DuraBlue Adhesive Melters -...

DuraBlue� Adhesive MeltersModels D10 and D16 (Gerotor)

Customer Product ManualPart 1073400A04

Issued 4/15

NORDSON CORPORATION DULUTH, GEORGIA USAwww.nordson.com

Part 1073400A04 � 2015 Nordson CorporationAll rights reserved

Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General informationabout Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2006.No part of this document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

Trademarks

AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray,ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat,Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove,

FoamMelt, FoamMix, HDLV, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, Kinetix, Little Squirt, LogiComm,Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix,Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink,

Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus,Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime,

Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Check Mate,Classicblue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, CScan, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail,Easy Clean, EasyOn, Eclipse, E-Nordson, EquiBead, ESP, FillEasy, Fill Sentry, FluxPlus, G−Net, G−Site,, iON, Iso-Flex, iTrend, Lacquer Cure, Lean Cell,

Maxima, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI,Powder Pilot, Powercure, Precise Coat, Primarc, Process Sentry, Pulse Spray, 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,Trade Plus, ThruWave, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design)

are trademarks of Nordson Corporation.

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

DeviceNet is a trademark of Open DeviceNet Vendor Association, Inc.Parker Lubricant is a registered trademark of Parker Seal.

Profibus is a trademark of Profibus International.Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.

Windows is a registered trademark of Microsoft Corporation.

Table of Contents i

Part 1073400A04� 2015 Nordson Corporation

Table of Contents

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

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

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

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

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

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

Safety Labels and Tags 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Sources of Information 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Guide 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .User’s Guide 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Online Support 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product Resource CD 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Description 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limitations of Use 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modes of Operation 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Identification 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key Components 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Equipment 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Part 1073400A04 � 2015 Nordson Corporation

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick-Start 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Tasks 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Experience of Installation Personnel 3-2. . . . . . . . . . . . . . . . . . . . . . . . .

Installation Requirements 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clearances 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Power 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Considerations 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking the Melter 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Contents of the Installation Kit 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Customer-Supplied Materials 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the Melter 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuring the Electrical Service 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Hoses and Applicators 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up the 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 Tank, Hoses, and Applicators 3-24. . . . . .Save and Restore Melter Settings 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . .Review Parameter and Setpoint Temperature Changes 3-28. . . . . . . .

Installing Melter Inputs 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Melter Outputs 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Optional Equipment 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting a Applicator Driver, Pattern Controller, or Timer 3-37. . . . . . .Flushing the Melter 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting the Pressure Control Valve 3-38. . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up Melter Communications 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Additional Information 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

More about Heated Components 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . .Filling the Tank 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting the Melter 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring the Melter 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Confirm that the Melter is Operating Correctly 4-6. . . . . . . . . . . . . . . .Monitor Component Temperatures 4-7. . . . . . . . . . . . . . . . . . . . . . . . . .Monitor Melter Faults 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How F1, F2, and F3 Faults are Handled 4-12. . . . . . . . . . . . . . . . . . .How F4 Faults are Handled 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor the Service Interval 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Component Temperatures 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . .Entering the Melter Password 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Melter Function Keys 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Key 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Key 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup Key 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-day Clock Key 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standby Key 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the Melter 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iii


Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving System Pressure 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Locking Out External Communications 5-2. . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the Melter 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing the Filter 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the Tank 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter Faults 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Operating Variables 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Troubleshooting Flow Chart 6-6. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Quick-checks 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Returning the Melter Setup to Factory Settings 6-7. . . . . . . . . . . . . . .Identifying Electrical Components 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

DuraBlue Troubleshooting Charts 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Panel Service Kits 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Component Service Kits 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Boards 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuses 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermostat 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTDs 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heaters 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cables and Harnesses 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Strainer 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Assembly Service Kits 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manifold 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Assembly (Complete) 7-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow/Pressure Control and Pressure Indication 7-18. . . . . . . . . . . . . . .Expansion and Control Kits 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FillMaster Accessory Kits 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Melter Accessory Kits 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Specifications 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Specifications 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater Specifications 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor and Pump Specifications 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Conduit Penetration Sizes 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Calculating Melter Power Requirements A-1. . . . . . . . . . . . . . . . . . . . .

Operating Parameters B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Control B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input Setup B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output Setup B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seven-day Clock B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example 1 B-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Example 2 B-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Example 3 B-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fill Timer B-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PID Selection B-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melter Communications C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Availability C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Requirements C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing the Software C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Software from Your PC C-3. . . . . . . . . . . . . . . . . . . . . . . .Connecting the PC and the Melter C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Nordson Configuration Manager C-4. . . . . . . . . . . . . . . . . . . . . . . . .

Saving and Restoring Melter Settings C-5. . . . . . . . . . . . . . . . . . . . . . .Upgrading or Restoring Melter Firmware C-6. . . . . . . . . . . . . . . . . . . . .

Troubleshooting C-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Nordson Configuration Manager C-9. . . . . . . . . . . . . . . . . . . . . .

Safety 1-1

A1EN−01−[XX−SAFE]−10� 2015 Nordson Corporation Issued 4-02

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”). Additionalsafety information, in the form of task-specific safety alert messages,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 SymbolsThe 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

A1EN−01−[XX−SAFE]−10 � 2015 Nordson CorporationIssued 4-02

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 Qualifications Equipment owners are responsible for ensuring that users:

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

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

� receive, equipment- and task-specific training from another qualifiedindividual

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

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

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

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

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

specified in this document.

� Do not modify the equipment.

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

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 at the end of this section.

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

Safety1-4


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 Safety Data Sheet (SDS)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 SDS for PPE requirements.

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

Safety 1-5


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 factory-authorized refurbished or replacement parts.

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

NOTE: SDSs 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 SDS orcontact the authority having jurisdiction for information.

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

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

� hot melt and cold adhesive application equipment and all relatedaccessories

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

Safety1-6


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

Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter-specific product manual forinstructions on relieving system hydraulic pressure.

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

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

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

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

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

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

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

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

Safety 1-7


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, applicators, etc.)

PC = Process control

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

Table 1-1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING: Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent-based material through acompatible Nordson melter, read and comply with the material’s SDS.Ensure that the material’s processing temperature and flashpoints willnot be exceeded and that all requirements for safe handling,ventilation, first aid, and personal protective equipment are met.Failure to comply with SDS requirements can cause personal injury,including death.

HM

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

HM, 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, clothing thatprotects 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...

Safety1-8


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 applicators. Beforeworking on or near an operating applicator, disable the applicator’striggering device and remove the air supply to the applicator’ssolenoid valve(s). Failure to disable the applicator’s triggering deviceand remove the supply of air to the solenoid valve(s) can result inpersonal 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 SDS 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 1-9



HM

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

HM

CAUTION: Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt.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 SDS supplied with the compound. Some cleaning compoundscan react unpredictably with hot melt or cold adhesive, resulting indamage 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.

Safety1-10


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

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

� Never point a dispensing hand-held applicator at yourself or others.

� Suspend dispensing hand-held applicators by their proper suspensionpoint.

First Aid If molten hot melt comes in contact with your skin:

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

2. Immediately soak the affected area in clean, cold water until the hot melta has 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 SDS for the hotmelt to the medical personnel providing treatment.

Safety Labels and Tags Figure1-1 illustrates the location of the product safety labels and tags affixedto the equipment. Table 1-2 provides an illustration of the hazardidentification symbols that appear on each safety label and tag, the meaningof the symbol, or the exact wording of any safety message.

The installation kit provided with the melter may contain label overlays thatare printed in a variety of languages. If required by governing safetyregulations, apply the appropriate overlay to the text portion of the labelsshown in Figure 1-1.

Safety 1-11


5

Figure 1-1 Safety labels and tags

Table 1-2 Safety Labels and Tags

Item Description

1

WARNING:Hazardous voltage.Disconnect all power supplyconnections before servicing.

2 CAUTION:Burn hazard. Hot surfaces.

3

WARNING:Hazardous voltage.Disconnect all power supplyconnections before servicing.

4 CAUTION:Burn hazard. Hot surfaces.

5

WARNING:Burn hazard.Hot adhesive.Release pressurebefore servicing.

NS

Tag, hazardous votage [located inside theelectrical cabinet on the main board—refer toSection 8, Parts, for an illustration that showsthe location of the main board]

NS: Not Shown

Safety1-12


Introduction 2-1


Section 2Introduction

This manual describes the installation and use of the DuraBlue 10 (D10)and DuraBlue 16 (D16) adhesive melters. When necessary, the reader isreferred to the documentation supplied with other Nordson products orproducts supplied by third parties.

With the exception of tank capacity, hose/gun capacity, and exteriorappearance, all DuraBlue melters are functionally identical. To simplify thepresentation of information in this manual, depictions of the model D16 areused generically throughout this manual to represent all DuraBlue melters.

Introduction2-2


Other Sources of Information Refer to the following additional resources for quick-reference information,technical support, and information about getting the most out of yourDuraBlue melter.

Installation GuideThe installation guide shipped with the melter provides a visualquick-reference for installing the melter.

User’s GuideThe user’s guide shipped with the melter provides a visual quick-referenceto the most common operator-level tasks. The guide is appropriately sizedand laminated so that it can be kept with the melter on the production floor.

Online SupportVisit www.enordson/support to download melter firmware updates and BlueSeries software utilities.

Product Resource CDThe resource CD, which is stored in the back of this manual, contains anelectronic version of this manual, parts information, and other usefulresources that are designed to assist you with using and servicing yourmelter.

Introduction 2-3


Product Description See Figure 2-1. Nordson DuraBlue adhesive melters are used inconjunction with Nordson hot melt hoses and applicators to create a hotmelt application system.

The melter liquifies solid-form hot melt and maintains the hot melt at thedesired temperature. When the applicators are activated, the melter pumpsthe liquified hot melt through the hoses and out the applicator nozzles,where it is commonly applied to the surface of a product.

1

2

3

Figure 2-1 System components

1. DuraBlue melter2. Hot melt hose

3. Hot melt hand-held applicator

Introduction2-4


Intended Use DuraBlue melters are specifically designed to:

� Melt and pump solid-form hot melt materials that are engineered tobe liquified and extruded at temperatures below 230 �C (450 �F)

� Be used with compatible hot melt hoses and applicators that aremanufactured by Nordson Corporation

� Be used in non-explosive environments

Limitations of Use Use DuraBlue melters only for the purpose for which they are designed.DuraBlue melters should not be used:

� to melt or pump polyurethane reactive hot melt materials or anyother material that creates a health or safety hazard when heated

� in environments that will require the melter to be cleaned using awater wash or spray

Modes of Operation DuraBlue melters operate in the following modes:

Automatic scan—The melter automatically checks and displays thecurrent temperature of the tank, hoses, and applicators to confirm thatthey are within their pre-defined temperature range. By default, themelter is always in the automatic scan mode unless it is placed intoanother operating mode.

Standby—The temperatures of the tank, hoses, and applicators arereduced down from their operating temperature (hereafter referred to assetpoint temperature) by a pre-set number of degrees.

Setup—The setup mode is used to configure melter control options andfeatures and to review stored operating data. To prevent unauthorizedchanges to the melter’s configuration, the melter can bepassword-protected.

Fault—The melter alerts the operator when an abnormal event occurs.

Introduction 2-5


Melter Identification See Figure 2-2. You will need the model and part number of your melterwhen requesting service or ordering spare parts and optional equipment.The model and part number are indicated on the equipment identificationplate that is located on the front of the melter.

Figure 2-2 Equipment identification plate

Introduction2-6


Key Components Figure 2-3 provides the name and the location of key melter components.

3

5

12

13

1

2

4

11

6

7

9

10

8

Figure 2-3 Key components

1. Electrical enclosure door2. Control panel (see Figure 2-4)3. Tank lid4. Side panels

5. Tank6. Hose/gun receptacles7. Tank isolation valve8. Manifold

9. Pressure control valve10. Filter11. Pump12. Mounting bracket13. Motor

Introduction 2-7


0.20

1”

11 22

00

44 55

77 88

33

66

99

1 3

5

78

2

10

6

4

9

Figure 2-4 Control panel

1. Fault LED2. Ready LED3. Component keys/LEDs4. Control switch

5. Keypad6. Serial port7. Right display and scroll keys

8. Left display and scroll key9. Function keys

10. Service LED

Introduction2-8


Optional Equipment Optional equipment may be ordered to expand the functionality of DuraBluemelters, including, but not limited to, the following:

� Input/output (I/O) expansion cards that allow you to expand thenumber of available control inputs.

� Communications cards that allow the melter to communicate withother process equipment or a controller using standard networkprotocols.

� Automatic pressure control kit that allows the melter toautomatically adjust adhesive output based on productionrequirements.

� Pressure gauge that provides a manifold hydraulic pressurereading.

� Footswitch that allows manual pump activation.

� Air control kit that controls the module-actuating air for a manualmanifold-mounted applicator or a manual spray applicator.

� Hand−held applicator hanger that provides a convenient and safemethod for storing a hand-held applicator that is not in use.

� Pressure control valve knob that replaces the hex screw pressureadjustment with a hand knob.

Refer to Section 7, Parts, for a complete list of optional equipment.

Installation 3-1


Section 3Installation

WARNING: Allow only personnel with appropriate training and experienceto operate or service the equipment. The use of untrained or inexperiencedpersonnel to operate or service the equipment can result in injury, includingdeath, to themselves and others, and damage to the equipment.

Quick-Start If you have already installed the melter using the installation guide(P/N 1024498) that is provided inside the shipping container, and you haveno questions concerning the installation, go to Setting Up the Melter later inthis section for information about how to prepare the melter to operate withyour manufacturing process.

Overview DuraBlue melters are factory-configured for each order and require only theassembly and set up tasks described in this section. If your melter wasordered as a complete system, the shipping container will also contain oneor more hot melt hoses and applicators.

The melter is shipped from the factory with an installation kit that containscomponents that must be assembled on the melter by the customer. Someadditional materials must also be supplied by the customer to complete theinstallation.

If optional equipment was ordered with the melter, refer to thedocumentation provided with the optional equipment for installation andoperating instructions.

The illustrations accompanying the procedures in this section depict theD16 melter. Unless otherwise noted, the instructions also apply to theD10 melter.

Installation3-2


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

Installation Tasks The installation sequence is as follows:

1. Verify that the required installation conditions and utilities exist.

2. Unpack and inspect the melter.

3. Mount the melter on the parent machine or support structure.

4. Configure the electrical service.

5. Connect hot melt hoses and applicators.

6. Set up the melter to work with the manufacturing process.

7. (Optional) Install inputs and outputs.

8. Install optional equipment.

9. (If used) Connect a applicator driver, pattern controller, or timer.

10. Flush the melter.

11. Adjust the pressure control valve.

12. Set up melter-to-PC communications

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

� Hot melt application processes

� Industrial power and control wiring

� Industrial mechanical installation practices

� Basic process control and instrumentation

Installation 3-3


Installation Requirements Before installing the melter, ensure that the desired installation locationprovides the required clearances, environmental conditions, and utilities.

Clearances Figure 3-1 illustrates the minimum clearances that are required between themelter and surrounding objects. Table 3-1 describes each clearance.

Figure 3-1 Minimum installation clearances

Table 3-1 Minimum Installation Clearances

Item Description RequiredClearance

AWidth of melter at the outside of the mountingbrackets.

393 mm(15.48 in.)

BClearance required between the melter and thenearest object in order to remove the filter.

203 mm(8.00 in.)

CClearance required between the front end of themelter (control panel) and the nearest object inorder to fully open the electrical enclosure door

330 mm(12.99 in.)

DMinimum horizontal space required for themelter when both the electrical enclosure doorand tank lid are fully opened.

1052 mm(41.40 in.)

EMinimum vertical space required for the melterwhen the tank lid is at its highest point.

878 mm(34.57 in.)

Installation3-4


Electrical Power Before installing the melter, ensure that the melter will not be overloadedand that the plant’s electrical service is rated to handle the power requiredby the melter and the hoses and applicators that you plan to use.

Refer to Appendix A, Calculating Melter Power Requirements, forinformation about how to calculate the maximum allowable hose lengthsand applicator wattages that can be used in your manufacturing application.

WARNING: Risk of electrocution! Install a lockable power disconnectswitch between the electrical service and the melter. Failure to install orproperly use the disconnect switch when servicing the melter can result inpersonal injury, including death.

Other Considerations Consider the following additional factors when determining where to installthe melter.

� The maximum distance between the melter and each applicator isdictated by the power requirement of each hose. Refer to Appendix A,Calculating Melter Power Requirements, for information about how todetermine the maximum allowable length.

� The operator must be able to safely reach the control panel andaccurately monitor the control panel indicators.

� The operator must be able to safely observe the level of hot melt insidethe tank.

� The melter must be installed away from areas with strong drafts orwhere sudden temperature changes occur.

� The melter must be installed where it will be in conformance with theventilation requirements specified in the Material Safety Data Sheet forthe hot melt being used.

Installation 3-5


This page intentionally left blank.

Installation3-6


Unpacking the Melter Before starting the installation, remove the melter from the pallet, locate theinstallation kit, and inspect the melter for damaged and missing parts.Report any problems to your Nordson representative.

Contents of the Installation KitThe installation kit provided with the melter contains the components shownin Figure 3-2. The quantity and type of hose fittings provided in the kitdepends upon the melter’s model number and configuration.

NOTE: Fuses are provided as spares.

The installation kit also contains a package of safety label overlays that areprinted in variety of languages. If required by local regulations, theappropriate language overlay should be applied over the English version ofthe same label. Refer to Safety Labels and Tags in Section 1, Safety, for thelocation of each safety label.

Customer-Supplied Materials The following additional materials are also required to install the melter:

� An 10 mm2 (8 AWG) power cable

� Four 8 mm (5/16 in.) machine bolts and locking hardware

Installation 3-7


Figure 3-2 Installation kit components

1. Voltage plug (2)2. Voltage plug with neutral (2)3. Input/output connectors (2)4. Spare fuses (5)5. Straight hose fitting6. 90-degree hose fitting (4-hose/gun

units only)

Mounting holes

Installation3-8


Mounting the Melter Before mounting the melter, ensure that the parent machine or supportstructure is level with respect to the floor, provides an even mountingsurface, is not subject to extreme vibration, and is capable of supporting theweight of the melter, a full tank of hot melt, and the hoses and applicators.

Refer to Section 8, Technical Data, for the weight of the melter. Refer to thetechnical data provided by the hot melt manufacturer for information aboutthe volumetric weight of the hot melt.

To mount the melter

See Figure 3-3. Use 8 mm (5/16 in.) machine bolts and locking hardware tosecure the melter mounting brackets to the mounting surface.

NOTE: The bolt mounting pattern of DuraBlue melters can be adapted tothat of many other Nordson melters. Refer to Table 3-2.

10 mm(0.38 in.)

16 mm(0.63 in.)

432 mm(17.00 in.)

381 mm(15.00 in.)

249 mm(9.80 in.)

318 mm(12.50 in.)

260 mm(10.25 in.)

Figure 3-3 Bolt mounting patterns (refer to Table 3-2)

Installation 3-9


Table 3-2 Comparison of DuraBlue Melter Dimensions with Other Melter Dimensions

Dimension 31003400

3500370038303930

LS10KB10 KB20

A B C D E

Opening the electrical enclosuredoor

Installation3-10


Configuring the Electrical Service DuraBlue melters are shipped from the factory without an attached powercable and without a designated service-type To configure the melter tofunction in your facility, you must connect a power cable to the melter anddesignate the service-type by installing a Nordson-supplied voltage plug intothe melter.

