

Installing Melter Inputs inSection 3, Installation

If the seven-day clock feature wasset up and turned on when themelter was last switched off, theclock will automatically turn on thenext time the melter is switched on.

Function Keys

If a power failure occurs, the melterwill restart in it’s normal heat-upcycle, even if the heaters were off orthe melter was in standby prior to thepower failure. If the seven-day clockwas on prior to the power failure, themelter will restart in the modedictated by the clock schedule at thetime the melter restarts.

Ready LED

Operation4-8


Monitoring the MelterThe melter provides indicators that allow you to:

� Quickly confirm that the melter is operating correctly

� Monitor the actual temperature of the tank group and each hoseand gun

� Identify melter faults

� Determine when service is required

The melter automatically determines the number and receptacle of allhoses and guns that are connected to it. Refer to Heated Components,earlier in this section, for information on identification of heatedcomponents.

Confirm that the Melter is Operating Correctly

The ready LED turns on (green) when all of the heated componentsare within 3 �C (5 �F) of their set-point temperature.

The ready LED will not turn on, or will turn off, if any of the following eventsoccur:

� The ready delay is still counting down.

� The operator or a remote input places the melter in the standbymode.

� The seven-day clock places the melter in the standby mode.

� There is a fault (the fault LED will turn on).

Refer to Monitor Melter Faults and Function Keys in this section forinformation about melter faults and using the seven-day clock and standbyfunctions. Refer to Appendix B, Parameter 4, for information about theready delay.

Operation 4-9


Heated components with a set-pointtemperature of zero degrees areskipped during the automatic scancycle.

The set-point temperature of thetank and the pump cannot be setindependently.

The time remaining on the readydelay appears in the right display atthe end of each scan cycle.


You can override the seven-dayclock at any time. If the clock hasturned the heaters off, pressing theheaters key will turn the heatersback on. If the clock has placed themelter into the standby mode,pressing the standby key will returnthe heated components to theirassigned set-point temperature.

Function Keys

Monitor Component Temperatures

The actual temperature of each heated component − tank and each hoseand gun − can be checked via normal mode or by manually selecting andchecking each component.

By default, the melter remains in the automatic scan mode except when:

� The melter is placed into the setup mode

� The set-point temperature of all hoses and guns is set to zerodegrees

� A fault occurs

LEDs on component keys


Component temperature display

Operation4-10


To Check Component Temperatures Using theAutomatic Scan Mode

1. When the ready LED is on, observe the LEDs on the component keys.

2. When the LED on the key that represents the desired componentgroup (tank, hose, or gun) turns on, observe the left display until itindicates the position number of the specific component you want tocheck.

3. When the position number of the desired component appears in theleft display, observe the right display to determine the component’sactual temperature.

To Manually Check a Component’s Temperature

1. Press the key (tank, hose, or gun) that represents the componentgroup you want to check.

The automatic scan stops and the left display indicates the numberof the first sequential component in the selected component group. Theright display indicates the component’s actual temperature.

NOTE: When the tank key is pressed, the left display does notindicate a component number (blank display).

2. If the first sequential component is not the component you wantto check, use the left-display scroll key to change to the correctcomponent number.

The right display indicates the actual temperature of theselected component.

3. Press the Setup key twice to return to the automatic scan mode.

Operation 4-11


To Manually Check a Component’s Temperature (Forts.)

When you scroll the left display pastthe number of the last sequentialcomponent in a component group,the number of the first sequentialcomponent in the next componentgroup appears in the left display.

The melter will return to theautomatic scan mode two minutesafter the last key is pressed.

When you press the Tank key, itis the pump temperature that isactually indicated in the right display.To check the actual temperature ofthe tank, simultaneously press theTank key and the left-display scrollkey.

The default unit for temperaturedisplay is degrees Celsius (C). Thismay be changed to degreesFahrenheit using operatingparameter 20.

Appendix B, Parameter 20

The LEDs on each component keywill change from green to yellow ifany component in the componentgroup drops more than 3 �C (5 �F)below its assigned set-pointtemperature.

You can check the set-pointtemperature of a component at anytime, by pressing the right-displayUP scroll key. Holding down thescroll key while the melter is in theautomatic scan mode reveals theset-point of each component that isscanned.

Operation4-12


Monitor Melter Faults

The melter alerts the operator to the faults listed in Table 4-2.

When a fault occurs, you must diagnose and correct the fault condition andthen place the melter back into operation. You can use the fault log todetermine the type, order, and relative time of the last ten faults.

Tab. 4-1 Melter Faults

DisplayCode/Sub-code Name Affect on the

Melter Cause

F1/None RTD Heaters turn offThe RTD for the component indicatedhas failed or the component wasdisconnected from the melter.

F2/None Under temperature Heaters turn off

The actual temperature of thecomponent indicated has droppedbelow the under temperature delta,which was set using parameter 22.

F3/None Over temperature Heaters turn off

The actual temperature of thecomponent indicated has increasedbeyond the over temperature delta,which was set using parameter 21.

F4/1 RAM test Melter stopsfunctioning

Internal RAM failure

F4/2 Internal Clock time

Heaters remainon, but faultcondition persists

Internal clock failure

F4/3 Internal Clock time Internal clock time faulty

F4/4Internal clockbattery backedRAM

Battery-backed RAM failure

F4/5 Internal clockbattery

Heaters remainon, but faultcondition persists

Battery-backed RAM battery dead

F4/6 Analog-to-digital Melter stopsfunctioning

RTD analog-to-digital converter failed

F4/7 Analog-to-digitalcalibration

Melter stopsfunctioning

RTD analog-to-digital converter couldnot be calibrated

F4/8 Main boardfeedback

Melter stopsfunctioning

Communication failure between mainboard and CPU

F4/A Thermostat Melter stopsfunctioning

Tank or pump thermostat is open

Fault LED (red)

Operation 4-13


F1, F2 and F3 Faults

When the melter detects an F1, F2, or an F3 fault:

1. The automatic scan stops and the melter begins to monitor the potentialfault for up to two minutes. The ready and heater LEDs remain on duringthe two-minute time period. If, at any time during the two-minute period,the melter detects that the fault condition no longer exists, the melter willreturn to the automatic scan mode.

2. The LED on the affected component key (tank, hose, or gun) turns on toindicate the type of component that has, or is, failing.

3. The right display indicates the type of fault (F1, F2, or F3).

4. The left display indicates, as follows, the component that has, or is,failing.

� If the LED on the tank key is on, the left display will indicate either 1for the tank or 2 for the pump.

� If the LED on the hose or gun key is on, the left display will indicatethe number of the affected hose or gun.

5. If the fault condition still exists at the end of the two-minute monitoringperiod, the ready LED will turn off, the red fault LED will turn on, theheaters turn off, and the melter records the fault in the fault log. Refer toFault log in this part.

To be able to put the melter back into operation, the fault must be remediedand the melter reset (reset key). Refer to section 6, Troubleshooting, forinformation about diagnosing and correcting fault conditions. Also refer toResetting Melter.

Operation4-14


F1, F2 and F3 Faults (contd.)

To view the temperature of aheated component when an F2 or F3fault exists, simultaneously press andhold both of the right-display scrollkeys.

You can temporarily dismiss anF1 fault (RTD) and return to theautomatic scan mode by pressing theClear/Reset key. The heaters will,however, remain off. If the faultcondition still exists two minutes afterpressing the clear/reset key, the faultLED will turn back on.

When an F1 fault code appears, youcan determine whether the fault wascaused by an open or a shorted RTDby simultaneously pressing both of theright-display scroll keys. If the rightdisplay indicates OP, the RTD is open,if it indicates SH, the RTD has shorted.

If, for any reason, a componentreaches 235 �C (458 �F), animmediate F3 fault will occur (notwo-minute monitoring period).

Clear/Reset key

Heater key

Operation 4-15


F4 Fault

When the melter detects an F4 fault:

1. The ready LED turns off and the red fault LED turns on.

2. All of the component key LEDs (tank, hose, and gun) turn off.

3. The right display indicates F4.

4. The left display indicates a sub-code. Sub-codes classify the fault asbeing fatal or nonfatal. The affect on the melter of each of these twoclasses of F4 faults is:

Fatal—The fault LED turns on and stays on and the melter stopsfunctioning completely.

Nonfatal—The fault LED turns on for five seconds, but the heaters andpump continue to operate normally. Nonfatal faults affect the internalclock.

5. The melter records the fault in the fault log. Refer to Fault Log in thispart.

Resetting Melter

1. Diagnose and correct the fault condition. Refer to Section 6,Troubleshooting, for information about diagnosing and correcting faultconditions.

2. Return the melter to the automatic scan mode by pressing the Setupkey twice.

3. Press the Clear/Reset key.

4. Press the Heater key to turn on the heaters.

If F4 appears in the right display whenyou press the clock key, the internal clockfunction has failed.

Setup Key

Left display and scroll key

Scrolling through the fault log

Operation4-16


Fault Log

1. Press and hold the Setup key.

The automatic scan stops and operating parameter 1 appears in theleft display.

2. Scroll the left display to parameter 2 (the fault log).

The right display indicates the last fault that occurred as follows:

� If the last fault was an F1, F2, or F3 fault, then the LED onthe affected component key turns yellow.

� If the last fault to occur was an F4 fault, then the LEDs on all ofthe component keys turn off.

� The right display indicates the log entry for the last fault tooccur. Table 4-2 provides the meaning of each digit in the logentry. Following the table are two example fault log entries.

3. Press the right-display scroll key to review each of the remainingnine log entries. Each press of the scroll key displays a progressivelyolder log entry.

NOTE: The fault log only stores the last ten faults. After ten faultsoccur, the existing log entries are overwritten, beginning with the oldestentry, by the eleventh and following log entries.

