duradrum bulk melters dd200 - nordsonemanuals.nordson.com/adhesives/english_manuals/7105731.pdf ·...

DuraDrum�

Bulk MeltersDD200

Manual P/N 7105731J− English −

Issued 11/07

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

P/N 7105731J � 2007 Nordson CorporationDD200

NoteThis manual applies to the entire series.

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2005.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.

© 2007 All rights reserved.

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem,Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry,Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan,OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus, ProBlue, Pro-Flo,ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure,Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure-Max,Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray,Walcom, Watermark, When you expect more. are registered trademarks − ® − of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series,CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat,DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site, HDLV, Ink-Dot, iON,Iso-Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, Minimeter, Multifil, Myritex, OptiStroke,Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue,Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix,SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Viper, Vista, VersaDrum, VersaPail,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 7105731J� 2007 Nordson Corporation DD200

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

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

Residual Risks 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of Term(s) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note on Manual 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ID Plate 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Cabinet 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Button Two-hand Control and Selector Raise/Lower Platen 2-6Main Switch 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan with Filter 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Melting Plates 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Hood (Accessory) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Tower (Accessory) 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Drum Jacket for Cardboard Drums (Accessory) 2-9. . . . . . .

Function 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising and Lowering Platen 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deaerating Drum 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aerating Drum 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melting Process and Material Flow 2-11. . . . . . . . . . . . . . . . . . . . . . . Heating and Temperature Control 2-12. . . . . . . . . . . . . . . . . . . . . . . .

Undertemperature Interlock 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . Undertemperature Indication 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . Overtemperature Indication / Shutdown 2-12. . . . . . . . . . . . . . . . Standby 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modes 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Mode 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked System) 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting with a Crane 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the System 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhausting Material Vapors 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connections 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Observe when Using Residual Current Circuit Breakers 3-4. . . . . Laying Cable 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Voltage 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Control and Switching Circuits 3-5. . . . . . . . . . . . . . . . . . . Hose Receptacles 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly Handgun Operation 3-5. . . . . . . . . . . . . . . . . . . . . . . . Additional Hose Receptacles 3-5. . . . . . . . . . . . . . . . . . . . . . . . .

Installing Hoses 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Open-jawed Wrench 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting and Adjusting Compressed Air 3-7. . . . . . . . . . . . . . . . . .

Pneumatic Cylinder Working Pressure 3-7. . . . . . . . . . . . . . . . . . . . Pressure Controller Up 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed Air for Aerating Drum 3-8. . . . . . . . . . . . . . . . . . . . . . . Adapting the System to the Drum Used 3-8. . . . . . . . . . . . . . . . . . . . .

Limiting How Far the Platen is Lowered 3-8. . . . . . . . . . . . . . . . . . . Speed Setpoint and Output Quantity 3-9. . . . . . . . . . . . . . . . . . . . . . . . Overtravel Time When Drum Empty 3-10. . . . . . . . . . . . . . . . . . . . . . . .

Setting Overtravel Time 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing System Inputs 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting up an Input 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing System Outputs 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting up an Output 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting up Communication 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting up the Bulk Melter 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Setup 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Parameters 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Operating Parameters 3-18. . . . . . . . . . . . . . . . . . . . . . . Reading or Editing Operating Parameters 3-19. . . . . . . . . . . . . .

Setpoint Temperature of the Platen, Hoses and Guns 3-24. . . . . . Save and Restore Settings 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Review Parameter and Setpoint Temperature Changes 3-27. . . . .

Accessories 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Tower 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Kit 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Hood 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Drum Jacket for Cardboard Drums 3-31. . . . . . . . . . . . . . . . . . Timer Relay Overtravel Time 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Timer Relay 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Startup 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detaching 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposing 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Bulk Melter 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To Start the System 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring the System 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Confirm that the System is Operating Correctly 4-5. . . . . . . . . . . .

Drum Empty LED 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitor Component Temperatures 4-6. . . . . . . . . . . . . . . . . . . . . . .

To Check Component Temperatures Using the Normal Mode 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To Manually Check a Component’s Temperature 4-7. . . . . . . .

Monitoring Faults 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1, F2 and F3 Faults 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4 Fault 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting System 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Log 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring the Service Interval 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . To Reset the Service LED 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Component Temperatures 4-14. . . . . . . . . . . . . . . . . . . . . . . . Recommended Temperatures 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . .

To Adjust the Setpoint Temperature Using the Global Method 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . To Adjust the Setpoint Temperature Using the Global-by-component Method 4-16. . . . . . . . . . . . . . . . To Adjust the Setpoint Temperature of an Individual Component 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Password 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function Keys 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Key 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Key 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Key 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven-day Clock Key 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby Key 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inserting and Replacing Drum 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising Platen 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering Platen 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Principle Wiring Diagrams 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising/Lowering Platen 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Enable 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED in Selector Raise/Lower Platen 4-30. . . . . . . . . . . . . . . . . . . . . .

Switching System ON/OFF 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Startup 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Switchoff 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switching Off in an Emergency 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Melting Plate 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan and Air Filter 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Valve 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activating the Piston 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for Leakage 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Gland Bolt 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening Fixing Screws 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor / Gear Box 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Lubricant 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant Selection 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed Air Filter 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining Condensate 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Filter Element 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Restrictor Valve 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Function 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Restrictor Valve for Aerating Drum 5-9. . . . . . . . . . . . Pressure Restrictor Valve at Compressed Air Connection 5-10.

Cleaning 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Record Form 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Tips 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light Tower (Accessory) 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Tables 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Codes 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System does not Function 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One Channel (Heating Zone) does not Heat 6-3. . . . . . . . . . . . . . . Control Panel does not Function 6-4. . . . . . . . . . . . . . . . . . . . . . . . . No Material (Motor does not Rotate) 6-4. . . . . . . . . . . . . . . . . . . . . No Material (Motor Rotating) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Little Material 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Pressure too High 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Pressure too Low 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Others 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEDs of Motor Controller 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVI


Repair 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Notes 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Sealing Ring 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing O-rings 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Platen Temperature Sensor and Thermostat 7-4. . . . . . .

Identifying Installed Thermostat 7-5. . . . . . . . . . . . . . . . . . . . . . . . . Replacing Control Panel 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Service Kit 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Technical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motors / Speed 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Quantity 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperatures and Thermostats 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identifying Installed Thermostat 9-2. . . . . . . . . . . . . . . . . . . . . . . . . Material Pressures 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Consumption 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Hood (Accessory) 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-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vapors and Gases A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Substrate A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processing Temperature A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Parameters B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Control B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Setup B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Setup B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven-day clock B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Set the Clock B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example 1 B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example 2 B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example 3 B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PID Selection B-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

O-1Introduction

� 2007 Nordson CorporationAll rights reserved

NI_EN_M-0307

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 39-02-904 691 39-02-9078 2485

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

Finishing 44-161-495 4200 44-161-428 6716

Nordson UV 44-1753-558 000 44-1753-558 100

Distributors in Eastern & Southern Europe

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

O-2 Introduction

� 2007 Nordson CorporationAll rights reserved

NI_EN_M−0307

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

� 2006 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 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 UseBulk melters of the series DuraDrum − hereafter also referred to as system− may only be used to melt and feed suitable materials. When in doubt,seek permission from Nordson.

CAUTION: Only undamaged and suitable drums may be used (Refer toTechnical Data).

CAUTION: PUR material may be processed only in models with exhausthood (accessory)!

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

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

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

� In defective condition

� With electrical cabinet door open

� In a potentially explosive atmosphere

� With unsuitable operating/processing materials

� When safety valves and pressure restrictor valves are not lead-sealed

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

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

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction2-2


Area of UseThe system is designed for use in industrial areas.

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

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

� Risk of burns from hot material

� Risk of burns from hot system components

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

� Risk of burns when attaching and removing heated hoses

� Material fumes can be hazardous. Avoid inhalation

� Risk of pinching parts of the body between platen and drum or drumjacket / bracket.

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

Definition of Term(s)The safety valve is also referred to as bypass and bypass valve in Nordsonliterature.

Note on Manual� This manual is valid only in conjunction with all documents included in

the complete set of documentation (blue binder)

� When the system has special features, customer specifications and/orsupplements or a higher-ranking system description may be added tothis manual

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

Introduction 2-3


ID Plate

DuraDrum

Nordson Engineering GmbHLilienthalstr. 6D 21337 Lüneburg − Germany

www.nordson.comSerial No:

3

4

5

1 2

Year

Fig. 2-1

1 Bulk melter designation

2 Order number

3

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

5 Serial number

Introduction2-4


Description

12 3 4

7

12

11

10

965

8

Fig. 2-2 Operating side

1 Electrical cabinet2 Drum aeration (tube and hose)3 Pressure controller Pneumatic

cylinder

4 Drum jacket5 Safety valve6 Pump / Adapter plate7 Drum deaeration8 Drum aeration (rod)9 Hose connection

10 Pneumatic cylinder11 Motor12 Hose holder

Introduction 2-5


13

56

247

Fig. 2-3 Back

1 Cable gland Power supply2 Compressed air connection

3 Additional hose receptacles4 Pressure controller

Aerating drum

5 Hose receptacles (XS10, XS11)6 Receptacles Assembly handgun

(XS18, XS19)7 Bracket

Introduction2-6


Electrical Cabinet

2

6

5

73

4

2

Fig. 2-4

1 −2 Button Two-hand control3 Selector Raise/lower platen4 Main switch

5 Air filter / Fan with filter6 Door lock7 Control panel

Button Two-hand Control and Selector Raise/LowerPlatenUsed to raise and lower the platen.

WARNING: The two-hand control may only be operated by one personusing both hands!

Introduction 2-7


Main SwitchThe main switch is used to switch the system on and off.

Position 0/OFF = System is switched off.Position I/ON = System is switched on.

Padlocks can be used to protect the main switch from being turned on byunauthorized personnel.

Fan with Filter

The fan reduces the temperature inside of the electrical cabinet. The filtermust be serviced regularly. Refer to Maintenance.

Door Lock

The electrical cabinet can be opened for installation, maintenance andrepair. Store the included key such that it is accessible only to qualified andauthorized personnel. The system may not be operated when the electricalcabinet is open.

Control Panel

8

1

6

9

2 3

4

5

10

7

Fig. 2-5 Control panel

1 Fault LED2 Ready LED3 Component keys / LEDs

4 Keypad5 Serial interface6 Right display and scroll keys7 Drum empty LED

8 Left display and scroll key9 Function keys

10 Service LED

Introduction2-8


PlatenThe platen consists of a heating punch, a melting plate and sealing rings.

NOTE: Models for cardboard drums have only the lower sealing ring on theplaten.

1

2

3

Fig. 2-6

1 Heating punch 2 Sealing rings 3 Melting plate

Melting PlatesDepending on what the bulk melter is used for, one of these melting platesis used. The melting plates are all release coated.

Axial melting plateFine blade melting plateSmooth melting plate

Fig. 2-7

Introduction 2-9


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

The exhaust hood must be connected to the customer’s exhaust device(Also refer to Installation, Exhausting Material Vapors and Technical Data ).

Light Tower (Accessory)The light tower shows the system operating modes.

White Switched on

Green Ready for operation

Yellow Drum empty

Red General alarm

Also refer to Troubleshooting and Installation.

High Drum Jacket for Cardboard Drums (Accessory)CAUTION: Do not use metal drums with this model! The drum jacket isdesgned only for cardboard drums!

NOTE: Models for cardboard drums have only the lower sealing ring on theplaten.

1

Introduction2-10


Function

Raising and Lowering PlatenThe pneumatic cylinders raise and lower the platen. When lowering theplaten, a two-hand control must be operated for safety reasons until theplaten is in the drum.

The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa /108.75 psi) by a pressure restrictor valve.

Deaerating DrumFor the air to be able to escape as the platen is lowered into the drum, thedrum deaeration valve must be opened with the lever (1). Also refer tosection Operation, Lowering Platen.

Aerating Drum

To prevent a vacuum from forming with the platen is lifted out of the drum,the drum must be aerated. Refer to section Operation, Raising Platen.

The air pressure in the drum is limited to 1.0 bar by a pressure restrictorvalve.

Deaerating Aerating

Air

Platen

Drum

Compressed air

Platen

Drum

Fig. 2-8

Introduction 2-11


Melting Process and Material FlowThe material is melted only directly below the melting plate (4). A gear pump(1) feeds the melted material to the hose connection (3). From there it flowsthrough a heated hose to a gun or an assembly handgun, possibly to amelter, to fill that unit.