To connect a power cable to the melter

WARNING: Risk of electrocution! Install a lockable power disconnectswitch between the electrical service and the melter. Failure to install orproperly use the disconnect switch when servicing the melter can result inpersonal injury, including death.

1. Select a 10 mm2 (8 AWG) power cable that meets applicable electricalcodes and standards. The maximum amperages of DuraBlue meltersoperating at a specified voltage are shown in Table 3-3.

Table 3-3 Maximum Amperages

Voltage (VAC) Model Maximum Amperage200−240, 1-phase200−240, 3-phase

400, 3-phaseD10 25

200−240, 1-phase200−240, 3-phase

400, 3-phaseD16 27

2. Open the electrical enclosure door.

3. Route the power cable between the power disconnect switch and themelter and then through the PG-21 or 1-inch conduit penetration on thefloor of the electrical compartment.

See Figure 3-4.

4. Connect each power cable lead to terminal block XT1. Table 3-4 lists theterminals that are used for each of the electrical service types that arecompatible with the melter.

5. Connect the ground lead from the power cable to the ground lug that islocated on the chassis. The ground lug is marked PE/G.

Installation 3-11


EXAMPLE ONLY(3/N/PE AC wiring shown)

PE/G

L1L2L3N

XT1

Figure 3-4 Connecting the power cable and ground lead

Table 3-4 Electrical Service Information

Use Electrical ConnectorTerminals..

Use Voltage Plug..

If the Electrical Service Type is..L1 L2 L3 N

400/230 VAC 3-phase (4-wire service, including aneutral) See note.

3/N/PE AC400/230V 227569

Red/Yellow

230 VAC 1-phase(2-wire service, including aneutral) See note.

1/N/PE AC200–240V 232617

Blue/Yellow

200 to 240 VAC 3-phase(3-wire service without aneutral)

3/PE AC200–240V 227568

Red/Green

200 to 240 VAC 1-phase(2-wire service without aneutral)

1/PE AC200–240V 227567

Blue/Green

NOTE: The 400/230 VAC 3-phase service (4-wire service including neutral) includes the 415/240 VAC 3-phase (4-wire service,including neutral) voltage. The 230 VAC 1-phase service (2-wire service, including a neutral) includes the 240 VAC 1-phase (2-wireservice, including a neutral) voltage.

Typical voltage plugs(plugs with and without the neutrallead shown)

Installation3-12


To connect a voltage plug to the melter1. Refer to Table 3-4 to determine the part number of the voltage plug that

matches the required electrical service. Each voltage plug is labeled withits part number and service type.

See Figure 3-5.

2. Insert the correct voltage plug into receptacle X1. Ensure that the plugsnaps into place. If the plug contains a neutral lead, connect the neutrallead to receptacle X2.

3. When the electrical service is completely installed and inspected inaccordance with local electrical codes and standards, close the electricalenclosure door and switch the local power disconnect switch on.

If the electrical service was configured correctly, the melter control panelwill display dashes.

X2

X1 X1

P/N 232617P/N 227569

P/N 227567P/N 227568

Figure 3-5 Connecting a voltage plug

Installation 3-13



Hose ports on manifold

Switch receptacle

Installation3-14


Connecting Hoses and ApplicatorsDuraBlue melters use standard Nordson hoses and applicators and supportthe connection of up to four hose/gun pairs. The hose/gun capacity of eachmelter is determined by the number of hose/gun receptacles on the melter.Each hose/gun receptacle supports the connection of one hose/gun pair.

WARNING: Risk of fire or equipment damage. Before connecting hosesand applicators to the melter, confirm that the power required by the hosesand the applicators does not exceed the maximum wattages specified inAppendix A, Calculating Melter Power Requirements.

To connect hoses

See Figure 3-6.

Observe the following guidelines:

� For information about choosing the correct Nordson hot melt hose foryour manufacturing process, refer to the latest edition of Nordson’s hotmelt dispensing equipment Replacement Parts Catalog or contact yourNordson representative.

� Connect hoses to any of the hose ports provided on the manifold. Themelter is shipped with one hose fitting (capped) pre-installed on themanifold.

� Use a 90-degree fitting when connecting a hose to any of the bottomhose ports or to the end hose port.

� Refer to the user’s guide provided with each Nordson hose. The guidecontains important information about routing and installing the hose.

� Save all of the plugs that were removed from the hose ports. A plug willneed to be reinstalled into a hose port if a hose is later removed.

� Connect switched hand-held applicator hoses or a footswitches, to theswitch receptacles on the back of the melter.

NOTE: Only connect a switched hand-held applicator, the optionalfootswitch, or a cordset that is approved by Nordson Corporation to theswitch receptacle.

Installation 3-15


P/N 1030542

12

4 3

12

4 3

B900

Figure 3-6 Connecting a switched hand-held applicator hose, footswitch, or a B900N electric applicator

To connect applicators

Observe the following guidelines:

� For information about choosing the most appropriate Nordson hot meltapplicator for your manufacturing process, refer to the latest edition ofNordson’s hot melt dispensing equipment Replacement Parts Catalog orcontact your Nordson representative. Refer to Appendix A, CalculatingMelter Power Requirements, for information about how to calculate thepower required by Nordson hot melt applicators.

� Refer to the user’s guide that is shipped with each applicator forinformation about installing the applicator and connecting a hose to theapplicator.

� See Figure 3-6. The B900N electric applicator can be connected directlyto the manifold. Operating parameter 12 or 13 must be enabled if aB900N is connected. Refer to Appendix B, Operating Parameters.

NOTE: DuraBlue melters are shipped with a 100-mesh (0.15 mm) hot meltfilter installed in the pump body. Filters with 50- and 150-mesh screens(0.11 mm and 0.07 mm respectively) are also available. Order theappropriate filter based on the smallest nozzle size used in your application.

Installation3-16


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

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

Quick Setup Table 3-5 describes the most commonly used operating parameters andtheir factory settings. Review the table to determine if the factory settings foreach parameter will support your manufacturing process. If the defaultvalues for each of these operating parameters are appropriate for yourmanufacturing process, then no melter setup is required. Go directly toSetpoint Temperature of the Tank, Hoses, and Applicators later in thissection to complete the installation process.

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

Installation 3-17


Table 3-5 Common Operating Parameters

Parameter Parameter Name Purpose Default Value

4 Ready Delay Time

A timer that delays the activation of the ready LED for apre-defined time period after the tank, hoses, and applicatorsare at the desired setpoint temperature. The ready delay timerwill only activate if the temperature of the tank, at the time themelter is turned on, is below its assigned setpoint temperatureby 27 C (50 F) or more.

0 minutes

5 Service Interval Time

A timer that turns on a service LED when the value set for thetimer equals the number of hours that the heaters have beenon. The service LED is used to signal the need formaintenance.

500 hours

7 Motor Off DelayIf the switch receptacle is used, this parameter determines theamount of time the motor will remain on after the switcheddevice is turned off.

0 seconds

8 Automatic Pump OnAllows the pump to start automatically when system ready isreached, provided that the pump has been enabled bypressing the pump key.

Enabled

11 Create PasswordSets a password that must be entered before any melteroperating parameter or setpoint temperature can be changed. 5000

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

21 Over Temperature DeltaSets the number of degrees that any heated component canexceed its assigned setpoint temperature before an overtemperature fault occurs.

15 C (25 F)

22 Under TemperatureDelta

Sets the number of degrees that any heated component candrop below its assigned setpoint temperature before an undertemperature fault occurs.

25 C (50 F)

23 Standby DeltaSets the number of degrees that the temperature of all heatedcomponents will be decreased when the melter is placed intothe standby mode.

50 C (100F)

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

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

Disabled

Installation3-18


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

Operating parameters are stored in the melter’s firmware in the form of asequentially numbered list. The list is organized into the logical groupsdescribed in Table 3-6.

Table 3-6 Parameter Groups

Group ParameterNumbers Group Description

Standard0 to 8 and10 to 14 Frequently used parameters

Pressure Control 15 to 17 Configure pressure settings

Temperature Control 20 to 26 Control heater function

Input Setup 30 to 39 Configure the standard and optional inputs

Output Setup 40 to 46 Configure the standard and optional outputs

Seven-day Clock 50 to 77 Configure the clock feature

Automatic Fill Timer 78 Configure the external motor control switch

PID Selection 80 to 91 Configure the 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 3-7 provides a complete list of the operating parameters. Review thelist to determine which operating parameters would best support yourmanufacturing process. Refer to Appendix B, Operating Parameters, fordetailed information about each parameter. Appendix B contains a completedescription of each parameter, including its affect on the melter, defaultvalue, and format.

NOTE: Parameters that are used to configure optional equipment or thatare otherwise reserved in the firmware are excluded from Table 3-7.

Control switch (on/off)

Setup key

Clear/Reset key

Enter key

Installation 3-19


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

To read or edit a parameter

1. Switch the melter on.

The melter performs a start-up check.

2. Press the Setup key.

The left display flashes parameter 1.

3. Use the numeric keypad to enter the number of the desired parameter.Refer to Table 3-7 for a complete list of parameters.

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

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

4. Do one of the following:

� If the value is noneditable, refer to Monitoring the Melter inSection 4, Operation.

� If the value is editable go to step 5.

5. Press the Enter key.

The right display flashes.

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

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

Installation3-20


Reading or Editing Operating Parameters (contd)

To read or edit a parameter (contd)


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

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

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

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

Table 3-7 Operating Parameters

Parameter Name Range of Values Default Value

Standard

0 Enter Password 0 to 9999 4000

1 Total Hours with Heaters 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 Time 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 ApplicatorActivation 0 (disabled) or 1 (enabled) 0 (disabled)

13Change Hose 2 Output to Electric ApplicatorActivation 0 (disabled) or 1 (enabled) 0 (disabled)

14 External Communications Lock-out 0 or 1 0 (disabled)

Temperature Control

20 Temperature Units (degrees �C or �F) C (degrees Celsius) or F (degreesFahrenheit) C (degrees Celsius)

21 Over Temperature Delta 5 �C (10 �F) to 60 �C (110 �F) 15 �C (25 �F)

22 Under Temperature Delta 5 �C (10 �F) to 60 �C (110 �F) 25 �C (50 �F)

23 Standby Delta 5 �C (10 �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)

Continued...

Installation 3-21



Input Setup

30 Standard Input 1 0–10 and 11−14 10 (Automatic Standby)

31 Standard Input 2 0−9, 11, and 13−14 1 (Standby on/off)

32 Standard Input 3 0−9, 11, and 13−14 2 (Heaters on/off)

33 Standard Input 40−9, 11, and 13−14

4 (Hose/gun 1enable/disable)

34 Optional Input 5 0−9, 11, and 13−14 0 (disabled)






Output Setup

40 Standard Output 1 0–6 1 (Ready)

41 Standard Output 2 0–6 3 (Fault)

42 Standard Output 3 0–6 4 (Not used)

43 Optional Output 4 0–6 0 (disabled)




Seven-day Clock

50 Current Day 1 to 7 (1 = Monday) —

51 Current Hour 0000 to 2359 —

55 Schedule 1 Heaters On 0000 to 2359 06:00

56 Schedule 1 Heaters Off 0000 to 2359 17:00

57 Schedule 1 Enter Standby 0000 to 2359 —:—

58 Schedule 1 Exit Standby 0000 to 2359 —:—

60 Schedule 2 Heaters On 0000 to 2359 —:—

61 Schedule 2 Heaters Off 0000 to 2359 —:—



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

Continued...

Installation3-22


Reading or Editing Operating Parameters (contd)

Table 3-7 Operating Parameters (contd)


Automatic Fill Timer

78 Automatic Fill Timer 0−99 seconds 0 (Disabled)

PID Selection

80−91 PID Selection for Hose/ApplicatorReceptacles 0−3 0 or 1

You can exit the setup mode at any time bypressing the Setup key.

Parameter numbers that are not applicableare skipped when you scroll through theoperating parameter list in the left display.

When the right display is flashing, you canquickly set the value of the current parameterto it’s lowest possible value by simultaneouslypressing both of the right-display scroll keys.

While in the setup mode, if no key is pressedfor two minutes, the melter will return to theautomatic scan mode.

You can also use the right-display scroll keysto enter or change a parameter’s value orcontrol option. After entering the parameter’snumber in the left display, press either of theright-display scroll keys to change the value orcontrol option.

Using a personal computer that is connectedto the melter through the serial port, you canview and change all of the operatingparameters from a single computer screen.

Refer to Appendix C, MelterCommunications

If password protection is enabled, the melterwill return to the password protected modewhenever you exit the setup mode.

Appendix B, parameter 10

Installation 3-23



Installation3-24


Setpoint Temperature of the Tank, Hoses, and ApplicatorsThe melter is shipped from the factory with the tank setpoint temperature at175 C (350 F) and the hose and applicator setpoint temperatures at 0degrees (turned off).

Before the melter can be used, a setpoint temperature must be assigned tothe tank, hoses, and applicators. Assign setpoint temperatures using any ofthe following methods:

� Global—The tank and all hoses and applicators are set to the samesetpoint temperature.

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

� Individual Component—The setpoint temperature of the tank and eachhose and applicator is set individually.

Since most manufacturing processes will require the tank, hoses, andapplicators to be set to the same temperature, only the global method ofassigning setpoint temperatures is described in this section. For informationabout the other two methods of assigning setpoint temperatures, refer toAdjusting Component Temperatures in Section 4, Operation.

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

Tank key

Left display andscroll key

Enter key

Ready LED

Installation 3-25


To assign a global setpoint temperature

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

The left display flashes 1.

2. Scroll the left display to 0.

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



4. Use the numeric keypad to enter the setpoint temperaturerecommended by the manufacturer of the hot melt.

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

5. Press the Tank key.

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

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

+

Saving current settings

+

Restoring saved settings

Installation3-26


Save and Restore Melter 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 you need to return themelter to its pre-change setup.

To save current settings

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

S-1 appears momentarily in the right display.

To restore saved settings

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

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

S-2 appears momentarily in the right display.

If you use the restore feature before the savefeature is used for the very first time, thefactory default setpoint temperatures will berestored. This will cause the hoses andapplicators to stop heating.

You can transfer melter settings from onemelter to another using the NordsonConfiguration Manager software utility.

Refer to Appendix C, MelterCommunications

Installation 3-27



Setup key


Component key LEDs

Scrolling through the log

Installation3-28


Review Parameter and Setpoint Temperature Changes The melter stores in a change history log, a record of the last ten changesthat were made to either operating parameters or 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 history log


Operating parameter 1 flashes in the left display.

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

The following occurs:

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

or

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

and

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

Table 3-8 provides the meaning, from left to right, of each digit in thelog entry. Following the table are two example log entries.

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

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

Installation 3-29


Table 3-8 Change History Log

First Digit SecondDigit Third and Fourth Digits

P (Parameter)

−

Indicates the number of the parameter that was changed

S (Setpoint)

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

When this LED ison..

And the FourthDigit Indicates..

The change wasto..

And the Methodof Change was..

Tank Key 1 The tank Individual

Hose Key 1– 6 A single hose Individual

Applicator Key 1– 6A singleapplicator Individual

All Keys 0 All components Global

Hose Key 0 All hosesGlobal-by-component

Applicator Key 0 All applicatorsGlobal-by-component

Change History Log Examples

Example 1:

Parameter 4 (ready delay) was changed.

Example 2:

If the LED on the applicator key is on, then this displaywould indicate that the global-by-component method was used to changethe temperature of the applicators.

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

To view how many heater hours have elapsedsince a specific change (displayed) was made,simultaneously press both of the right-displayscroll keys.


Connector P/N 277909

Installation3-30


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

� Place the melter into the standby mode

� Turn the heaters on and off

� Enable or disable a specific hose or applicator

� Turn the motor on and off

The inputs require a 10 to 30 VDC signal voltage. The inputs are notpolarity-sensitive.

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

To wire inputs to the melter

1. Route a 2-, 4-, 6-, or 8-conductor signal cable from the controlequipment to the melter and through the PG-16 penetration on the floorof the electrical compartment. Use rigid or flexible conduit or a suitablestrain relief to protect the cable from the sharp edge of the conduitpenetration.

NOTE: Use a signal cable suitable for NEC class1 remote control andsignaling circuits. To reduce the possibility of electrical shorting, routethe cable so that it does not touch nearby circuit boards.

See Figure 3-7.

2. Connect each pair of input wires to the appropriate terminals (8 through14) on connector P/N 277909. If input number four is used, terminal 7 onconnector P/N 277908 must also be used. Both connectors are providedin the installation kit. Table 3-9 lists the terminal numbers thatcorrespond to each input.

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

3. Plug the connector (P/N 277909) into the bottom receptacle of terminalXT7, which is located on the expansion board. If input number four isused, plug connector P/N 277908 into the top receptacle on terminalXT7.

Installation 3-31


Figure 3-7 Wiring inputs

To set up an input

Set up the parameter control option for each input that you connected to themelter. Table 3-9 lists the available control options. Refer to Setting Up theMelter earlier in this section, for information about how to select operatingparameters and edit parameter control options.

With the exception of the pumpenable/disable control option, all inputsare transition-based.

Input Setup in Appendix B

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

Section 7, Parts

Installation3-32


Installing Melter Inputs (contd)

Table 3-9 Input Data

Input Terminals Operating Parameter Control Option NoteStandard Inputs

1 8 and 9 30

0 - Input Disabled

1 - Standby On/Off

2 - Heaters On/Off

3 - Motor 1 Enable/Disable

4 - Hose/Gun 1 Enable/Disable






10 – Automatic standby (Default)


13 − Automatic Fill Timer No. 1


A

B

2 10 and 11 31

0 - Input Disabled

1 - Standby On/Off (Default)

2 - Heaters On/Off

3 - Motor Enable/Disable










A

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


Continued...

Installation 3-33


Table 3-9 Input Data (contd)

Input Terminals Operating Parameter Control Option NoteOptional Inputs

5 11 and 12 34 Same as parameter 31 (Default=0) C, D






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

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

C: Parameters 34 through 39 are reserved for the inputs created when either the optional I/O expansion card or optionalI/O board is installed. Refer to Appendix B, Operating Parameters, for more information.

D: Refer to the instruction sheet provided with the optional I/O expansion card or analog I/O board for wiringinformation.


Output connector P/N 277908

Installation3-34


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

Each output is customer-wired and then set up in the melter’s firmware toprovide one of the following outputs:

� The melter is ready

� The melter is ready and the motor is on

� A fault has occurred

� The hot melt level is low

� The service LED is on

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

To connect an output to the melter

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

NOTE: Use a signal cable suitable for NEC class1 remote control andsignaling circuits. To reduce the possibility of electrical shorting, routethe cable so that it does not touch nearby circuit boards.

See Figure 3-8.

2. Connect each pair of output wires to the appropriate terminals(1 through 7) on connector P/N 277908. The connector is provided inthe installation kit. Table 3-10 lists the terminal numbers that correspondto each output.

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

3. Plug connector P/N 277908 into the top receptacle on terminal XT7,which is located on the expansion board.

Installation 3-35


Figure 3-8 Wiring outputs

To set up an output

Set up the parameter control option for each output that you connected tothe melter. Table 3-10 lists the available control options. Refer to Setting Upthe Melter earlier in this section for information about how to selectoperating parameters and edit parameter control options.