4. Press the Setup key to return to the automatic scan mode.

Operation 4-17


Tab. 4-2 Fault Log

First Digit Second and Third Digits Fourth Digit

Component:

- F

Type of fault:

1 = Tank or hose/gun 1 0 = Unused log entry

2 = Pump or hose/gun 2 1 = RTD (open or short)

3 = Hose 3 or gun 3 2 = Component under temperature

4 = Hose 4 or gun 4 3 = Component over temperature

5 = Hose 5 or gun 5 4 = Processor or electrical failure

6 = Hose 6 or gun 6

Operation4-18


Fault Log Examples

Example 1:

An unused log entry.

Example 2:

If the LED on the tank key were on, this log entrywould indicate that the tank is under temperature. If the LED on the hosekey were on, this log entry would indicate that hose 1 is under temperature.

To view the number of heater hoursthat have elapsed since a log entrywas created, simultaneously pressboth of the right-display scroll keys.The hours are indicated in the rightdisplay.

The melter will return to the automaticscan mode if the fault log is left openfor a period of two minutes without anykey being pressed.

When an F1 fault is the result of ahose/gun pair being disconnected fromthe melter, two fault log entries arecreated. The first entry is for the gunand the second entry is for the hose.

Service LED (yellow)

Clear/Reset key

Operation 4-19


Monitor the Service Interval

The melter can be set up so that the service LED located on the left sideof the control panel turns on after a customer-defined time period haselapsed. The service LED may be used to signal the need to change thehot melt filter or to complete any other customer-specified maintenanceactivity. Once the specified maintenance is performed, the service LED mustbe reset.

To Reset the Service LED

With the melter in the scan mode, press the Clear/Reset key to turn off theservice LED and reset the service interval time.

The default setting for the service interval time is 500 hours.


Operation4-20


Adjusting Component TemperaturesYou can adjust the set-point temperature of heated components using thefollowing methods:

� Global—The tank and all hoses and guns are set to the sameset-point temperature.

� Global-by-component group—All of the hoses or all of the gunsare set to the same set-point temperature.

� Individual Component—The set-point temperature of the tankand each hose and gun is adjusted independently.

Before adjusting set-point temperatures, confirm that each hose/gun pairis connected to the correct hose/gun receptacle. For example,hose/gun pair 1 should be connected to the receptacle 1. Refer to HeatedComponents earlier in this section for information about hose/gun positions.

Recommended TemperaturesThe temperature setting is determined by the processing temperatureprescribed by the material supplier. The maximum operating temperature forthe melter and heated components described here may not be exceeded.

CAUTION: Nordson will grant no warranty and assume no liability fordamage resulting from incorrect temperature settings.

Grid (low melt) Up to 20 °C (36 °F) below prescribed processing temperature

Reservoir (high melt) Prescribed processing temperature

(Material quantity used <50 g/min: 0 to 10 °C (18 °F) below prescribedprocessing temperature

Undertemperature value(warning)

10 °C (18 °F) below set processing temperature

Undertemperature value(fault)

15 °C (27 °F) below set processing temperature

Overtemperature value(warning)

10 °C (18 °F) above set processing temperature

Overtemperature value (fault) 15 °C (27 °F) above set processing temperature

Gun (accessory) Prescribed processing temperature(s)

Hose (accessory) Prescribed processing temperature

Tank key


Enter key

Ready LED

Operation 4-21


To Adjust the Setpoint Temperature Using the GlobalMethod

1. Press and hold the Tank key for three seconds.

The left display flashes 1.

2. Scroll the left display to 0 (flashing).

The right display indicates all dashes (----) and the LEDs on all ofthe component keys turn green.



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt.

NOTE: If the keypad or the right-display scroll keys have no affecton the right display, the melter is password protected. You must entera valid password before you can change set-point temperatures. Referto Enter Password in this section.

5. Press the Tank key.

All components begin to heat or cool to the new globalset-point temperature. When all of the components reach theirset-point temperature, the ready LED turns on (green).

Tank, hose, and gun keys

Operation4-22


To Adjust the Setpoint Temperature Using theGlobal-by-component Method

1. Press and hold the Hose or Gun key for three seconds.

The left display indicates the number of the first sequential hose orgun. The right display indicates the current set-point temperature of thehose or the gun.

2. Scroll the left display to 0.

The right display indicates all dashes (- - - -).



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt.



The hoses or the guns begin to heat or cool to their newset-point temperature.

Operation 4-23


To Adjust the Setpoint Temperature of an IndividualComponent

1. Press and hold the Tank, Hose, or Gun key for three seconds.

If the tank key was pressed, the left display indicates 1 (Flashing). If ahose or gun key was pressed, the left display indicates the number ofthe first sequential hose or gun (Flashing). The right display indicatesthe current set-point temperature of the component indicated in the leftdisplay.

2. Scroll the left display to the number of the desired component.

The right display indicates the current set-point temperature of thecomponent that you selected in the left display.



4. Use the keypad to enter the set-point temperature recommended bythe manufacturer of the hot melt. Refer to the technical datasheet provided by the manufacturer of the hot melt to determine theoptimal set-point temperature.


5. Do one of the following:

� To register the new set-point temperature and then move on tochange the set-point temperature of the next sequential component,press the Enter key and then repeat steps 4 and 5.

� To register the new set-point temperature and return to the automaticscan mode, go to step 6.

6. Press any component key (tank, hose, or gun).

The selected component begins to heat or cool to its newset-point temperature.

Operation4-24


To Adjust the Setpoint Temperature of an IndividualComponent (contd.)

If you enter a valid set-point temperaturefor a hose/gun that is not connected tothe melter or if you enter a set-pointtemperature that is out of range, the rightdisplay will indicate dashes (----) for threeseconds and then change back to theoriginal set-point temperature.

When the right display is flashing, you canquickly change the current set-pointtemperature to 0 degrees (off) bysimultaneously pressing both ofright-display scroll keys.

After removing a hose or a gun, usethe individual component method ofset-point temperature adjustment to set thecomponent’s temperature to zero degrees(off). This will avoid causing an F1 fault.When a hose or gun is added, use theindividual component method to set thedesired temperature.

The factory set-point temperature of thetank is 175 �C (350 �F). The factoryset-point temperature of all otherscomponents is zero degrees (off).

When the units of temperature is setto degrees Celsius, the minimum andmaximum set-point temperatures are 40 �Cand 230 �C. When the units of temperatureare set to degrees Fahrenheit, the minimumand maximum set-point temperatures are100 �F and 450 �F.

When using the right-display scroll keys toadjust a set-point temperature, the rightdisplay automatically increments between0, 175, and 230 �C or between 0, 350,and 450 �F.

Operation 4-25


To Adjust the Setpoint Temperature of an IndividualComponent (contd.)

If you make a mistake while you arechanging a set-point temperature, but youhave not yet pressed the enter key, pressthe Clear/Reset key to reset the rightdisplay to the original temperature.

The melter will exit the setup modeand return to the automatic scan modetwo minutes after the last key is pressed.

A global set-point temperature of zerodegrees (Celsius or Fahrenheit) turns allcomponents off.

When scrolling through componentnumbers in the left display, componentnumbers that are associated with unusedhose/gun receptacles are skipped.

The melter stores a record of the lastten changes made to the set-pointtemperatures (and operating parameters) in the change history log.

Section 3, Installation,Review Parameterand Set-point TemperatureChanges

You can save set-point temperaturechanges by simultaneously pressing the 1 key and the Setup key.

Section 3, Installation, Saveand Restore Melter Setting

Operation4-26


Enter Password

If the melter is password protected, a valid password must beentered before any set-point temperature or melter parameter can bechanged.

To Enter a Melter Password


The left display indicates parameter 0 (flashing) and the rightdisplay indicates 4000.


The right display begins flashing.

3. Use the keypad to enter the melter password.


One of the following occurs:

� If the password is correct, the left display indicates parameter 1.

� If the password is incorrect, the left display remains at 0 and theright display momentarily indicates dashes (----) and then returns to4000.

If the password is incorrect, re-enter it and then press the Enter key.

The melter will automatically revertback to the password-protectedmode two minutes after the last keypress (any key). To force the melterback into the passwordprotected mode before two minuteshas elapsed, press the Setup keytwice.

The melter password is created andenabled/disabled during systemsetup.

Setting Up the Melter inSection 3, Installation

Heater key

Operation 4-27


Function keysThe control panel provides the following standard and special function keys:

Standard function keys

� Heater

� Pump (1 and 2)

� Setup

Special function keys

� Seven-day clock

� Standby

CAUTION: Unintentionally activating function keys can, under thecorrect circumstances, have undesirable effects on the melter or themanufacturing process. Only personnel who are familiar with the melter’ssetup and its connection with the manufacturing process should use thefunction keys. Improper use of the function keys can result in erratic processbehavior or personal injury.

Heater Key

Use the heater key to manually turn the component heaters on andoff. Pressing the heater key overrides the control (on or off) of the heatersby either the seven-day clock feature or a remote input. The LED on theheater key illuminates when the heaters are on.

When a fault occurs (refer to Monitor Melter Faults in this section) theheaters automatically turn off. The heater key is used to turn theheaters back on after correcting a fault condition.

1

2Pump key

Setup key

Operation4-28


Pump Keys

Press the pump keys (1 resp. 2) to enable, start or stop the pump. The LEDon the pump key is yellow when the pump is enabled (not yet running) andgreen when the pump is running. Switching the pump on or off has no effecton the heater control.

If the automatic pump on feature (parameter 8) is disabled, then thepump key must be used to start the pump when the melter is ready.

If any of the inputs are set up to use the pump enable/disable control option(option 3 and option 11), the pump motor will not start until the pump isenabled and the correct voltage is applied to the input contacts. If the pumpis enabled, but the input voltage is not present, the pump LED will flashgreen.

Setup Key

Use the setup key to place the melter into and take the melter out ofthe setup mode. When the melter is placed into the setup mode, theautomatic scan stops and the left and right displays are used to select andread or edit operating parameters.

Seven-day clock key

Operation 4-29


Seven-day Clock Key

Use the seven-day clock key to turn the melter’s clock feature on and off.When the clock is on, the temperature of each heated component isautomatically regulated based on a set of user-defined schedules.