A safety valve (2) limits the material pressure generated by the pump andkeeps it constant.

3

4

1 2

Fig. 2-9 Prinziple drawing

Introduction2-12


Heating and Temperature ControlThe platen is heated by cast-in heating elements.

Temperatures are measured by sensors and electronically controlled.

Undertemperature Interlock

The undertemperature interlock prevents the system from being started upbefore the material has exceeded the temperature setpoint minusundertemperature value. However, every time initial heating occurs, theinterlock is not released until the actual temperature is 3 °C (5.4 °F) belowthe temperature setpoint.

The undertemperature interlock locks the motor, solenoid valves and, insome cases, other components of the application system. Refer to thewiring diagram to determine which components are locked.

Undertemperature Indication

If during operation the actual temperature falls below the setpoint minus theundertemperature value, the relay output General alarm switches and thefault LED lights up on the control panel (Refer to Fig. 2-5). The systemcontinues to operate despite the fault.

Overtemperature Indication / Shutdown

The independently operating overtemperature shutdown mechanismsprotect the system and the material from overheating. For overtemperatureshutdown, the heater and motor are switched off.

� Overtemperature indication through temperature controller: When thetemperature setpoint plus overtemperature value has been reached, therelay output General alarm is switched and the fault LED lights up on thecontrol panel. The system continues to operate or remains ready despitethe fault.

� Overtemperature shutdown by temperature controller: The temperaturecontroller switches the heater off if the temperature is more than 30 °Cabove the highest temperature setpoint.

� Overtemperature shutdown by thermostat(s): Serves as an emergencyswitch OFF in case the overtemperature shutdown of the temperaturecontroller does not function properly. Refer to section Technical Data forshutdown value.

WARNING: When the overtemperature shutdown is triggered, there iseither a fault in settings or system malfunction. Switch off the system andhave the fault remedied by qualified personnel.

StandbyServes to protect the material and save energy during interruptions inproduction or work stoppages. Standby value and standby period areadjustable.

Introduction 2-13


ModesDuraDrum bulk melters operate in the following modes:

Normal Mode

When the system is first switched on, it is in normal mode. In normal modethe system checks the current temperature of the platen, the hoses and theguns to verify that they are within the set temperature ranges.

StandbyThe temperatures of the platen, the hoses and the guns are lowered fromtheir operating temperature (hereafter referred to as setpoint temperature)by a set number of degrees.

SetupSetup mode (configuration) is used to configure the control options andfeatures of the system as well as to check the saved operating data. Thesystem is protected by password from unauthorized changes to theconfiguration.

FaultThe system alerts the user when a fault occurs, e.g. a sensor fault (RTD) ora temperature that is not within the permitted range.

Introduction2-14


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.

UnpackingUnpack carefully and check for damage caused during transport. Savepallet and fastening and packing material for later use, or dispose ofproperly according to local regulations.

Lifting (Unpacked System)Refer to Technical Data for weight. Lift only with a suitable floor conveyor(lift truck or fork lift) or a crane.

Lifting with a CraneThere are four eye bolts in the base plate of the bulk melter.

CAUTION: Guide the ropes such that they do not damage the bulk melter.

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

� If possible, use the pallet on which the system was delivered, and fastenthe system to the pallet.

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

� Avoid jolts and vibrations.

Installation3-2


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

Mounting the System� Mount only in an environment that corresponds to the stated Degree of

Protection (Refer to Technical Data). Do not mount in a potentiallyexplosive atmosphere!

� Protect from vibration. Remove transport protection (if present).

� Ensure that there is sufficient clearance around the system, especiallyabove it. Refer to Technical Data for dimensions.

Fig. 3-1

Installation 3-3


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

If necessary, exhaust material vapors and/or provide sufficient ventilation ofthe location of the system. On systems with exhaust hoods, material vaporsare suctioned off directly at the drum.

NOTE: The exhaust hood must be connected to the customer’s exhaustdevice. Also refer to Technical Data.

Customer’s

System without exhaust hood System with integrated exhaust hood

Fig. 3-2 Prinziple drawing

Installation3-4


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

Observe when Using Residual Current Circuit Breakers

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

Then observe the following points:

� The residual current circuit breaker is to be installed only between thepower supply and the bulk 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 thesystem. Ensure that cables do not touch rotating and/or hot parts. Do notpinch cables and check regularly for damage. Replace damaged cablesimmediately!

Line VoltageWARNING: Operate only with the line voltage stated on the ID plate.

NOTE: Permitted deviation from the rated line voltage is +5% / -10%.

NOTE: The power connection cable must have a cross-section matchingthe power consumption Pmax. (Refer to ID Plate).

Power SupplyThe system must be installed securely (permanent power supplyconnection). Refer to wiring diagram for connecting arrangement.

1

1

Installation 3-5


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.

Hose ReceptaclesThe hose receptacles (XS10 and XS11) are located in the terminal box (1).

For electrical connection values, refer to Technical Data.

Assembly Handgun Operation

The receptacles for assembly handguns (XS18 and XS19) are located inthe terminal box (1).

Additional Hose Receptacles

Depending on the model, two or four additional receptacles are available(1). Two heating zones (usually for hose and gun) can be controlled viaeach receptacle.

1 32

Installation3-6


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

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

ConnectingIf 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).

1. First connect the hose (3) electrically to the unit. For more than onehose: Every hose connection is allocated to a corresponding receptacle.Do not mistakenly exchange!

2. Heat the system and hose to approx. 80 �C (176 °F).

3. Screw the hose onto the unit.

NOTE: Close unused hose connections with Nordson port plugs.

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

Relieving Pressure1. Switch off motor.

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. Properly dispose of material according to local regulations.

1 2

3

4 6

Installation 3-7


Connecting and Adjusting Compressed AirConnect dry, clean and non-lubricated compressed air to the compressedair receptacle on the back of the system (2).

Minimum air pressure: 2.5 bar / 0.25 MPa / 36.25 psi

The pressure restrictor valve (1) behind the compressed air receptacle limitsthe air pressure to 7.5 bar / 0.75 MPa / 108.75 psi.

Pneumatic Cylinder Working PressureSet the pneumatic cylinder working pressure to approx. 5 bar (0.5 MPa /72.5 psi) on the pressure control valve with condensate collector (3)

The setting must be modified according to the material processed (max. 7.5 bar / 0.75 MPa / 108.75 psi).

Pressure Controller UpSet the compressed air to raise the platen to approx. 1.5 bar (0.15 MPa / 21 psi) with the pressure controller (4, behind the cover (6)). The pressure restrictor valve limits the pressure to 2.0 bar (0.2 MPa / 29 psi).

5 6

-197B5

Installation3-8


Compressed Air for Aerating DrumAdjust the compressed air for aerating the drum with the pressure controller(5, behind the cover (6) ). The pressure restrictor valve limits the airpressure to 1,0 bar (0,1 MPa / 14,5 psi).

Adapting the System to the Drum Used

Limiting How Far the Platen is LoweredThe proximity switch Drum empty (-197B5) limits how far the platen islowered:

� Drum is not completely emptied:Slide proximity switch down

� Drum empty is not indicated:Slide proximity switch up

Installation 3-9


Speed Setpoint and Output QuantityWARNING: Disconnect the system from line voltage before opening theelectrical cabinet.

The speed is set with the terminal blocks (1 and 2) in the electrical cabinet.

1 2

Fig. 3-3

1. Terminal 1 2. Terminal 3

The resulting output quantity is a factor of the pump used.

NOTE: Refer to separate document Parts List to identify the pump used.

Pump / Output quantity in kg/h

Terminal 1 Terminal 3 Speed SN0371(PR12m2)

SN0773(PR25m2)

PU15/85 PU 25/85 PU35/85 PU50/85

In Out 50 min−1 11 23 48 81 108 159

Out In 65 min−1 14,5 30 62 105 140 206

In In 129 min−1 29 60 124 210 280 412

Out Out 0 min−1 0 0 0 0 0 0

-197B5

Installation3-10


Overtravel Time When Drum EmptyIf the accessory Timer relay is used, an Overtravel time can be set. Duringthe overtravel time, feeding can continue despite the Drum empty indication.

NOTE: The accessory Timer relay must be installed for the functionOvertravel time. Refer to Accessories, Timer Relay Overtravel Time.

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

1. Locate the timer relay -197K4 in the electrical cabinet.

2. Verify that the selectors Time range and Mode on the timer relay are setas shown in the wiring diagram.

3. Set time as required.

CAUTION: Do not operate Nordson pumps without material. For thisreason, the overtravel time should be set as short as possible. If necessary,slide the proximity switch Drum empty (-197B5) up somewhat so that theindication Drum empty occurs when there is still some material in the drum.

Installation 3-11


Page remains empty.

Installation3-12


Installing System InputsDuraDrum bulk melters are equipped with four standard inputs.

Fig. 3-4 XL2

The customer wires each input all the way to the system and thenconfigures it for one of the following control options:

� Change system to standby

� Switch heaters on or off

� Enable or disable a certain hose or gun

� Switch motor on or off

The inputs can be activated with the 24VDC signal (terminal 20) via theexternal relay contact.

WARNING: The operator can bypass the inputs via the function keys onthe control panel. Ensure that the control unit for external devices thattransmit a signal to the system is programmed such that unsafe conditionscan not occur when the operator bypasses an external input on the system.

Installation 3-13


Setting up an InputSet up the parameter control option for each input connected to the system.Table 3-1 shows the control options available. Information on selectingoperating parameters and editing control options can be found underSetting up the Bulk Melter.

Tab. 3-1 Input data

Input TerminalsXL2

Operatingparameter Control options Note

Standard inputs

NOTE: Terminals 9, 11, 13, 14, 18, 19 (0VDC) are jumpered at the factory. Refer to wiring diagram

1 8 and 9 30

0 - Input disabled

1 - Enter/exit standby

2 - Heaters on/off

3 - Enable/disable motor 1

4 - Enable/disable hose/gun 1






10 - Automatic standby (default)


A

B

2 10 and 11 31

0 - Input disabled

1 - Enter/exit standby (standard)

2 - Heaters on/off









A

3 12 and 13 32 Like parameter 31 (default = 2)

4 7 and 14 33 Like parameter 31 (default = 4)

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

B When control option 10 is selected for the input, a time must be set in parameter 24.

Installation3-14


Installing System OutputsThe system has three outputs that the customer can configure as needed.The outputs are used to exchange data with the customer’s productionequipment and control hardware such as a PLC.

NOTE: If a light tower (accessory) is installed, the outputs are alreadyassigned and can not be used otherwise.

Fig. 3-5 XL2

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

� System ready

� A fault has occurred

� Material level low

� Service LED on

� A potential fault is detected

Refer to wiring diagram for connecting arrangement.

Installation 3-15


Setting up an OutputSet up the parameter control option for each output connected to thesystem. Table 3-2 shows the control options available. Information onselecting operating parameters and editing control options can be foundunder Setting up the Bulk Melter.

CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must beset to the default.

Tab. 3-2 Output data

Output TerminalsXL2

Operatingparameter Control options Note

Standard outputs

NOTE: Terminals 1, 3, 5, 15, 20 (24VDC) are jumpered at the factory. Refer to wiring diagram

1 1 and 2 40 0 - Output disabled

1 - Ready (default)

2 - Ready and the motor is ON

3 - Fault

4 - Drum empty

5 - Service LED is ON

6 - Alert C

2 33 and 34 41 Same as parameter 40 (Default=3, may not be modified)

3 5 and 6 42 Same as parameter 40 (Default=4)

NOTE A:

B:

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.

1

Installation3-16


Setting up CommunicationWith a computer connected to the system’s serial interface (1), all settingscan be displayed and changed, settings can be transferred betweensystems and the system’s operating firmware can be up- and downgraded.

Setting up the Bulk MelterThe system can be set up to suit your manufacturing process, meaning thatthe settings can deviate from the factory setup. System setup consists ofenabling or making changes to factory-set operating parameters that affectthe use and function of the system. The operating temperature (setpoint) ofthe platen, each hose and each gun is established during setup.

The system 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 SetupTable 3-3 describes the most commonly used operating parameters andtheir factory settings. Review the table to determine whether the factorysettings for each parameter will support your manufacturing process. If thedefault values for the operating parameters are appropriate for yourmanufacturing process, then no system setup is required. To complete theinstallation process, refer to Setpoint Temperature of Platen, Hoses andGuns.