The output capacity of the melter may beincreased from three outputs to seven outputsby adding an optional I/O expansion card thatis available from Nordson Corporation.

Refer to Section 7, Parts

Installation3-36


Installing Melter Outputs (contd)

Table 3-10 Output Data

Output Terminals OperatingParameter Control Options Note

Standard Outputs

1 1 and 2 40 0 - Output Disabled

1 - Ready (Default)

2 - Ready and the Motor is On

3 - Fault

4 - Tank Low Level (not available)

5 - Service LED is On

6 - Alert

A

A

B

A

A

C


3 5 and 6 42

Same as parameter 40 (Default=4)

Optional Outputs


D, E5 3 and 4 44 Same as parameter 40 (Default=0)



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

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

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

D: Parameters 43 through 45 are reserved for the outputs created when either the optional I/O expansion card oroptional I/O board is installed. Refer to Appendix B, Operating Parameters, for more information.

E: For wiring information, refer to the instruction sheet that is provided with the optional I/O expansion card or analogI/O board.

Installation 3-37


Installing Optional Equipment Each item of optional equipment is shipped with instructions for installingand operating the equipment. Refer to Section 7, Parts, for equipment partnumbers.

Connecting a Applicator Driver, Pattern Controller,or Timer

If applicable, complete the melter installation by connecting the applicatorsto the desired applicator driver, pattern control, or timer. Refer to the productmanual provided with the device for information about installing andoperating the equipment.

Flushing the Melter WARNING: Risk of Burns! New melters contain a small quantity oflow-viscosity test fluid. Test fluid may splatter when discharged under highpressure. Before flushing the melter, ensure that the pressure control valveis set to low pressure.

Before using the melter for production, it should be flushed to remove anyresidue left over from factory-testing. Flushing the melter is accomplishedby processing a minimum of one tank volume of hot melt through the melter,hoses, and applicators.

Refer to Section 4, Operation, for information about filling the tank andoperating the melter.

Adjusting the pressure control valve

Installation3-38


Adjusting the Pressure Control Valve NOTE: The pressure control valve screw is turned fully counterclockwise(at or near the valve’s lowest pressure setting) at the factory and then thelock nut is tightened.

CAUTION: Do not exceed 16 N�m (12 ft-lb) of torque when adjusting thepressure control valve.

Before placing the melter into routine operation, loosen the lock nut andadjust the pressure control valve to achieve the desired adhesive outputrate for your manufacturing process. With the melter at operatingtemperature, the line running, and the applicators dispensing adhesive, turnthe adjustment screw on the pressure control valve

� clockwise to increase the adhesive output

� counterclockwise to decrease the adhesive output

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

Refer to Appendix C, Melter Communications, for information aboutdownloading, installing, and using the software that is required in order toconnect a personal computer to your melter.

Operation 4-1


Section 4Operation


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

� Filling the melter tank

� Starting the melter

� Monitoring melter operation

� Adjusting the operating temperature of heated components

� Using the melter function keys

� Shutting the melter down

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

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

Component keys(tank, hose, and applicator)

Operation4-2


More about Heated Components The melter contains three groups of heated components. These are thetank group, which contains the tank and the pump, the hose group, and theapplicator group. Component groups are represented on the control panelby the component keys shown to the left.

Heated components within each group are identified by their positionnumber. The position of the tank and pump is fixed at 1. Hose andapplicator position numbers are automatically assigned based on thehose/applicator receptacle they are connected to. For example, the positionnumbers of a hose/applicator pair that is connected to the secondreceptacle would be hose position 2 and applicator position 2.

The number of hose/applicator receptacles available on each melterdepends on the configuration in which the melter was ordered. DuraBluemelters may have either two or four hose/applicator receptacles.

NOTE: In some installations, auxiliary devices (such as a heated airmanifold) may be connected to a hose/applicator receptacle. In such cases,you should label (or otherwise identify) the auxiliary device as to the hose orapplicator position number that represents the device. The control panel willidentify such devices as a hose or applicator, regardless of what the deviceactually is.

Filling the tank

Operation 4-3


Filling the TankBefore filling the tank, confirm that the hot melt material is compatible withthe melter. Refer to Intended Use in Section 2, Introduction, for informationabout hot melt materials that should not be used in DuraBlue melters.

To fill the tank

WARNING: Hot! Risk of burns! Use a scoop to fill the tank with hot meltNever use your bare hands. Using your bare hands to fill the tank mayresult in personal injury.

1. Open the tank lid.

2. Use a scoop to fill the tank with hot melt. Table 4-1 lists the tank capacityof each DuraBlue melter.

NOTE: Nordson Corporation recommends that the tank be kept at leastone-half full while the melter is operating.

3. Close the tank lid when you are finished filling the tank.

Table 4-1 Tank Capacity

ModelCapacity*

Liters Kilograms PoundsD10 10 10 22

D16 16 16 35

*Assumes a hot melt with a specific gravity of 1

Melter control switch (on/off)

Heaters LED

Automatic scan sequence

Ready LED

Pump key

Operation4-4


Starting the Melter Before starting the melter for the first time, confirm that the

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

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

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

To start the melter

1. Switch the melter on.

The melter:

� Tests the control panel LEDs

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

� Begins to automatically scan through and display theactual temperature of the tank and each hose and applicator thathas a setpoint temperature that is greater than zero degrees. Thesequence of the automatic scan is: tank, each hose andapplicator pair, and then back to the tank.

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

2. Press the pump key to enable the pump.

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

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

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

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

Operation 4-5


If the melter is switched on whenthe temperature of the tank is 27 �C (50 �F)or greater below its assignedsetpoint temperature (cold start condition), theready LED will not turn on until the readydelay (defined when the melter was setup) has elapsed.


The time remaining on the ready delay (inminutes) appears in the right display at theend of every scan cycle. When only oneminute remains in the ready delay time, theright display counts down in seconds.


You can by-pass the ready delay time bypressing the Heaters key twice.

The appearance of F4 in the rightdisplay immediately after the melter isswitched on indicates a problem with themelter’s processor or main board.

Section 4, Monitor Melter Faults

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

Section 6, Troubleshooting

If the melter is set up for manual pumpactivation and parameter 7 (motor off delay)has been changed from the default, the pumpwill not stop until a user-specified amount oftime has elapsed.


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

Installing Melter Inputs in Section 3,Installation

If the seven-day clock feature was set up andturned on when the melter was last switchedoff, the clock will automatically turn on the nexttime the melter is switched on.

Section 4, Using Melter FunctionKeys

If a power failure occurs, the melter will restartin it’s normal heat-up cycle, even if the heaterswere off or the melter was in standby prior tothe power failure. If the seven-day clock wason prior to the power failure, the melter willrestart in the mode dictated by the clockschedule at the time the melter restarts.

Ready LED

Operation4-6


Monitoring the Melter The melter provides indicators that allow you to:

� Quickly confirm that the melter is operating correctly

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

� Identify melter faults

� Determine when service is required

The melter automatically determines the number and location of allhoses and applicators that are connected to it. Refer to More AboutHeated Components, earlier in this section, for information abouthose/applicator capacity and the identification of heated components.

You can also use a personal computer to monitor the melter. Refer toAppendix C, Melter Communications, for information about connecting apersonal computer to the melter and installing the required software.

Confirm that the Melter is Operating Correctly The ready LED turns on (green) when all of the heated componentsare within 3 �C (5 �F) of their 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 melter in the standbymode.

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

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

Refer to Monitoring Melter Faults and Using Melter Function Keys laterin this section for information about melter faults and using the seven-dayclock and standby functions. Refer to Appendix B, parameter 4, forinformation about the ready delay.

LEDs on component keys

Operation 4-7


Heated components with asetpoint temperature of zero degrees areskipped during the automatic scan cycle.

The setpoint temperature of the tank andthe pump cannot be set independently.

The time remaining on the ready delayappears in the right display at the end of eachscan cycle.


You can override the seven-day clock atany time. If the clock has turned the heatersoff, pressing the heaters key will turnthe heaters back on. If the clock has placedthe melter into the standby mode, pressingthe standby key will return theheated components to their assigned setpointtemperature.

Section 4, Using Melter FunctionKeys

Monitor Component Temperatures You can check the actual temperature of each heated component—the tankand each hose and applicator—using the automatic scan mode or bymanually selecting and checking each component.

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

� The melter is placed into the setup mode

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

� A fault occurs

To check component temperatures using the automatic scan mode

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

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

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


Component temperature display

Operation4-8


Monitor Component Temperatures (contd)

To manually check a component’s temperature

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

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

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

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

The right display indicates the actual temperature of theselected component.

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

When you scroll the left display pastthe number of the last sequential componentin a component group, the number of thefirst sequential component in the nextcomponent group appears in the left display.

The melter will return to the automaticscan mode two minutes after the last keyis pressed.

When you press the Tank key, it is the pumptemperature that is actually indicated in theright display. To check the actual temperatureof the tank, simultaneously press the Tankkey and the left-display scroll key.

The default unit for temperature displayis degrees Celsius (C). This may bechanged to degrees Fahrenheit usingoperating parameter 20.

Appendix B, Parameter 20

The LEDs on each component key will changefrom green to yellow if any component in thecomponent group drops more than 3 �C (5 �F)below its assigned setpoint temperature.

You can check the setpoint temperature of acomponent at any time, by pressing theright-display UP scroll key. Holding down thescroll key while the melter is in the automaticscan mode reveals the setpoint of eachcomponent that is scanned.

Operation 4-9



Operation4-10


Monitor Melter Faults The melter alerts the operator to the faults listed in Table 4-2. Faults affectthe melter in one of three ways: the heaters turn off; the heaters remain on,but the fault condition persists; or the melter stops functioning.

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

Table 4-2 Melter Faults

DisplayCode/Sub-code Name Affect on Melter Cause Corrective Action

F1/None RTD Heaters turn off

The RTD for thecomponent indicatedhas failed or thecomponent wasdisconnected fromthe melter.

Replace RTD

Check hose/applicatorconnections

See flowchart T.2

F2/NoneUndertemperature Heaters turn off

The actual temperatureof the componentindicated has droppedbelow the undertemperature delta,which was set usingparameter 22.

Check for conditionsthat may cause a dropin ambient temperature

Raise the setpointtemperature of thecomponent

Replace RTD

See flowchart T.2

F3/None Over temperature Heaters turn off

The actual temperatureof the componentindicated has increasedbeyond the overtemperature delta,which was set usingparameter 21.

Replace RTD

See flowchart T.2

F4/1 RAM testMelter stopsfunctioning

Internal RAM failure Replace CPU

F4/2Internal Clocktime

Heaters remain on,but fault conditionpersists

Internal clock failure Replace CPU

F4/4Internal clockbattery backedRAM


Battery-backed RAMfailure

Replace CPU

F4/5Internal clockbattery


Battery-backed RAMbattery dead

Replace CPU

Continued...

Operation 4-11


Table 4-2 Melter Faults (contd)


F4/6 Analog-to-digitalMelter stopsfunctioning

RTD analog-to-digitalconverter failed

Replace main board orCPU

F4/7Analog-to-digitalcalibration

Melter stopsfunctioning

Failed hose orapplicator

RTD analog-to-digitalconverter could not becalibrated

Replace hose orapplicator. Note: Setsetpoint to zero to avoidF1 fault.

Replace main board orribbon cable, or CPU

F4/8Main boardfeedback


Communication failurebetween main boardand CPU

Replace main board,ribbon cable, or CPU

F4/A ThermostatMelter stopsfunctioning

Tank or manifoldthermostat is open

Replace thermostat,XP6 harness, or mainboard

F4/CExpansion boardconnection


Ribbon cableP/N 1026662 is notconnected at J1 on themain board and/or at J2on the expansion board

Check the ribbon cableconnections and makeconnections asapplicable.

F4/dCommunicationswith optional I/Ocard


Communication failurebetween CPU and theoptional I/O card

Replace the I/O card orCPU

F4/EFieldbuscommunicationsfailure

Alert output (ifoutput option 6 isselected)Melter continues tooperate normally.

Fieldbus card failure. Replace the Fieldbuscard

Fault LED (red)

Operation4-12


How F1, F2, and F3 Faults are Handled

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

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

2. The LED on the affected component key (tank, hose, or applicator) turnson to indicate the type of component that has, or is, failing.

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

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

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

� If the LED on the hose or applicator key is on, the left display willindicate the number of the affected hose or applicator.

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

Operation 4-13


How F4 Faults are Handled When the melter detects an F4 fault:

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

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

3. The right display indicates F4.

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

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

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

Refer to Section 6, Troubleshooting, for information about diagnosing F4faults.

5. The melter records the fault in the fault log. Refer to To review the faultlog later in this section.

Clear/Reset key

Heater key

Operation4-14


Monitor Melter Faults (contd)

To put the melter back into operation

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

NOTE: When a fatal F4 fault exists, the control switch will not function.Remove power to the melter at the local disconnect switch.

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

3. Press the Clear/Reset key.

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

To view the temperature of a heated componentwhen an F2 or F3 fault exists, simultaneouslypress and hold both of the right-display scrollkeys.

You can temporarily dismiss an F1 fault (RTD)and return to the automatic scan mode bypressing the Clear/Reset key. The heaters will,however, remain off. If the fault condition stillexists two minutes after pressing the clear/resetkey, the fault LED will turn back on.

When an F1 fault code appears, youcan determine whether the fault was causedby an open or a shorted RTD bysimultaneously pressing both of the right-displayscroll keys. If the right display indicates OP,the RTD is open, if it indicates SH, the RTDhas shorted.

If, for any reason, a component reaches235 �C (458 �F), an immediate F3 fault will occur(no two-minute monitoring period).

If F4 appears in the right display when you pressthe clock key, the internal clock function hasfailed.

Operation 4-15



Setup Key

Left display and scroll key

Scrolling through the fault log

Operation4-16


Monitor Melter Faults (contd)

To review the fault log

1. Press and hold the Setup key.

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

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

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

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

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

� The right display indicates the log entry for the last fault tooccur. Table 4-3 provides the meaning of each digit in the logentry. Following the table are two example fault log entries.

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

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

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

Table 4-3 Fault Log

First Digit Second and Third Digits Fourth Digit

Component:

- FType of fault:

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

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

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

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

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

6 = Hose 6 or gun 6

Operation 4-17


Fault Log Examples

Example 1:

An unused log entry.

Example 2:

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

To view the number of heater hours that haveelapsed since a log entry was created,simultaneously press both of the right-displayscroll keys. The hours are indicated in the rightdisplay.

The melter will return to the automaticscan mode if the fault log is left open for a periodof two minutes without any key being pressed.

When an F1 fault is the result of ahose/applicator pair being disconnected from themelter, two fault log entries are created. The firstentry is for the applicator and the second entry isfor the hose.

Service LED (yellow)

Clear/Reset key

Operation4-18


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

To reset the service LED

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

The default setting for the service interval timeis 500 hours.


Operation 4-19



Tank key


Enter key

Ready LED

Operation4-20


Adjusting Component Temperatures You can adjust the setpoint temperature of heated components using thefollowing methods:

� Global—The tank and all hoses and applicators are set to the samesetpoint temperature.

� Global-by-component group—All of the hoses or all of theapplicators are set to the same setpoint temperature.

� Individual Component—The setpoint temperature of the tankand each hose and applicator is adjusted independently.

Before adjusting setpoint temperatures, confirm that each hose/applicatorpair is connected to the correct hose/applicator receptacle. For example,hose/applicator pair 1 should be connected to the receptacle 1. Refer toMore About Heated Components earlier in this section for information abouthose/applicator positions.

To adjust setpoint temperatures using the global method

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

The left display flashes 1.

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

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



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

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

5. Press the Tank key.

All components begin to heat or cool to the new globalsetpoint temperature. When all of the components reach theirsetpoint temperature, the ready LED turns on (green).

Tank, hose, and applicator keys

Operation 4-21


To adjust the setpoint temperature using the global-by-componentmethod

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

The left display indicates the number of the first sequential hose orapplicator. The right display indicates the current setpoint temperature ofthe hose or the applicator.

2. Scroll the left display to 0.

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




NOTE: If the keypad or the right-display scroll keys have no affecton the right display, the melter is password protected. You must entera valid password before you can change setpoint temperatures. Refer toEntering the Melter Password later in this section.


The hoses or the applicators begin to heat or cool to their newsetpoint temperature.

Operation4-22


Adjusting Component Temperatures (contd)

To adjust the setpoint temperature of an individual component

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

If the tank key was pressed, the left display indicates 1 (Flashing). If ahose or applicator key was pressed, the left display indicates thenumber of the first sequential hose or applicator (Flashing). The rightdisplay indicates the current setpoint temperature of the componentindicated in the left display.

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

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




NOTE: If the keypad or the right-display scroll keys have no affecton the right display, the melter is password protected. You must entera valid password before you can change setpoint temperatures. Refer toEntering the Melter Password later in this section.


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

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

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

The selected component begins to heat or cool to its newsetpoint temperature.

Operation 4-23


If you enter a valid setpoint temperature for ahose/applicator that is not connected to the melter orif you enter a setpoint temperature that is out ofrange, the right display will indicate dashes (----) forthree seconds and then change back to the originalsetpoint temperature.

When the right display is flashing, you can quicklychange the current setpoint temperature to 0degrees (off) by simultaneously pressing both ofright-display scroll keys.

After removing a hose or a applicator, usethe individual component method of setpointtemperature adjustment to set the component’stemperature to zero degrees (off). This willavoid causing an F1 fault when a hose or applicatoris added, use the individual component method to setthe desired temperature.

The factory setpoint temperature of the tank is 175�C (350 �F). The factory setpoint temperature of allothers components is zero degrees (off).

When the units of temperature is set to degreesCelsius, the minimum and maximum setpointtemperatures are 40 �C and 230 �C. When the unitsof temperature are set to degrees Fahrenheit, theminimum and maximum setpoint temperatures are100 �F and 450 �F.

When using the right-display scroll keys to adjust asetpoint temperature, the right displayautomatically increments between 0, 175, and 230�C or between 0, 350, and 450 �F.

If you make a mistake while you are changing asetpoint temperature, but you have not yet pressedthe enter key, press the Clear/Reset key to reset theright display to the original temperature.

The melter will exit the setup mode and return to theautomatic scan mode two minutes after the last keyis pressed.

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

When scrolling through component numbers in theleft display, component numbers that are associatedwith unused hose/applicator receptacles are skipped.

The melter stores a record of the last ten changesmade to the setpoint temperatures (and operatingparameters) in the change history log.

Refer to Section 3, Installation,Review Parameter and setpointTemperature Changes

You can save setpoint temperature changes bysimultaneously pressing the 1 key and the Setupkey.

Refer to Section 3, Installation, Saveand Restore Melter Settings

Operation4-24


Entering the Melter Password If the melter is password protected, a valid password must beentered before any setpoint temperature or melter parameter can bechanged.

To enter a melter password


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


The right display begins flashing.

3. Use the keypad to enter the melter password.


One of the following occurs:

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

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

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

The melter will automatically revert back to thepassword-protected mode two minutes afterthe last key press (any key). To force themelter back into the password protected modebefore two minutes has elapsed, press theSetup key twice.

The melter password is created andenabled/disabled during system setup.