To accommodate daily shift work and non-working days, fourclock schedules are available. Schedules 1, 2, and 3 are used to specifywhen the heaters should turn on and off or when the melter should enterand exit the standby mode. Schedule 0 is used to keep the melter in the lastcondition dictated by the clock (heaters on or off, or standby).

When a clock schedule calls for the heaters to be on, the heatersare regulated at their pre-assigned set-point temperatures. When theclock activates the standby mode, the set-point temperature of eachcomponent is temporarily reduced by a pre-set standby delta.

Refer to Appendix B, Operating Parameters, for information about setting upthe seven-day clock and the standby delta.

If the melter is switched off while theclock is on, the clock will automaticallyturn back on the next time the melter isswitched back on.

If the heaters are manually turned off atthe time that a clock schedule calls forthe heaters to be on, the heaters willnot turn back on until the next clockschedule calls for them to be on.

The clock will still operate when themelter is faulting or is in the setupmode.

If F4 appears in the right display whenyou press the clock key, the internalclock function has failed.

Section 7, Troubleshooting

Standby key

Operation4-30


Standby Key

Use the standby key to manually place the melter into, and take it out of, thestandby mode. Using the standby mode during periods of time when themelter is inactive helps conserve energy and allows heated components toquickly return to their set-point temperatures when the melter is once againneeded.

When the melter is placed into the standby mode, the temperatures of allcomponents are reduced down from their set-point temperature by a pre-setstandby delta. The melter will remain in the standby mode until the standbykey is pressed or the function of one of the operating parameters takes themelter out of the standby mode.

If the melter was set up to use the manual standby timer (parameter 26),pressing the standby key will place the melter in the standby mode for theperiod of time specified by the timer. After the manual standby time haselapsed, the melter will once again begin heating all of the components totheir assigned set-point temperature.

Using the standby key overrides the control of the melter (on or off) by theseven-day clock or a remote input.

Refer to Section 3, Installation, Setting Up the Melter, and to Appendix B,Operating Parameters, for information about setting the standby delta andthe standby timer.

The melter may also be set upto automatically enter the standby mode using a variety of operatingparameters.

Appendix B, Parameters 25,26, 57, 30–33, 62, and 67

Whenever manual standby is enabled, the standby LED blinks.

Appendix B, Parameter 26

Operation 4-31


Shutting Down the MelterShut the melter down when it will not be used for an extended period oftime.

To Shut the Melter Down

1. Set the main switch to 0/OFF.

2. Disable the guns as follows:

� Air-operated guns: Turn off the air supply to the guns.

� Electric guns: Turn off the gun driver, pattern controller, or timer.

Operation4-32


Settings Record

Production information:

Material: Manufacturer

Processing Temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Reference channel: High melt/reservoir (factory-set)

Processing temperatures (Setpoint temperatures):

Grid (low melt)

Reservoir (high melt)

Hose (accessory) 1) 2) 3) 4) 5) 6)

Gun (accessory) 1) 2) 3) 4) 5) 6)

Air heater (accessory) 1) 2) 3) 4) 5) 6)

Pump speeds:

Pump 1) 2)

Air pressures at gun (accessories):

Control air 1) 2) 3) 4) 5) 6)

Spray air 1) 2) 3) 4) 5) 6)

Notes:

Name Date

Maintenance 5-1


Section 5Maintenance


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

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

Some maintenance work can only be done when the melter is heated up.

Relieving PressureWARNING: System and material pressurized. Relieve system of pressurebefore disconnecting hoses, guns and hot melt handguns. Failure toobserve can result in serious burns.

1. Switch off the motor(s) (Refer to section Operation).



4. Properly dispose of material according to local regulations.

Maintenance5-2


Important when Using Cleaning Agents� Use only a cleaning agent recommended by the hot melt material

manufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

� Properly dispose of cleaning agent according to local regulations.

Processing Materials

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 394 769

� Tube 250 g P/N 783 959

� Cartridge 400 g P/N 402 238

Sealing paste Stucarit 203: Applied to sealing surfaces

� Tube 100 ml P/N 255 369

Temperature-resistantadhesive Loctite 640

Secures screw connections

� 50 ml P/N 230 359

Heat transfer compoundNTE303

To improve heat conducting oftemperature sensors

� 1 g P/N 1023441

Maintenance 5-3


Preventive MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the operating environment, production conditions and melterhours of operation, other scheduled maintenance tasks may provenecessary.

Melter part Activity Interval Refer to page

Complete melter External cleaning Daily 5-4

Inspect for externaldamage

Daily 5-4

Purge with cleaningagent

When material is changed 5-5

Fan and air filter Check filter, clean orreplace if necessary

Clean fan screen

Depending on dustaccumulation; daily if necessary

5-6

Power cable Inspect for damage Every time the melter is serviced −

Air hoses Inspect for damage Every time the melter is serviced −

Pump

(beginning 12/2008,model with Variseal�)

Pumps with gland:Check for leakage,tighten gland bolt ifnecessary

Dependent on hours ofoperation, pump speed andpump temperature

Recommendation: Monthly

5-7

Tighten fixing screws Every 500 hours of operation

Motor / gear box Clean fan cover Depending on dustaccumulation; daily if necessary

−

Change lubricant Every 15000 hours of operationor every 4 years

5-8

Pressure control valve Disassemble and clean Every six months 5-9

Filter cartridge Replace filter cartridge

Disassemble and cleanfilter cartridge

Depending on degree of materialpollution

Recommendation: Every 1000hours of operation

5-10

Tank Clean tank by hand When there is material residue intank

5-12

Tighten fixing screws Every 500 hours of operation

Safety valve Activating the piston Monthly 5-13

NOTE: Coupling and motor controller are maintenance-free.

Maintenance5-4


External CleaningExternal cleaning prevents impurities created during production fromcausing the melter to malfunction.

CAUTION: Observe the unit’s Degree of Protection when cleaning (Referto section 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.

Nordson recommends the orange cleaning agent P/N 771 192 (12 spraybottles, 0.5 l each).

Visual Inspection for External DamageWARNING: When damaged parts pose a risk to the operational safety ofthe melter and/or safety of personnel, switch off the melter and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

Changing Type of Material1. Run the melter until empty.

2. Determine whether the new material may be mixed with the old material.

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

� May not be mixed: Thoroughly purge the unit with a cleaning agentrecommended by the material supplier.

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

Maintenance 5-5


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

Cleaning agent residue can be flushed out of the unit with new materialbefore production begins again.

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

Detaching Protective PanelsOpen the protective panels with a 4 mm Allan key.

On the inside

Fig. 5-1

Detaching Insulation Blanket1. Release Velcro and clamps.

2. Take insulation blanket out of hooks.

2

1

2

1

Fig. 5-2

Maintenance5-6


Fan and Air FilterThe air filters must be cleaned (knocked out) or replaced, depending ondust accumulation.

Refer to section Parts for filter order number.

1

2

Fig. 5-3

1 Fan with filter 2 Air filter, air outlet

Maintenance 5-7


PumpAll melters delivered in December 2008 and later have pumps with aVariseal� seal instead of a gland.

Checking for LeakageThe pump is equipped with a shaft seal. Material may seep out along theshaft at irregular intervals.

� Pumps with Variseal�: Replacing Pump Shaft Seal

� Pumps with gland: Retighten gland bold.

Retighten Gland Bolt

NOTE: Retighten only when melter is warm.

Retighten the gland approx. ¼ of a revolution in the operating direction ofthe pump. If tightening is no longer possible, the gear pump must bereplaced.

Fig. 5-4

Replacing Pump Shaft SealWhen the pump shaft seal needs to be replaced, Nordson recommendsreplacing the pump and sending the old one in to be repaired. Only trainedpersonnel can replace the pump shaft seal.

Tightening Fixing ScrewsNormal heat cycling (heating and cooling) can cause the fixing screws tobecome loose.

NOTE: Tighten fixing screws only using a torque wrench (25 Nm / 220 Ibin)and when the melter is cold.

Maintenance5-8


Motor / Gear BoxThe only motor maintenance required is cleaning the fan cap.

Changing LubricantNOTE: Use only the stated lubricant or one that has proven to beequivalent (Refer to Lubricant Selection). Using any other lubricant canresult in premature wear and/or damage to the gear box.

NOTE: Drain lubricant when warm.

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

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

Lubricant Changing Interval

Operating temperature < 100 ° C / 212 ° F:Every 15000 hours of operation or every 4 years.

Capacity

The lubricant quantity is indicated on the ID plate. Ensure that the uppergears and rolling bearings are properly lubricated.

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

+−

Maintenance 5-9


Pressure Control Valve

Disassembling and CleaningWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

WARNING: System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

Measure and make a note of the insertion depth of the setting screw(dimension X). This way the insertion depth can be replicated afterreassembly.

Fig. 5-5

X

Fig. 5-6 Pressure control valve

NOTE: Screw in only when valve and pump are warm and material is soft.

1. Apply high temperature grease to all threads and O-rings. Forinformation on high temperature grease refer to Processing Materials.

2. Slide the valve into the hole and tighten with torque wrench (15 Nm / 133 lbin).

3. Adjust the setting screw to the recorded dimension X.

� Turning to the right increases material pressure.

� Turning to the left decreases material pressure.

Fig. 5-7

Maintenance5-10


Filter Cartridge

Replacing Filter CartridgeWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

WARNING: System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

Removing Filter CartridgeNOTE: Remove filter cartridge only when the melter is hot and not underpressure.

M10

SW 24

Fig. 5-8

Installing Filter Cartridge

NOTE: Install filter cartridge only when melter is hot.

1. Apply high temperature grease to all threads and O-rings.

Refer to Processing Materials.

2. Insert filter cartridge and tighten somewhat (approx. 1 Nm).

3. Feed material by allowing the pump to run until the material comes outof the hose connection or gun free of bubbles.

4. Properly dispose of material according to local regulations.

Fig. 5-9

Maintenance 5-11


Installing Service Kit

Each kit contains three O-rings, filter sheath, filter screen andhigh-temperature grease.

