Section 6 Troubleshooting - Welcome to Nordson...

Troubleshooting 6-1

Part 1024496C� 2004 Nordson Corporation Manual 41-PROBLUE-MA-01

Section 6Troubleshooting

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.

This section provides quick-reference information for diagnosing melterfaults indications as well as comprehensive melter diagnostic informationthat is provided in flowchart format. When required, the troubleshootingflowchart will refer you to diagnostic procedures provided later in thissection.

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

400/480 Volt Melters Refer to Appendix E for information about troubleshooting the transformer,400/480 volt heater information, and information about parts that arespecific to 400/480 volt melters.

NOTE: With the exception of power supply and heater failure problems, theinformation provided in this section applies to all ProBlue adhesive melters.

Safety� Never disconnect cables from, or reconnect cables to, the main board

while the melter is energized.

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

� Refer to the safety information provided with optional equipment.

� If the melter is removed from its sub-base for diagnostic checks orservice, ensure that the ground lead between the chassis and thesub-base is re-attached when the melter is reconnected to the sub-base.

Troubleshooting6-2

Part 1024496C � 2004 Nordson CorporationManual 41-PROBLUE-MA-01

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

Table 6-1 Melter Faults

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

F1/None RTD Heaters turn off

The RTD for thecomponent indicated hasfailed or the componentwas disconnected fromthe melter.

Replace RTD

Check hose/gunconnections

See flowchart T.2

F2/None Under temperature Heaters turn off

The actual temperature ofthe component indicatedhas dropped below theunder temperature delta,which was set usingparameter 22.

Check for conditions thatmay cause a drop inambient temperature

Raise the set-pointtemperature of thecomponent

Replace RTD

See flowchart T.2

F3/None Over temperature Heaters turn off

The actual temperature ofthe component indicatedhas increased beyond theover temperature delta,which was set usingparameter 21.

Replace RTD

See flowchart T.2

F4/1 RAM test Melter stopsfunctioning

Internal RAM failure Replace CPU

F4/2 Internal Clock time Heaters remain on, butfault condition persists

Internal clock failure Replace CPU

F4/4Internal clockbattery backedRAM

Heaters remain on, butfault condition persists

Battery-backed RAMfailure

Replace CPU

F4/5 Internal clockbattery


Battery-backed RAMbattery dead

Replace CPU

F4/6 Analog-to-digital Melter stopsfunctioning

RTD analog-to-digitalconverter failed

Replace main board orCPU

F4/7 Analog-to-digitalcalibration

Melter stopsfunctioning

RTD analog-to-digitalconverter could not becalibrated

Replace main board orribbon cable, or CPU

F4/8 Main boardfeedback

Melter stopsfunctioning

Communication failurebetween main board andCPU

Replace main board,ribbon cable, or CPU

F4/A Thermostat Melter stopsfunctioning

Tank or manifoldthermostat is open

Replace thermostat, J7harness, or main board

F4/dCommunicationswith optional I/Ocard


Communication failurebetween CPU and theoptional I/O card

Replace the I/O card orCPU

F4/EFieldbuscommunicationsfailure

Alert output (if outputoption 6 is selected)Melter continues tooperate normally.

Fieldbus card failure. Replace the Fieldbus card

Troubleshooting 6-3


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a

b

Troubleshooting question and actionblocks

a) Question b) Action

Troubleshooting6-4


Using the Troubleshooting FlowchartThe 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 guns. The chart is organized in a simple question-actionblock format. If your response to a question is yes (Y), continue downwardin the chart to the next question or action block. If you response is no (N),continue to the right to the next question or action block. All diagnostic pathswithin the chart end with an action block that specifies one of the followingthree 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 that:

� the correct voltage plug is installed on terminal J1. Refer to Section 4,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).

Identifying Electrical ComponentsTables 6-2 through 6-5 describe the circuit board indicators, connectionpoints, and test points that are referred to in the troubleshooting flowchart.Figure 6-1 illustrates the location of each of these circuit board components.