Setting Up the Melter in Section 3,Installation

Operation 4-25



Heater key

Pump key

Operation4-26


Using Melter Function Keys The control panel provides the following standard and special function keys:

Standard function keys

� Heater

� Pump

� Setup

Special function keys

� Seven-day clock

� Standby

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

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

When a fault occurs (refer to Monitoring Melter Faults earlier in thissection) the heaters automatically turn off. The heater key is used to turn theheaters back on after correcting a fault condition.

Pump Key Use the pump key to enable, start, and stop the pump. The LED on thepump key is yellow when the pump is enabled (not running) and is greenwhen the pump is running.

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

If any of the inputs are set up to use the pump enable/disable control option,the pump motor will not start until the pump is enabled and the correctvoltage is applied to the input contacts. If the pump is enabled, but the inputvoltage is not present, the pump LED will flash green.

Setup key

Seven-day clock key

Operation 4-27


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

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

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

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

Refer to Appendix B, Operating Parameters, Seven-day Clock, forinformation about setting up the seven-day clock and the standby delta.

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

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

The clock will still operate when the melteris faulting or is in the setup mode.

If F4 appears in the right display when you pressthe clock key, the internal clock function hasfailed.

Section 7, Troubleshooting

Standby key

Operation4-28


Using Melter Function Keys (contd)

Standby Key Use the standby key to manually place the melter into, and take it out of, thestandby mode. Using the standby mode during periods of time whenthe melter is inactive helps conserve energy and allows heated componentsto quickly return to their setpoint temperatures when the melter is onceagain needed.

When the melter is placed into the standby mode, the temperatures ofall components are reduced down from their setpoint temperature by apre-set standby delta. The melter will remain in the standby mode until thestandby key is pressed or the function of one of the operating parameterstakes the melter out of the standby mode.

If the melter was set up to use the manual standby timer(parameter 26), pressing the standby key will place the melter in thestandby mode for the period of time specified by the timer. After the manualstandby time has elapsed, the melter will once again begin heating all of thecomponents to their assigned setpoint temperature.

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

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

The melter may also be set up to automaticallyenter the standby mode using a variety ofoperating parameters.

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

Whenever manual standby is enabled, thestandby LED blinks.

Appendix B, Parameter 26

Melter control switch (on/off)

Operation 4-29


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

To shut the melter down

1. Switch the melter off.

2. Disable the applicators as follows:

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

� Electric applicators: Turn off the applicator driver, pattern controller,or timer.

Operation4-30


Maintenance 5-1


Section 5Maintenance


Table 5-1 describes the preventive maintenance tasks required to keepDuraBlue melters operating within their specified limits and to preventequipment malfunctions. For information about maintaining optionalequipment that was supplied by Nordson, refer to the instructions providedwith the equipment.

If the melter stops operating or is operating incorrectly, refer to Section 6,Troubleshooting, for information about diagnosing common problems andperforming corrective maintenance.

Table 5-1 Preventive Maintenance Tasks

Task Frequency Reference

Relieving system pressure Before performing any maintenancetask that requires opening ahydraulic connection or port

Relieving System Pressure

Cleaning the exterior of the melter,hoses, and applicators

Daily Cleaning the Melter

Replacing the filter � As needed

� When changing the type or grade of

hot melt

Replacing the Filter

Instruction sheet provided withreplacement filter

Cleaning the tank � When changing the type or grade ofhot melt

� When excessive charring occurs

Cleaning the Tank

Pump key

Maintenance5-2


Relieving System Pressure Before disconnecting any hydraulic fitting or opening any pressurized port,always complete the following procedure to safely relieve hydraulic pressurethat may be trapped inside the melter, hoses, and applicators.

To relieve system pressure

1. Press the Pump key to stop the pump.

2. Trigger the applicators until hot melt no longer flows from theapplicators.

Locking Out External Communications WARNING: Disable external inputs and fieldbus communcations with themelter before performing maintenance. Failure to disable external inputs orfieldbus communications with the melter can result in personal injury due tounexpected operation of the melter while performing maintenance.

To lockout external communications with the melter

� Set the control option for operating parameter 14 to 1 (enabled).

Refer to Section 3, Setting Up the Melter, for information about changingoperating parameters.

Maintenance 5-3



Maintenance5-4


Cleaning the Melter To prevent components from overheating due to heat build-up or loss of aircirculation, regularly remove any hot melt that collects on the exterior of themelter, hoses, and applicators.

If hot melt inadvertently spills inside the melter’s interior spaces, the sidepanels can be removed in order to clean out the spilled hot melt.

WARNING: Risk of electricution and fire! Do not clean the melter with adirect stream of water or steam. Use only water or an appropriate,non-flammable cleaning solution that is applied using a clean cloth.Cleaning the melter using a direct stream of water or steam or a flammablesolvent can result in property damage and personal injury, including death.

To clean the exterior of the melter

� Use only cleaning compounds that are compatible with polyester.

� Apply cleaning compounds using a soft cloth.

� Do not use pointed or sharp tools to clean the exterior surface.

To remove and replace the exterior panels

See Figure 5-1.

1. De-energize the melter. Refer to Section 1, Safety.

2. Use a 4 mm (5/32-inch) hex-head wrench to turn the 1/2-turn fastenerlocated in the center of each side panel counterclockwise.

3. Lift the panel out of the melter’s frame.

4. Reverse steps 2 and 3 to reinstall each panel.

Maintenance 5-5


Figure 5-1 Removing the exterior panels

Hot melt flow path

Maintenance5-6


Replacing the Filter Some DuraBlue melters are equipped with a 100-mesh (0.15-mm)disposable hot melt filter. The filter removes debris and char from the hotmelt as it flows from the tank. Hot melt flows from the inside to the outsideof the filter, trapping contaminants inside the filter. There is no need toback-flush or clean the filter.

When the filter reaches the end of its service life, it should be replaced. Thefactors that determine the service life of the filter are:

� the type, grade, and purity of the solid-form hot melt

� the set point temperature of the tank

� the period of time that the hot melt remains in the tank

The filter should also be replaced when making the change to a differenttype or grade of hot melt.

To determine the optimal service life for the filter, monitor and compare thetotal number of hours that the heaters are on with observations of:

� the purity of the dispensed hot melt

� increases in operating pressure

� the frequency of applicator nozzle replacement or cleaning

As an aid to ensuring that the filter is replaced at the end of its service life,the melter is equipped with a service LED that turns on at the end of acustomer-defined time period. Refer to Setting Up the Melter in Section 3,Installation, for information about the service interval time.

Pump key

Loosening the filter

Maintenance 5-7


To replace the filter

1. Relieve the system pressure. Refer to Relieving System Pressure at thebeginning of this section.

2. Use an 8 mm (5/16-inch) hex-head wrench or an adjustable wrench toloosen (counterclockwise) and then remove the filter.

3. Properly dispose of the old filter.

4. Confirm that the O-ring on the new filter is in good condition (100-meshfilter is P/N 1028305).

NOTE: 50- and 150-mesh filters are also available (P/Ns 1021941 and1034720).

5. Screw the filter into the pump body and then tighten the filter to4.5 Nm (40 in.-lb).

6. Resume normal operation.

Pump key

Maintenance5-8


Cleaning the Tank To avoid the problems that can occur when different hot melt materials aremixed or when hot melt char forms in the tank, clean the tank when:

� changing to a different type of hot melt

� excessive char builds up inside the tank

NOTE: The tank cleaning procedures provided in this section require thatan appropriate flushing material be used. The flushing material should becompatible with both the previous adhesive and the new adhesive, ifapplicable.

To clean the tank when changing hot melt

1. Operate the melter normally until the tank is empty.

2. Press the Pump key to stop the pump.

3. Allow the melter to heat or cool to the temperature recommended by themanufacturer of the flushing material.

4. While wearing the appropriate protective equipment, wipe any residualhot melt from the inside of the tank.

5. Add the appropriate type and quantity of flushing material to the tank.

6. Press the Pump key to start the pump.

7. Pump all of the flushing material from the tank and through the hosesand applicators.

8. Return the melter to normal operation and pump a minimum of one tankvolume of fresh hot melt through the tank, hoses, and applicators.

Pump key

Tank strainer

Closing the pressure control valve

Maintenance 5-9


To clean the tank of excessive char

1. Remove the old hot melt and loose char as follows:

a. Operate the melter normally until the tank is empty.

b. Press the Pump key to stop the pump.

c. Allow the melter to heat or cool to the temperature recommended bythe manufacturer of the flushing material.

d. While wearing the appropriate protective equipment, wipe anyresidual hot melt and loose char from the inside of the tank.

e. Remove the tank strainer, clean it with an appropriate flushingmaterial, and then reinstall it.

2. Add the appropriate type and quantity of hot melt solvent to the tank.

3. Disconnect a hose from a applicator and direct the hose into a wastecontainer.

4. Close the pressure control valve by turning the valve all the wayclockwise.

WARNING: Risk of burns! Wear protective equipment and use cautionwhen pumping hot material into a waste container.

5. Press the Pump key to start the pump.

6. When the tank is empty, stop the pump.

7. Fill the tank with fresh hot melt.

8. Repeat steps 5 and 6 to pump all of the hot melt out of the tank.

9. Reconnect the disconnected hose to its applicator.

10. Replace the filter. Refer to Replacing the Filter earlier in this section.

11. Fill the tank with fresh hot melt and then purge all of the hoses andapplicators with the fresh hot melt.

12. Restore the system to normal operation.

Maintenance5-10


Troubleshooting 6-1


Section 6Troubleshooting


This section provides quick-reference information for diagnosing melterfaults and pump operating variables as well as comprehensive melterdiagnostic information that is provided in flowchart format.

If you cannot resolve the problem using the troubleshooting flowchart,contact your Nordson representative for technical assistance.

Safety� Never disconnect cables from, or reconnect cables to, any circuit board

while the melter is energized.

� Before breaking any hydraulic connection, always relieve systempressure. Refer to Relieving System Pressure in Section 5,Maintenance.

� Refer to the safety information provided with optional equipment.

Troubleshooting6-2


Melter Faults Table 6-1 lists the four types of melter faults, potential causes, and expectedcorrective actions.

Table 6-1 Melter Faults


F1/None RTD Heaters turn off

The RTD for thecomponent indicatedhas failed or thecomponent wasdisconnected fromthe melter.

Replace RTD

Check hose/applicatorconnections

See flowchart T.2

F2/NoneUndertemperature Heaters turn off

The actual temperatureof the componentindicated has droppedbelow the undertemperature delta,which was set usingparameter 22.

Check for conditionsthat may cause a dropin ambient temperature

Raise the setpointtemperature of thecomponent

Replace RTD

See flowchart T.2

F3/None Over temperature Heaters turn off

The actual temperatureof the componentindicated has increasedbeyond the overtemperature delta,which was set usingparameter 21.

Replace RTD

See flowchart T.2

F4/1 RAM testMelter stopsfunctioning

Internal RAM failure Replace CPU

F4/2Internal Clocktime


Internal clock failure Replace CPU

F4/4Internal clockbattery backedRAM


Battery-backed RAMfailure

Replace CPU

F4/5Internal clockbattery


Battery-backed RAMbattery dead

Replace CPU

Continued...

Troubleshooting 6-3


Table 6-1 Melter Faults (contd)


F4/6 Analog-to-digitalMelter stopsfunctioning

RTD analog-to-digitalconverter failed

Replace main board orCPU

F4/7Analog-to-digitalcalibration


Failed hose orapplicator

RTD analog-to-digitalconverter could not becalibrated

Replace hose orapplicator. Note: Setsetpoint to zero to avoidF1 fault.

Replace main board orribbon cable, or CPU

F4/8Main boardfeedback


Communication failurebetween main boardand CPU

Replace main board,ribbon cable, or CPU

F4/A ThermostatMelter stopsfunctioning

Tank or manifoldthermostat is open

Replace thermostat,XP6 harness, or mainboard

F4/CExpansion boardconnection


Ribbon cableP/N 1026662 is notconnected at J1 on themain board and/or at J2on the expansion board

Check the ribbon cableconnections and makeconnections asapplicable.

F4/dCommunicationswith optional I/Ocard


Communication failurebetween CPU and theoptional I/O card

Replace the I/O card orCPU

F4/EFieldbuscommunicationsfailure

Alert output (ifoutput option 6 isselected)Melter continues tooperate normally.

Fieldbus card failure. Replace the Fieldbuscard

Troubleshooting6-4


Pump Operating Variables When diagnosing apparent melter malfunctions, it is helpful to understandthe following variables that control the status of the pump—enabled,disabled, running—and the associated indication that is provided by thepump LED.

� Use/activation of a remote input to control the motor

� Use of parameter 8, Automatic Pump On

� Ready status of the melter

� Activation of a switched input (hand-held applicator or footswitch)

� Activation of the pump key

Table 6-2 provides the status of the pump LED for each combination of thepump operating variables.

Troubleshooting 6-5


Table 6-2 Pump Operating Variables

Pump LEDStatus

RemoteMotor Input

Assigned(See Note A)

RemoteMotor Input

Status(See Note B)

AutomaticPump On

(Parameter 8)

Motor Mode(See Note C)

UnitReadyStatus

Pump KeyPress Status(See Note D)

SwitchedInput

Status

MotorRotating

Single greenflash, thenoff

Not Assigned N/A Disabled Standard No Ignored N/A No

Off Not Assigned N/A Disabled Standard Yes Off N/A No

Green Not Assigned N/A Disabled Standard Yes On N/A Yes

Off Not Assigned N/A Enabled Standard No Off N/A No

Yellow Not Assigned N/A Enabled Standard No On N/A No

Off Not Assigned N/A Enabled Standard Yes Off N/A No

Green Not Assigned N/A Enabled Standard Yes On N/A Yes


Not Assigned N/A Disabled Manual No Ignored On/Off No

Off Not Assigned N/A Disabled Manual Yes Off On/Off No

Yellow Not Assigned N/A Disabled Manual Yes On Off No

Green Not Assigned N/A Disabled Manual Yes On On Yes

Off Not Assigned N/A Enabled Manual No Off On/Off No

Yellow Not Assigned N/A Enabled Manual No On On/Off No

Off Not Assigned N/A Enabled Manual Yes Off On/Off No

Green Not Assigned N/A Enabled Manual Yes On On Yes

Yellow Not Assigned N/A Enabled Manual Yes On Off No


Assigned On/Off Disabled Standard No Ignored N/A No

Off Assigned On Disabled Standard Yes Off N/A No

FlashingGreen

Assigned Off Disabled Standard Yes On N/A No

Green Assigned On Disabled Standard Yes On N/A Yes

Off Assigned On/Off Enabled Standard No Off N/A No

Off Assigned On/Off Enabled Standard Yes Off N/A No

Yellow Assigned On/Off Enabled Standard No On N/A No

FlashingGreen

Assigned Off Enabled Standard Yes On N/A No

Green Assigned On Enabled Standard Yes On N/A Yes

NOTE A: If any of Parameters 30−39 are set to 3 or 11, then the remote motor input is assigned.

B: If the remote motor input is assigned, then its status is described in this column.

C: Manual mode is for hand-held applicator and footswitch applications.

D: “On” means the pump key was pressed and the unit accepted the key press. “Ignored” means that thepump key will not respond to a key press.

a

b

Troubleshooting question and actionblocks

a) Question b) Action

Troubleshooting6-6


Using the Troubleshooting Flow Chart The flowchart, which is provided at the end of this section, is designed toassist you in diagnosing and correcting a complete or partial stop in hot meltoutput from the applicators. The chart is organized in a simplequestion-action block format. If your response to a question is yes (Y),continue downward in the chart to the next question or action block. If youresponse is no (N), continue to the right to the next question or action block.All diagnostic paths within the chart end with an action block that specifiesone of the following three courses of action:

� Refer to information provided elsewhere in this manual

� Replace a component

� Complete a diagnostic procedure (DP.x)

To return your melter to service as quickly as possible, the chart is designedunder the assumption that it is preferable to immediately replace a faultyassembly as opposed to conducting detailed diagnostics and repair of theassembly while the melter is out of service.

Use of the chart assumes that the melter is installed correctly and that it isset up to support the current manufacturing process. Refer to Section 3,Installation, for information about installing and setting up the melter.

Troubleshooting Quick-checksBefore using the troubleshooting charts confirm:

� whether or not service was recently performed on the melter or themelter’s settings were recently adjusted.

� the correct voltage plug is installed on terminal J1. Refer to Section 3,Installation, for information about selecting the correct voltage plug.

� external inputs (if used) are functioning properly.

� the standby or clock functions are not turned on (if not required orexpected at the current time).

Troubleshooting 6-7


Returning the Melter Setup to Factory Settings By returning the melter to its factory setting many common melter problemscan be isolated to either a problem with the melter settings or the melterhardware.

To return the melter to its factory settings, simultaneously press and holdthe Setup key and the right-display DOWN arrow key, and then, whileholding down these keys, cycle the melter control switch off and on. Whenthe melter restarts, release the two keys.

Identifying Electrical Components Tables 6-3 through 6-6 provide detailed descriptions of the circuit boardindicators, connection points, and test points that are referred to in thetroubleshooting chart. Figure 6-1 illustrates the location of each of thesecircuit board components.

Table 6-3 Main Board Components

Item Number Type DescriptionIndicators

DS2 Neon Power to tank heater

DS3 Neon Power to pump heater

DS4 Neon Power to 5 VDC and 24 VDC power supplies

DS5 Neon Power to hose/gun 1 heaters

DS6 Neon Power to hose/gun 2 heaters

DS7 Neon Power to motor

DS8 LED Control signal for hose 1 heater

DS9 LED Control signal for applicator 1 heater

DS10 LED Control signal for tank heaters

DS11 LED Control signal for motor

DS12 LED Control signal for applicator 2 heater

DS13 LED Control signal for hose 2 heater

DS14 LED Control signal for pump heater

DS15 LED +5 VDC control voltage present

DS17 LED Trigger closure present at XP3 or XP4

Fuses

F1/F2 −− Tank heaters (10 A, 250 V, fast-acting)

F3/F4 −− 5 VDC and 24 VDC power supplies (2A, 250 V, slow-blow)

F5/F6 −− Pump heater (5 A, 250 V, fast-acting, 5 x 20 mm)

F7/F8 −− Hose/gun 1 heaters (6.3 A, 250 V, 5 x 20 mm)

F9/F10 −− Hose/gun 2 heaters (6.3 A, 250 V, 5 x 20 mm)

F11/F12 −− Motor power (6.3 A, 250 V, 5 x 20 mm)

Continued...