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.

Installation 3-17


Tab. 3-3 Common operating parameters

Parameter Parameter name Purpose Default value

4 Ready delay time

A timer that delays enabling of the ready LED for apre-defined time period after the platen, hoses andguns have reached the desired setpoint temperature.The ready delay timer will only enable if thetemperature of the platen, at the time the system isturned on, is below its assigned setpoint temperatureby 27 °C (50 °F) or more.

0 minutes

5 Service interval

A timer that turns on a service LED when the valueset for the timer equals the number of hours that theheaters have been on. The service LED signals theneed for maintenance.

500 hours

7 Motor off delayIf the switch receptacle is used, this parameterdetermines the amount of time the motor will remainon after the switched device is turned off.

0 seconds

8 Automatic pump onSwitches the pump on automatically as soon as thesystem is ready. Prerequisite: The pump has beenenabled by pressing the pump key.

Enabled

11 Create passwordSets a password that must be entered before anyoperating parameter or setpoint temperature can bechanged.

5000

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

21Overtemperaturedelta

Sets the number of degrees that any heatedcomponent can exceed its assigned setpointtemperature before an overtemperature fault occurs.

15 °C (25 °F)

22Undertemperaturedelta

Sets the number of degrees that any heatedcomponent can drop below its assigned setpointtemperature before an undertemperature fault occurs.

25 °C (50 °F)

23 Standby deltaSets the number of degrees that the temperature of allheated components will be decreased when thesystem enters the standby mode.

50 °C (100 °F)

26 Manual standby timeSets the amount of time that the system will remain inthe standby mode after the standby key is pressed. Disabled

50 to 77 Seven-day clockA group of parameters that control the system’s clock.The clock is used to automatically turn the heaters onand off and to enter standby.

Disabled

Installation3-18


Operating ParametersThe system uses operating parameters to store noneditable and editablevalues. Noneditable values are those that provide information about thehistorical performance of the system. Editable values are either a numericsetpoint or a control option setting. Control option settings affect the displayof information or the function of the system.

Operating parameters are stored in the system’s firmware in the form of asequentially numbered list. The list is divided into the groups described intable 3-4.

Tab. 3-4 Parameter groups

Group Parameters Description

Standard 0 to 11 Frequently used parameters

Temperature Control 20 to 29 Controls heater function

Input setup 30 to 38 Configure the standard and optional inputs

Output setup 40 to 46 Configure the standard and optional outputs

Seven-day clock 50 to 77 Configure the clock function

PID selection 80 to 91 Changes preset 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 ParametersTable 3-5 lists all of the operating parameters. Review the list to determinewhich operating parameters would best support your manufacturingprocess. Refer to Appendix B, Operating Parameters, for detailedinformation about each parameter. Appendix B contains a completedescription of each parameter, including its effect on the system, defaultvalue and format.

NOTE: Parameters that are used to configure optional equipment or thatare otherwise reserved in the firmware are excluded from Table 3-5 andAppendix B.

Setup key

Clear/Reset key

Enter key

Installation 3-19


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 on the system.

The system performs a startup check.

2. Press Setup key.

Parameter 1 flashes in the left display.

3. Use the keypad to enter the number of the desired parameter. Refer toTable 3-5 for a complete list of parameters.

NOTE: If you incorrectly enter the parameter number, press theClear/Reset key to return to parameter 1, 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 Monitoring the System insection 4, Operation.

� If the value is editable, proceed to step 5.

5. Press the Enter key.

The right display flashes.

6. Use the keypad to enter the desired numeric setpoint or control option inthe right display. Refer to Appendix B, Operating Parameters, forinformation about the numeric value or control option choices for eachparameter.

NOTE: If the information you entered does not appear in the rightdisplay, the system is protected by a password. You must enter a validpassword before parameters can be edited. Refer to section 4Operation, Enter Password.

Installation3-20


To Read or Edit a Parameter (contd.)


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

� If the numeric setpoint or control option is accepted, the left and rightdisplays show the next parameter number and value.

� If the numeric setpoint or control option is not accepted, the rightdisplay shows dashes (----) for three seconds and then changesback to the original value.

8. Repeat steps 5 to 7 to read or change the next parameter number, orpress the Setup key to exit the setup mode.

Tab. 3-5 Operating parameters

Parameter Name Value range Default value

Standard

0 Enter password 0 to 9999 4000

1 Total hours with heater on(noneditable) 9999 0

2 Fault log (noneditable) — _- F0 (empty)

3 Change history log (noneditable) — P-_ (empty)

4 Ready delay time 0 to 60 minutes 0 minutes

5 Service interval 0 to 8736 hours 500 hours

6 Service LED heater hours 0 to 9999 hours 0

7 Motor off delay 0 to 360 seconds 0 seconds

8 Automatic pump on 0 (disabled) or 1 (enabled) 1 (enabled)

10 Enable or disable password 0 (disabled) or 1 (enabled) 0 (disabled)

11 Create password 0 to 9999 5000

12Change hose 1 output to electric gunactivation 0 (disabled) or 1 (enabled) 0 (disabled)

13Change hose 2 output to electric gunactivation 0 (disabled) or 1 (enabled) 0 (disabled)

Continued...

Installation 3-21


Parameter Default valueValue rangeName

Temperature control

20 Temperature units (degrees �C or �F) C (degrees Celsius) or F(degrees Fahrenheit) C (degrees Celsius)

21 Overtemperature delta 5 �C (10 �F) to 60 �C (110 �F) 15 �C (25�F)

22 Undertemperature delta 5 �C (10 �F) to 60 �C (110 �F) 25 �C (50�F)

23 Standby delta 25 �C (50 �F) to 190 �C (350�F) 50�C (100�F)

24 Automatic standby timeout 0 to 1440 minutes 0 (disabled)

25 Automatic heaters off time 0 to 1440 minutes 0 (disabled)

26 Manual standby time 0 to 180 minutes 0 (disabled)

27A Hose standby delta 1 �C to 190�C (1�F to 350�F) 0 (disabled)

28A Gun standby delta 1 �C to 190�C (1�F to 350�F) 0 (disabled)

29A Internal zone temperature offset 0 �C to -15 �C (0 �F to -30 �F) 0�C (0�F)

Input setup

30 Standard input 10–11

10 (Automaticstandby)

31 Standard input 20–9, 11

1 (Enter/exitstandby)

32 Standard input 3 0–9, 11 2 (Heaters on/off)

33 Standard input 40–9, 11

4 (Hose/gun 1enable/disable)

Output setup

40 Standard output 1 1–6 1 (Ready)

41 Standard output 2 1–6 3 (Fault)

42 Standard output 3 1–6 4 Low level

Continued...

Installation3-22


Parameter Default valueValue rangeName

Seven-day clock

50 Current day 1 to 7 (1 = Monday) —

51 Current time 0000 to 2359 —

55 Schedule 1 Heaters on 0000 to 2359 06:00

56 Schedule 1 Heaters off 0000 to 2359 17:00

57 Schedule 1 Enter standby 0000 to 2359 —:—

58 Schedule 1 Exit standby 0000 to 2359 —:—

60 Schedule 2 Heaters on 0000 to 2359 —:—

61 Schedule 2 Heaters off 0000 to 2359 —:—



65 Schedule 3 Heaters on 0000 to 2359 —:—

66 Schedule 3 Heaters off 0000 to 2359 —:—



71 Schedule for Monday 0−7 0

72 Schedule for Tuesday 0−7 0

73 Schedule for Wednesday 0−7 0

74 Schedule for Thursday 0−7 0

75 Schedule for Friday 0−7 0

76 Schedule for Saturday 0−7 0

77 Schedule for Sunday 0−7 0

PID Settings

80–91PID selection for receptacles,hose/gun 1 and 2

0=hose; 1=standard gun;2=large gun; 3=air heater

0 or 1 (depending onselectedcomponent)

NOTE A: Only with software version 2.023 and higher

Installation 3-23


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

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

When the right display is flashing, youcan set the value of the currentparameter to its lowest possible value bysimultaneously pressing both of the rightdisplay scroll keys.

If no key is pressed for two minutes whilein setup mode, the system will return tothe normal mode.

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

Using a personal computer that isconnected to the system through theserial interface, you can view and changeall of the operating parameters.

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

Appendix B, Parameter 10

Installation3-24


Setpoint Temperature of the Platen, Hoses and Guns

The system is shipped from the factory with the platen setpoint temperatureat 175 °C (350 °F) and the hose and gun setpoint temperature at 0 degrees(turned off).

Before the system can be used, a setpoint temperature must be assigned tothe platen, hoses and guns. Setpoint temperatures are assigned with any ofthe following methods:

� Global — The platen and all hoses and guns are set to the samesetpoint temperature.

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

� Individual component — The setpoint temperature of the platen andeach hose and gun is set individually.

Since most manufacturing processes require the platen, hoses and guns tobe set to the same temperature, only the global method of assigningsetpoint temperatures is described in this section. For information about theother two methods, refer to Adjusting Component Temperatures in Section 4, Operation.

As with operating parameters, setpoint temperatures can be saved andrestored, and past changes that were made to setpoint temperatures can bereviewed.

Platen key

Left display and scroll key

Enter key

Ready LED

Installation 3-25


To Assign a Global Setpoint Temperature

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

The left display flashes 1.

2. Scroll the left display to 0.

The right display shows dashes (----) and the LEDs on the platen, hoseand gun keys turn green.



4. Use the keypad to enter the setpoint temperature recommended by themanufacturer of the material.

Refer to the data sheet provided by the manufacturer of the material forthe optimal setpoint temperature.

5. Press the Platen key.

Each component begins to heat or cool to the new global setpointtemperature, and the system returns to normal mode.

When all of the components have reached their global setpointtemperature, the ready LED turns on (green).

+

Saving current settings

+

Restoring saved settings

Installation3-26


Save and Restore SettingsThe current value of all editable operating parameters and the setpointtemperature 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 the system is to bereturned to its original state.

To Save Current Settings

With the system in normal mode, simultaneously press the number key 1and the Setup key.

S-1 appears briefly in the right display.

To Restore Saved Settings

CAUTION: All settings will be deleted! Before restoring saved settings,ensure that use of the restored settings will not disrupt the current processor create unsafe operating conditions.

With the system in normal mode, simultaneously press the number key 2and the Setup key.

S-2 appears briefly in the right display.

If the restore feature is used before thesave feature is used for the first time, thefactory default setpoint temperatures willbe restored. This will cause the hosesand guns to stop heating.

Settings can be transferred from onesystem to another using the NordsonConfiguration Manager software utility.

Setup key


Component key LEDs

Scrolling through the log

Installation 3-27


Review Parameter and Setpoint Temperature ChangesThe system stores in a change history log a record of the last ten changesthat were made to either operating parameters or setpoint 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 Log History

1. Press Setup key.

Operating parameter 1 flashes in the left display.

2. Press the left display scroll key to change the display to parameter 3(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 setpoint temperature, the LED on theassociated component key(s) turns on.

and

� The right display shows the four-digit log entry associated with thelast change that was made.Table 3-6 indicates the meaning, from left to right, of each digit in thelog entry. Two sample log entries are shown following the table.

3. Press a right display scroll key to review each of the remaining nine logentries. Each time a scroll key is pressed, a progressively older log entryappears.

4. Press the Setup key to return to the normal mode.

Installation3-28


Tab. 3-6 Change history log

First digit Seconddigit Third and fourth digit

P(Parameter)

−

Indicates the number of the parameter that was changed

S (Setpoint)

Used in conjunction with the LEDs on the component keys to indicate the locationand method of a setpoint temperature change.

When this LED ison..

And the fourthdigit indicates..

The change wasto..

And the methodof change was..

Platen key 1 Platen 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

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.

Installation 3-29


Unused log entries in the change historylog are indicated by ”P-_” in the rightdisplay.

To view how many heater hours haveelapsed since the last change,simultaneously press both of the rightdisplay scroll keys.

Installation3-30


AccessoriesThe following components can also be installed later as accessories:

Light Tower

Installing Kit

WARNING: Disconnect the system from the line voltage.

5

3

4 1

2

Fig. 3-6

CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must beset to the default.