Fig. 5-10

Service kit P/N: 394590

Required tools:Open-jawed wrench, size 24 and size 13

3

2

2

2

Size 13

1

Size 24

1. Disassemble the filter cartridge when hot.

2. Replace filter sheath (1), O-rings (2) and filter screen (3).

3. Clean all other parts.

4. Apply grease to all threads and O-rings.

MXTK007S050A0495

Maintenance5-12


Tank

Draining MaterialPump material out of the melter.

CAUTION: Do not feed charred material though the gun. Particles canblock the gun. Instead unscrew hose (Refer to section Installation).

Cleaning Tank by Hand

Cold material can usually be peeled off of the sides of the tank (Refer to Fig. 5-11). If necessary, first heat tank to material softening temperature,usually approx. 70 °C / 158 °F.

NOTE: The inside of the tank is release coated. Do not use metallic tools toclean. Do not use wire brushes! This could damage the release coating.

Fig. 5-11

Tightening Fixing ScrewsHeating and cooling that occurs during daily operation can cause the fixingscrews to loosen. Tighten screw as indicated in the table.

NOTE: Tighten fixing screws only using a torque wrench and when themelter is cold.

Fig. 5-12

Connection Thread Torque

Tank / melter chassis M 8 25 Nm / 220 lbin

Grid (low melt) / reservoir(high melt)

M 8 20 Nm / 177 lbin

X

Maintenance 5-13


Safety ValveActivate the safety valve piston. This prevents the material from blocking thesafety valve.

Procedure:

1. Relieve pressure as described in section Installation.

2. Disconnect all hoses.

3. Close hose connections with Nordson port plugs (Fig. 5-13).

Fig. 5-13

4. Mechanical pressure control valves: Measure insertion depth ofsetting screw (Fig. 5-14, dimension X) and make a note. This ensuresthat insertion depth can be reproduced. Then close pressure controlvalve.

Pneumatic pressure control valves: Set the compressed air supply to6 bar.

5. Operate the melter at maximum motor speed and with hose connectionsclosed. Switch the motor on and off several times.

Fig. 5-14

ÂÂÂÂ

ÂÂÂÂ

Maintenance5-14


Pneumatic Safety Valve (Option)The safety valves, preset at the factory and lead sealed, prevent higherpressurization than permitted of the subsequent pneumatic components.When the factory settings are exceeded, compressed air audibly escapes.

NOTE: The safety valves for the pneumatic options are located in themelter tower.

Performance Check

The performance of the safety valve should be checked approx. every sixmonths. Turn the knurled screw until compressed air audibly escapes. If thesafety valve does not function properly, it should be cleaned. If it still doesnot function, it must be replaced.

NOTE: A defective safety valve may be replaced only with an original sparepart. Only the manufacturer may perform repairs to the safety valve!

Cleaning

Pollution that has penetrated fitting surfaces and conical nipples can beremoved by unscrewing the entire top piece − without changing theminimum operating pressure. Use a sickle wrench to unscrew.

Maintenance 5-15


Maintenance Record Form

Schmelzgeräteteil Datum / Name Datum / Name Datum / Name

Pump

Motor / gear box

Fixing screws on pump andtank

Air filter

Maintenance5-16


Maintenance Record Form (contd.)

Schmelzgeräteteil Datum / Name Datum / Name Datum / Name

Tank

Pressure control valve

Filter cartridge

Pneumatic safety valve(Option)

Troubleshooting 6-1


Section 6Troubleshooting


WARNING: Troubleshooting activities may sometimes have to be carriedout when the melter 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?

� Do all plug connections have sufficient contact?

� Have circuit breakers been activated?

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

� Provide recovery diodes for external, inductive loads (e.g. solenoidvalves)

Troubleshooting6-2


Troubleshooting Tables

Melter not Functioning

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 melter oraccessories

−

6. 24 VDC power supplydefective

− Replace

7. Frequent meltershutdown

Electromagnetic compatibilitydisruptions

Add mains filter

One Channel (Heating Zone) does not Heat


1. Channel is disabled /switched off

− Enable / switch on

Control Panel does not Function

Problem Possible Cause Corrective Action

1. Display is blank SPS broad-band cable notconnected

Connect

Troubleshooting 6-3


No Material (Motor does not Rotate)


1. Melter not yet readyfor operation (heatupphase)

− Wait until the melter has heated upand the green indication lamp is lit

2. Motor not switchedon

− Switch on motor

3. Speed (rpm) not set − Set speed (rpm)

4. Standby entered − Exit or wait until standby period hasexpired

5. Motor overheated Ambient temperature too high Decrease ambient temperature bycooling or airing out

Fan cap dirty Clean

Pump blocked by foreign matter Replace pump

Pump operates too sluggish Replace pump

Material too cold Set temperature accordingly

6. Motor defective − Replace

7. Motor not suppliedwith voltage

− Technical inspection

8. Motor controller fault − Switch melter off and on again withmain switch

Motor overheated See above

Motor controller overheated Decrease ambient temperature bycooling or airing out

Clean cooling section of motorcontroller

Short circuit Check motor cable

Overload (pump blocked byforeign matter, pump too sluggish,material too cold)

Refer to 5.

9. Motor controllerdefective

− Replace

Troubleshooting6-4


No Material (Motor Rotating)


1. Tank empty − Fill tank

2. Filter cartridgeclogged

− Clean or replace filter screen

3. Material supply holeto pump or pumpsuction hole clogged

− Detach pump and clean supply holeor suction hole

Too Little Material


1. Material supply holeto pump or pumpsuction hole partiallyclogged

− Detach pump and clean supply holeor suction hole

2. Filter cartridge partlyclogged

− Clean or replace filter screen

3. Pressure controlvalve defective

− Clean or replace

4. Processingtemperature set toolow

− Correct temperature setting

5. Pump block is worn − Replace pump

Troubleshooting 6-5


Material Pressure too High


1. Safety valve orpressure controlvalve dirty and thusblocked

− Disassemble and clean or replace

2. Safety valve orpressure controlvalve defective

− Replace

3. Pressure controlvalve set incorrectly

− Set to default

Material Pressure too Low


1. Pump is worn − Replace pump

2. Safety valve does notclose any more

− Replace

3. Pressure controlvalve dirty and thusclogged

− Disassemble and clean or replace

4. Pressure controlvalve defective

− Replace

5. Pressure controlvalve set incorrectly

− Set to default

Material Residue in Tank


1. Tank setpointtemperature set toohigh


Material of low quality or notappropriate for application(temperature resistance poor)

Consult material supplier

Troubleshooting6-6


Material Hardens in Tank


1. Tank setpointtemperature set toohigh


Others

Problem Possible Cause Corrective Action

1. Leakage at pumpshaft seal

Pump shaft seal is worn Pumps with gland: tighten

− Replace pump

2. Material pressure toolow, output quantitytoo low

Pump is worn Replace pump

3. Pump blocked Processed material too cold Correct temperature setting (observedata sheet of material manufacturer)

Foreign material in pump Replace pump

4. Leakage at gunduring heatup phase

Safety valve does not open(expansion pressure)

Replace safety valve

Troubleshooting 6-7


LEDs of Motor ControllerDuring operation the operating mode of the motor controller is displayed bytwo LED’s on the front of the unit.

Fig. 6-15 LEDs

LED display Operating mode

Green Red

On Off Motor controller enabled

On On Mains switching and automatic start blocked

Flashing Off Motor controller blocked

Off Flashing (every 1 s) Fault message

Off Flashing (every 0.4 s) Over- or undervoltage shutdown

Off Off Missing voltage supply

Troubleshooting6-8


Repair 7-1


Section 7Repair


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

Some melter components can only be detached when the melter is heatedup.

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

WARNING: Disconnect melter from line voltage before any repairs.

Relieving PressureWARNING: System and material pressurized. Relieve system pressurebefore disconnecting hoses. Failure to observe can result in serious burns.

1. Switch off the motor(s) (Refer to section Operation).



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

Repair7-2


Replacing Motor Controller

CAUTION: The connection terminals may only be connected ordisconnected when the melter is de-energized. The motor controller is stillenergized after switching off. Wait at least 3 minutes before beginning anywork!

Use only original Nordson motor controllers. They are parameterized andguarantee the required function.

Replace Standard I/O Module of Motor Controller1. Disconnect motor controller from power supply and wait at least

3 minutes.

2. Disconnect standard I/O connections

3. Use a screwdriver to pry away the male connector (1) first and then thestandard I/O module (2).

4. Remove protective cap (3) of the new Standard I/O module.

5. Insert Standard I/O module into the serial port of the motor controller.

6. Insert male connector (1) into female connector of the standard I/Omodule.

7. Connect standard I/O module according to cable designation.

NOTE: The DIP-switch of the standard I/O module is factory-set and neednot be changed.

3

1

1

2

Fig. 7-1

1

0

Tank side

Pump side

2

Repair 7-3


PumpNordson recommends replacing the pump and sending the old one in to berepaired.

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

Tank Isolation ValveNOTE: Operate the tank isolation valve only when the melter is heated tooperating temperature.

Pin in position 0: Closed

Pin in position 1: Open

Fig. 7-2

Detaching Pump

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

WARNING: The motor is precisely aligned and may not be be slid backwith the bracket in the slot.

Fig. 7-3

1. Remove protective panel.

2. Turn the coupling until the screws of the coupling half shells areaccessible.

3. Release the screws (2) of the coupling half shells on the pump side.

4. Remove the coupling half shell carefully from the pump side to preventthe coupling from falling apart.

Fig. 7-4

4

3

11

1 12

2

3 4444

Repair7-4


Detaching Pump (contd.)