Troubleshooting6-8


Identifying Electrical Components (contd)

Table 6-3 Main Board Components (contd)

Item Number Type DescriptionConnection Points

XT1 Input High-voltage power connection to board

J1 Input/output Signal ribbon cable between main board and CPU

XP1 Output Control voltage to applicator solenoid 1

XP2 Output Control voltage to applicator solenoid 2

XP3 Input Switch closure from hand-held applicator 1

XP4 Input Switch closure from hand-held applicator 2

XP5 Output Control voltage to pump RTD

XP6 Output Control voltage to tank RTD and tank overtemperature thermostat

X1 Output High-voltage to pump heater

X2 Output High-voltage to tank heaters

X3 Output High-voltage to motor

X4 Output High-voltage and control voltage out to hose/gun 1

X5 Output High-voltage and control voltage out to hose/gun 2

X6 Output 24 VDC to expansion board

X7 Input Unit on/off control switch

Test Points

TP7 Contact +5 VDC control voltage present

TP2 Contact Circuit common of low-voltage power supply

Table 6-4 Expansion Board Components


DS1 LED 24 VDC present at X3

Connection Points

XT1 Output AC power into board

XT2 Output AC power out to power module (Hose/Guns 3 and 4)

XT3 Input AC power out to main board

XT7 Output/Input Positions 1–6 are control outputs; Positions 7–14 are control inputs

X1/X2 Jumper Input voltage configuration plugs

X3 Input 24 VDC in from main board

X4 Input/output Ribbon cable connection between expansion board and power module(Hose/gun 3 and 4)

J2 Input/output Ribbon cable connection between expansion board and main board

Troubleshooting 6-9


Table 6-5 Power Module Components


N1 Neon Hose 4 is turned on

N2 Neon Applicator 4 is turned on

N3 Neon Hose 3 is turned on

N4 Neon Applicator 3 is turned on

Connection Points

J1 Input/output Ribbon cable connection between power module and expansion board

J2 Input/output Connection point for the wire harness between hose/gun 4 and the powermodule

J3 Input/output Connection point for the wire harness between hose/gun 3 and the powermodule

J4/J5 Input AC power input from XT2 on the expansion board

Fuses

F1, F2 −− Hose 4 and applicator 4

F3, F4 −− Hose 3 and applicator 3

Troubleshooting6-10


Identifying Electrical Components (contd)

Table 6-6 Part Numbers of Cable and Boards in Figure 6-1

Identifier Component Connection One Connection Two Part NumberB1 Expansion board Not applicable Not applicable 1031201

B2 Main board Not applicable Not applicable 1097997

B3 Power module Not applicable Not applicable 1031202

B4 CPU board Not applicable Not applicable 1028325

C1 Cable Tank heaters X2 (TANK CONN) onmain board

See Note A

C2 Cable Tank thermostat and RTD XP6 (TANK RTD) onmain board

1031234

C3 Cable Pump RTD XP5 (PUMP RTD) onmain board

1031233

C4 Cable Pump heater X1 (PUMP CONN) onmain board

See Note A

C5 Cable Motor bulkheadconnector

X3 (MOTOR CONN) onmain board

1055958 (240V)

NOTE: The motor cable is included with the motorassembly and is not available separately.

C6 Cable XT2 on expansion board J4/J5 on power modules 1027340

C7 Cable XT3 on expansion board XT1 on main board 1027341

C8 Cable X3 (24V SUPPLY) onexpansion board

X6 on main board 1027342

C9 Cable XP1 or XP2 on mainboard

Applicator solenoid 1 or 2 1045269

C10 Cable X4 or X5 (HOSE/GUN)on main board

Hose/gun 1 and 2receptacles on backpanel

1024925 (240V)

Cable J3 or J2 (HOSE/GUN) onpower module

Hose/gun 3 and 4receptacles on backpanel

1024925 (240V)

C11 Cable X7 (PWR SWITCHINPUT) on main board

Control switch onelectrical cabinet door

1026663

C12 Cable XP3 or XP4 (HANDGUNTRIG INPUT) on mainboard

Switch receptacles onback panel

1025746

RC1 Ribbon cable X4 on expansion board J1 on power module 189211

RC2 Ribbon cable J1 on CPU board J1 on main board and J2on expansion board

1026662

RC3 Ribbon cable J3 on CPU board RS232 connector onelectrical cabinet door

1029938

NOTE A: Refer to Heaters in Section 7, Parts, for heater kit part numbers.

Troubleshooting 6-11


Exp

ansi

on

Bo

ard

(B

1)

C6

RC

1

RC

2

C1

C2

C3 C4

C5

C7

C8

C9

C9

C10

C10

Mai

n B

oar

d (

B2)

C11

C12

C12

C10

C10

RC

3

CP

U B

oar

d (

B4)

Po

wer

Mo

du

le (

B3)

Bac

k P

anel

Co

ntr

ol S

wit

ch

Fig

ure

6-1

Loca

tion

of e

lect

rical

com

pone

nts

(ref

er to

Tab

le 6

-6 fo

r pa

rt n

umbe

rs)

Troubleshooting6-12


Thi

s pa

ge in

tent

iona

lly le

ft bl

ank.



+

−

No

ad

hes

ive

ou

tpu

t fr

om

on

e o

r m

ore

ap

plic

ato

rs

Go

toT.

3

+

−

+

−

Do

dash

es a

ppea

r in

bot

hth

e le

ft an

d rig

ht d

ispl

ay?

Turn

the

cont

rol s

witc

h on

.D

oes

the

mel

ter

star

t?

Sto

p.

+

−

Upl

oad

new

sof

twar

e.

Ref

er to

App

endi

x C

.

+

−

Do

the

wor

ds U

P L

OA

Dap

pear

acr

oss

the

disp

lays

?

Is th

e w

ire h

arne

ss th

at is

conn

ecte

d to

term

inal

X7

on th

e m

ain

boar

d lo

ose?

Turn

the

cont

rol s

witc

h of

f,se

cure

the

harn

ess

tote

rmin

al X

7, a

nd th

en tu

rnth

e co

ntro

l sw

itch

back

on

+

−

Is th

e fa

ult L

ED

illum

inat

ed?

Rep

lace

the

cont

rol s

witc

h.

P/N

101

7947

.

Has

glu

e ou

tput

sto

pped

from

all

appl

icat

ors?

+

−

Is th

e re

ady

LED

illum

inat

ed?

+

−

Is th

e co

ntro

l pan

elill

umin

ated

?G

o to

T.1

Go

toT.

5

Go

toT.

4

Du

raB

lue

Tro

ub

lesh

oo

tin

gC

har

ts

Sta

rt

Go

toT.

2

Troubleshooting6-14




Con

trol

pan

el is

not

illu

min

ated

T.1

+

−

+

−

Is th

ere

pow

er a

t ter

min

albl

ock

XT

1 on

the

expa

nsio

n bo

ard?

See

Fig

ure

6-1.+

−

Is th

e po

wer

dis

conn

ect

switc

h th

at is

ser

ving

the

mel

ter

turn

ed o

n?

Is th

e co

rrec

t vol

tage

plu

gse

cure

ly a

ttach

ed to

conn

ecto

rs X

1/X

2 on

the

mai

n bo

ard?

Ref

er to

Tabl

e 3-

4, S

ectio

n3,

Inst

alla

tion.

+

−

Is th

ere

pow

er a

t ter

min

alX

T1

on th

e m

ain

boar

d?

Che

ck th

e pl

ant w

iring

betw

een

the

disc

onne

ctsw

itch

and

the

mel

ter.

Turn

the

disc

onne

ct s

witc

hon

.

Rep

lace

/sec

ure

the

volta

ge p

lug.

Che

ck th

e w

ire h

arne

ssbe

twee

n co

nnec

tor

XT

3 on

the

expa

nsio

n bo

ard

and

term

inal

blo

ck X

T1

on th

em

ain

boar

d.

See

Fig

ure

6-1.

+

−

Hav

e fu

ses

F3/

F4

on th

em

ain

boar

d bl

own?

See

Fig

ure

6-1.

Rep

lace

bot

h fu

se F

3 an

dfu

se F

4.

P/N

103

1203

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

+

−

Is th

e po

wer

on

the

plan

tsi

de o

f the

dis

conn

ect

switc

h th

at is

ser

ving

the

mel

ter?

Che

ck/r

epai

r th

e pl

ant

wiri

ng.

Go

to T

.1.1

+

−

Is in

dica

tor

DS

4 on

the

mai

n bo

ard

illum

inat

ed?

See

Fig

ure

6-1.

Troubleshooting6-16




T.1.

1

+

−

+

−

Is th

e gr

een

pow

er L

ED

on

the

CP

U b

oard

illum

inat

ed?

See

Fig

ure

6-1.+

−

Is th

e vo

ltage

acr

oss

TP

7(+

) an

d T

P2

(−)

on th

em

ain

boar

d be

twee

n 4.

75an

d 5.

25 V

DC

?

See

Fig

ure

6-1.

Is th

e vo

ltage

acr

oss

TP

2(+

) an

d T

P4

(−)

on th

eC

PU

boa

rd b

etw

een

4.75

and

5.25

VD

C?

See

Fig

ure

6-1. +

−

Is th

e re

d C

PU

faul

t LE

Dill

umin

ated

?

See

Fig

ure

6-1.

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

Che

ck th

e rib

bon

cabl

e or

repl

ace

the

CP

U b

oard

.

CP

U -

P/N

102

8325

Rep

lace

the

CP

U b

oard

.

P/N

102

8325

+

−

+

−

Doe

s ch

angi

ng th

e m

ain

boar

d co

rrec

t the

pro

blem

?

P/N

109

7997

Sec

ure

or r

epla

ce th

eca

ble.

P/N

102

6662

Is th

e rib

bon

cabl

ebe

twee

n th

e m

ain

boar

dan

d th

e C

PU

boa

rd lo

ose

or v

isib

ly d

amag

ed?

See

Fig

ure

6-1.

Sec

ure

or r

epla

ce th

eca

ble.

P/N

102

6662

+

−

Con

tact

Nor

dson

for

tech

nica

l ass

ista

nce.

Rep

lace

the

CP

U b

oard

.

P/N

103

1179

Doe

s ch

angi

ng th

e C

PU

boar

d co

rrec

t the

pro

blem

?

P/N

102

8325

Sto

p.

+

−

Is L

ED

DS

15 o

n th

e m

ain

boar

d ill

umin

ated

?

See

Fig

ure

6-1.

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

+

−

Is th

e rib

bon

cabl

ebe

twee

n th

e m

ain

boar

dan

d th

e C

PU

boa

rd lo

ose

or v

isib

ly d

amag

ed?

See

Fig

ure

6-1.

Con

trol

pan

el is

not

illum

inat

ed >

Dis

conn

ect s

witc

h is

on

>

DS

4 is

illu

min

ated

Troubleshooting6-18




Fau

lt LE

D is

illu

min

ated

T.2

?

+

−

Is th

e ta

nk k

ey L

ED

illum

inat

ed?

Con

firm

that

the

RT

D h

asfa

iled.

+

−

Go

toT.

2.1

+

−

Are

all

of th

eap

plic

ator

-to-

hose

and

hose

-to-

mel

ter

elec

tric

alco

rdse

ts s

ecur

ely

conn

ecte

d?

Doe

s th

e fa

ult r

eocc

ur if

you

mov

e th

e fa

ultin

gho

se/a

pplic

ator

pai

r to

akn

own

good

hose

/app

licat

or c

onne

ctor

?

Rep

lace

the

hose

or

repl

ace

the

appl

icat

orR

TD

.

Ref

er to

the

hose

or

appl

icat

or m

anua

l.

Go

toT.

2.2

Sec

ure

the

elec

tric

alco

nnec

tors

and

then

pre

ssth

e re

set k

ey.

Con

tact

Nor

dson

for

tech

nica

l ass

ista

nce.

Rec

ord

the

faul

t cod

esin

dica

ted

in b

oth

the

left

and

right

dis

play

s an

d th

enco

ntac

t Nor

dson

for

tech

nica

l ass

ista

nce.

+

−

Is a

n F

1 (R

TD

) fa

ult

indi

cate

d in

the

right

disp

lay?

+

−

Is a

n F

2(u

nder

tem

pera

ture

) fa

ult

indi

cate

d in

the

right

disp

lay?

+

−

Is a

n F

3 (o

vert

empe

ratu

re)

faul

t ind

icat

ed in

the

right

disp

lay?

+

Is a

n F

4 fa

ult i

ndic

ated

inth

e rig

ht d

ispl

ay?

Troubleshooting6-20




+

−

+

−

Res

et t

he

mel

ter

and

tu

rn t

he

hea

ters

bac

k o

n

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

T.2.

1

Go

toT.

2.3

Was

hot

mel

t rec

ently

adde

d to

the

tank

?

? Allo

w th

e ta

nk to

rea

chse

tpoi

nt te

mpe

ratu

re.

Sec

ure

the

loos

e co

rdse

tan

d th

en p

ress

the

Res

etke

y.

+

−

Rep

air

the

hose

or

appl

icat

or c

ords

et. R

efer

toth

e ho

se o

r ap

plic

ator

man

ual.

Is th

e po

wer

indi

cato

r fo

rth

e af

fect

ed h

ose/

gun

illum

inat

ed?

See

Fig

ure

6-1. +

Rep

lace

the

mai

n bo

ard

(hos

e/gu

n 1

or 2

affe

cted

)or

rep

lace

the

pow

erm

odul

e (h

ose/

gun

3 or

4).

Mai

n bo

ard

P/N

109

7997

Pow

er m

od. P

/N 1

0312

02

+

−

Is th

e vo

ltage

acr

oss

the

fuse

pai

r fo

r th

e af

fect

edho

se/g

un c

orre

ct?

See

Fig

ure

6-1

and

refe

r to

Tabl

e 6-

3.

Rep

lace

the

hose

or

repl

ace

the

appl

icat

orR

TD

. Ref

er to

the

hose

or

appl

icat

or m

anua

l.

Cor

rect

the

fact

ory

volta

geor

rep

lace

the

hose

/app

licat

or w

ith a

prop

erly

rat

edho

se/a

pplic

ator

.

+

−

Are

any

one

of i

ndic

ator

sD

S2,

DS

3, o

r D

S7

on th

em

ain

boar

d ill

umin

ated

?

See

Fig

ure

6-1.

Che

ck/r

epla

ce fu

se p

airs

F7/

F8

or F

9/F

10 o

n th

em

ain

boar

d.

P/N

103

1203

See

Fig

ure

6-1.

+

−

Is th

e ta

nk k

ey L

ED

illum

inat

ed?

+

−

Is th

e af

fect

ed a

pplic

ator

or

hose

cor

dset

loos

e? (

The

tank

or

the

hose

key

LE

Dis

illu

min

ated

.)

+

−

Are

the

hose

or

appl

icat

orco

rdse

t pin

s be

nt, l

oose

, or

corr

oded

?

Doe

s th

e fa

ult r

eocc

ur if

you

mov

e th

e fa

ultin

gho

se/a

pplic

ator

pai

r to

akn

ow g

ood

hose

/app

licat

orco

nnec

tor?

Che

ck th

e op

erat

ion

of th

epo

wer

rel

ay o

r th

erm

osta

t.

Troubleshooting6-22




+

−

Res

et t

he

mel

ter

and

tu

rn t

he

hea

ters

bac

k o

n

Fau

lt LE

D is

illu

min

ated

>

F3

faul

t exi

sts

T.2.

2

Is th

ere

a D

C d

rive

near

the

mel

ter?

? Sto

p.

+

−

Doe

s in

stal

ling

an R

Csn

ubbe

r on

the

DC

driv

ean

d re

setti

ng th

e m

elte

rcl

ear

the

faul

t?

P/N

332

182

Sto

p.

+

−

Doe

s el

ectr

ical

ly g

roun

ding

the

mel

ter’s

cha

ssis

to th

epa

rent

mac

hine

/sup

port

and

then

res

ettin

g th

em

elte

r cl

ear

the

faul

t?

Cor

rect

the

setp

oint

tem

pera

ture

of t

heco

mpo

nent

or

incr

ease

the

over

tem

pera

ture

set

poin

t.

Inst

all a

n R

C s

nubb

er o

nth

e m

elte

r.

P/N

332

182

+

−

Is th

e ta

nk/p

ump

TR

IAC

oper

atin

g pr

oper

ly?

Rep

lace

the

grid

or

rese

rvoi

r R

TD

.

P/N

103

1234

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

Go

toT.

2.4

+

−

Is m

ore

than

one

com

pone

nt o

verh

eatin

g?(C

heck

the

actu

alte

mpe

ratu

re o

f the

faul

ting

com

pone

nt.)

+

−

Is th

e ta

nk L

ED

illum

inat

ed?

+

−

Was

the

setp

oint

tem

pera

ture

of t

he fa

ultin

gho

se/a

pplic

ator

just

redu

ced?

Troubleshooting6-24




+

−

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

>

Tank

key

LE

D is

illu

min

ated

>

No

hot m

elt w

as r

ecen

tly a

dded

to th

eta

nkT.2.

3?

+

−

Is th

e re

sist

ance

cor

rect

for

the

tank

hea

ters

(2)

and

the

pum

p he

ater

(1)

?R

efer

to H

eate

rS

peci

ficat

ions

in S

ectio

n 8

for

resi

stan

ce v

alue

s.

+

−

Is th

e vo

ltage

acr

oss

the

dow

nstr

eam

sid

e of

fuse

sF

1 an

d F

2 on

the

mai

nbo

ard

180−

265

VA

C?

See

Fig

ure

6-1.

Are

the

tank

and

pum

pT

RIA

CS

func

tioni

ngpr

oper

ly?

?C

onta

ct N

ords

on fo

rte

chni

cal a

ssis

tanc

e.

+

−

Are

the

tank

and

man

ifold

RT

Ds

func

tioni

ngpr

oper

ly?

Rep

lace

the

tank

or

the

pum

p he

ater

.

Ref

er to

Sec

tion

7, P

arts

.

Che

ck/c

orre

ct h

ouse

volta

ge.

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

Rep

lace

the

mal

func

tioni

ng R

TD

.

Tank

- P

/N 1

0312

34P

ump

- P

/N 1

0312

33

Sto

p.

+

−

Doe

s re

plac

ing

fuse

s F

1an

d F

2 on

the

mai

n bo

ard

and

then

res

ettin

g th

em

elte

r cl

ear

the

faul

t?

P/N

102

8329

Rep

lace

the

mai

n bo

ard.

P/N

109

7997

+

−

Are

any

of t

he in

dica

tors

DS

2, D

S3,

or

DS

7 on

the

mai

n bo

ard

illum

inat

ed?

See

Fig

ure

6-1.

+

−

Is th

e po

wer

indi

cato

r fo

rth

e af

fect

ed h

ose/

gun

illum

inat

ed?

See

Fig

ure

6-1.

Che

ck th

e op

erat

ion

of th

epo

wer

rel

ay o

r th

eth

erm

osta

t.

Troubleshooting6-26




Fau

lt LE

D is

illu

min

ated

>

An

F3

faul

t exi

sts

on a

hos

e or

ap

plic

ator

>

The

set

poin

t tem

pera

ture

was

not

chan

ged

T.2.

4

Sto

p.R

epla

ce th

e m

ain

boar

d.

P/N

109

7997

+

−

Doe

s re

plac

ing

the

mai

nbo

ard

and

rese

tting

the

mel

ter

clea

r th

e fa

ult

Rep

lace

the

CP

U b

oard

.

P/N

103

1179

+

−

Doe

s th

e fa

ult c

lear

if y

ousw

itch

the

faul

ting

hose

/gun

pai

r to

a k

now

ngo

od h

ose/

gun

conn

ecto

ran

d th

en r

eset

the

mel

ter?

+

−

Doe

s th

e fa

ult c

lear

if y

oure

plac

e ju

st th

e ho

se o

rju

st th

e ap

plic

ator

RT

Dan

d th

en r

eset

the

mel

ter?

+

−

Hav

e LE

Ds

DS

8/D

S9

orD

S12

/DS

13 o

n th

e m

ain

boar

d st

oppe

d fla

shin

g?

See

Fig

ure

6-1.

Sto

p.