6

Installation 3-31


1. Break out the plate from the top of the tower (1, Fig. 3-6) along thepunched lines and remove.

2. Swivel tower open.

3. Guide cable through the resulting hole.

4. Use the two screws M5 to fasten the light tower.

5. Guide the cable through the top opening of the tower and to the insidewall (drum side) of the electrical cabinet.

6. Release knurled nut (4) from the bracket Cable duct (3). Slide bracketup in the slot.

7. Guide the cable through the resulting opening to the terminal blocks (6, Fig. 3-7) in the electrical cabinet door.

8. Place wire ends and bridges according to their designations (e.g. no. 5to terminal 5). Refer to wiring diagram.

9. Use a cable tie to fasten the cable to one of the metal teeth (5) belowthe bracket Cable duct.

10. Slide the bracket down and tighten knurled nut.

11. Close tower.

Fig. 3-7

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

The exhaust hood must be connected to the customer’s exhaust device(Also refer to Installation, Exhausting Material Vapors and Technical Data ).

High Drum Jacket for Cardboard DrumsCAUTION: Do not use metal drums with this model! The drum jacket isdesgned only for cardboard drums!

NOTE: Bulk melters for cardboard drums have only the lower sealing ringon the platen.

Installation3-32


Timer Relay Overtravel TimeIf the accessory Timer relay is used, an Overtravel time can be set. Duringthe overtravel time, feeding can continue despite the Drum empty indication.

Installing the Timer RelayWARNING: Disconnect the system from the line voltage.

1. Refer to Fig. 3-8, A: Find the relay -197K4 in the electrical cabinet.

NOTE: The relay -197K4 is not standard until April 2005. The timerrelay can not be used in older systems.

2. Refer to Fig. 3-8, B: Release the clips (1) and extract the relay.

3. Press the strap (3) down with a screwdriver and remove the relay basefrom the top hat rail (2).

4. Remove the clips and insert the new, longer clips.

5. Put the relay base back into place and secure with the strap.

6. Refer to Fig. 3-8, C: Verify that the selectors Time range and Mode onthe timer relay are set.

7. Insert the timer relay and secure with the clips.

8. Set the overtravel time. Refer to Overtravel Time When Drum Empty.

-197K4

TIME RANGE

MODE

XX

XX

A B C

2

1

3

Fig. 3-8

Installation 3-33


Initial StartupAfter the system has been correctly installed, initial startup may begin. Referto section Operation.

Detaching1. Convey all material out of the system and remove drum.

2. When system will not be used for longer periods of time, purge withcleaning agent if necessary (Refer to Maintenance).

3. Wipe off sealing ring and clean melting plate (Refer to Maintenance).

4. Disconnect all lines to the system, and allow system to cool.

DisposingWhen your Nordson product has exhausted its purpose and/or is no longerneeded, dispose of it properly according to local regulations.

Installation3-34


Operation 4-1


Section 4Operation


Initial Startup

NOTE: Some of the following steps are described in detail in this section.

1. Set selector Raise/lower platen to 0.

2. Set main switch to I/ON.

3. Operator panel: Set values and parameters.

4. Wait until the system has heated up and is ready for operation (LED onthe control panel lights up green).

5. Insert drum.

6. Pre-select motor and switch on.

7. Optimize settings and record in settings record form.

NOTE: All system functions were tested before the system left the factory.Special test material was used. There may be residue from this material onthe melting plate, in the pump, etc. To remove such residue, melt and feedseveral kilograms of material before starting production.

Component keys(platen, hose and gun)

Operation4-2


Heated ComponentsThe system contains three groups of heated components: the platen, thehose group and the gun group. Component groups are represented on thecontrol panel by the component keys shown to the left.

Heated components within each group are identified by their positionnumber. The position number of the platen 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.

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

Heater LED

Automatic scan sequence

Ready LED

1

Pump key

Operation 4-3


Starting the Bulk Melter

Before starting the system for the first time, confirm that

� The system is fully installed, including any required inputs andoutputs, gun drivers, pattern controllers or timers.

� The system’s operating parameters are set up to support the currentmanufacturing process.

Refer to section 3, Installation, if any of the items listed above are notcomplete.

To Start the System

1. Switch on the system.

The system

� Tests the control panel LEDs

� Turns on the heaters (the heater LEDs turn green)

� Begins to automatically scan through and display the actualtemperature of the platen, hoses and guns. The sequence of theautomatic scan is: platen, each hose/gun pair and then back to theplaten.

� Turns on the ready LED (green) when the platen and all of the hosesand guns are within 3 �C (5 �F) of their assigned setpointtemperature.

CAUTION: Do not operate pump without material. Before switching on themotor, ensure that the system is equipped with a filled drum.

2. Press the pump key (1) 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.

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

NOTE: The key for pump 2 has no function.

Operation4-4


If the system is switched on when the temperatureof the platen is 27 �C (50 �F) or greater below itsassigned setpoint temperature (cold start condition),the Ready LED will not turn on until the ready delay(defined when the system was set up) has elapsed.


The time remaining on the ready delay (in minutes)appears in the right display at the end of every scancycle. When less than one minute remains in theready delay time, the right display counts down inseconds.


You can bypass the ready delay time by pressingthe Heater key twice.

The appearance of F4 in the right displayimmediately after the system is switched onindicates a problem with the system’s processor ormain board.

Monitoring Faults

The appearance of F1 in the right displayimmediately after starting the system indicates thata hose or gun cordset may be loose ordisconnected.

Section 6, Troubleshooting.

If the system is set up for manual pump activationand the parameter 7 (motor off delay) has beenchanged from the default, the pump will not stopuntil a user-specified amount of time has elapsed.


The (logical) state of one or more inputs mayprevent the heaters from being turned on.

Installing System Inputs in section3, Installation

If the seven-day clock feature was set up and turnedon when the system was last switched off, the clockwill automatically turn on the next time the system isswitched on.

Function Keys

If a power failure occurs, the system will restart in itsnormal heat-up cycle, even if the heaters were off orthe system was in standby prior to the power failure.If the seven-day clock was on prior to the powerfailure, the system will restart in the mode dictatedby the clock schedule at the time the systemrestarts.

Ready LED

Drum empty LED

Operation 4-5


Monitoring the System

The system has display elements that

� Quickly confirm that the system is operating correctly

� Monitor the actual temperature of the melting plate and each hoseand gun

� Identify faults

� Alert the operator when service is required.

� Indicate Drum empty.

The system automatically determines the number and location of all hosesand guns that are connected to it. Refer to Heated Components, earlier inthis section, for information on the identification of heated components.

A computer can also be used to monitor the system.

Confirm that the System is Operating CorrectlyThe ready LED turns on (green) when all of the heated components arewithin 3 �C (5 �F) of their assigned setpoint 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 system in standby mode

� The seven-day clock places the system in standby mode

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

� Drum is empfty.

Refer to Monitoring Faults and Function Keys later in this section forinformation on system faults and using the seven-day clock and standbyfunctions. Refer to Appendix B for information on the ready delay.

Drum Empty LED

When the platen is far enough down a proximity switch on the pneumaticcylinder closes and the Drum empty LED (yellow) will turn on.

LEDs on component keys

Operation4-6


Heated components with a setpoint temperature ofzero degrees are skipped during the automatic scancycle.

The time remaining on the ready delay appears inthe right display at the end of every scan cycle.


You can override the seven-day clock at any time. Ifthe clock has turned the heaters off, pressing theheater key will turn the heaters back on. If the clockhas placed the system in standby mode, pressingthe standby key will return the heated componentsto their assigned setpoint temperatures.

Function Keys

Monitor Component TemperaturesThe actual temperature of each heated component − platen and each hoseand gun − can be checked using the normal mode or by manually selectingand checking each component.

By default, the system remains in the normal mode except when:

� The system is in setup mode

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

� A fault occurs.

To Check Component Temperatures Using the NormalMode

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 component group(platen, hose or gun) turns on, observe the left display until it shows theposition number of the specific component to be checked.

3. When the position number of the desired component appears in the leftdisplay, the right display shows the component’s actual temperature.


Component temperature display

Operation 4-7


To Manually Check a Component’s Temperature

1. Press the key (platen, hose or gun) that represents the componentgroup to be checked.

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

NOTE: When the platen key is pressed, the left display does not show acomponent number (blank display).

2. If the first sequential component is not the component to be checked,use the left display scroll key to move to the correct component number.

The right display shows the actual temperature of the selectedcomponent.

3. Press the Setup key twice to return to the normal mode.

When you scroll the left display past the number ofthe last sequential component on a componentgroup, the number of the first component in the nextgroup appears.

The systems returns to normal mode two minutesafter the last key is pressed.

The default for the temperature display is degreesCelsius (C). This may be changed to degreesFahrenheit with parameter 20.


The LEDs on each component key will change fromgreen to yellow if any component in the group dropsmore than 3 �C (5 �F) below its assigned setpointtemperature.

The setpoint temperature of a component can bechecked at any time by pressing the right displayUP scroll key. Holding down the scroll key while thesystem is in normal mode reveals the setpoint ofeach component that is scanned.

Typical error code display

Fault LED (red)

Operation4-8


Monitoring FaultsThe system alerts the operator to the faults listed in Table 4-1.

Tab. 4-1 Fault codes

Fault code Type of fault Description

F1RTD (resistancetemperature detector)

The RTD for the component indicated has failed or the component wasdisconnected from the system.

F2 UndertemperatureThe actual temperature of the component indicated has dropped below theundertemperature delta, which was set using parameter 21.

F3 OvertemperatureThe actual temperature of the component indicated has increased beyond theovertemperature delta, which was set using parameter 21.

F4 Electrical or control failureProblem with a board, cable harness or control component. The sub-code inthe left display shows the failed component or the cause of the fault.

F1, F2 and F3 Faults

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

1. The automatic scan stops and the system begins to monitor thepotential fault for up to two minutes. The ready and heater LEDs remainon during the two minute period. If the system detects during this timethat the fault condition no longer exists, the system returns to normalmode.

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

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

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

� If the LED on the heater key is lit, the left display shows either 1 forthe platen or 2 for the pump.

� If the LED on the hose or gun key is lit, the left display shows thenumber of the affected hose or gun.

5. If the fault condition still exists at the end of the two minutes, the ReadyLED turns off, the red fault LED lights up and the system records thefault in the fault log. Refer to section Fault Log in this section.

To be able to put the system back into operation, the fault must be remediedand the system reset (reset key). Refer to section 6, Troubleshooting forinformation on diagnosis and remedies. Also refer to Resetting System.

Fault LED (red)

Operation 4-9


To view the temperature of a heated componentwhen an F2 or F3 fault exists, simultaneously pressand hold down both of the right display scroll keys.

An F1 fault (RTD) can be temporarily dismissed andthe system returned to normal mode by pressing theClear/reset key. The heaters will remain off. If thefault condition still exists two minutes after pressingthe clear/reset key, the fault LED will light up again.

When an F1 fault code appears, you can determinewhether the fault was caused by an open or shortedRTD by simultaneously pressing both of the rightdisplay scroll keys. If the right display indicates OP,the RTD is open; if it indicates SH, the RTD hasshorted.

If, for any reason, a component reaches 235 �C(458 �F), an immediate F3 fault will occur (no twominute monitoring period).

F4 Fault

When the system detects an F4 fault:

1. The Ready LED turns off and the red fault LED lights up.

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

3. The right display indicates F4.

4. The left display shows a fault subcode. The subcode identifies the faultycomponent or the specific source of the fault.

NOTE: If the F4 fault is nonfatal (subcode 3, 4 or 5 in the left display),the fault LED lights up for five seconds and the system returns to normalmode. Nonfatal F4 faults affect only the functions dependent on theseven-day clock.

5. The system records the fault in the fault log. Refer to Fault Log in thissection.

To be able to put the system back into operation, the fault must be remediedand the system reset (reset key). Refer to section 6, Troubleshooting forinformation on diagnosis and remedies. Also refer to Resetting System.

Clear/Reset key

Heater key

Operation4-10


Resetting System

1. Correct the fault. Refer to section 6, Troubleshooting for information ondiagnosis and remedies.

2. Return the system to normal mode by pressing the Setup key twice.

3. Press the Clear/Reset key.

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

If the clock key is pressed when a nonfatal F4 faulthas occurred, the right display shows F4 and theclock does not work.

Setup key


Scrolling through the fault log

Operation 4-11


Fault Log

1. Hold down Setup key.

The automatic scan stops, and parameter 1 appears in the left display.

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

The right display indicates the last fault as follows:

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

� If the last fault was an F4 fault, all of the component key LEDs turnoff.