5. Place a container under the pump (3) to collect any material left.

6. Slide coupling part off of the pump shaft.

7. Detach pump.

8. Clean sealing surface on the plate (4). If necessary, heat materialresidue with a hot air fan, then remove.

9. Allow melter to cool to room temperature.

Fig. 7-5

Attaching PumpNOTE: The pump may only be screwed on when the melter is cold.

NOTE: The sealing surfaces on the plate and the pump must be clean.Always replace all O-rings.

1. Apply sealing paste (Refer to section Maintenance, ProcessingMaterials) to the new pump.

2. Apply high temperature grease to the fixing screws of the pump, thentighten screws crosswise using a torque wrench; the tank must be coldwhen screws are tightened. Starting torque: 25 Nm / 220 lbin

3. Refer to Important Regarding Coupling.

The axial offset, meaning the sum of the four gaps (4, Fig. 7-6), mustresult in at least 2 mm (0.08 in) of air to accommodate the heatexpansion during operation.

Permitted radial offset: 1 mm (0.04 in)Permitted angle offset: 1 °

4. Slide coupling half onto the shaft of the new pump.

5. Center the coupling disks (1) to one another and allow the coupling links(2) to hang vertically (Refer to Fig. 7-6). Turn the coupling half on themotor shaft to its position by hand.

6. Tighten coupling screws (3).

7. Heat melter to operating temperature and open tank isolation valveagain.

Fig. 7-6

Repair 7-5


Important Regarding Coupling

1 1 1 1

=

=2

Fig. 7-7

� The coupling half shells (1) such that the diagonal surfaces of the pumpshaft (2) rest on those of the coupling half shells (Refer to Fig. 7-7).

� The coupling half shells must be tightened such that the gaps are thesame size (Refer to Fig. 7-7).

Extract from manufacturer’s installation and operating instructions:

� The drive shaft and output shaft should be parallel* to one another. If theaxes lean towards one another, excess load is applied to the edges ofthe bearings, causing premature wear.

� The coupling may not be twisted axially. Intermediate disk should movefreely.

� The coupling should not be disassembled. Interchanging of couplinglinks and disks, damaged sealing rings, polluted bearings, etc. cancause premature malfunctioning.

� All three coupling disks must be aligned to the dimension** of the shaftoffset. If the intermediate disk is extremely off-center − meaning that thecoupling links are no longer parallel − the coupling may be destroyedupon startup.

* = axially aligned

** = within the permitted shaft offset

Repair7-6


Replacing VarisealNOTE: When the pump shaft seal needs to be replaced, Nordsonrecommends replacing the pump and sending the old one in to be repaired.Only trained personnel can replace the pump shaft seal.

NOTE: Nordson cannot provide a guarantee for Variseals that have beenreplaced by anyone besides a Nordson employee.

1. Remove the gear pump from the melter but do not disassemble it!

Refer to Replacing Pump in this section.

2. Have a new seal and a suitable assembly tool ready.

Assembly ToolThe assembly tool is used to slide new seals over the shaft journal and thepump shaft pulley key groove without damaging the seals.

CAUTION: The seal must be put into place using the tool; otherwise theseal will be destroyed.

1. Follow the instructions Assembly Tools for Sealing Kits with VarisealSeals (P/N 7146229) to proceed.

2. Put the gear pump back into place.

1

Repair 7-7


Replacing Motor

NOTE: Perform work only when the material is soft (approx. 70 °C/158 °F,depending on material); otherwise the coupling can not be turned.

1. Disconnect motor power cable in the electrical cabinet.

2. Detach plug connector from motor controller.

3. Turn the coupling until the screws of the coupling half shells areaccessible.

4. Release the screws of the coupling half shells on the motor side.

5. Remove the coupling half shell carefully from the motor side to preventthe coupling from falling apart.

WARNING: The bracket may not be slid back in the slot or unscrewed.

6. Unscrew motor from bracket (1).

7. If necessary, remove protective varnish from the shaft of the new motor.

8. Attach the coupling to the shaft without using force (no jolts orpounding). If necessary, sand pulley keys and shaft with emery cloth.Lubricate pulley keys and shaft if needed.

Fig. 7-8

9. Install new motor in the bracket.

10. Attach coupling (Refer to Important Regarding Coupling)

Reconnect motor electrically.

11. Secure power cable with strain relief. Ensure that cable shield andclamp have contact.

12. Verify that the connection effects the desired direction of rotation (seearrow).

Fig. 7-9 Direction of pumprotation

1

1

2

Repair7-8


Replacing Filter CartridgeProceed as described in chapter Maintenance to replace filter cartridge.

Replacing Safety Valve

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

WARNING: System and material pressurized. Relieve system pressurebefore removing the safety valve. Failure to observe can result in seriousburns.

NOTE: Screw in/out only when valve (1) and pump are warm and materialis soft (approx. 70 °C, depending on material).

1. Unscrew old valve.

2. New valve: Apply mounting paste to all threads and the O-rings.

3. To prevent damage to the O-rings, carefully guide the new valve into thehole when the melter is warm.

4. Tighten valve with a torque wrench. Starting torque: 15 Nm (133 lbin)

Fig. 7-10

TankWARNING: The electrical cover (1) of the heater connections is linked toground conductors. The ground conductor (2) must be reconnected afterevery repair.

Fig. 7-11

Repair 7-9


Replacing Heater Connection InsulationWARNING: The melter may not be operated without properly insulatedheater connections. Use only Nordson spare parts for insulation.

The heater connection insulation may be damaged when maintenance andrepair work is performed.

Fig. 7-13 shows the Nordson spare parts kit for insulating heaterconnections as well as properly attached heater insulation.

Spare parts kit order no.: P/N 263 274

1. Remove nut (4), washers (3 and 5) and insulating cylinder (2).

2. Remove all of the ceramic powder from the heater connection.

Fig. 7-12

3. Guide new insulating cylinder (1) into the heater connection.

4. Attach new insulating cylinder (2), washer (3) and nut (4). Tighten nutcarefully until the insulating cylinder (2) is tight and has contact with theheater connection.

5. Attach heater cable, spring washer (5) and nut (4) and tighten nut.

54

3

2

1

MCTK020L050A0497

Fig. 7-13 Spare parts kit

1 Insulating cylinder, small2 Insulating cylinder, large

3 Washer4 Hexagonal nut

5 Spring washer

Repair7-10


Replacing Temperature Sensor

Installing Service Kit

The kit contains a temperature sensor and heat transfer compound.

Service kit P/N: 394597 (Ni120)

Required tools:PliersSide cutting pliers

1. Remove electrical equipment cover.

2. Disconnect connecting wires and extract old temperature sensor by theconnecting wires or with the aid of a pliers.

3. Apply heat transfer compound to new sensor.

4. Insert sensor and reconnect electrically.

5. Attach electrical equipment cover again.

Repair 7-11


Replacing Thermostat1. Remove electrical equipment cover.

2. Release fixing screws and remove thermostat.

3. Connect connecting wires to the new thermostat.

4. Apply heat transfer compound to the bottom of the thermostat (Refer toProcessing Materials in section Maintenance), then fasten it to the tankagain.

5. Attach electrical equipment cover again.

Fig. 7-14

Repair7-12


Parts 8-1


Section 8Parts

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

Item— Identifies parts that can be obtained from Nordson.

Part— Nordson part number for each spare part shown in theillustration. A row of hyphens in the column Part (- - - - -) indicates thatthis part can not be 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.The abbreviation AR (as required) is used when this item is a bulk itemor when the quantity per assembly depends on the product version ormodel.

Unit — Identifies the melter of which the spare part is a component.

NOTE: Refer to separate document Parts List, P/N 7146820 or 7156101.

FastenersFasteners 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


Technical Data 9-1


Section 9Technical Data

General Data

Type Designation D25 D25H D50 D100Storage temperature − 45° C to + 75 ° C

− 49 ° F to + 167 ° F

Max. operating height 3000 m 9840 ftType of heating Cast-in electrical resistance heating elementsTemperature sensor Ni120 � 1 ° C− Measuring precisionMaterial pressure 5 to 85 bar 0.5 to 8.5 MPa 72.5 to 1233 psi

The pressure control valve is preset at the factory. Default:

35 bar 3.5 MPa 508 psiMelting capacity 1 tankfull per hourDegree of protection IP 54Noise emission 1 motor: 60 dBA

− − 2 motors: 62 dBAMotor type 3 ph AC motor

Gear box type Helical gearMotor/pump speeds 50 min-1, 65 min-1, 129 min-1

Heatup time <45 min

Temperatures

Min. ambient temperature - 5 °C 23 °FMax. ambient temperature 40 ° C 104 °FHumidity 10 to 95 %, not condensingMin. operating temperature(setpoint)

40 ° C 100 °F

Max. operatingtemperatures

230 ° C 450 °F

Overtemperature shutdownby thermostat

260 ° C 500 °F

Technical Data9-2


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

Available operating voltages 200 VAC 3-phase without neutral (Delta)

230 VAC 3-phase without neutral (Delta)

400 VAC 3-phase with neutral (star − WYE)



Mains filter P/N 394908 for 200 VAC 3-phase without neutral230 VAC 3-phase without neutral

P/N 394907 for 400 VAC 3-phase with neutral400 VAC 3-phase without neutral480 VAC 3-phase without neutral

Operating voltagefrequency

50/60 Hz

Fuse protection Refer to ID plate

Max. load per hosereceptacle (2 channels)

1000 W per single hose or gun

1200 W per hose/gun pair

2000 W total, hose/gun pairs 1 and 2



Technical Data 9-3


Mechanical Data

Typenbezeichnung D25 D25H D50 D100

Weight Refer to consignment note

Tank opening [mm]

Length & width

242 x 284 306 x 685

Tank volume [liters] Approx. 25 Approx. 45 Approx. 50 Approx. 100

Maximum number of single stream pumps

1 1 2 2

Number of hose connections One pump: 6

− − Two pumps: 3 per pump

Two pumps:3 per pump

Assignment of hoseconnections with two pumps

Pump 2 (P2)

Pump 1 (P1)

2.1 2.2

1.1 1.2

2.3

1.3

P1 P2

Technical Data9-4


Dimensions

1361

1382

1382 17

1145

2

400

174,5

1224

1270

366

835

245

582

885

121

210

D25

D25H

*)

Fig. 9-1

*) For minimum bending radius refer to the hose manual

Technical Data 9-5


Dimensions (contd.)