Rep

lace

the

mai

n bo

ard

(hos

e/gu

n 1

or 2

affe

cted

)or

rep

lace

the

pow

erm

odul

e (h

ose/

gun

3 or

4).

Mai

n bo

ard

P/N

109

7997

Pow

er m

od. P

/N 1

0312

02

Troubleshooting6-28




+

−

No

faul

ts >

Rea

dy L

ED

is n

ot il

lum

inat

ed

T.3

Doe

s th

e rig

ht d

ispl

ayin

dica

te th

at c

ompo

nent

sar

e st

ill h

eatin

g up

?

? Wai

t for

all

com

pone

nts

tore

ach

setp

oint

tem

pera

ture

.

+

−

Wai

t the

the

inpu

t to

initi

ate

the

heat

ers

or u

se th

eH

eate

rs k

ey to

man

ually

turn

the

heat

ers

on.

Is th

e re

ady

dela

y co

untin

gdo

wn?

Wai

t for

the

read

y de

lay

toco

unt d

own.

Ref

er to

App

endi

x B

,pa

ram

eter

4.

+

−

The

cur

rent

clo

ck s

ched

ule

has

the

heat

ers

turn

ed o

ff.

Is th

e st

andb

y LE

D o

n?

The

mel

ter

is in

the

stan

dby

mod

e.

Ref

er to

Sta

ndby

Key

inS

ectio

n 4,

Ope

ratio

n.

Con

tact

Nor

dson

for

tech

nica

l ass

ista

nce.

+

−

Is th

e H

eate

rs k

ey L

ED

illum

inat

ed?

+

−

Is a

rem

ote

inpu

t bei

ngus

ed to

con

trol

the

heat

ers?

+

−

Is th

e cl

ock

LED

on?

Pre

ss th

e H

eate

rs k

ey to

turn

the

heat

ers

on.

?

+

−

Rep

lace

the

tank

or

the

pum

p he

ater

.

Ref

er to

Sec

tion

7, P

arts

.

Is th

e re

sist

ance

cor

rect

for

the

tank

hea

ters

(2)

and

the

pum

p he

ater

(1)

?R

efer

to H

eate

rS

peci

ficat

ions

in S

ectio

n 8

for

resi

stan

ce v

alue

s.

Troubleshooting6-30




No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll ap

plic

ator

s

T.4

Go

toT.

4.2

The

mel

ter

is w

aitin

g fo

r an

exte

rnal

inpu

t bef

ore

the

mot

or w

ill s

tart

.

Sto

p.

+

−

Doe

s th

e m

otor

sta

rt if

you

activ

ate

the

appl

icat

ortr

igge

r or

foot

sw

itch?

+

−

Is th

e se

tpoi

nt te

mpe

ratu

reof

the

tank

bel

ow th

ete

mpe

ratu

rere

com

men

ded

by th

em

anuf

actu

rer

of th

e ho

tm

elt?

+

−

Is th

e ap

plic

ator

trig

ger

cord

set o

r fo

ot s

witc

hpr

oper

ly c

onne

cted

to th

eba

ck o

f the

mel

ter.

Ref

er to

Con

nect

ing

Hos

es a

ndA

pplic

ator

s in

Sec

3,

Inst

alla

tion.

Adj

ust t

he s

etpo

int

tem

pera

ture

of t

he ta

nk.

Con

nect

the

cord

set o

rfo

ot s

witc

h.

Go

toT.

4.1

+

−

Is th

e m

otor

run

ning

?

+

−

Is th

e pu

mp

key

LED

flash

ing

yello

w?

+

−

Is th

e pu

mp

key

LED

illum

inat

ed y

ello

w, b

ut n

otfla

shin

g?

+

Pre

ss th

e pu

mp

key

toen

able

the

pum

p.

Troubleshooting6-32




No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll ap

plic

ator

s >

Mot

or is

not

turn

ing

>

All

mot

or s

tart

con

ditio

ns a

re c

orre

ct >

Tank

set

poin

t tem

pera

ture

is c

orre

ct

T.4.

1

?

+

−

Is th

e m

otor

exc

essi

vely

hot?

+

−

Is th

e el

ectr

ical

har

ness

that

exi

ts th

e m

otor

junc

tion

box

conn

ecte

d to

the

rece

ptac

le u

nder

neat

hth

e m

elte

r?

Rep

lace

the

driv

eas

sem

bly.

Ref

er to

Sec

tion

7, P

arts

,fo

r dr

ive

asse

mbl

y pa

rtnu

mbe

rs.

+

−

Doe

s sw

appi

ng th

e m

ain

boar

d w

ith a

kno

wn

good

boar

d co

rrec

t the

pro

blem

?

Con

nect

the

harn

ess.

Sto

p.C

onta

ct N

ords

on fo

rte

chni

cal a

ssis

tanc

e.

+

−

Is in

dica

tor

DS

7 on

the

mai

n bo

ard

illum

inat

ed?

Rep

lace

fuse

s F

11 a

ndF

12.

P/N

103

1203

?

+

−

Allo

w th

e m

otor

to c

ool

and

then

aut

omat

ical

lyst

art o

nce

its in

tern

alth

erm

osta

t res

ets.

Doe

sth

is c

orre

ct th

e pr

oble

m?

Sto

p.

?

+

−

Is th

e pu

mp

oper

atin

gco

rrec

tly?

Rep

lace

the

pum

p.

Ref

er to

Sec

tion

7, P

arts

,fo

r pu

mp

part

num

bers

.

Troubleshooting6-34




No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll ap

plic

ator

s >

Mot

or is

turn

ing

T.4.

2

Fill

the

tank

.

Rep

air

the

pum

p or

man

ifold

sea

ls.

Ref

er to

Sec

tion

7, P

arts

,fo

r se

rvic

e ki

ts.

+

−

Is th

e di

rect

ion

of th

epu

mp

shaf

t rot

atio

nco

rrec

t?

+

−

Is th

e ta

nk is

olat

ion

valv

ecl

osed

?

See

Fig

ure

6-2.

Turn

the

valv

eco

unte

rclo

ckw

ise

to o

pen.

+

−

Is th

e pr

essu

re c

ontr

olva

lve

turn

ed fu

llyco

unte

rclo

ckw

ise

(no

pres

sure

)?

Adj

ust t

he p

ress

ure

cont

rol

valv

e.

Ref

er to

Adj

ustin

g th

eP

ress

ure

Con

trol

Val

ve in

Sec

tion

3, In

stal

latio

n.

+

−

Che

ck a

nd c

lean

or

repl

ace

the

pres

sure

cont

rol v

alve

.

Ref

er to

Sec

tion

7, P

arts

.

Is th

e fil

ter

exce

ssiv

ely

dirt

y?

Ref

er to

Rep

laci

ng th

eF

ilter

in S

ectio

n 5,

Mai

nten

ance

.

Rep

lace

the

filte

r.

50-m

esh

P/N

102

1941

100-

mes

h P

/N 1

0283

0520

0-m

esh

P/N

102

1918

+

−

Is th

e ta

nk e

mpt

y?

+

−

Is th

e pu

mp

inpu

t sha

fttu

rnin

g?R

epla

ce th

em

otor

-to-

pum

p co

uplin

g or

repl

ace

the

shaf

t key

.

−

+

Is th

ere

hot m

elt l

eaka

gear

ound

the

pum

p or

man

ifold

?

Rep

lace

the

capa

cito

r.R

efer

to th

e m

otor

par

tslis

t in

Sec

tion

7, P

arts

, for

the

corr

ect c

apac

itor

part

num

ber.

Troubleshooting6-36


Thi

s pa

ge in

tent

iona

lly le

ft bl

ank.



No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m s

ome

appl

icat

ors

T.5

?The

hea

ters

in th

e af

fect

edho

se/a

pplic

ator

may

be

turn

ed o

ff by

the

rem

ote

inpu

t.

−

+

Is th

e m

elte

r se

t up

for

are

mot

e ho

se/a

pplic

ator

inpu

t?

?

Che

ck th

e op

erat

ion

of th

eap

plic

ator

, app

licat

orso

leno

id, a

nd a

pplic

ator

driv

er. R

efer

to th

eap

prop

riate

equ

ipm

ent

man

uals

.

+

−

Is th

e sw

itchi

ng d

evic

epr

oper

ly c

onne

cted

to th

eba

ck o

f the

mel

ter?

Ref

er to

Con

nect

ing

Hos

esan

d A

pplic

ator

s in

Sec

tion

3.

+

−

Are

you

usi

ng a

sw

itche

dha

nd-h

eld

appl

icat

or o

r a

foot

sw

itch

to tr

igge

r th

epu

mp?

Con

nect

sw

itchi

ng d

evic

e.

+

−

Is th

e se

tpoi

nt te

mpe

ratu

reof

the

affe

cted

hose

/app

licat

or w

ithin

the

tem

pera

ture

ran

gere

com

men

ded

by th

e ho

tm

elt m

anuf

actu

rer?

Adj

ust t

he s

etpo

int

tem

pera

ture

.

+

−

Is th

e af

fect

edho

se/a

pplic

ator

at i

tste

mpe

ratu

re s

etpo

int?

?

+

−

Is th

e sy

stem

hyd

raul

icpr

essu

re c

orre

ct (

allo

win

gth

e ap

plic

ator

sol

enoi

ds to

oper

ate

prop

erly

)?

Cor

rect

the

syst

empr

essu

re.

Troubleshooting6-38


Thi

s pa

ge in

tent

iona

lly le

ft bl

ank.



1

2

Figure 6 2 Opening the tank isolation valve

1. Open2. Closed

Troubleshooting6-40


Parts 7-1


Section 7Parts

Using the Illustrated Parts List The parts lists provided in this section are organized into the followingcolumns:

Item—Identifies illustrated parts that are available from NordsonCorporation.

Part—Provides the Nordson Corporation part number for each saleablepart shown in the illustration. A series of dashes in the parts column(- - - - - -) means the part cannot be ordered separately.

Description—Provides the part name, as well as its dimensions andother characteristics when appropriate. Bullets in the description,indicate the relationships between assemblies, subassemblies, andparts.

Quantity—The quantity required per unit, assembly, or subassembly.The code AR (As Required) is used if the part number is a bulk itemordered in quantities or if the quantity per assembly depends on theproduct version or model.

NOTE: Illustrations of the model D16 melter are used throughout thissection to represent all DuraBlue melters.

Parts7-2


Front Panel Service Kits

Figure 7-1 Front panel service kit parts

Item Part Description Quantity Note— 1031178 Service Kit, panel, front, D10/D16, with tags —

1 - - - - - - � Panel, front 1

2 1017947 Switch, rocker, SPsT, 250 V, 16 A 1

Parts 7-3



Parts7-4


Electrical Component Service Kits Electrical components include circuit boards, fuses, thermostats, heaters,RTDs, and ribbon cables.

Circuit Boards

Figure 7-2 Circuit board service kit parts

Parts 7-5


Item Part Description Quantity Note— 1028325 Service kit, board, display/central processing unit

(CPU)— A

1 - - - - - - � PCA, display/CPU 1

NS - - - - - - � Stand-off, hex, M3 x 8 mm 6

NS - - - - - - � Washer, lock, M3 6

— 1122064 Service kit, main PCA, IP54 & IP32 — A, B

2 - - - - - - � Board, with heat-sink 1

— 1031201 Service kit, board, expansion — A

3 - - - - - - � PCA , expansion 1

— 1031202 Service kit, PCA, power module, 4-channel — A

4 - - - - - - � PCA, power module, 4-channel, 240 V 1

5 - - - - - - Capacitor 1 C

NOTE A: Circuit board service kits include an anti-static wrist strap.

B: For fuses, see Figure 7-3.

C: For the part numbers of kits that include the capacitor, refer to Motor in Drive Assembly Service Kitslater in this section.

Parts7-6


Fuses

Figure 7-3 Fuse service kit parts

Item Part Description Quantity Note— 1031203 Service kit, fuses, main board —

1 105419 � Fuse, fast, 10 A, 250 VAC, 1/4 x 11/4 in., F1−F2 2

2 939955 � Fuse, slow, 2 A, 250 VAC, 5 x 20 mm, F3−F4 2

3 - - - - - - � Fuse, fast, 5 A, 250 VAC, 5 x 20 mm, F5−F6 2

4 939683 � Fuse, 6.3 A, 250 VAC, 5 x 20 mm, F7−F12 6

Parts 7-7


Thermostat

Item Part Description Quantity NoteNS 1028321 Service kit, thermostat, —

NS - - - - - - � Thermostat, 500-degree, open-on-rise 1

NS - - - - - - � Screw, M4 x 6 2

NS - - - - - - � Compound, thermal, 1 gram 1

NS: Not Shown

RTDs

Item Part Description Quantity NoteNS 1031233 Service kit, RTD, pump — A

NS 1031234 Service kit, RTD, tank — A

NOTE A: All RTD service kits include thermal compound.

NS: Not Shown

Heaters

Item 240V Part Description Quantity NoteNS 1031228 Service kit, heater, pump, 7.8 cc/rev — A

NS 1031229 Service kit, heater, tank, D10 — A

NS 1031230 Service kit, heater, tank, D16 — A

NOTE A: All heater service kits include thermal compound.

NS: Not Shown

Cables and Harnesses Refer to Identifying Electrical Components in Section 6, Troubleshooting, foran illustration and part numbers for cables and harnesses.

Parts7-8


Tank Strainer

1

Figure 7-4 Tank strainer

Item Part Description Quantity Note1 1028334 Strainer, tank, D10 1

1 1028336 Strainer, tank, D16 1

Parts 7-9


Drive Assembly Service Kits Table 7-1 lists the motor, pump, and manifold service kits associated witheach melter part number. The seven-digit part number for your melter isprovided on the ID plate, which is located on the front of the melter.

Standard melters are recommended for use in applications with operatingtemperatures up to 191 �C (375 �F). Melters and parts designated as “PA”are recommended for use in product assembly applications with operatingtemperatures greater than 191 �C (375 �F). PA-type O-rings provideexceptionally high chemical and temperature resistance.

Table 7-1 Drive Assembly Components (Standard)

Melter P/N Motor P/N Pump P/N Manifold P/N Complete DriveAssembly P/N

1026756 1056358 1050729 1031208 1031217

1026757 1056358 1050729 1031208 1031217

1026758 1031212 1050729 1031208 1031219

1026759 1031212 1050729 1031208 1031219

1026762 1056358 1050729 1031208 1031217

1026763 1056358 1050729 1031208 1031217

1026764 1031212 1050729 1031208 1031219

1026765 1031212 1050729 1031208 1031219

1039107 1031213 1050729 1043464 1043469

Table 7-2 Drive Assembly Components (PA)

Melter P/N Motor P/N Pump P/N Manifold P/N Complete DriveAssembly P/N

1069739 1056358 1067875 1069148 —

1069740 1031212 1067875 1069148 —

1069741 1056358 1067875 1069148 —

1069742 1031212 1067875 1069148 —

1069743 1031212 1067875 1067878 —

Parts7-10


Motor

WHITE

ORANGE

YELLOW

BROWN

1

3

2

GRN/YEL

6

RED

WHITE

BLACK

RED

BLUE7

4

BLACK

Figure 7-5 1/6 and 1/4 hp motor service kit parts

Parts 7-11


Item Part Description Quantity Note1 1056358 Motor, 1/6 hp, with pigtail, 55.3 rpm 1

NS 1056056 � Capacitor, 18 F, 240 VAC 1 A

1 1031212 Motor, 1/4 hp, with pigtail, 89 rpm 1

NS - - - - - - � Capacitor, 25 F, 440 VAC 1 A

1 1031213 Motor, 1/4 hp, with pigtail, 131 rpm 1

NS - - - - - - � Capacitor, 25 F, 440 VAC 1 A

NOTE A: For the location of the capacitor, see Figure 7-2.

NS: Not Shown

Parts7-12


Pump

Figure 7-6 Pump service kit parts

Parts 7-13


Item StandardPart

PA Part(Note A) Description Quantity Note

— 1050729 1067875 Service kit, pump, 7.8 cc/rev —

1 - - - - - - - - - - - - � Pump 1

2 1033445 1033445 � Key, machine drive, 0.1875 x .70 in. 1

3 - - - - - - - - - - - - � O-ring, -118, Viton, 0.862 x 0.103 in. 1

4 - - - - - - - - - - - - � O-ring, -116, 0.737 x 0.103 in. 1

5 - - - - - - - - - - - - � O-ring, -123, 1.174 x 0.103 in. 1

NS - - - - - - - - - - - - � Screw, hex, cap, M8 x 90, 304stainless-steel

2 B

NS - - - - - - - - - - - - � Washer, flat, narrow, M8 2 B

NS - - - - - - - - - - - - � Grease, high-temperature, 0.50 oz 1

— 1031232 1067874 Service kit, pump O-rings —

3 940024 1047564 � O-ring, -118, 0.862 x 0.103 in. 1

4 941161 1047563 � O-ring, -116, 0.737 x 0.103 in. 1

5 941250 1067551 � O-ring, -123, 1.174 x 0.103 in. 1


— 1037757 1067876 Service kit, seal, pump, 7.8 cc/rev —

NS - - - - - - - - - - - - � Shaft, pump, 7.8 cc 1

NS - - - - - - - - - - - - � Retaining ring, external, 75 2

NS - - - - - - - - - - - - � Pin, dowel, 0.185/0.184 dia. x 0.438long

1

NS - - - - - - - - - - - - � Seal, spring, 1/8 x 1 x 0.250 3

NS - - - - - - - - - - - - � Washer, 0.989 x 0.789 x 0.040 1

NS - - - - - - - - - - - - � Retaining ring, internal, 100, inverted 1

NS - - - - - - - - - - - - � O-ring,-147, 2.675 x 0.103 in. 1

NS - - - - - - - - - - - - � O-ring,-116, 0.737 x 0.103 in. 1

NS - - - - - - - - - - - - � O-ring, -123, 1.174 x 0.103 in. 1

NS - - - - - - - - - - - - � O-ring, -118, 0.862 x 0.103 in. 1

NS - - - - - - - - - - - - � Grease, high-temperature, 0.50 oz. 1

NS - - - - - - - - - - - - � Key, machine drive, 0.1875 x 0.70 1

NS - - - - - - - - - - - - � Tool, seal insertion 1

NOTE A: Parts designated as “PA” are recommended for use in product assembly applications with operatingtemperatures greater than 191 �C (375 �F). PA-type O-rings provide exceptionally high chemical andtemperature resistance.

B: Refer to Drive Assembly (Complete).