� The right display indicates the log entry for the most recent fault.Table 4-2 provides the meaning of each digit in the log entry. Twosample fault log entries are shown following the table.

3. Press a right display scroll key to review each of the remaining nine logentries. Each time a scroll key is pressed, a progressively older log entryappears.

NOTE: The fault log only stores the last ten faults. After ten faults occur,the existing log entries are overwritten, beginning with the oldest entry,by the eleventh and subsequent log entries.

4. Press the Setup key to return to the normal mode.

Tab. 4-2 Fault Log

First digit Second and third digit Fourth digit

Component:

- F

Type of fault:

1 = Platen 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 undertemperature

4 = Hose 4 or gun 4 3 = Component overtemperature

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

6 = Hose 6 or gun 6

Subcode for fault type F4:

Assigned by Nordson

Operation4-12


Fault Log Examples

Example 1:

Unused log entry

Example 2:

If the LED on the platen key is lit, the log entry indicatesplaten undertemperature. If the LED on the hose key is lit, the log entryindicates hose 1 undertemperature.

To view the number of heater hours since the lastlog entry, simultaneously press both of the rightdisplay scroll keys. The hours appear in the rightdisplay.

The system will return to the normal mode if thefault log is left open for a period of two minuteswithout any key being pressed.

When an F1 fault is the result of a hose/gun pairbeing disconnected from the system, two fault logentries are created. The first entry is for the gun, thesecond for the hose.

Service LED (yellow)

Clear/Reset key

Operation 4-13


Monitoring the Service IntervalThe system can be set up such that the service LED on the left side of thecontrol panel lights up after a customer-defined time period has elapsed.The service LED can be used to signal any customer-specified maintenancetask. When maintenance is completed, the service LED must be reset.

To Reset the Service LED

Press the Clear/Reset key to turn off the service LED and reset the serviceinterval.

The default setting for the service interval is 500 hours.


Operation4-14


Adjusting Component Temperatures

The setpoint temperatures of the heated components can be adjusted asfollows:

� Global − The platen and all hoses and guns are set to the samesetpoint temperature.

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

� Individual component − The setpoint temperature of the platen andeach hose and gun is set individually.

Before adjusting setpoint temperatures, verify that each hose/gun pair isconnected to the correct receptacle. For example, hose/gun pair 1 shouldbe connected to receptacle 1. Refer to Heated Components, earlier in thissection, for information on hose/gun positions.

Recommended TemperaturesThe temperature setting is determined by the processing temperatureprescribed by the material supplier. The maximum operating temperature forthe system 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.

Platen Prescribed processing temperature

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

Undertemperature value(warning)

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

Undertemperature value(fault)

15 °C (18 °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

Hose (accessory) Prescribed processing temperature

Platen key


Enter key

Ready LED

Operation 4-15


To Adjust the Setpoint Temperature Using the GlobalMethod

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

The left display flashes 1.

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

The right display shows dashes (----) and the LEDs on all componentsturn green.



4. Use the keypad to enter the setpoint temperature recommended by themanufacturer of the materal. Refer to the data sheet provided by themanufacturer of the materal for the optimal setpoint temperature.

NOTE: If the keypad or the right display scroll keys have no effect onthe right display, the system is protected by a password. Enter a validpassword before changing the setpoint temperatures. Refer to EnterPassword in this section.

5. Press the Platen key.

All of the components begin to heat or cool to the new global setpointtemperature. When all of the components have reached their setpointtemperatures, the Ready LED lights up (green).

Platen, hose and gun keys

Operation4-16


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 setpoint temperature of thehose or gun.

2. Scroll the left display to 0.

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






The hoses or guns begin to heat or cool to the new global setpointtemperature.

Operation 4-17


To Adjust the Setpoint Temperature of an IndividualComponent

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

If the platen key has been pressed, the left display flashes 1. If a hose orgun key was pressed, the left display flashes the number of the firstsequential hose or gun. The right display then indicates the currentsetpoint temperature of the component shown in the left display.

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

The right display then indicates the current setpoint temperature of thecomponent selected in the left display.





5. Do one of the following:

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

� To register the new setpoint temperature and return to normal mode,go to step 6.

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

The selected component begins to heat or cool to its new setpointtemperature.

Operation4-18


If you enter a valid setpoint temperature for a hose/gunthat is not connected to the system or if you enter asetpoint temperature that is out of range, the right displaywill indicate dashes (----) for three seconds and thenchange back to the original setpoint temperature.

When the right display is flashing, you can change thecurrent setpoint temperature to 0 degrees bysimultaneously pressing both of the right display scrollkeys.

If the global or global-by-component method is used to setthe setpoint temperature and then a hose or gun is addedlater, the setpoint temperature of the hose or gun must beadapted or adjusted. If a hose or gun is removed, use theindividual component method to set the setpoint tempera-ture of the removed component to 0 degrees. This willavoid an F1 fault. When a hose or gun is added, use theindividual component method to set the desired tempera-ture.

The factory setpoint temperature of the platen is 175 �C(350 �F). The factory setpoint temperatures of all othercomponents is zero degrees (off).

When the temperature unit is set to degrees Celsius, theminimum and maximum setpoint temperatures are 40 �Cand 230 �C. When the temperature unit is set to degreesFahrenheit, the minimum and maximum setpointtemperatures are 100 �C and 450 �C.

When a setpoint temperature is set with the right scrollkeys, the right display automatically jumps from 0 to 175 �C or from 0 to 350 or 450 �F.

If you make a mistake while changing a setpointtemperature but have not yet pressed the Enter key, pressthe Clear/Reset key to reset the right display to theoriginal temperature.

The systems exits setup mode and returns to normalmode two minutes after the last key is pressed.

A global setpoint temperature of zero degrees (Celsius orFahrenheit) turns all components off.

When scrolling through component numbers in the leftdisplay, component numbers assigned to unusedhose/gun receptacles are skipped.

The system stores a record of the last ten changes madeto setpoint temperatures (and operating parameters) in achange history log.

Section 3, Installation, ReviewParameter and SetpointTemperature Changes

Changes to setpoint temperatures can be saved bysimultaneously pressing the keys 1 and Setup.

Section 3, Installation, Saveand Restore Settings

Operation 4-19


Enter PasswordIf a system is password protected, a valid password must be entered beforeany setpoint temperature can be entered or any parameter changed.

1. Press Setup key.

Parameter 0 flashes in the left display, and the right display shows 4000.


The right display begins to flash.

3. Enter the password with the keypad.

NOTE: The password is created and enabled/disabled during systemsetup.


Then 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, while theright display briefly indicates dashes (----) then returns to 4000.

If the password is incorrect, reenter it and then press the Enter key.

The system reverts to password protected mode 2 minutes after the last key (any key) is pressed. Toreturn to password protected mode before 2 minuteshave elapsed, press the Setup key twice.

The password is created and enabled/disabled duringsystem setup.

Setting Up the System in section3, Installation

Heater key

Operation4-20


Function Keys

The control panel provides the following standard and special function keys:

Standard function keys

� Heater

� Pump

� Setup

Special function keys

� Seven-day clock

� Standby

VORSICHT: Unintentionally activating function keys can have undesirableeffects on the system or the manufacturing process. Only personnel familiarwith the system’s setup and its connection with the manufacturing processshould use the function keys. Improper use of the function keys can result inerratic process behavior or personal injury.

Heater KeyUse the heater key to manually turn the component heaters on and off.Pressing the heater key overrides the heater control by the seven-day clockfeature or a remote input. The LED on the heater key is lit when the heatersare on.

When a fault occurs (Refer to Monitoring Faults in this section) the heatersautomatically turn off. The heater key is used to turn the heaters back onafter correcting a fault condition.

1

Pump key

Setup key

Operation 4-21


Pump KeyPress the pump key (1) to enable, start or stop the pump. The LED on thepump key is yellow when the pump is enabled (not yet running) and greenwhen the pump is running. Switching the pump on or off has no effect on theheater control.

If the automatic pump on feature (parameter 8) is disabled, then the pumpkey must be used to start the pump when the system 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.

NOTE: The key for pump 2 has no function.

Setup KeyThe setup key is used to place the system into and take the system out ofsetup mode. In setup mode the automatic scan stops. The left and rightdisplays are used to select, read and edit operating parameters.

Seven-day clock key

Operation4-22


Seven-day Clock KeyUse the seven-day clock key to turn the clock feature on and off. When theclock is on, the temperature of each heated component is automaticallyregulated based on a set of user-defined schedules.

Four clock schedules are available to accommodate daily shift work andnon-working days. Three of the schedules are used to specify when theheaters should turn on or when the system should enter and exit standbymode. The fourth schedule determines the days on which the systemshould be switched off.

When the heaters switch on as dictated by the schedule, they are regulatedto their assigned setpoint temperatures. When the clock activates thestandby mode, the setpoint temperatures are all temporarily reduced by apreset standby delta.

For information about setting up the seven-day clock and the standby delta,refer to Setting up the Bulk melter in section 3, Installation as well as toappendix B, Operating Parameters.

If the system is switched off while the clock is on,the clock will automatically turn back on the nexttime the system is switched on.

If the heaters are manually turned off during the timethat a clock schedule calls for the heaters to be on,the heaters will not turn back on until the next clockschedule calls for them to be on.

The clock will still operate when the system isfaulting or in setup mode.

If F4 appears in the right display when the clock keyis pressed, the clock function has failed. ContactNordson customer service to remedy the fault.

Standby key

Operation 4-23


Standby KeyThe standby key is used to enter and exit standby mode. Using the standbymode during periods when no material is being fed helps to conserveenergy and allows heated components to quickly return to their setpointtemperatures when the system is once again needed.

When the system enters standby mode, the temperatures of all componentsare reduced from their setpoint temperatures by a preset standby delta. Thesystem remains in standby mode until the standby key is pressed or one ofthe operating parameters causes the system to exit standby mode.

If the system was set up to use the manual standby timer (parameter 26),pressing the standby key places the system in standby mode for the periodof time specified by the timer. After the manual standby time has expired,the system once again begins heating all of the components to theirassigned setpoint temperatures.

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

For information on setting the standby delta and the standby timer, refer toSetting up the Bulk Melter in section 3, Installation as well as to appendix B,Operating Parameters.

The system may be set up to automatically enterstandby mode using a variety of operatingparameters.

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

Whenever manual standby is activated, the standbyLED flashes.


Operation4-24


Inserting and Replacing DrumCAUTION: Place only undamaged, suitable drums in the system; otherwisethe platen sealing ring will be damaged. Always keep the base plate of thesystem clean so that the drum is positioned straight.

WARNING: Risk of burns! Hot material can splash out when the platenexits the drum. Hot material may flow out of the deaeration valve. Wearsuitable protective clothing!

1. Raise platen (Refer to the next page). If there is no drum in place − e.g.upon initial startup − the two hand control must be operated to raise thepunch:

a. Set selector Raise/lower platen to Raise.

b. Operate the two hand control until the platen is higher than the baseplate by more than the height of one drum.

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

3. Insert or replace drum.

4. Lubricate sealing ring. Refer to Processing Materials in the sectionMaintenance.

5. Lower platen (Refer to the page after next).

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

Operation 4-25


Raising PlatenNOTE: Refer to Principle Wiring Diagrams in this section.

1

4

2

3

5

Fig. 4-1

If the platen is inside of the drum, the drum must be aerated to supportraising. Aerating means that compressed air is forced under the platen.

1. Verify that the selector Raise/lower platen (1) is set to 0.

2. Screw the rod (4) out of the aeration connection (5).

3. Screw in the aeration tube (3).

4. Open the shutoff valve Compressed air to aerate drum (2).

5. Set selector Raise/lower platen to Raise.

The air pressure in the drum is limited to 1.0 bar (100 kPa / 14.5 psi) by apressure restrictor valve.

Operation4-26


Lowering PlatenNOTE: Refer to Principle Wiring Diagrams on the following pages.

CAUTION: If the platen is lowered when no drum is inserted − e.g. totransport the system − place a squared timber underneath. This protects thesensor Drum inserted from damage.

Fig. 4-2

Operation 4-27


1

32

4

Fig. 4-3

The drum must always be deaerated when the platen is moved into thedrum. When the drum is deaerated, the air that is under the platen escapes.

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

2. Place the drip pan (3) in front of the deaearation valve (4).

3. Open the deaeration valve with the lever (2).

4. Press both buttons on the two-hand control at the same time (within 0.5 seconds) until the platen is inside of the drum. Lowering continuesautomatically as soon as the platen reaches the material. The greenLED on the selector Raise/lower lights up when the platen reaches thematerial.