Troubleshooting 6-5


Table 6-2 Main PCA

Item Number Type DescriptionIndicators

DS1 LED (Yellow) Control signal for tank heater

DS2 Neon (Orange) Power available for tank and manifold heaters

DS3 LED (Yellow) Control signal for manifold heater

DS4 Neon (Orange) Power available into main board after fuses F3/F4

DS5 LED (Green) +5 VDC control voltage present on board

Fuses

F1/F2 — 15 A, 250 V, Fast-acting, 1/4 inch

F3/F4 — 2 A, 250 V, Slow-blow, 5 x 20 mm

Connection Points

J1/J2 Jumper Voltage configuration plug with and without neutral

TB1 Input AC power into board

TB2 Input/output Output contacts 1–6. Input contacts 7–14

J5 Input/output Control signal between main board and 6-hose expansion board

J6 Output Power harness for tank and manifold heaters

J7 Input/Output Control signal harness (RTD, control switch, thermostat, solenoid). See Figure6-2 for pin-out.

J8 Input/Output Analog/digital signal cable

J9 Output Control signal to 400/480 VAC transformer

J10 Input AC power out to 6-hose expansion board

Table 6-3 CPU board


Red LED — Indicates that CPU board has failed

Green LED — + 5 VDC control voltage is present at the CPU board

Connection Points

J1 Input/Output Control signal between main PCA and CPU

J5 Input/Output Control signal between I/O expansion card or Anybus card and the CPU

Test Points

TP2/TP4 Contacts 4.75–5.25 V control voltage present at CPU

Table 6-4 Hose/Gun Power Module


DS1 LED (Yellow) Control power present for odd numbered hose

DS2 LED (Yellow) Control power present for odd numbered gun

DS3 LED (Yellow) Control power present for even numbered hose

DS4 LED (Yellow) Control power present for even numbered gun

DS5 Neon (Orange) AC power present at module for odd hose/gun pair

DS6 Neon (Orange) AC power present at module for even hose/gun pair

Fuses

F1/F2 and F3/F4 — 6.3 A, 250 V, Fast-acting, 5 x 20 mm

Troubleshooting6-6


Table 6-5 6-Hose Expansion Board (optional)

Item Number Type DescriptionConnection Points

J1 Input/output Control signal between 6-hose expansion board and main board J5

J2 Input AC power input to 6-hose expansion board from main board J10

Troubleshooting 6-7


Figure 6-1 Electrical components

Troubleshooting6-8


Figure 6-2 Power and control harness

Troubleshooting 6-9


Figure 6-90 Location of the return port

Troubleshooting6-10


1

2

3

Figure 6-91 Pneumatic flow diagram

1. Pump air inlet2. Pressure discharge valve3. Melter air supply inlet

Troubleshooting 6-11


Diagnostic Procedures Use these diagnostic procedure when directed by the troubleshootingflowchart. If a diagnostic procedure fails to identify or correct the problem,return to the troubleshooting flowchart or contact your Nordsonrepresentative for technical assistance.

DP.1 Isolate a Failed Control Component 1. De-energize the melter. Refer to Section 1, Safety.

See Figure 6-1.

2. Disconnect the ribbon cable (P/N 1018283) from the main board.

3. Remove all of the hose/gun modules.

4. Re-energize the melter.

5. Check LED DS5 on the main board, and then do one of the following:

� If DS5 does not illuminate, replace the main board (P4 or P7melters, use P/N 1028322; P10 melter, use P/N 1038323).

� If DS5 does illuminate, go to step 6.

6. Complete the following steps to Isolate the cause of the problem bychecking individually checking each of the components that weredisconnected from the main board in steps 2 and 3 (CPU and eachhose/gun module).

a. De-energize the melter.

b. Reconnect each component (ribbon cable, and then each hose/gunmodule).

c. Re-energize the melter.

d. Observe LED DS5 (main board).

Replace the component (CPU or hose/gun module) that causes LEDDS5 not to illuminate when the melter is re-energized.

Troubleshooting6-12


DP.2 Check the Tank or Manifold RTD 1. Check the left display to determine which RTD (tank or manifold) is

faulting. The display indicates 1 if the tank RTD is faulting or 2 if themanifold RTD is faulting.

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

NOTE: If the melter has already cooled down, solidified hot melt within thepump/manifold will prevent you from removing the pump. To remove thepump, you must reheat the melter. Refer to Reheating the Melter During anF1 Fault at the end of this procedure.

See Figure 6-2.