NS: Not Shown

Parts7-14


Manifold

Figure 7-7 Manifold service kit parts (filtered manifold shown)

Parts 7-15


Item StandardPart

PA Part(Note A) Description Quantity Note

— 1031208 1069148 Service kit, manifold, 4-port, 1100 psi,filtered

—

— — 1067878 Service kit, manifold, 4-port, 1100 psi,non-filtered

—

— 1043464 — Service kit, manifold, 4-port, 600 psi,filtered

—

1 - - - - - - - - - - - - � Manifold assembly 1

2 - - - - - - - - - - - - � O-ring, -116, 0.737 x 0.103 in. 1

3 - - - - - - - - - - - - � O-ring, -123, 1.174 x 0.103 in. 1

4 - - - - - - - - - - - - � Screw, hex, cap, M8 x 90, 304stainless-steel

2

5 - - - - - - - - - - - - � Washer, flat, narrow, M8 2

6 - - - - - - - - - - - - � Connector, with O-ring, hose, 9/16-18 2

NS - - - - - - - - - - - - � Connector, 90 degree, 9/16-18 x9/16-18

1


— 1031222 1067877 Service kit, valve, pressure control,1100 psi

—

7 - - - - - - - - - - - - � Valve, PCV, 1100 psi 1

— 1031221 1071502 Service kit, valve, pressure control,600 psi

—

7 - - - - - - — � Valve, PCV, 600 psi 1

8 1031235 — Filter, with O-ring, 50-mesh 1 B

1028305 1070899 Filter, with O-ring, 100-mesh 1 B

1031236 — Filter, with O-ring, 200-mesh 1 B

NS - - - - - - - - - - - - � O-ring, Viton, 3/4 in. tube 1

NS - - - - - - - - - - - - � Lubricant, Parker, high-temperature 1

NOTE A: Parts designated as “PA” are recommended for use in product assembly applications with operatingtemperatures greater than 191 �C (375 �F). PA-type O-rings provide exceptionally high chemical andtemperature resistance.

B: Present only on filtered manifolds.

NS: Not Shown

Parts7-16


Drive Assembly (Complete)

13

13.5−16.3 N�m (10−12 ft-lb)

6.1−6.8 N�m (54−60 in.-lb)

Figure 7-8 Drive assembly (complete)

Parts 7-17


Item StandardPart Description Quantity Note

— 1031217 Service kit, drive assembly, 1/6 hp, 1100 psi,filtered

—

— 1031219 Service kit, drive assembly, 1/4 hp, 1100 psi,filtered

—

— 1043469 Service kit, drive assembly, 1/4 hp, 600 psi, filtered —

1 - - - - - - � Pump 1 A

2 - - - - - - � Manifold 1 B

3 - - - - - - � Motor 1 C

4 - - - - - - � Coupling, drive, 5/8 x 5/8 in. 1 D

5 - - - - - - � O-ring, -118, Viton, 0.862 x 0.103 in. 1

6 - - - - - - � O-ring, Viton, 1.188 x 1.388 x 0.094 in. 1 A

7 - - - - - - � O-ring, Viton, 0.750 x 0.938 x 0.094 in. 1 A

8 - - - - - - � Key, machine, drive, 0.1875 x 0.70 in. 1 D

9 - - - - - - � Screw, hex, cap, M8 x 90, 304 stainless-steel 2 A

10 - - - - - - � Washer, flat, narrow, M8 2 A

11 - - - - - - � Screw, hex, cap, M6 x 25 4

12 - - - - - - � Washer, lock, split, M6 4

13 - - - - - - � Bracket, pump support 1

NS - - - - - - � Capacitor 1 C

NS - - - - - - � Grease, high-temperature, 0.50 oz 1

— 1043467 Service kit, motor coupling, gerotor —

4 - - - - - - � Coupling, drive, 5/8 x 5/8 in. 1

8 - - - - - - � Key, machine, drive, 0.1875 x 0.70 in. 1

NOTE A: Provided in pump service kit. Refer to Pump earlier in this section for kit part numbers.

B: Refer to Manifold earlier in this section.

C: Refer to Motor earlier in this section.

D: Provided in the motor coupling service kit.

NS: Not Shown

Parts7-18


Optional Equipment

Flow/Pressure Control and Pressure Indication

Part Description Quantity1032537 Flow controller, FC1, DuraBlue (also requires 1034042, 1028627, and 1030537) —

1034042 Valve, run-up PCV, 1100 psi —

1028627 Assembly, tachometer, generator, and cable, FC1, 0−225 VDC —

1030537 Kit, gauge, 1500 psi —

1034248 Kit, knob, adjustment, pressure control valve —

1037495 Kit, drain valve —

Expansion and Control Kits

Part Description Quantity1036607 Kit, I/O expansion card (digital) —

1063740 Kit, analog I/O board —

1053288 Kit, DeviceNet card —

1053289 Kit, Ethernet card —

1053300 Kit, PROFIBUS card —

1031175 Kit, 2-hose to 4-hose conversion, D10/D16 —

1050598 Kit, air control —

1030542 Kit, footswitch —

1047093 Kit, remote trigger —

FillMaster Accessory Kits

Part Description Quantity735162 Kit, lid, FillMaster, D10/D16 —

735161 Kit, sensor, FillMaster, D10/D16 —

General Melter Accessory Kits

Part Description Quantity1050595 Kit, support, hose, double —

1030530 Kit, hand-held applicator hanger —

1043074 Kit, return feed, D10/D10L/D16/D16L —

Technical Data 8-1


Section 8Technical Data

General Specifications

Item Data NoteMelter weight (empty)

D10 74 kg (162 lb)

D16 80 kg (176 lb)

Hose ports 2 to 4 A

Melt rate

D10 7.7 kg/hr (17.0 lb/hr)

D16 11.2 kg/hr (24.7 lb/hr)

Noise 64dB (A) at maximum pump speed B

Workplace temperature 0 to 50C (32 to 120 F)

Throughput rate

D10 12.5 kg/hr (27.5 lb/hr)

D16 20 kg/hr (44 lb/hr)

Pump rate22 or 35 kg/hr (48 or 77 lb/hr) at 60 Hz18 or 29 kg/hr (40 or 64 lb/hr) at 50 Hz C

NOTE A: Depends on the melter configuration.

B: The noise level is measured at a distance of 1 m (3.3 ft.) from the surface of the melter.

C: The pump rate for melter P/N 1039107 is 50 kg/hr (110 lb/hr) at 60 Hz.

Technical Data8-2


Electrical Specifications NOTE: Refer to Configuring the Electrical Service in Section 3, Installation,for maximum amperage specifications.

Item Data NoteHose/gun heating capacity 2 or 4 hose/gun pairs A

Control temperature range 40 to 230 C (100 to 450 F)

Control temperature accuracy � .5 C (� 1 F)

IP rating IP 32

NOTE A: Depends on melter configuration

Heater Specifications NOTE: Refer to the hose and applicator manuals for hose/applicator heaterspecifications.

Location Voltage Wattage(see Note A)

Cold Resistance(see Note B)

Pump 240 V 400 130−152 ohms

Tank, D10 240 V 2 x 650 80.2−93.5 ohms each

Tank, D16 240 V 2 x 900 57.9−67.6 ohms each

NOTE A: Nominal wattage at 177−204 �C (350−400 �F).

B: Measured at room temperature for a previously heated element.

Technical Data 8-3


Motor and Pump Specifications

Item Data NoteViscosity range 1000–30,000 cps. A

Maximum hydraulic pressure 75 bar (1100 psi) B

Displacement 7.8 cc/rev

Motor size and speed C1/6 hp 54.6 rpm at 60 Hz or 45 rpm at 50 Hz1/4 hp 86.25 rpm at 60 Hz or 71.25 rpm at 50 Hz

NOTE A: The viscosity range for melter P/N 1039107 is 1000–10,000 cps.

B: The maximum hydraulic pressure for melter P/N 1039107 is 40 bar (600 psi).

C: The motor size and speed for melter P/N 1039107 is 135 rpm at 60 Hz.

Technical Data8-4


Dimensions

392 mm(15.44 in.)307 mm

(12.07 in.)

878 mm(34.57 in.)

851 mm(33.50)

393 mm(15.48 in.)

584 mm(23.00 in)

647 mm(25.45 in.)

330 mm(12.99 in.)

1052 mm(41.40 in.) 163 mm

(6.40 in.)

Figure 8-1 D10/D16 melter dimensions

Figure 8-2 B900N mounting dimensions (from manifold)

Technical Data 8-5


Conduit Penetration Sizes

Figure 8-3 Conduit penetration sizes

Technical Data8-6


Calculating Melter Power Requirements A-1


Appendix ACalculating Melter Power Requirements

Before locating the melter on the production floor or attaching hoses andapplicators to the melter, you must calculate the electrical power required bythe hoses and applicators and confirm that the required power does notexceed maximum allowable wattages. Properly calculating melter powerrequirements will prevent damage to the melter and identify the maximumallowable distance between the melter and the point at which the hot melt isdispensed.

The following three maximum wattages must be considered whencalculating melter power requirements.

� Single-component maximum—The wattage of any single hose orapplicator

� Hose/applicator pair maximum—The combined wattage of anyhose and applicator (hose/applicator pair)

� Two hose/applicator pair maximum—The combined wattage ofhose/applicator pairs 1 and 2 or hose/applicators pairs 3 and 4

If your Nordson representative has already calculated the hose/applicatorpower requirements and confirmed that the maximum allowable wattageswill not be exceeded, then no further calculation is necessary. However, youshould re-evaluate the hose and applicator power requirements before you:

� add a new hose or applicator to the melter that was not factored intothe original wattage evaluation

� replace an existing hose with a higher wattage hose or an existingapplicator with a higher wattage applicator

Calculating Melter Power RequirementsA-2


To evaluate the hose/applicator power requirements

1. Identify all hose/applicator pairs based on the hose/applicator receptacleto which they are connected.

2. Examine the identification tag or plate on each hose and applicator andrecord the wattage of each in Column A of Table A-1. Enter a zero forany hose or applicator that is not installed.

3. Add the wattages of each hose/applicator pair and place the sum inColumn B of Table A-1.

4. Add the wattages of hose/applicator pairs 1 and 2 and hose/applicatorpairs 3 and 4 and place the sum in Column C of Table A-1.

5. Compare each of the wattages tabulated in Columns A, B, and C ofTable A-1 with the associated maximum allowable wattages inTable A-2.


� If each of the wattages calculated in step 5 do not exceed theassociated maximum allowable wattages listed in Table A-2, then thepower required by the hoses and applicators is within acceptablelimits.

� If any of the wattages calculated in step 5 does exceed anassociated maximum allowable wattage listed in Table A-2, then theconfiguration or position of the hose/applicator pairs must berearranged, shorter hoses must be used, or lower power applicatorsmust be used in order to reduce the power requirement.

Calculating Melter Power Requirements A-3


Table A-1 Hose/Gun Wattages

ComponentNumber Type/Size

A B C

ComponentWattage

Hose/Gun PairWattage

Two Hose/GunPair Wattage

Hose 1

Gun 1

Hose 2

Gun 2

Hose 3

Gun 3

Hose 4

Gun 4

Table A-2 Maximum Allowable Hose/Gun Wattages

Column inTable A-1 Component Maximum Wattage

A Any single hose or applicator 1000 W

B Any hose/gun pair 1200 W

CSum of hose/gun pairs 1 and 2 2000 W

Sum of hose/gun pairs 3 and 4 2000 W

Calculating Melter Power RequirementsA-4


Operating Parameters B-1


Appendix BOperating Parameters

Operating parameters are organized in this appendix according to thelogical groups listed in Table B-1. For information about selecting andediting operating parameters, refer to Section 3, Installation, Setting Up theMelter.

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

Table B-1 Parameter Groups

Group ParameterNumbers Group Description

Standard0 to 8 and10 to 14 Frequently used parameters

Pressure Control 15 to 17 Configure pressure settings

Temperature Control 20 to 26 Control heater function

Input Setup 30 to 39 Configure the standard and optional inputs

Output Setup 40 to 46 Configure the standard and optional outputs

Seven-day Clock 50 to 77 Configure the clock feature

Automatic Fill Timer 78 Configure the external motor control switch

PID Selection 80 to 91 Configure the 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 Value: 4000

Format: —

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

NOTE: The melter remains in the password-protected mode for twominutes after the last key press. After exiting the setup mode, attemptingto re-enter the setup mode, even before two minutes has elapsed, willrequire you to re-enter the password.

1 Total Hours with Heaters On (Noneditable)

Description: A noneditable value that indicates the total number of hours that theheaters have been on.

Value: 999,999 (using abbreviated convention described below)

Resolution: 1 hour

Default Value: 0

Format: —

Use: The right display indicates up to 9999 hours of heater operation. Whenthe accumulated heater hours reaches 10,000, the display alternatesevery two seconds between the three left most digits (thousands) and thethree right digits (hundreds). For example, 10,001 hours would bedisplayed as ”10,” for two seconds and then ”001” for two seconds. Thecomma is present if parameter 20, Temperature Units, is set to degreesFahrenheit. A period is present if parameter 20 is set to degrees Celsius.

2 Fault Log (Noneditable)

Description: Stores a record of the last ten faults.

Value: —

Resolution: —

Default Value: _-F0 (unused log entry)

Format: F1, F2, F3, and F4

Use: Use the right-display scroll keys to review the log entries for the last tenfaults. Empty log entries are indicated by “_-F0.” Refer to Monitoring theMelter in Section 4, Operation.



3 Change History Log (Noneditable)

Description: Records the last ten changes made to either the setpoint temperatures orthe operating parameters.

Value: —

Resolution: —

Default Value: P-_ (unused log entry)

Format: Refer to Section 3, Installation, Review Parameter and SetpointTemperature Changes.

Use: Use the right-display key to review the log entries for the last ten changesthat were made to the operating parameters or the setpoint temperatures.Empty log entries are indicated by “P-_.”

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

have reached their setpoint temperature before the ready LEDwill turn on. The ready delay time only functions when thetemperature of the tank, at the time the melter is turned on, ismore than 27 C (50 F) from its setpoint temperature. Theready 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 Value: 0 minutes

Format: Left display “rd.” Right display, minutes or seconds remaining.

Use: The ready delay allows the contents of the tank an additionalamount of time to heat before pump turns on.

NOTE: The time remaining on the ready delay is indicated inminutes in the right display at the end of every automatic scancycle. When the delay time reaches 1 minute, the timeremaining appears in seconds.

5 Service Interval TimeDescription: The number of heater-on hours that must elapse before the service LED

turns on.

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

Resolution: 1 hour

Default Value: 500 hours

Format: —

Use: Set the service interval time to signal a user-defined service check ormaintenance event, such as changing the filter. The service LED will turnon after the pre-set time elapses. With the melter in the scan mode, pressthe Clear/Reset key to turn off the service LED and reset the time.



Standard (contd)

6 Service LED Heater Hours (Noneditable)

Description: A timer indicates how many more hours the heaters need to remain onbefore the service LED illuminates (service required).

Value: 0 hours (disabled) to 9999

Resolution: 1 hour

Default Value: 0

Format: —

Use: The service interval time (parameter 5) must be enabled before thisparameter will work.

Note: Heater hours accumulate whenever the heaters LED is illuminated.

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

switching device turns off.

Value: 0 to 360 seconds

OR

- - - - (infinite)

Resolution: seconds

Default Value: 0 seconds

Format: —

Use: This parameter functions only when a switching device (switchedhand-held applicator hose, footswitch, etc.) is connected to the switchreceptacle.

8 Automatic Pump OnDescription: Determines if the pump will turn on automatically when the melter is

ready.

Value: 0 = disabled or 1 = enabled

Resolution: —

Default Value: 1 (enabled)

Format: —

Use: If Automatic Pump On is disabled, you must press the pump key to turnthe pump on.

If Automatic Pump On is enabled, the pump will turn on automaticallywhen the melter is ready.

NOTE: If Automatic Pump On is disabled (0) while the pump is running,the pump will remain on until the pump key is pressed.



10 Enable or Disable the Melter PasswordDescription: Activates or deactivates the melter password. When password protection

is activated, component setpoint temperatures or melter operatingparameters cannot be changed until a valid password is entered usingparameter 0.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default Value: 0

Format: —

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

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

operating parameters or setpoint temperatures.

Value: 0 to 9999

Resolution: 1

Default Value: 5000

Format: —

Use: Refer to Section 4, Operation, Entering the Melter 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 ApplicatorActivation

Description: Changes the proportioned 240 VAC current that is provided to the hose 1heater to a switched 240 VAC current that is used to activate amanifold-mounted electric applicator.

Value: 0 (disabled)

1 (enabled)

Resolution: —

Default Value: 0 (disabled)

Format: —

Use: Use only when a Nordson manifold-mounted electric applicator isinstalled and a switching device is connected to the melter’s switchreceptacle. Refer to the electric applicator manual for information onmounting and using the applicator.



Standard (contd)

13 Change Hose 2 Output to Electric ApplicatorActivation

Description: Changes the proportioned 240 VAC current that is provided to the hose 1heater to a switched 240 VAC current that is used to activate amanifold-mounted electric applicator.

Value: 0 (disabled)

1 (enabled)

Resolution: —


Format: —

Use: Use only when a Nordson manifold-mounted electric applicator isinstalled and a switching device is connected to the melter’s switchreceptacle. Refer to the electric applicator manual for information onmounting and using the applicator.

14 External Communications Lock-outDescription: Used as a safety feature when performing maintenance on the melter.

Prevents external control of the melter through standard or optionalinputs/outputs or network communications (optional)

Value: 0 (disabled)

or

1 (enabled)

Resolution: —

Default Value: 0 (disabled

Format: —

Use: Set parameter to 1 (enabled) before performing any maintenance on themelter. When enabled, all external control of the melter stops until theparameter is once again set to 0 (disabled).



Pressure Control

15 Pressure SetpointDescription: Used to set the percentage of maximum output pressure (from

0−100 percent).

Value: 0 to 100 (percent)

Resolution: —


Format: —

Use: This parameter is available only when the optional analog input/output(I/O) board is installed on the melter. Refer to Section 7, Parts, for the I/Oboard kit part number. The pressure is displayed after the last applicatortemperature: the left display shows a P (for pressure) and the rightdisplay shows the pressure reading.

16 Over Pressure SetpointDescription: If the pressure in the system exceeds the value of this setting, an

over-pressure alarm will occur.

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

Resolution: —

Default Value: 0

Format: —

Use: This parameter is available only when the optional analog I/O board isinstalled on the melter. Refer to Section 7, Parts, for the I/O board kit partnumber.

17 Under Pressure SetpointDescription: If the pressure in the system drops below the value of this setting, an

under-pressure alarm will occur.

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

Resolution: —

Default Value: 0

Format: —

Use: This parameter is available only when the optional analog I/O board isinstalled on the melter. Refer to Section 7, Parts, for the I/O board kit partnumber.



Temperature Control

20 Temperature UnitsDescription: Sets the units for temperature display.

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

Resolution: 1 degree

Default Value: C

Format: —

Use: —

21 Over Temperature DeltaDescription: The number of degrees that the temperature of any component can

increase over its assigned setpoint temperature before an overtemperature fault (F3) will occur.

Value: 5 �C (10 �F) to 60 �C (110 �F)

Resolution: 1�C

1�F

Default Value: 15 �C (25 �F)

Format: —

Use: —

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

decrease from its setpoint temperature before an under temperature 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 by which all heated components will be

decreased when the applicator is placed into the standby mode.

Value: 5 �C to 190 �C (10 �F to 350 �F)

Resolution: 1 �C 1 �F


Format: —

Use: A standby delta should be selected that results in a balance betweenmelter energy savings during periods of inactivity, the amount of time andenergy required to bring the melter back up to setpoint temperature, anda temperature at which the hot melt can be held in the tank for extendedperiods of time without charring. Refer to Section 4, Operation, UsingMelter Function Keys.

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

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

driver) is sent to input 1 before the melter will enter the standby mode.The automatic standby timeout feature saves energy by allowing themelter to automatically go into the standby mode if the melter detects thatthe applicators are no longer firing.

Value: 0 to 1440 minutes (24 hours)



Format: —

Use: 1. Change parameter 23 if required.