1661

1381

D50

600

658

175

1516

1585

543

1129

245

782

1000

121 21

2 *)

Fig. 9-2


Technical Data9-6


Dimensions (Forts.)

D100

1101

121

911

751

1306

245

175

1837

*)

1935

212

1246

1585

1381

Fig. 9-3


General Instructions Regarding Working with Application Materials A-1


Appendix AGeneral Instructions Regarding Working with

Application Materials

Definition of TermsApplication materials can be e.g. thermoplastic hot melt materials, adhe-sives, sealants, liquid adhesives and similar application materials. They arereferred to as materials.

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

Manufacturer InformationMaterials may be processed only when the manufacturer’s product descrip-tions and Safety Data Sheets (MSDS) are observed.

They provide information, amongst other things, on correct processing ofthe product, transport, storage and disposal. Information regarding reactivityand potentially hazardous decomposition products, toxic properties, flashpoints, 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 MaterialsA-2


Vapors and GasesEnsure that vapors and gases do not exceed the prescribed limits. If neces-sary, exhaust vapors and gases and/or provide sufficient ventilation of thework space.

SubstrateThe substrate should be free of dust, grease and moisture. The suitable ma-terial, optimum working conditions, and possible pre-treatment of the sub-strate 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, resultingin malfunctioning or unit failure.

Material should always be melted gently. Extended, unnecessary tempera-ture load should be avoided. The temperature should be reduced duringbreaks in work. The temperature in the tank should be attuned to the mate-rial consumption. Thus it is close to the prescribed processing temperaturefor 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.

Operating Parameters B-1


Appendix BOperating Parameters

The operating parameters are organized in this appendix according to thelogical groups listed in Table B-1. For information on selecting and editingoperating parameters, refer to Setting up the Melter in section 3, Installation.

NOTE: Parameter numbers that are reserved or that are not used do notappear in this appendix.

Tab. B-1 Parameter groups

Group Parameters Description

Standard0 to 8 and 10 to 14 Frequently used parameters

Pressure control 15 to 17 Configure the pressure settings

Temperature control 20 to 29 Control heater function

Input setup 30 to 39 Configure the inputs

Output setup 40 to 46 Configure the outputs

Seven-day clock 50 to 77 Set up the clock function

Automatic fill timer 78Configures the external motor controlswitch

PID selection 80 to 91 Change the default PID settings

Operating ParametersB-2


Standard

0 Enter PasswordDescription: A user-defined password that prevents unauthorized changes to

setpoint temperatures and operating parameters.

Value: 0 to 9999

Resolution: 1

Default: 4000

Format: —

Use: This parameter only appears if a password is created usingparameter 11 and then enabled using parameter 10.

NOTE: The melter remains in password-protected mode for twominutes after the last key was touched. If the user exits setup modeand then tries to enter setup mode again, he must enter thepassword again, even if two minutes have not yet elapsed.

1 Total Hours with Heater On (Non-editable)

Description: Non-editable value. Shows the total number of hours that the heaterswere on.

Value: 999.999 (Refer to Use)

Resolution: 1 hour

Default: 0

Format: —

Use: The right display shows up to 9999 hours of heater operation. Whenthe heater hours counter reaches 10,000, the display alternates everytwo seconds between the three left numerals (thousands) and thethree right numerals (hundreds). For example: If the counter is at10,001 hours, the display would show ”10,” for two seconds and”001” for two seconds. If parameter 20 (temperature units) is set toFahrenheit, a comma appears. If parameter 20 is set to Celsius, adecimal point appears.



2 Fault Log (Non-editable)

Description: Stores a record of the last ten faults.

Value: —

Resolution: —

Default: _−F0 (unused log entry)

Format: F1, F2, F3 and F4

Use: Touch the right display scroll keys to review the last ten faults in thelog. Empty log entries are indicated by ”_ −F0”. Refer to Monitoringthe Melter in section 4, Operation.

3 Change History Log (Non-editable)

Description: Records the last ten changes made to either the setpointtemperatures or the operating parameters.

Value: —

Resolution: —

Default: P-_ (unused log entry)

Format: Refer to Review Parameter and Setpoint Temperature Changes insection 3, Installation

Use: Use the right display scroll key to review the last ten changes madeto either the setpoint temperatures or the operating parameters.Empty log entries are indicated by ”P-_”



Standard (contd.)

4 Ready Delay TimeDescription: The amount of time that will elapse after all of the components have

reached their setpoint temperatures before the ready LED turns on.The ready delay time only functions when the temperature of thetank, at the time the melter is turned on, is more than 27 °C (50 °F) ormore below its setpoint temperature. The ready delay time beginswhen all components are within 3 °C (5°F) of their respectivesetpoint temperature.

Value: 0 to 60 minutes

Resolution: 1 minute

Default: 0 minutes

Format: Left display, ”rd” (ready). Right display, remaining minutes orseconds.

Use: The ready delay allows the tank additional time to heat up before thepump starts up.

NOTE: The time remaining on the ready delay is indicated in minutesin the right display at the end of every automatic scan cycle. Whenthe delay time reaches one minute, the time remaining appears inseconds.

5 Service IntervalDescription: The number of hours of heater operation that must elapse before the

service LED lights up.

Value: 0 hours (disabled) to 8736 hours (one year)

Resolution: 1 hour

Default: 500 hours

Format: —

Use: Set the service interval time to signal a user-defined service check ormaintenance event, such as changing the filter. The service LEDlights up after the preset time has elapsed. Touch the Clear/Resetkey to turn off the service LED and reset the time when the melter isin normal mode.



6 Service LED Heater HoursDescription: A counter indicates how many more hours the heaters must remain

on before the service LED lights up (service required).

Value: 0 (disabled) to 9999 hours

Resolution: 1 hour

Default: 0

Format: —

Use: Enable the service interval (parameter 5) for this parameter to work.

Note: Heater hours are counted whenever the heater LED isilluminated.

7 Motor Off DelayDescription: Determines the amount of time that the motor will remain on

after the switching device turns off.

Value: 0 to 360 seconds

OR

- - - - (infinite)

Resolution: Seconds

Default: 0 seconds

Format: —

Use: This parameter functions only when a switching device(handgun with switch, foot switch, etc.) is connected to theswitch receptacle.

8 Automatic Pump OnDescription: Determines whether the pump switches on automatically when the

melter is ready.

Value: 0 (disabled) or 1 (enabled)

Resolution: —

Default: 1 (enabled)

Format: —

Use: If disabled, the pump must be started by touching the pump key afterthe melter is ready.

NOTE: If a pump is set to automatic and is deactivated (0) while it isswitched on, it continues to run until the pump key is touched.



Standard (contd.)

10 Enable or Disable PasswordDescription: Enables or disables the password of the melter. When password

protection is activated, component setpoint temperatures or melteroperating parameters can not be changed until a valid password isentered using parameter 0.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default: 0

Format: —

Use: A password must first be created using parameter 11 before it can beenabled or disabled with parameter 10.

11 Create PasswordDescription: A user-defined password that prevents unauthorized changes to

setpoint temperatures and operating parameters.

Value: 0 to 9999

Resolution: 1

Default: 5000

Format: —

Use: Refer to section 4, Operation, Enter Password.

NOTE: When the password is created and enabled, parameter 10 willnot appear again in the right display until the password is entered.



12 Change hose 1 output toelectric gun activation

Description: Changes the proportioned 240 VAC current that is provided to thehose 1 heater to a switched 240 VAC current that is used to activatea manifold mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default: 0 (disabled)

Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installedand a switching device is connected to the melter’s switch receptacle.Refer to the electric gun manual for information on mounting andusing the gun.

13 Change hose 2 output toelectric gun activation

Description: Changes the proportioned 240 VAC current that is provided to thehose 2 heater to a switched 240 VAC current that is used to activatea manifold mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —


Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installedand a switching device is connected to the melter’s switch receptacle.Refer to the electric gun manual for information on mounting andusing the gun.



Standard (contd.)

14 External Communication InterlockDescription: Serves as a safety lock during melter maintenance work. Prevents

the the melter from being controlled externally via standard oroptional inputs/outputs (optional).

Value: 0 (disabled) or 1 (enabled)

Resolution: —


Format: —

Use: Before beginning maintenance work to the melter, set the parameterto 1 (activated). External control of the melter is completely disableduntil the parameter is set to 0 (deactivated) again.

15 Pressure SetpointDescription: Used to set a percentage value of the maximum output pressure

(from 0 − 100 %).

Value: 0 to 100 (percent)

Resolution: —


Format: —

Use: This parameter is available only if the analog I/O module is installedin the melter. The pressure is displayed after the last guntemperature. The left display indicates P (pressure), and the rightdisplay shows the pressure value.

16 Overpressure SetpointDescription: If the pressure in the system exceeds this setting, an overpressure

alarm is triggered.

Value: 0 to 50 (percent) above the pressure setpoint (parameter 15)

Resolution: —


Format: —

Use: This parameter is available only if the analog I/O module is installedin the melter.



17 Underpressure SetpointDescription: If the pressure in the system falls below this setting, an

underpressure alarm is triggered.

Value: 0 to 50 (percent) below the pressure setpoint (parameter 15)

Resolution: —

Default: 0

Format: —

Use: This parameter is available only if the analog I/O module is installedin the melter.

20 Temperature UnitsDescription: Sets the units for temperature display.

Value: C (degrees Celsius) or F (degrees Fahrenheit)

Resolution: 1 degree

Default: C

Format: —

Use: —

21 Overtemperature DeltaDescription: The number of degrees that a component can exceed its assigned

setpoint temperature before an overtemperature fault (F3) occurs.