3. Remove the RTD from its retention slot.

� For the tank RTD, refer to Remove the Tank RTD.

� For the manifold RTD, refer to Remove the Manifold RTD.

4. Allow the RTD to cool to room temperature or use a pyrometer toaccurately determine the temperature of the RTD.

5. When the temperature of the RTD is known, measure the resistance ofthe RTD across terminals 1 and 2 (tank RTD) or 3 and 4 (manifoldRTD).

See Figure 6-5.

6. Determine the expected resistance of the RTD at the knowntemperature. Compare the expected and measured resistance valuesand then do one of the following:

� If the measured resistance is within the expected resistance range,the RTD is functioning properly. Replace the main board (P4 or P7melters, use P/N 1028322; P10 melter, use P/N 1038323).

� If the measure resistance is not within the expected resistancerange, the RTD is defective. Replace the RTD (P/N 1028320).

Removing the tank RTD



DP.2 Check the Tank or Manifold RTD (contd)

Reheating the Melter During an F1 Fault 1. While holding both the Setup key and the Tank key, cycle the system

control switch on and then off.

The left display will flash dashes at one second intervals to indicate thatthe melter is heating in the override mode. The melter will remain in theoverride mode for 20 minutes and then automatically switch off.

WARNING: Risk of electrocution!The control switch will remain in the on position when the melterautomatically switches off after 20 minutes. Ensure that the control switch ismoved back to the off position.

2. If necessary, repeat step 1 to continue reheating the melter.

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

2. Open the pump enclosure door.

3. While gently pulling the retention clip away from the RTD, slide the RTDout of its retention slot.

NOTE: If the RTD is functioning properly, apply thermal compound(provided in RTD service kit P/N 1028320) to the RTD before replacing it inthe retention slot.

Troubleshooting6-14


Remove the Manifold RTD 1. Relieve system pressure. Refer to Section 5, Relieving System

Pressure.

See Figure 6-93.

2. Isolate the pump from the manifold by rotating the isolation valve handleto its full vertical position (valve closed).

3. Remove the three pump-mounting bolts from the front of the pump body.

4. Rotate the top of the pump slightly toward the front of the melter, andthen pull the pump up and away from the manifold.

NOTE: The face of the pump body contains two M6 threaded holes.Bolts can be threaded into these holes to gain leverage when removingthe pump.

5. Remove the air line from the back of the pump.

6. Lift the pump clear of the melter.

7. Remove the RTD from its retention slot.

8. To replace the RTD and pump, reverse the order of steps 2 through 7.

CAUTION: Before replacing the pump, ensure that the cross-over tube isin-place between the pump and the manifold.

NOTE: Before replacing the RTD, apply thermal compound (P/N 1023441)to the RTD and its retention slot. To avoid damage to the RTD, ensure thatthe RTD is correctly inserted into its retention slot before replacing thepump.

Removing a hose/gunmodule



DP.3 Check the Operation of the Power Relay or Thermostats

The pre-conditions for this diagnostic procedure are as follows:

� The heater LED is illuminated.

� Indicator DS2 on the main board is not illuminated.

� Indicators DS5 and DS6 on all hose/gun modules are notilluminated.


2. Remove all of the hose/gun modules.

3. Re-energize the melter.

NOTE: If an F1 fault re-occurs after re-energizing the melter, reset themelter and turn the heaters back on.

4. Press the Heaters key.

See Figure 6-1.

5. Check indicator DS2 on the main board, and then do one of thefollowing:

� If indicator DS2 does illuminate, go to step 6.

� If indicator DS2 does not illuminate, got to step 7.

6. Locate a failed hose/gun module by individually replacing and checkingeach module as follows:

a. De-energize the melter.

b. Replace the hose/gun module.

c. Re-energize the melter.

d. Check if LED DS5 illuminates.

Replace the hose/gun module that causes LED DS5 not to illuminatewhen the melter is re-energized.

7. Complete one or both of the following checks to determine if the mainboard or a thermostat has failed:

a. Check for 21–27 VDC across receptacle J9, pins 1 and 4. If thevoltage is incorrect, replace the main board, otherwise go to b.

b. Check for 21–27 VDC across receptacle J9, pins 2 and 4. If thevoltage is incorrect, one or both of the thermostats or the wireharness connected to receptacle J7 has failed. Refer to DP.6 Checkthe Resistance of the Tank/Manifold Thermostat. If the voltage iscorrect, replace the main board.