5. Close deaeration valve when material flows out free of bubbles.

6. Properly dispose of material according to local regulations.

Operation4-28


Principle Wiring Diagrams

Raising/Lowering Platen

P

Drum empty

Proximity switch

Drum not empty

LED Drum empty

Two hand control

Solenoid valveLower

Solenoid valveRaise

SelectorLower

SelectorRaise

Pressure switchSensorDrum in place

24 VDC

Fig. 4-4

Operation 4-29


Motor Enable

Drum empty

Proximity switch

Drum not empty

Pressure switch

Enable motor tomotor controller

Fig. 4-5

Operation4-30


LED in Selector Raise/Lower Platen

Pressure switch

Selector LED Platen has contact with adhesive

Fig. 4-6

Operation 4-31


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

NOTE: The main switch must be set to I/ON (switched on) when using theweek timer.

Daily StartupNOTE: Do not operate Nordson pumps without material. Before switchingon motor, ensure that a drum that is not empty is in the system and that theplaten has contact with the material.

1. Set main switch to I/ON.

2. Set selector Raise/lower platen to Lower.

3. Wait until system is ready.

4. Switch on motor.

Daily Switchoff1. Set main switch to 0/OFF and protect from unauthorized access with

padlocks if necessary.

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

3. Perform daily maintenance.

Switching Off in an EmergencyWARNING: Immediately switch off the system in any emergency situation.

1. Set main switch to 0/OFF.

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

3. After standstill and before switching the system back on, have the faultremedied by qualified personnel.

Operation4-32


Settings Record

Production information:

Material: Manufacturer

Processing temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Reference channel: Factory-set

Processing temperatures (setpoint temperatures)

Platen

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

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

Assembly handgun (accessory) 1) 2) 3) 4)

Motor/pump speeds:

Motor/pump

Air pressure: bar MPa psi

Operating pressure

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 BurnsSome maintenance work can only be done when the system is heated up.

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

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 motor.

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 dispose of properly according to localregulations.

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 MaterialsBefore using, read the included EU safety data sheet.

Designation Order number Use

High temperature grease To be applied to O-rings andthreads

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

� Can 10 g P/N 394 769

� Tube 250 g P/N 783 959

� Cartridge 400 g P/N 402 238

Grease Centoplex H0

� 1 k g

P/N 285 600 Lubricating platen sealing ring

Temperature-resistantadhesive Loctite 640

Secures screw connections

� 50 ml P/N 230 359

Heat transfer compound To improve heat conducting oftemperature sensors

� 500 g P/N 257 326

Maintenance 5-3


Preventive MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the surrounding conditions, production conditions andoperating time of the system, other maintenance intervals may provenecessary.

NOTE: Coupling and motor controller are maintenance-free.

System part Activity Interval Refer to

Complete system External cleaning Daily 5-4

Inspect for external damage 5-4

Power cable Inspect for damage −

Air hoses Inspect for damage −

Melting plate Check melting plate for charredmaterial, clean if necessary

Every time the drum is changed 5-5

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

Every time the drum is changed −

Pressure switch Check that the green LED on theselector Raise/lower lights upwhen the platen reaches thematerial.

Every time the drum is changed −

Electrical cabinetventilation

Clean fan screens, clean orreplace filter

Daily, if dust accumulation issevere

5-5

Safety valve Activate the safety valve piston Weekly 5-6

Pump Tighten gland bolt After initial startup 5-6

Check for leakage, tighten glandbolt if necessary

Dependent on hours ofoperation, pump speed andpump temperature

Recommendation: Monthly

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 2 to 3 years

5-7

Compressed air filter Drain condensate Weekly 5-8

Clean filter element Every three months

Cleaning condensate collector When cleaning filter element

Pressure restrictorvalves

Performance check Every six months 5-9

Clean When not functioning correctly

Maintenance5-4


External CleaningExternal cleaning prevents pollution created by production from causingsystem malfunctions.

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.

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

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

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

� May not be mixed: Purge thoroughly and clean melting plate with acleaning agent recommended by the material manufacturer (Refer toCleaning Melting Plate).

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

Maintenance 5-5


Purging with Cleaning AgentInsert drum filled with cleaning agent for purging the system. Feed cleaningagent until it comes out free of adhesive residue.

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

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

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

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

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

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

Refer to separate document Parts List for filter order numbers.

1

2

Fig. 5-1

1 Fan 2 Air filter, air outlet

Maintenance5-6


Safety Valve

Activating the PistonNOTE: Activating the piston helps to prevent adhesive from causingblockage.

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

Pump

Checking for Leakage

The pump is equipped with a self-sealing pump shaft seal. Material mayseep out of the seal at irregular intervals. The gland bold must then betightened.

NOTE: 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.

Tightening Gland BoltNOTE: Tighten only when the system is warm.

Tighten the gland bolt approx. ¼ of a revolution in the operating direction ofthe pump. If tightening is no longer possible, the pump must be replaced.

Fig. 5-2

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

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

Maintenance 5-7


Motor / Gear Box

Changing LubricantNOTE: Use only the stated lubricant or one that has proven to beequivalent. Using any other lubricant can result in premature wear and/ordamage to the gear box.

NOTE: Drain lubricant when warm.

Unscrew gear box from 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 at least every 2 to 3 years.

Capacity

The lubricant quantity is indicated on the power 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

10 m

m 7

7

6

5

4

3

2

1

Maintenance5-8


Compressed Air FilterThe compressed air filter dehydrates and cleans the compressed air.

Draining Condensate

Drain condensate before it reaches a level approx. 10 mm below the filterdisk.

To do this, open the condensate drain valve (7).

Cleaning Filter Element

Under normal conditions, clean filter element (5) approx. every threemonths. Clean sooner if compressed air filter outlet pressure falls.

1. Shut off compressed air supply and release residual pressure byopening the condensate drain valve (7).

2. Unscrew condensate collector (6).

3. Unscrew filter element (5) by turning to the left.

4. Rinse filter element (5) with suitable cleaning agent. Then blow out fromthe inside. The condensate collector (6) may not come into contact withthe cleaning agent!

5. Clean condensate collector (6) if necessary. Use only water!

6. Reassemble compressed air filter.

Maintenance 5-9


Pressure Restrictor ValveThe factory-set, lead-sealed pressure restrictor valves preventunpermissibly high pressurization of subsequent pneumatic components.When the factory settings are exceeded, compressed air audibly escapes.

Checking Function

Functioning of the pressure restrictor valves should be checked approx.every six months. When functioning is not correct, a pressure restrictorvalve should be cleaned. If it still does not function, it must be replaced.

NOTE: A defective pressure restrictor valve may be replaced only with anoriginal spare valve. Repairs to the pressure restrictor valve may be madeonly by the manufacturer!

Pressure Restrictor Valve for Aerating Drum

If the customer’s equipment has a pressure gauge with a 1/4’’ fitting:

1. Reduce compressed air to 0 bar on pressure controller (1).

2. Release the fitting (2) on the tube (3) far enough that it can be turnedforward.

3. Replace the tube with a pressure gauge (4).

4. On the pressure controller, increase the compressed air to higher than 1.0 bar and observe whether the pressure restrictor valve (behind thecover (5)) opens.

1

2

3 4

5

Fig. 5-3

6

1 2

Maintenance5-10


Pressure Restrictor Valve for Aerating Drum (contd.)

If the customer’s equipment has no pressure gauge with a 1/4’’ fitting:

1. Reduce compressed air to 0 bar on pressure controller.

2. Unscrew cover (5, Fig. 5-3).

3. Detach the pressure restrictor valve (6).

4. Check pressure restrictor valve functioning outside of the system, in thecustomer’s compressed air system.

Pressure Restrictor Valve at Compressed AirConnection

On the compressed air connection (2), increase the compressed air tohigher than 7.5 bar and observe whether the pressure restrictor valve (1)opens.

Maintenance 5-11


Cleaning

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

ÂÂÂÂ

Â

Performance check Unscrewing top

Fig. 5-4

Maintenance5-12


Maintenance Record Form

System part Date / name Date / name Date / name

Electrical cabinet ventilation

Compressed air filter

Pressure restrictor valves

Safety valve

Pump

Motor / gear box

Troubleshooting 6-1


Section 6Troubleshooting


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

Some TipsBefore systematic troubleshooting is begun, the following should bechecked:

� Are all parameters set correctly?

� Do all plug connections have sufficient contact?

� Have circuit breakers been activated?

� Are external, inductive loads (e.g. solenoid valves) equipped withrecovery diodes? The recovery diodes must be directly allocated to theinductive load.

Light Tower (Accessory)

� White = Switched ON. After switching on and during the heatup phase,at first only the white indication lamp is lit (normal condition). A fault hasonly occurred when the temperature does not increase (observetemperature display) and when the green indication lamp is not lit afterthe heatup phase has ended (1 hour and longer).

� Green = Ready. The green indication lamp lights when all channels havereached their setpoint temperatures.

� Orange = Drum empty.

� Red = General alarm.

Troubleshooting6-2


Troubleshooting TablesThe troubleshooting tables serve as an orientation for qualified personnel.They cannot, however, replace targeted fault location with the help of wiringdiagrams and measuring instruments. They also do not include all possibleproblems, only those which most typically occur.

Fault Codes

DisplayCode/Sub-

codeName Affect on

System Cause Corrective Action

F1/None RTD

Heaters turn off

The RTD for the componentindicated has failed or thecomponent was disconnected fromthe system.

Replace RTD

Check hose/gun connections

F2/None Under tempera-ture

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

Check for conditions that maycause a drop in ambienttemperature

Raise the set-point temperature ofthe component

Replace RTD

F3/None Over tempera-ture

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

Replace RTD

F4/1 RAM test System stopsfunctioning

Internal RAM failure Replace CPU

F4/2 Internal Clocktime

Heaters remainon, but faultconditionpersists

Internal clock failure Replace CPU

F4/3 Internal Clocktime

Internal time failure Replace CPU

F4/4Internal clockbattery backedRAM

Battery-backed RAM failure Replace CPU

F4/5 Internal clockbattery

Battery-backed RAM battery dead Replace CPU

F4/6 Analog-to-digi-tal

System stopsfunctioning

RTD analog-to-digital converterfailed

Replace main board or CPU

F4/7 Analog-to-digi-tal calibration

RTD analog-to-digital convertercould not be calibrated

Replace main board or ribboncable, or CPU

F4/8 Main boardfeedback

Communication failure betweenmain board and CPU

Replace main board, ribbon cable,or CPU

F4/9 Expansionboard feedback

Communication failure betweenexpansion board and CPU

Replace expansion board, ribboncable, or CPU

F4/A Thermostat Tank or manifold thermostat isopen

Replace thermostat, J7 harness, ormain board

F4/CExpansionboard connec-tion

Faulty connection betweenexpansion board and CPU

Check or replace four single wiresbetween main board andexpansion board

Troubleshooting 6-3


Corrective ActionCauseAffect onSystemName

DisplayCode/Sub-

code

F4/d

Communica-tions withoptional I/Ocard

Heaters remainon, but faultconditionpersists

Communication failure betweenCPU and the optional I/O card

Replace the I/O card or CPU

F4/EFieldbus com-municationsfailure

Alert output (ifoutput option 6is selected)

System contin-ues to operatenormally

Fieldbus card failure. Replace the Fieldbus card

NOTE: Sub-code F4/b does not exist. Thus, confusion with F4/6 is avoided.

System does not Function

Problem Possible Cause 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 system oraccessories

−

6. System has nopneumatic function

There is no compressed air Connect compressed air

One Channel (Heating Zone) does not Heat


1. Channel is disabled /switched off

− Enable / switch on

Troubleshooting6-4


Control Panel does not Function


1. Display is blank PLC broad-band cable notconnected

Connect

No Material (Motor does not Rotate)


1. System not yet readyfor operation (heatupphase)

− Wait until system is heated up.