Value: 5 �C (10 �F) to 60 �C (110 �F)

Resolution: 1�C

1�F

Default: 15 �C (25�F)

Format: —

Use: —



Standard (contd.)

22 Undertemperature DeltaDescription: The number of degrees that the temperature of any component can

fall below its setpoint temperature before an undertemperature fault(F2) occurs.

Value: 5 �C (10 �F) to 60 �C (110 �F)

Resolution: 1�C

1�F


Format: —

Use: —

23 Standby DeltaDescription: The number of degrees that the temperature of all heated

components will be decreased when the melter enters standby mode.

Value: 25�C to 190�C (50�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: A standby delta should be selected that results in a balance betweenmelter energy savings during periods of inactivity, the amount of timeand energy required to bring the melter back up to setpointtemperature, and a temperature at which the hot melt adhesive canbe held in the tank for extended periods without charring. Refer tosection 4 Operation, Using Melter Keys.

NOTE: The standby delta does not affect the undertemperature delta(parameter 22).



24 Automatic Standby TimeoutDescription: The amount of time that must elapse after the last signal (gun driver)

is sent to input 1 before the melter enters standby mode. Theautomatic standby timeout feature saves energy by allowing themelter to enter standby mode as soon as the guns are no longerapplying material.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: 1. Change parameter 23 if required.

2. Set the control option for parameter 30 (input 1) to option 10(automatic standby).

NOTE: Only enable parameter 24 when a 24 VDC signal voltage isconnected to input 1. If there is no voltage on the input contactswhen the melter is ready, the melter will enter standby mode after theautomatic standby time.

25 Automatic Heaters OFF TimeDescription: The amount of time that must elapse after the automatic standby time

expires (parameter 24) before the heaters turn off.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: Set parameter 24 (automatic standby timeout) to the desired valuebefore setting parameter 25.



Standard (contd.)

26 Manual Standby TimeDescription: The amount of time that the melter will remain in standby mode after

the standby key is touched.

Value: 0 to 180 minutes


Default: 0

Format: —

Use: Set the standby time when the operator is to cause the melter toenter standby for a limited period (break, lunch, etc.). Whenevermanual standby is activated (value greater than 0 minutes), thestandby LED flashes.

Set the standby delta (parameter 23) to the desired value beforesetting parameter 26.

Note: If a time of one minute or longer was entered, the LED in thestandby key flashes, indicating that the manual standby timer iscounting down.

27 Standby delta (all hoses)Software version 2.023 and higher

Description: A standby value that applies only to the hoses.

Value: 1�C to 190�C (1�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: If this parameter is deactivated, the standby value of parameter 23 Standbydelta (global) applies instead.

NOTE: For control purposes, the hopper is hose 5.

28 Standby delta (all guns)Software version 2.023 and higher

Description: A standby value that applies only to the guns.

Value: 1�C to 190�C (1�F to 350�F)

Resolution: 1�C

1�F


Format: —

Use: If this parameter is deactivated, the standby value of parameter 23 Standbydelta (global) applies instead.



29 Temperature offset Software version 2.023 and higher

Description: The grid and reservoir may be assigned different temperature setpoints.

The setpoint temperature entered on the control panel is that of the reservoir.The grid setpoint temperature is lowered internally by the value set here.

Value: 0�C to −15�C (0�F to −30�F)

Resolution: 1�C

1�F

Default: 0

Format: —

Use: In case different temperatures for grid and reservoir are needed.

Setpoint Reservoir + Temperature offset = Setpoint GridExample: 150 �C + (−15 �C) = 135 �C

NOTE: For control purposes, the hopper is hose 5. To ensure a steadilyincreasing temperature hopper − grid − reservoir, its setpoint temperature mustbe taken into consideration when setting the temperature offset.



Input Setup

30 Input 1Description: Control options that determine the function of input 1.

Value: 0 − Input disabled

1 – Standby on/off

2 – Heaters on/off

3 – Motor 1 enabled/disabled

4 – Hose/gun 1 enabled/disabled






10 – Automatic standby

11 – Motor 2 enabled/disabled (only with DuraBlue D50 and D100)

13 – Automatic fill timer 1

14 – Automatic fill timer 2 (only with DuraBlue D50 and D100)

Resolution: 1

Default: 10

Format:

Use: Multiple inputs can be set to the same input value. After one or moreinputs that have the same input value are energized, the inputfunctionality will not be considered inactive (off) until all of the inputswith the same input value are de-energized (Multiple inputs set to thesame input value are logical ORed).

HINWEIS: To be able to use option 13 or 14, parameter 78(automatic fill timer) must be set to 1 or higher. Output option 6(alarm) can be used to signal that the timer has expired.

















Resolution: 1

Default: 1

Format: —


NOTE: To be able to use option 13 or 14, parameter 78 (automatic filltimer) must be set to 1 or higher. Output option 6 (alarm) can be usedto signal that the timer has expired.



Input Setup (contd.)















Resolution: 1

Default: 2

Format: —


NOTE: To be able to use option 13 or 14, parameter 78 (automatic filltimer) must be set to 1 or higher. Output option 6 (alarm) can be usedto signal that the timer has expired.




Value: 0 – Input disabled










11 – Motor 2 enabled/disabled (only with DuraBlue D50 andD100)


14 – Automatic fill timer 2 (only with DuraBlue D50 andD100)

Resolution: 1

Default: 4

Format: —

Use: Multiple inputs can be set to the same input value. After oneor more inputs that have the same input value areenergized, the input functionality will not be consideredinactive (off) until all of the inputs with the same input valueare de-energized (Multiple inputs set to the same inputvalue are logical ORed).

NOTE: To be able to use option 13 or 14, parameter 78(automatic fill timer) must be set to 1 or higher. Outputoption 6 (alarm) can be used to signal that the timer hasexpired.



Input Setup (contd.)

34 – 39 Optional Inputs 5, 6, 7, 8, 9 and 10Description: Control options that determine the function of the two

optional inputs, provided the optional I/O expansion card isinstalled on the main board.

NOTE: Melters that have an Ethernet card can not beequipped with the optional I/O expansion board.

Value: 0 – Input disabled



3 – Pump 1 enabled/disabled







11 – Motor 2 enabled/disabled (only with DuraBlue D50 andD100)


14 – Automatic fill timer 2 (only with DuraBlue D50 andD100)

Resolution: 1


Format: —

Use: Multiple inputs can be set to the same input value. After oneor more inputs that have the same input value areenergized, the input functionality will not be consideredinactive (off) until all of the inputs with the same input valueare de-energized (Multiple inputs set to the same inputvalue are logical ORed).

NOTE: To be able to use option 13 or 14, parameter 78(automatic fill timer) must be set to 1 or higher. Outputoption 6 (alarm) can be used to signal that the timer hasexpired.



Output Setup

40 − 42 Outputs 1, 2 and 3Description: Determines the function of the output.

Value: 0 = Output disabled

1 = Ready

2 = Ready and pump on

3 = Fault

4 = Low level (not available)

5 = Service LED lit

6 = Alarm

Resolution: 1

Default: Output 1 = 1

Output 2 = 3

Output 3 = 4

Format: —

Use: Refer to Installing Melter Outputs in section 3, Installation forinformation about setting up outputs.

When control options 6, Alarm, is selected, the output is active assoon as the melter enters the two minute fault monitoring period. Ifthe potential fault condition clears before the end of the two minuteperiod, the output signal ends. Refer to section 4, Operation, MonitorMelter Faults, for information about fault monitoring.



43 Optional Output 4Description: Control options that determine the function of the optional output,

provided the optional I/O expansion card is installed on the mainboard.

NOTE: Melters that have an Ethernet card can not be equipped withthe optional I/O expansion board.


1 = Ready

2 = Ready and motor ON

3 = Fault

4 = Pump ON

5 = Service LED ON

6 = Alarm

Resolution: 1

Default: 0 (all optional outputs)

Format: —

Use: For information on wiring and setting the optional outputs, refer to theinstruction sheet included with the optional I/O expansion card or theanalog I/O module.




Output Setup (contd.)

44 − 46 Optional Outputs 5, 6, and 7Description: Control options that determine the function of the three optional

outputs, provided the optional I/O expansion card is installed on themain board.

NOTE: Melters that have an Ethernet card can not be equipped withthe optional I/O expansion board.


1 = Ready

2 = Ready and motor ON

3 = Fault

4 = Pump ON

5 = Service LED ON

6 = Alarm

Resolution: 1

Default: 0 (all optional outputs)

Format: —

Use: For information on wiring and setting the optional outputs, refer to theinstruction sheet included with the optional I/O expansion card or theanalog I/O module.




Seven-day clockBefore setting the clock, refer to Function Keys in section 4, Operation, tofamiliarize yourself with the function and use of the clock feature.

If you are unfamiliar with the procedure for accessing and editing operatingparameters, refer to section 3 Installation, Setting Up the Melter.

To Set the Clock

1. Enter the current day of the week with parameter 50.

2. Enter the current time of day with parameter 51.

3. Create schedule 1:

a. Set parameters 55 and 56 to the time of day that the heaters shouldturn on and off.

b. Set parameters 57 and 58 to the time of day that the melter shouldenter and exit standby mode.

4. Repeat step 3 to create schedules 2 and 3 with parameters 60 to 68.

5. Determine which of the four schedules should be used on each day ofthe week with parameters 71 to 77. Up to three schedules can beassigned for each day (to support three work shifts). Each of the eightcontrol options (0 to 7) available in parameters 71 to 77 offers a differentcombination of the three schedules. Option 0 is used to hold the melterin the state dictated by the last clock transition until the next clocktransition occurs.

In order for the clock to operate continuouslythroughout the week, a valid schedule must beassigned to every day of the week (parameters 71 to 77).

To prevent unintentional activation of the clock, thestandard setting for parameters 71 to 77 is schedule0 (no times set). If the clock key is touchedunintentionally when the standard setting is schedule0, the melter is not affected.



Seven-day Clock (contd.)