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

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



Temperature Control (contd)

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

the standby key is pressed.

Value: 0 to 180 minutes


Default Value: 0

Format: —

Use: Set the standby time when you want the operator to be able to place themelter into the standby mode for a limited period of time (break, lunch,etc.). When manual standby is enabled (value greater than 0 minutes),the standby LED blinks.

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

Note: When a time value equal to or greater than 1 minute is entered, thestandby LED will flash to indicate that the manual standby timer iscounting down.



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 Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable10 – Automatic standby11 – Motor 2 Enable/Disable (DuraBlue D50 and D100 melters only)13 − Automatic Fill Timer 114 − Automatic Fill Timer 2 (DuraBlue D50 and D100 melters only)

Resolution: 1

Default Value: 10

Format: —

Use: Multiple inputs can be set to the same input value. After one or moreinputs that have the same input value are energized, the inputfunctionality will not be considered inactive (off) until all of the inputs withthe same input value are de-energized (Multiple inputs set to the sameinput value are logical ORed.).

NOTE: Parameter 78, Automatic Fill Timer, must be set to a value of 1 orgreater in order to use option 13 or 14. Output option 6, Alert, can beused to signal when the Automatic Fill Timer expires.


Value: 0 – Input Disabled1 – Standby On/Off2 – Heaters On/Off3 – Motor Enable/Disable4 – Hose/Gun 1 Enable/Disable5 – Hose/Gun 2 Enable/Disable6 – Hose/Gun 3 Enable/Disable7 – Hose/Gun 4 Enable/Disable8 – Hose/Gun 5 Enable/Disable9 – Hose/Gun 6 Enable/Disable11 – Motor 2 Enable/Disable (DuraBlue D50 and D100 melters only)13 − Automatic Fill Timer 114 − Automatic Fill Timer 2 (DuraBlue D50 and D100 melters only)

Resolution: 1

Default Value: 1

Format: —





Input Setup (contd)



Resolution: 1

Default Value: 2

Format: —





Resolution: 1

Default Value: 4

Format: —





34 – 35 Optional Inputs 5 and 6Description: Control options that determine the function of two of the optional inputs

provided when either the optional I/O expansion card (digital) or theanalog I/O board is installed on the CPU board.


Resolution: 1


Format: —



36 − 39 Optional Inputs 7, 8, 9, and 10Description: Control options that determine the function of four of the optional inputs

provided when the optional I/O expansion card (digital) is installed on theCPU board.


Resolution: 1


Format: —





Output Setup

40 − 42 Standard Outputs 1, 2, and 3Description: Determines the function of the output.

Value: 0 = Output Disabled1 = Ready2 = Ready and motor is on3 = Fault4 = Low level5 = Service LED is on6 = Alert (Potential fault)

Resolution: 1

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

Format: —

Use: Refer to Installing Melter Outputs in Section 3, Installation, for informationon setting up outputs.

When control option 6, Alert is selected, the output is active whenever themelter 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, Monitor Melter Faults, forinformation about fault monitoring.

43 Optional Output 4Description: Control options that determine the function of one of the optional outputs

provided when either the optional I/O expansion card (digital) or the I/Oanalog board is installed on the CPU board.


Resolution: 1

Default Value: 0 (all optional outputs)

Format: —

Use: Refer to the instruction sheet provided with the optional I/O expansioncard or analog I/O board for information about wiring and setting up theoptional outputs.




44 − 46 Optional Outputs 5, 6, and 7Description: Control options that determine the function of three of the optional

outputs provided when the optional I/O expansion card (digital) isinstalled on the CPU board.


Resolution: 1

Default Value: 0 (all optional outputs)

Format: —

Use: Refer to the instruction sheet provided with the optional I/O expansioncard for information about wiring and setting up the optional outputs.


Seven-day clock key



Seven-day Clock Before setting up the clock, refer to Using Melter Function Keys inSection 4, Operation, to familiarize yourself with the function and use of theclock feature.

If you are unfamiliar with the procedure for accessing and editing operatingparameters, refer to Section 3, Installation, Setting Up the Melter.

To set the clock

Refer to the examples on the next page.

1. Use parameter 50 to select the current day of the week.

2. Use parameter 51 to set the current time of day.

3. Create schedule 1 by:

a. Setting parameters 55 and 56 to the time of the day that the heatersshould turn on and off.

b. Setting parameters 57 and 58 to the time of the day that the meltershould enter and exit the standby mode.

4. Using parameters 60 through 68, create schedules 2 and 3 by repeatingstep 3.

5. Use parameters 71 through 77 to assign which of the four schedulesshould be used on each day of the week. Up to three schedules may beassigned each day (to support three work shifts). Each of the eightcontrol options (0 to 7) that is available in parameters 71 through 77assigns a different combination of the three schedules. Option 0 is usedhold the melter in the state dictated by the last clock transition until thenext clock transition occurs.

6. Press the Clock key.

In order for the clock to operate continuouslythroughout the week, a valid schedule mustbe assigned to every day of the week (param-eters 71 through 77).

To prevent unintentional activation of the clockthe default setting for parameters 71 through77 is schedule 0, which has no time valuesassigned to it. With the default set to sched-ule 0, unintentionally pressing the clock keywill have no affect on the melter.



Example 1 To turn the heaters on at 0600 and turn them off at 0015 every day of theweek:

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

Example 2 To turn the heaters on at 0700 and off at 1700 Monday through Friday, andturn the heaters off Saturday and Sunday:

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

Example 3 To turn the heaters on at 0600 each morning, go into standby for lunch at1130, come out of standby after lunch at 1230, and turn the heaters off at1600 at the end of the day, every day of the week:

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



Seven-day Clock (contd)

50 Current DayDescription: Used to set the current day of the week.

Value: 1 to 7 (1 = Monday, 2 = Tuesday, etc.)

Resolution: 1

Default Value: —

Format: —

Use: Refer to Section 4, Operation, Using Melter Function Keys, forinformation about the use and affects of the seven-day clock feature.

51 Current HourDescription: Used to set the local time of the day.

Value: 0000 to 2359 (European time format)


Default Value: (Time set at factory)

Format: Hours, 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 Value: 0600


Use: Set the desired time for the heaters to turn 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 Value: 1700


Use: To disable this parameter, set the parameter’s value to “- - - -” bysimultaneously pressing both of the right-display scroll keys.



57 Schedule 1 Enter StandbyDescription: Used to set the time that the melter will enter the standby mode during

schedule 1.

Value: 0000 to 2359, - - - -


Default Value: - - - -

Format: Hour, Hour: Minute, Minute

Use: Set the time that the applicator will enter the standby mode duringschedule 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 melter cannot enterthe standby mode when the heaters are off.

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

schedule 1.

Value: 0000 to 2359, - - - -




Use: Set the time that the applicator will exit the standby mode duringschedule 1.


Note: Do not set an exit standby time that is outside of the time perioddefined by the schedule’s heater on and off time. The melter cannot enterthe standby mode when the heaters are off.


schedule 2.

Value: 0000 to 2359, - - - -










schedule 2.

Value: 0000 to 2359, - - - -

Resolution: 1 e





schedule 2.

Value: 0000 to 2359, - - - -








schedule 2.

Value: 0000 to 2359, - - - -










schedule 3.

Value: 0000 to 2359, - - - -







schedule 3.

Value: 0000 to 2359, - - - -






schedule 3.

Value: 0000 to 2359, - - - -











schedule 3.

Value: 0000 to 2359, - - - -







71 Schedules for MondayDescription: Used to select which schedule(s) should be used on Monday.

Value: 0 – Remain at last clock transition1 – Use just schedule 12 – Use just schedule 23 – Use just schedule 34 – Use schedule 1 and 25 – Use schedule 2 and 36 – Use schedule 1 and 37 – Use schedule 1, 2, and 3

Resolution: 1

Default Value: 0

Format: —

Use: Selects the active schedule(s) for the day.

NOTES: If the 0 schedule option is used, the heaters will not turn onagain until the next scheduled heaters on time arrives.



72 Schedules for TuesdayDescription: Used to select which schedule(s) should be used on Tuesday.


Resolution: 1

Default Value: 0

Format: —



73 Schedules for WednesdayDescription: Used to select which schedule(s) should be used on Wednesday.


Resolution: 1

Default Value: 0

Format: —






74 Schedules for ThursdayDescription: Used to select which schedule(s) should be used on Thursday.


Resolution: 1

Default Value: 0

Format: —



75 Schedules for FridayDescription: Used to select which schedule(s) should be used on Friday.


Resolution: 1

Default Value: 0

Format: —





76 Schedules for SaturdayDescription: Used to select which schedule(s) should be used on Saturday.


Resolution: 1

Default Value: 0

Format: —



77 Schedules for SundayDescription: Used to select which schedule(s) should be used on Sunday.


Resolution: 1

Default Value: 0

Format: —





Automatic Fill Timer

78 Automatic Fill TimerDescription: A count-down timer that can be associated with a switch connected to an

input.

Value: 0 to 90 seconds

Resolution: 1

Default Value: 0 (Disabled)

Format: —

Use: Used in conjunction with input control option 13 or 14. Enable outputcontrol option 6, Alert, to send a signal when the timer expires.

PID Selection

80−87 PID Selection for Hose/Gun Receptacles 1, 2, 3,and 4

Description: Used to change the preset PID selections. Use parameter 80 to selectthe value for hose 1, parameter 81 to select the value for applicator 1,and so on, up to hose 4/gun 4.

Value: 0 = Hose1 = Standard applicator2 = Large applicator3 = Air heater

Resolution: —

Default Value: 0 or 1 depending on the channel type (hose or applicator)

Format: —

Use: Consult your Nordson representative before changing PID settings.

88 − 91 PID Selection for Hose/Gun Receptacles 5, 6, 7,and 8 (DuraBlue D25, D50, and D100 melters only)

Description: Used to change the preset PID selections. Use parameter 88 to selectthe value for hose 5, parameter 89 to select the value for applicator 5,and so on, up to hose 8/gun 8.

Value: 0 = Hose1 = Standard applicator2 = Large applicator3 = Air heater

Resolution: —

Default Value: 0 or 1 depending on the channel type (hose or applicator)

Format: —

Use: Consult your Nordson representative before changing PID settings.

Melter Communications C-1


Appendix CMelter Communications

This appendix describes the installation and use of the NordsonConfiguration Manager (NCM) communications utility. With this utility youcan:

� transfer operating parameters and temperature set-points betweenmelters

� upgrade or reload your melter’s firmware

Software Availability If you do not already have the NCM utility, you can download it from theinternet by navigating to www.enordson.com/support.

If you do not have a connection to the internet, you can request a softwareCD from your Nordson representative.

System Requirements The following hardware and software requirements are necessary to installand run Blue Series software:

� Any ProBlue adhesive melter or a DuraBlue 10/16 adhesive melter

� Serial cable

� Personal computer with:

� CD-RW drive or 3.5-inch floppy drive

� Available COM port

� 640 x 480 color monitor

� Windows 95, 98 (second edition), ME, XP, or 2000

� Internet Explorer version 4.0 or later (IE 5.0 is recommended)

� Administrative privileges (Windows XP, 2000, and NT)

Melter CommunicationsC-2


Installing the Software To meet your specific installation conditions, two versions of the softwareare available. Refer to Table C-1 to determine which version you need.

Table C-1 Blue Series Software Versions

Version Use When...

Single installation file:

BlueSeries.exe

You are downloading the software from www.enordson.com and the PC you aredownloading onto is connected or can be connected to the melter

OR

You are downloading the software from www.enordson.com onto a PC that can not beconnected to the melter, but the PC does have a CD-RW and the PC that is connected tothe melter does have a CD drive

OR

You have a CD with the software and you have a PC with a CD drive that can beconnected to the melter

Self-extracting span diskette set:

BlueSeriesSpan.exe

You are downloading the software from www.enordson.com onto a PC that cannot beconnected to the melter and the PC that is connected to your melter only has a 3.5-inchfloppy drive

When the installation file is executed, an installation wizard will detect youroperating system and start the installation routine.

NOTE: Installing the NCM for the first time also installs the latest version ofthe melter’s firmware.



To install Blue Series software1. Do one of the following:

� If you are installing using the single file installation, locate anddouble-click on the file BlueSeries.exe.

� If you are installing from the span diskette set, insert Disk 1, andthen locate and double-click on the file Setup.exe.

The Blue Series Software Setup wizard appears.

2. Click Next, and then follow the on-screen instructions. If you areinstalling from the span disk set, you will be prompted to insert additionaldiskettes (2 through 5) as required by your operating system.

NOTE: When prompted to select an installation location, NordsonCorporation recommends that you select the default location offered.

3. When the installation complete message appears, click Finished.

Removing the Software from Your PCUse the Remove feature provided by the Blue Series InstallShield� Wizardto remove the software from your PC. Removing Blue Series software fromyour PC will not remove melter settings files that you have saved using theNCM. Settings files (.ncm extension) are stored in your Windows MyDocuments folder.

NOTE: Windows XP, 2000, and NT users must have administrator rights inorder to remove software from their PC.

To remove Blue Series software 1. From the Windows Start menu, select Settings > Control Panel, and

then double-click Add/Remove Programs.

The Add/Remove Programs dialog box appears.

2. Select Blue Series Software from the list, and then click Remove.

11 22

00

44 55

33

66

99

Serial port

Configuration Managerdesktop icon



Connecting the PC and the Melter

Connect a serial cable between the PC COM port (selected during thesoftware installation routine) and the serial port connection (COM port) onyour melter’s control panel.

Using Nordson Configuration ManagerConfiguration Manager is launched from your Windows desktop using theicon shown to the left.

Use Configuration Manager when you want to... � copy melter settings from one melter to another melter

� create and save more than one version of melter settings

� upgrade or restore a melter’s firmware

Configuration Manager communicates with your melter through a PCconnected to your melter’s serial port. Once connected, ConfigurationManager offers the choice of saving settings, restoring settings, orupgrading the melter’s firmware.

The first time you download and install Configuration Manager, the latestversion of the melter’s firmware is also downloaded.



Saving and Restoring Melter Settings Saving settings copies all current set-point and operating parameter valuesto your PC. Saved settings can be transferred back to the same melter or toany other compatible Blue Series adhesive melter.

To save melter settings 1. Place the melter into the configuration mode by simultaneously pressing

the Standby and Setup keys.

“COnF” appears in the right display.

2. Double-click the NCM icon on the Windows desktop.

The NCM dialog box appears.

3. Click Select Device.

The Select Product dialog box appears.

4. Select your melter from the list, and then click Ok.

The Select COM Port dialog box appears.

5. Select the COM port you are using to connect to the melter, and thenclick Ok.

The PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates “CONNECTED”.

6. Click Save Settings.

The Save As dialog box appears.

NOTE: The default location for saving settings files is Windows MyDocuments folder. To avoid loosing saved settings files, NordsonCorporation recommends that you do not change the default savelocation.

7. Type a file name to identify the group of settings you are saving, andthen click Save.

The save settings progress bar indicates the status of the save. Whenthe save is complete, the melter automatically returns to the scan mode.

NOTE: If you are using the NCM to save multiple variations of meltersettings, use a file naming convention that will allow you to easilyassociate each settings file (.ncm extension) with its related process orend-use.

8. Click Ok to close the NCM.



Saving and Restoring Melter Settings (contd)

To restore melter settings 1. Follow steps 1 through 5 of To save melter settings.

2. Click Restore Settings.

The Open dialog box appears.

3. Select the settings file (.ncm extension) that you want to restore, andthen click Open.

The Restore Settings progress bar indicates the status of the restore.When the restore is complete, the melter automatically returns to thescan mode.

Upgrading or Restoring Melter Firmware Use the NCM to upgrade your melter to a newer version of firmware orreload the current version of the firmware. The version of Blue Seriesadhesive melter firmware that is currently available is posted on the internetat www.enordson.com/support.

NOTE: The version of firmware that is loaded on your melter appears onthe control panel when the melter is first switched on.

During the upgrade process, all current melter settings are downloaded andsaved on your PC. After upgrading or restoring a melter’s firmware, you canuse the NCM to restore the pre-upgrade settings.

CAUTION: The upgrade process returns the melter’s settings to factoryconfiguration, with the exception that current heater hours data is saved.Data in both the fault log and the change log is lost after upgrading thefirmware.



To upgrade or reload melter firmware 1. Connect your PC to the melter. Refer to Connecting the PC and the

Melter earlier in this guide.

2. Place the melter into the upgrade mode by switching the melter off andthen on again, and then immediately pressing and holding both theSetup and left display Scroll key.

UPLOAd appears in the right display.

3. Double-click the NCM icon on the Windows desktop.

The NCM dialog box appears.

4. Click Select.

The device dialog box appears.

5. Select your melter from the list, and then click Ok.



The PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates Connected.

7. Click Upgrade.

The Select Upgrade dialog box appears.

8. In the Available Upgrades list, select the firmware version you want toupload to the melter, and then click Ok.

The upgrade warning message appears.

9. Click OK.

The Upgrade in Progress dialog box appears. The upgrade can takeas long as 12 minutes. When the upgrade is complete, the Successdialog box appears and the melter restarts.



To upgrade or reload melter firmware (contd)

CAUTION: Once the uprade progress bar appears, do not interrupt theupgrade process for any reason. Interupting the upgrade can corrupt themelter’s firmware, which will require replacement of the IC chip(IC service kit P/N 1018817).

10. Click OK.

The communications link between the melter and the PC is terminated.


� To restore pre-upgrade melter settings, go to To restore pre-upgrademelter settings on the next page.

� To close the NCM, click Exit.

� To restore melter settings other than the settings that were in use bythe melter before the upgrade, go to Saving and Restoring MelterSettings earlier in this guide.

To restore pre-upgrade melter settings 1. Place the melter into the configuration mode by simultaneously pressing

the Standby and Setup keys.

“COnF” appears in the right display.

2. Click Connect.



The PC and melter establish communications and a picture of the melteryou selected appears in the device status area. The right side of thestatus area indicates “CONNECTED”.

4. Click Restore Pre-Upgrade Settings.

The pre-upgrade settings are restored and the melter returns to the scanmode.

5. Click Exit to close the NCM.



Troubleshooting

Using Nordson Configuration Manager Symptom/Message Action

After selecting a device and the COM port, an Access Deniedmessage appears.

PC-to-Blue communications may be running or anotherapplication may be using the COM port. Close Internet Explorerand end the communications connection (if prompted). Close allother applications.

Melter in UPLOAd mode, the update process has not beeninitiated, and you want to stop and exit the UPLOAd mode, butyou cannot get the melter out of UPLOAd.

Cycle power to the melter at the local power disconnect switch.

CAUTION: Ensure that the firmware update process is notrunning before taking power off of the melter.

UPLOAd does not appear on the melter’s display when you pressthe Setup and left display scroll keys.

You must cycle the control switch while holding the Setup and leftdisplay scroll keys.

Attempted a firmware update, but the melter display still indicatesUPLOAd.

OR

Attempted a firmware update, but the PC has stopped respondingor was interrupted during the update process.

Using the local power disconnect switch, cycle power to themelter, and then re-attempt the update.

If the update is unsuccessful or the melter will not reboot, thecentral processor chip may be corrupted. Replace the CPUboard.



Date post:	06-Apr-2020
Category:	Documents
Upload:	others
View:	19 times
Download:	0 times