2. Motor not switchedon

− Switch on motor

3. Proximity switchDrum empty does notswitch

Cable pulled off

Switch defective

Connect

Replace

4. Pressure switch doesnot switch

Switch defective Replace

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

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

Fan cap dirty Clean

Pump blocked by foreign matter Replace pump

Pump operates too sluggish Replace pump

Material too cold Set temperature accordingly

7. Motor defective − Replace

8. Motor not suppliedwith voltage

− Technical inspection

9. Motor controllerdefective

− Replace

Troubleshooting 6-5


No Material (Motor Rotating)


1. Drum empty − Replace drum

2. Material supply holeto pump or pumpsuction hole clogged

− Remove pump and clean supply holeor suction hole

Too Little Material


1. Material supply holeto pump or pumpsuction hole partiallyclogged

− Remove pump and clean supply holeor suction hole

2. Processingtemperature set toolow

− Correct temperature setting

3. Pump block is worn − Replace pump

Material Pressure too High


1. Safety valve dirty andthus clogged

− Disassemble and clean or replace

2. Safety valve defective − Replace

3. Too much pressureapplied to safetyvalve

− Reduce pressure

Troubleshooting6-6


Material Pressure too Low


1. Pump is worn − Replace pump

2. Safety valve does notclose any more

− Replace

Others


1. Leakage at pumpshaft seal

Pump shaft seal is worn Tighten gland bolt

− Replace pump

2. Material pressure toolow, output quantitytoo low

Pump is worn Replace pump

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

Foreign material in pump Replace pump

4. Leakage at gunduring heatup phase

Safety valve does not open(expansion pressure)

Replace safety valve

5. Platen lifts the drum Lifting speed too high Refer to Installation, Adapting theSystem to the Drum Used6. Drum is not

completely emptiedProximity switch Drum empty is setincorrectly

7. Drum empty is notindicated

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. 6-1 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) Undervoltage shutdown

Off Off Programming mode or no voltage supply

Troubleshooting6-8


Repair 7-1


Section 7Repair


WARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Some maintenance work can only be done when thesystem is heated up.

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

General Notes� Material hoses can not be repaired. However, defective hoses can be

exchanged for overhauled hoses with full guarantee through Nordson’sAT program (replacement program).

� The processed material must be soft for disassembly of somecomponents. Heat the system to softening temperature. Use a hot airfan if necessary.

� Use only original Nordson spare parts. Refer to separate documentParts List for details.

� Also refer to separate manuals for the individual components.

Repair7-2


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

NOTE: Models for cardboard drums have only the lower sealing ring on theplaten (configurations code: Box 16 = F).

1. Heat platen to operating temperature.

2. Aerate drum.

3. Set pneumatic switch to Raise until the platen exits the drum.

4. Set pneumatic switch to 0/Stop.

5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) onthe drum under the melting plate.

6. Set pneumatic switch to Lower until the melting plate reaches the restingsurface.


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

CAUTION: Do not damage release coating.

9. Heat solid rubber or PTFE-coated sealing rings in an oven.

10. Clean and lubricate grooves. For information on lubricant refer toProcessing Materials in section Technical Data.

11. Put heated sealing rings into place on heated platen with two people.

180 - 200 °C356 - 392 °F

Fig. 7-1

Repair 7-3


Replacing O-ringsWhen leakage occurs, e.g. at the hose connections, the O-rings must bereplaced. Observe the following:

� Clean and lubricate O-ring groove. Nordson recommendshigh-temperature grease; refer to Processing Materials in sectionMaintenance.

� Also lubricate O-ring.

� Do not use removed O-rings again.

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

Repair7-4


Replacing Platen Temperature Sensor and ThermostatWARNING: Hot! Risk of burns. Wear heat-protective gloves.

1. Heat platen to operating temperature.

2. Aerate drum.

3. Set pneumatic switch to Raise until the platen exits the drum.


5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) onthe drum under the melting plate.

6. Set pneumatic switch to Lower until the melting plate reaches the restingsurface.


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

8. Disconnect the system from the line voltage.

9. Remove the cover (1).

3 2

1

Fig. 7-2

Repair 7-5


NOTE: If the temperature sensor is defective: Continue with step 16.

10. Remove thermostat (2) along with fastening screws and spring washers.

11. Extract connecting cable from porcelain terminals.

12. Apply heat transfer compound to contact surfaces of the new thermostat(Refer to Processing Materials in section Technical Data), then installthe thermostat with spring washers and screws.

13. Connect thermostat wires to porcelain terminals.

14. Screw on cover.

15. Start up system.

Replacing Temperature Sensor

First perform steps 1 to 9.

16. Remove temperature sensor (3).

17. Apply heat transfer compound to the new temperature sensor, thenfasten the sensor.

18. Attach cover again (1).

19. Start up system.

Identifying Installed ThermostatNOTE: Refer to section Parts to identify the thermostat installed.

2

Repair7-6


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

Installing Service KitWARNING: Disconnect the system from the line voltage.

Service kit P/N: 394734

Required tools:Electrical cabinet keyOpen-jawed or box wrench, size 7

1. Set main switch to 0/OFF.

2. Open electrical cabinet door.

3. Unplug bus cable from old control panel.

4. Release the M4 hexagon nuts and remove with the tooth lock washers.

5. Press old control panel and old seal forwards and out of the electricalcabinet door.

6. Insert new control panel with new seal.

7. Screw on new control panel. Use tooth lock washers.

8. Plug bus cable into new control panel.

9. Close the electrical cabinet door.

NOTE: When a new control panel has been installed, two default settingsmust be renewed:

1. Simultaneously turn on the main switch and hold down the key Motor 2and the scroll key on the control panel until the LEDs on the controlpanel light up.

2. Switch off main switch.

3. Simultaneously turn on the main switch and hold down the key Heaterand the platen icon on the control panel until the LEDs on the controlpanel light up.

Parts 8-1


Section 8Parts

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

Item— Identifies illustrated 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.

NOTE: Refer to separate document Parts List, P/N 7135705.

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 of heating Cast-in electrical resistance heating elements

Temperature sensor Ni 120

Heating time 30 to 60 minutes, depending on system, materialused and ambient temperature

Noise emission < 72 dBA

Electrical DataWARNING: Operate only at the operating voltage shown on the ID plate.

Operating voltage Refer to ID plate

Operating voltage frequency 50/60 Hz

Fuse rating Refer to ID plate

Power consumption P Refer to ID plate

Power consumption Pmax Refer to ID plate

Max. load per hose receptacle (2 channels) 1000 W per individual hose or gun

1200 W per hose/gun pair

2000 W total, hose/gun pairs 1 and 2

2000 W total, hose/gun pairs 3 and 4

Degree of protection IP 54

Technical Data9-2


Motors / Speed

Motor Fixed speeds

3-phase AC motor with helical gear 50 min−1 65 min−1 129 min−1

Output Quantity

Note: The maximum output quantity is afactor of the pump type used and differentparameters. Refer to Installation, SpeedSetpoint and Output Quantity

Max. 270 kg/h Max. 595 lb/h

Temperatures and Thermostats

Temperatures System / components °C °F

Min. ambient temperature − 10 50

Max. ambient temperature − 40 104

Min. operating temperature − 50 122

Identifying Installed ThermostatNOTE: Refer to separate document Parts List to identify the thermostatused.

Technical Data 9-3


Material Pressures

Motor/pump model (standard) bar MPa psi

3-phase AC motor with gear pump 5 to 60 0.5 to 6 72.5 to 870

Note: Safety valve setting is decisive for maximumoutlet pressure. Factory setting:

35 3,5 507,5

Dimensions

Drum diameter Max. drum height

567 or 571 mm, depending on the melting plateused. Refer to separate document Parts List 900 mm

1830,00

max.2497

1570,00 760,00

Fig. 9-1

Technical Data9-4


Weight

Weight Approx. 663 kg (depending on accessories)

Air Consumption

Per cycle (platen down and up) Approx. 600 l

Exhaust Hood (Accessory)

Nominal air quantity (recommendation) 510 m3/h

Pressure loss at nominal air quantity Approx. 180 Pa

Connecting sleeve ∅ 150 mm

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.

General Instructions Regarding Working with Application MaterialsA-2


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

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 Bulk 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

Standard 0 to 11 Frequently used parameters

Temperature control 20 to 29 Controls heater function

Input setup 30 to 38 Configure the standard and optional inputs

Output setup 40 to 46 Configure the standard and optional outputs

Seven-day clock 50 to 77 Configure the clock function

PID selection 80 to 91 Changes preset 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 using parameter 11 andthen enabled using parameter 10.

NOTE: If a password is entered to change a setpoint temperature, always exitsetup mode by pressing one of the component keys. If the setup key is usedto exit setup mode, the system immediately reverts to password protectedmode.

1 Total Hours with Heater On (Noneditable)

Description: Noneditable value. Shows the total number of hours that the heaters were on.

Value: 9999 (control panel) and 999.999 on web browser

Resolution: 1 hour

Default: 0

Format: —

Use: The display registers up to 9999 hours and then rolls over to 0000. Theregister on the web browser rolls over after 999,000 hours.

2 Fault Log (Noneditable)

Description: Stores a record of the last ten faults.

Value: —

Resolution: —

Default: _−F0 (unused log entry)

Format: F1, F2 F3 and F4

Use: Press the right display scroll keys to review the last ten faults in the log. Emptylog entries are indicated by ”_ −F0”. Refer to Monitoring the System in section4, Operation.



3 Change History Log (Noneditable)

Description: Records the last ten changes made to either the setpoint temperatures or theoperating parameters.

Value: —

Resolution: —

Default: P-_ (unused log entry)

Format: Refer to section 3, Installation. Review Parameter and Setpoint TemperatureChanges.

Use: Use the right display scroll key to review the last ten changes made to eitherthe setpoint temperatures or the operating parameters. Empty log entries areindicated by ”P-_”.

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 delaytimer only functions if the temperature of the platen, at the time the system isturned on, is below its assigned setpoint temperature by 27 °C (50 °F) ormore. The ready delay time begins when all components are within 3 °C (5 °F) of their respective setpoint temperature.

Value: 0 to 60 minutes

Resolution: 1 minute

Default: 0 minutes

Format: —

Use: The ready delay allows the platen additional time to heat up before the pumpstarts up.

NOTE: The time remaining on the ready delay is indicated in minutes in theright display at the end of every automatic scan cycle. When the delay timereaches one minute, the time remaining appears in seconds.

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 task, such as checking functioning of the pressure restrictorvalve. The service LED lights up after the preset time has elapsed. Press theClear/reset key to turn off the service LED and reset the service interval time.



6 Service LED Heater HoursDescription: A counter indicates how many more hours the heaters may 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 is illuminated.

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 the switch receptacle.

8 Automatic Pump OnDescription: Determines whether the pump can be enabled before the system is ready.

Value: 0 (disabled) or 1 (enabled)

Resolution: —

Default: 1 (enabled)

Format: —

Use: If the function is enabled, the pump can be enabled before the system isready.

If the function is disabled, the pump must be started by pressing the pump keywhen the system is ready.

NOTE: If Automatic pump on is disabled (0) while one of the pumps isrunning, the pump will remain on until the key for this pump is pressed.



10 Enable or Disable PasswordDescription: Enables or disables the password. When password protection is activated,

component setpoint temperatures or system operating parameters can not bechanged until a valid password is entered 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 be enabledor 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 will notappear again in the right display until the password is entered.

12 Change Hose 1 Output to Electric Gun ActivationDescription: Changes the proportioned 240 VAC current that is provided to the hose 1

heater to a switched 240 VAC current that is used to activate amanifold-mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default: 0 (disabled)

Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installed and aswitching device is connected to the bulk melter’s switch receptacle. Refer tothe electric gun manual for information on mounting and using the gun.



13 Change Hose 2 Output to Electric Gun ActivationDescription: Changes the proportioned 240 VAC current that is provided to the hose 2

heater to a switched 240 VAC current that is used to activate amanifold-mounted electric gun.

Value: 0 (disabled)

1 (enabled)

Resolution: —


Format: —

Use: Use only when a Nordson manifold-mounted electric gun is installed and aswitching device is connected to the bulk melter’s switch receptacle. Refer tothe electric gun manual for information on mounting and using the gun.



Temperature Control

20 Temperature UnitsDescription: Sets the units for temperature display.

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

Resolution: 0 = Celsius

1 = Fahrenheit

Default: 0

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: —

22 Undertemperature DeltaDescription: The number of degrees that a component can fall below its assigned 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 system enters the 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 between systemenergy savings during periods of inactivity, the amount of time and energyrequired to bring the system back up to setpoint temperature, and atemperature at which the material can be held in the tank for extended periodswithout charring. Refer to Section 4, Operation, Function 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 system enters standby mode. The automatic standbytimeout feature saves energy by allowing the system to automatically enterstandby mode as soon as the guns are no longer applying 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 (automaticstandby).