50 Current dayDescription: Used to set the current day of the week.

Value: 1 to 7 (1 = Monday, 2 = Tuesday, etc.)

Resolution: 1

Default: —

Format: —

Use: For information about the use and effects of the seven-day clock,refer to Function Keys in Section 4, Operation.

51 Current timeDescription: Used to set the current time of day.

Value: 0000 to 2359 (European time format)


Default: (Time set at factory)

Format: Hour, Hour: Minute, Minute

Use: This setting only needs to be made once for all daily schedules.

55 Schedule 1 Heaters onDescription: Used to set the time that the clock will turn on the heaters during

schedule 1.

Value: 0000 to 2359, - - - -


Default: 0600


Use: Set the desired time for the heaters to switch on.

To disable this parameter, set the parameter’s value to ”- - - -” bysimultaneously touching both of the right display scroll keys.

56 Schedule 1 Heaters offDescription: Used to set the time that the clock will turn off the heaters during

schedule 1.

Value: 0000 to 2359, - - - -


Default: 1700


Use: Set the desired time for the heaters to switch off.




57 Schedule 1 Enter StandbyDescription: Used to set the time that the melter will enter standby mode during

schedule 1.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Set the time that the melter will enter standby mode during schedule1.


Note: Do not set an enter standby time that is outside of the timeperiod defined by the schedule’s heater on and off time. The meltercan not enter standby mode when the heaters are off.

58 Schedule 1 Exit StandbyDescription: Used to set the time that the melter will exit standby mode during

schedule 1.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Set the time that the melter will exit standby mode during schedule 1.


Note: Do not set an exit standby time that is outside of the timeperiod defined by the schedule’s heater on and off time. The meltercan not enter standby mode when the heaters are off.


schedule 2.

Value: 0000 to 2359, - - - -


Default: - - - -








schedule 2.

Value: 0000 to 2359, - - - -


Default: - - - -





schedule 2.

Value: 0000 to 2359, - - - -


Default: - - - -





63 Schedule 2 Exit StandbyDescription: Used to set the time that the melter will exit standby mode during

schedule 2.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Used to set the time that the melter will exit standby mode duringschedule 2.


Note: Do not set an exit standby time that is outside of the timeperiod defined by the schedule’s heater on and off time. The meltercan not enter standby mode when the heaters are off.




schedule 3.

Value: 0000 to 2359, - - - -


Default: - - - -





schedule 3.

Value: 0000 to 2359, - - - -


Default: - - - -





schedule 3.

Value: 0000 to 2359, - - - -


Default: - - - -








68 Schedule 3 Exit StandbyDescription: Used to set the time that the melter will exit standby mode

during schedule 3.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Set the time that the melter will exit standby mode duringschedule 3.

To disable this parameter, set the parameter’s value to ”- - --” by simultaneously touching both of the right display scrollkeys.

Note: Do not set an exit standby time that is outside of thetime period defined by the schedule’s heater on and off time.The melter can not enter standby mode when the heatersare off.

71 - 77 Schedules for the Days of the WeekDescription: Used to select which schedule(s) should be used each day.

Value: 0 – Remain at last clock transition1 – Use only schedule 12 – Use only schedule 23 – Use only schedule 34 – Use schedules 1 and 25 – Use schedules 2 and 36 – Use schedules 1 and 37 – Use schedules 1, 2 and 3

Resolution: 1

Default: 0

Format: —

Use: Selects the active schedules for the day.

NOTES: If schedule 0 is used, the heaters will not switch onagain until the next scheduled heaters on time arrives.



78 Automatic Fill TimerDescription: A timer that counts down; it can be connected to a switch at one

of the inputs.

Value: 0 to 90 seconds

Resolution: 1


Format: —

Use: Used in conjunction with input control option 13 or 14. Activateoutput control option 6, alarm, to transmit a signal when thetimer expires.

NOTE: If the filling process is not ended within the specifiedtime, a message runs up and the melter stops. In this case,check why the filling process was not ended and fix the cause.hen press the Clear/Reset key to reset the melter to normalmode.

PID Selection

80−87 PID selection for receptacles, hose/gun 1, 2, 3 and 4Description: Changes preset PID selection. Use parameter 80 to select the value

for hose 1, parameter 81 to select the value for gun 1, and so on.

Value: 0 = Hose1 = Standard gun2 = Large gun3 = Air heater

Resolution: —

Default: 0 or 1, depending on channel type (hose or gun)

Format: —

Use: Consult your Nordson representative before changing PID settings.



PID Selection (contd.)

88−91 PID Selection for Hose/Gun Receptacles 5 and 6(Only with DuraBlue D25, D50, and D100)

Description: Changes preset PID selection. Use parameter 80 to select the valuefor hose 1, parameter 81 to select the value for gun 1, and so on.

Value: 0 = Hose1 = Standard gun2 = Large gun3 = Air heater

Resolution: —

Default: 0 or 1, depending on channel type (hose or gun)

Format: —

Use: Consult your Nordson representative before changing PID settings.

Glossary C-1


Appendix CGlossary

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 MeltAn 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 sameis done with the coated substrate. The number of samples taken dependson how 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 usedin the USA is psi. Refer to Conversions.

GlossaryC-2


Bd (Baud)Rate of data transfer: Bit/s.

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

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

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

Class of protectionProtective measures are required to ensure electrical safety of the units.The measures prevent accessible metal parts from conducting voltagewhen a fault occurs. Assignment of classes of protection indicates theprotective measures.

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 groundconductor.

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 anapplication 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).

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

ControlNetInternationally 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 VoltageElectrical 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

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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

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Conversions (contd.)

Unit Multiplied by Result

Masse 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.

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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 ProtectionAccording 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 aheight of 20 cm

4 Foreign object > 1 mm Splash water −

5 Dust accumulation Water stream 2,0 J = Impact of 500 g from aheight of 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.

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EncoderThe 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.

FirmwareInternal software that cannot be changed by and that is not accessible tothe customer.

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

Free-wheeling DiodeElectronic component that protects electronic assemblies from powersurges that occur when relays or solenoid valves are switched off.

GrammageRefer to Application Weight.

Gun, Hot MeltSystem component used to apply material as a bead, dot, surface or sprayapplication.

Heater CartridgeA replaceable, cylindrical resistance heating element. It is inserted into ahole in the component to be heated.

HopperUnheated tank extension, used to increase tank volume.

HostHigher-order control unit.

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Hot MeltSynonym for hot melt adhesive.

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

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

InitiatorComponent 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 ModeMode of operation for guns/application heads. Instead of materialapplication being continuous, it occurs with pauses to create the desiredapplication pattern.

LEDLight Emitting Diode.

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

Line VoltageVoltage in the customer’s network. It may need to be converted to operatingvoltage by a transformer.

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Machine EnableA control unit is enabled by a signal from the parent machine. In Nordsonliterature the enable feature is also referred to as Parent Machine Interlockor Security.

Master-SlaveThe 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.

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

MelterMelts and feeds hot melt adhesives or similar materials.

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

min−1

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

MSDSMaterial Safety Data Sheet.

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

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

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Noise EmissionNoise level that a unit produces in the immediate vicinity. The noiseemission is stated in dB (A).

Nominal Air QuantityStates suction volume of exhaust hoods. The pressure drop from theexhaust hood to the customer’s fan must also be taken into consideration.

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

Open TimeThe 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 PressureThe customer’s compressed air supply is usually reduced by pressurecontrollers in the units. The operating air pressure is the reduced pressureat which pneumatic components are operated.

Operating VoltageThe 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 QuantityThe material volume fed by the pump. Stated e.g. in cm3/min.

PaPascal, SI unit for pressure. Refer to Conversions.

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

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Parent MachineThe user’s machine that generates the line speed signal for key-to-linemode. Refer to Line Speed Signal.

PasPascal second, SI unit for dynamic viscosity.

PID ControllerA 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.

PLCProgrammable Logic Controller.

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

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

Power Consumption PThe electrical power consumption (wattage) of the unit (motor, heater andthe electrical 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.

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Processing TemperatureThe 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)

PROFIBUSInternationally 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 DisposalDisposal of all types of waste in compliance with all local regulations.

Proportional Pressure Control ValveElectropneumatic component that enables control of pneumatic pressurewith an electrical variable (usually control voltage).

Protective GasRefer to Inert Gas.

Pt 100Abbreviation 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.

PURRefer to Polyurethane Hot Melt Adhesive.

Rated CurrentThe setpoint for current to a unit, determined by standards or as agreedupon by the manufacturer and the customer.

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Release CoatingLargely prevents hot melt adhesive from burning onto the surface andmakes it easier to clean the application system parts coming into contactwith the adhesive.

Residual RisksHazards that can pose a danger to the user, even when all safetyregulations for manufacturing a product are followed and when the unit isused only as intended. Residual risks are noted - as extensively as themanufacturer is aware of them - in the manual and/or with waning signs onthe unit.

Resistance Temperature SensorComponent 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 ModeA pump motor operates counter to the direction of material feeding.Prevents material from dripping.

RPMRevolutions per minute, same as min−1 = 1/min.

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

Safety Valve PlateA component in which material circulates when the installed safety valve isopen.

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

SISystème International d’ Unités (international standardization system).

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

Solid State RelayElectronic assembly without mechanical parts but with the function of anelectromechanical relay.

SolventSolvents 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.

SubstrateThe product − fabric, foil, etc. − to which a material is applied.

Tach GeneratorA component that generates electrical voltage (pilot voltage). The voltage isproportional to the speed at which the tach generator is driven.

Temperature SensorA part of a temperature control system that compiles the temperature andtransmits it to the control system. Resistance temperature sensor are usedin Nordson units.

ThermostatComponent 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.

TransformerVoltage converter.Used in Nordson units to convert the customer’s line voltage to theoperating voltage.

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VACAbbreviation for Alternating Current. AC voltage.

VDCAbbreviation for Direct Current. DC voltage.

ViscosityStrength; 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).

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durablue adhesive melters model d25, d25h, d50,...

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