NOTE: Only enable parameter 24 when a 24 VDC signal voltage is connectedto input 1. If there is no voltage on the input contacts when the system isready, the system will enter standby mode after the automatic standby time.

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

(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 value beforesetting parameter 25.



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

standby key is pressed.

Value: 0 to 180 minutes


Default: 0

Format: —

Use: Set the standby time when the operator is to cause the system to enterstandby for a limited period (break, lunch, etc.). Whenever manual standby isactivated (value greater than 0 minutes), the standby LED flashes.

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

Note: When a value greater than 0 minutes is set, the remaining time instandby mode appears in the right display.

27 Hose Standby DeltaSoftware version 2.023 and higher

Description: The number of degrees that the temperature of all hoses will be decreasedwhen the system enters standby mode.

Value: 1 �C to 190�C (1�F to 350�F)

Resolution: 1 �C 1�F


Format: —

Use: This parameter works the same as parameter 23, except when it is set to 0.Then it returns to the setting for parameter 23.


28 Gun Standby DeltaSoftware version 2.023 and higher

Description: The number of degrees that the temperature of all guns will be decreased whenthe system enters standby mode.

Value: 1 �C to 190�C (1�F to 350�F)

Resolution: 1 �C 1 �F


Format: —

Use: This parameter works the same as parameter 23, except when it is set to 0.Then it returns to the setting for parameter 23.




29 Internal Zone Temperature OffsetSoftware version 2.023 and higher

Description: NOTE: Parameter 29 is not used with DuraPail.

Difference in degrees with which the bulk melter’s internal zones work. Ifthis parameter is used, the primary internal zone (Platen) works at alower temperature than the secondary internal zone (Pump), as definedby the value of this parameter.

Value: 0 �C to -15 �C (0 �F to -30 �F)

Resolution: 1 �C 1 �F

Default: 0

Format: —

Use: Used when different temperatures are needed for the melting plate andthe pump.

Setpoint Platen + Internal zone temperature offset = Setpoint Pump

Example: 150 �C + (−15 �C) = 135 �C



Input Setup

30 Standard Input 1Description: Control options that determine the function of input 1.

Value: 0 − Input disabled1 − Standby on/off2 − Heaters on/off3 − Motor enabled/disabled4 − Hose/gun 1 enabled/disabled5 − Hose/gun 2 enabled/disabled6 − Hose/gun 3 enabled/disabled7 − Hose/gun 4 enabled/disabled8 − Hose/gun 5 enabled/disabled9 − Hose/gun 6 enabled/disabled10 − Automatic standby11 − Motor 2 enabled/disabled

Resolution: 1

Default: 10

Format:

Use: If Motor enabled/disabled (3) is selected, the motor will turn on whenevervoltage is present on the input contacts. To require that the pump key bepressed (pump enabled) and that there be voltage on the input contactsbefore the motor can turn on, set the value of parameter 8, Automatic pumpon, to 0 (disabled).

Refer to Installing System Inputs in section 3, Installation for information aboutsetting up inputs.

NOTE: Only input 1 offers control option 10.

Multiple inputs can be set to the same input value. After one or more inputs thathave the same input value are energized, the input functionality will not beconsidered inactive (off) until all of the inputs with the same input value arede-energized (Multiple inputs set to the same input value are logical ORed).




Value: 0 − Input disabled1 − Standby on/off2 − Heaters on/off3 − Motor 1 enabled/disabled4 − Hose/gun 1 enabled/disabled5 − Hose/gun 2 enabled/disabled6 − Hose/gun 3 enabled/disabled7 − Hose/gun 4 enabled/disabled8 − Hose/gun 5 enabled/disabled9 − Hose/gun 6 enabled/disabled11 − Motor 2 enabled/disabled

Resolution: 1

Default: 1

Format: —

Use: If Motor enabled/disabled (3) is selected, the motor will not turn on unless thepump is enabled and the correct voltage is present on the input contacts.Refer to Installing System Inputs in section 3, Installation for information aboutsetting up inputs.

NOTE: Multiple inputs can be set to the same input value. After one or moreinputs that have the same input value are energized, the input functionality willnot be considered inactive (off) until all of the inputs with the same input valueare de-energized (Multiple inputs set to the same input value are logicalORed).



Resolution: 1

Default: 2

Format: —


NOTE: Multiple inputs can be set to the same input value. After one or moreinputs that have the same input value are energized, the input functionality willnot be considered inactive (off) until all of the inputs with the same input valueare de-energized (Multiple inputs set to the same input value are logical ORed).





Resolution: 1

Default: 4

Format: —



34 – 39 Optional Inputs 1, 2, 3, 4, 5 and 6Description: Control options that determine the function of the six optional inputs, provided

the optional I/O expansion card is installed on the main board.


Resolution: 1

Default: 1 (all optional inputs)

Format: —

Use: If Motor enabled/disabled (3) is selected, the motor will turn on only when thepump is enabled and the correct voltage is present on the input contacts.

Refer to Installing System Inputs in section 3, Installation for information aboutsetting up inputs.




Output Setup

40 − 42 Standard Outputs 1, 2 and 3(Do not Edit)

Description: Determines the function of the output.

Value: 0 = Output disabled1 = Ready2 = Ready and pump on3 = Fault4 = Low level (not available)5 = Service LED lit6 = Alarm (voltage fault)

Resolution: 1

Default: Output 1 = 1Output 2 = 3Output 3 = 4

Format: —

Use: Refer to Installing System Outputs in section 3, Installation for informationabout setting up outputs.

When control options 6, Alarm, is selected, the output is active as soon as thesystem enters the two minute fault monitoring period. If the potential faultcondition clears before the end of the two minute period, the output signalends. Refer to section 4, Operation, Monitoring Faults for information on faultmonitoring.

NOTE: If a light tower (accessory) is installed, the outputs 1 - 3 must be set tothe default.

43 − 46 Optional Outputs 4, 5, 6, and 7Description: Control options that determine the function of the four optional outputs,

provided the optional I/O expansion card is installed on the main board.

Value: 0 = Output disabled1 = Ready2 = Ready and pump on3 = Fault4 = Low level (not available)5 = Service LED lit6 = Alarm (voltage fault)

Resolution: 1

Default: 0 (all optional outputs)

Format: —

Use: Refer to the instruction sheet provided with the optional I/O expansion card forinformation about wiring and setting up the optional outputs.

When control options 6, Alarm, is selected, the output is active whenever thesystem enters the two minute fault monitoring period. If the potential faultcondition clears before the end of the two minute period, the output signalends. Refer to section 4 Operation, Monitoring Faults.

Seven-day clock key



Seven-day clock

Before 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 Setting Up the Bulk Melter in section 3, Installation.

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 system 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 systemin the state dictated by the last clock transition until the next clocktransition occurs,

6. Press the Clock key.

In order for the clock to operate continuouslythroughout the week, a valid schedule must be assigned to every day of the week (parameters 71 to 77).

To prevent unintentional activation of the clock, thedefault setting for parameters 71 to 77 is schedule 0,which has no time values assigned to it. With thedefault set to schedule 0, unintentionally pressing theclock key will have no effect on the system.



Example 1

Switch heaters on at 0600 and turn them off at 0015 every day of the week:

Par 55 = 0600Par 56 = 0015Par 60 = − − − −Par 61 = − − − −Par 71 to 77 = 1

Example 2

Switch heaters on at 0700 and off at 1700 Monday through Friday, andswitch heaters off Saturday and Sunday:

Par 55 = 0700Par 56 = 1700Par 57 = − − − −Par 58 = − − − −Par 71 to 75 = 1Par 76 and 77 = 0

Example 3

Switch heaters on at 0600 each morning, go into standby for lunch at 1130,come out of standby after lunch at 1230, and switch the heaters off at 1600at the end of the day, every day of the week:

Par 55 = 0600Par 56 = 1600Par 57 = 1130Par 58 = 1230Par 71 to 75 = 1Par 71 and 77 = 1



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 toFunction Keys in Section 4, Operation.

51 Current timeDescription: Used to set the time.

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 pressing 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 system will enter standby mode during schedule

1.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Set the time that the system will enter standby mode during schedule 1.


Note: Do not set an enter standby time that is outside of the time perioddefined by the schedule’s heater on and off time. The system can not enterstandby mode when the heaters are off.

58 Schedule 1 Exit StandbyDescription: Used to set the time that the system will exit standby mode during schedule 1.

Value: 0000 to 2359, - - - -


Default: - - - -


Use: Set the time that the system will exit standby mode during schedule 1.


Note: Do not set an exit standby time that is outside of the time period definedby the schedule’s heater on and off time. The system can not enter standbymode when the heaters are off.


Value: 0000 to 2359, - - - -


Default: - - - -







Value: 0000 to 2359, - - - -


Default: - - - -





2.

Value: 0000 to 2359, - - - -


Default: - - - -






Value: 0000 to 2359, - - - -


Default: - - - -








Value: 0000 to 2359, - - - -


Default: - - - -





Value: 0000 to 2359, - - - -


Default: - - - -





3.

Value: 0000 to 2359, - - - -


Default: - - - -








Value: 0000 to 2359, - - - -


Default: - - - -





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 on again until thenext scheduled heaters on time arrives.



PID Selection

80−91 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.

Glossary C-1


Appendix CGlossary

Advance DistanceDistance between initiator and gun.

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 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 and pressure sensors exchange data with theindustrial PC via the CAN bus. The CAN bus is used as an internal networkfor Nordson unit control and is not intended to be an interface for thecustomer’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 (pattern controller) dependent on the speed of the parentmachine.

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

GlossaryC-4


Conversions (contd.)

Unit Multiplied by Result

Density SI unit: [kg/m3]

Kilograms per cubic meter kg/m3 1,0 x 10−3 Kilograms per liter kg/l

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

Kilograms per liter kg/l 8,35 Pounds per gallon (US) lb/gal

Pounds per gallon (US) lb/gal 0,12 Kilograms per liter kg/l

Torque SI unit: [Nm]

Newtonmeter Nm 8,85 Pound inch (US) lbin

Newtonmeter Nm 0,74 Pound foot (US) lbft

Pound inch (US) lbin 0,113 Newtonmeter Nm

Pound foot (US) lbft 1,36 Newtonmeter Nm

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

Pascal Pa 1,0 x 10−5 Bar bar

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

Bar bar 14,5 Pounds per square inch (US) psi

Pounds per square inch (US) psi 0,069 Bar bar

Speed SI unit: [m/s]

Meters per second m/s 196,89 Feet per minute ft/min

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

Length SI basic unit: Meter [m]

Meter m 3,2808 Foot ft

Foot ft 0,3048 Meter m

Centimeter cm 0,3937 Inch in

Inch in 2,54 Centimeter cm

Glossary C-5


Conversions (contd.)

Unit Multiplied by Result

Ground 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.

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.

GlossaryC-6


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 and the end of

material application.

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

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.

Glossary C-7


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.

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.

GlossaryC-8


Inert GasRefer to Protective 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. Instead of material application beingcontinuous, it occurs with pauses to create the desired application 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.

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 configuration of two or more units in which one assumes control of oneor more slaves.

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

Glossary C-9


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 torque. Refer to Conversions.

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. The nozzledetermines the volume, shape and direction of the material outlet.

GlossaryC-10


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 indicated onthe ID plate. A transformer may be required 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.

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

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.

Glossary C-11


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.

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).

GlossaryC-12


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 GasGas (e.g. nitrogen) used to protect the adhesive from contact with humidityand therefore from undesired reactions. Protective gas is also referred to asinert 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 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.

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.

Glossary C-13


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).

Solenoid ValveUsually part of the gun. A control valve that is activated by anelectromagnetic coil.

GlossaryC-14


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 SensorAlso referred to as temperature detector.

A part of a temperature control system that compiles the temperature andtransmits it to the control system. Resistance temperature sensors 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.

VAC

Abbreviation for Alternating Current.

Glossary C-15


VDCAbbreviation for Direct Current.

ViscosityStrength; an indication of the force that must be generated to move a liquid:

1. Viscosity (also called dynamic viscosity). Unit: Pas (Refer toConversions).

2. Kinematic viscosity (dynamic viscosity divided by material density). Unit:m2/s (Refer to Conversions).

GlossaryC-16


duradrum bulk melters dd200 - nordsonemanuals.nordson.com/adhesives/english_manuals/7105731.pdf ·...

Documents