Troubleshooting6-16


DP.4 Check the Operation of the Tank or Manifold TRIAC

See Figure 6-1.

WARNING: Risk of electrocution! Ensure that disconnect switch that servesthe melter is in the off position and locked.


2. Remove the protective rubber cover from the tank or the manifold heaterterminals (Whichever component is faulting).

3. Re-energize the melter and turn the heaters back on.

4. Press the Heaters key.

5. While watching LEDs DS1 and DS3 on the main board, measure thevoltage across the heater terminals as follows:

� For an F2 fault, voltage across the terminals should be within10 VAC of the voltage being supplied to the melter when DS1 andDS3 are illuminated.

� For an F3 fault, voltage across the terminals should be less than5 VAC when DS1 and DS3 are not illuminated.

Replace the main board if either of the above voltage conditions areincorrect (P4 or P7 melters, use P/N 1028322/P10 melter, useP/N 1038323).



DP.5 Check the Resistance of the Tank and Manifold Heaters

WARNING: Risk of electrocution! Ensure that disconnect switch that servesthe melter is in the off position and locked.


See Figure 6-1.

2. Disconnect the power harness plug (P/N 1024529) from receptacle J6on the main board.

3. Measure the resistance across pins 1 and 2 (tank) or pins 3 and 4(manifold) on the power harness plug, and then do one of the following:

� If the resistance is within the range shown in Table 6-6, go to step 4.

� If the resistance is not within the range shown in Table 6-6, go tostep 8.

NOTE: Refer to Appendix E for 400/480 Volt heater resistance data.

Table 6-6 Heater Resistance

Resistance

Model Tank Manifold

P4 46–58 ohms

P740 50 ohms

46–58 ohms

P1040–50 ohms

46 58 ohms

4. Individually check that the resistance between the chassis and pins1 and 2 (tank) or pins 3 and 4 (manifold) on the power harness plug, andthen do one of the following:

� If the resistance is greater than 1 Meg ohm, return to thetroubleshooting chart.

� If the resistance is less than 1 Meg ohm, go to step 5.

5. Remove the front and rear panels from the melter. Refer to Section 5,Cleaning the Melter, for the procedure to remove the panels.

Troubleshooting6-18


DP.5 Check the Resistance of the Tank and Manifold Heaters (contd)

CAUTION: Use two wrenches and minimal force when loosening ortightening the heater terminal connections. Using a single wrench orexcessive force to remove or tighten the terminals nuts can damage theheater.

6. Using two wrenches, loosen the nuts that hold the power harness leadsto the tank or the manifold heater terminal posts.

7. Individually check that the resistance between the chassis and eachtank or each manifold heater terminal post, and then do one of thefollowing:

� If the resistance is greater than 1 Meg ohm, replace the powerharness (P/N 1024529).

� If the resistance is less than 1 Meg ohm for the tank heater, replacethe tank. If the resistance is less than 1 Meg ohm for the manifold,replace the manifold heater. Refer to Section 7, Parts.

8. Remove the front and rear panels from the melter. Refer to Section 5,Cleaning the Melter, for the procedure to remove the panels.

9. Measure the resistance across the tank heater posts and the manifoldheater posts terminals, and then do one of the following:

� If the resistance is within the range shown in Table 6-6, replace thepower harness (P/N 1024529).

� If the resistance is not within the range shown in Table 6-6 replacethe tank or replace the manifold heater.

NOTE: The tank heater cannot be replaced independently.



250

240

230

220

210

200

190

180

170

160

150

140

130

RE

SIS

TA

NC

E I

N O

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250

240

230

220

210

200

190

180

170

290

280

270

260

RE

SIS

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NC

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S

TEMPERATURE

TEMPERATURE

Figure 6-92 RTD resistance vs. temperature

Troubleshooting6-20


Figure 6-93 Removing the pump


Part 1024496C� 2004 Nordson Corporation Manual 41−PROBLUE−MA−01

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Troubleshooting6-22

Part 1024496C � 2004 Nordson CorporationManual 41−PROBLUE−MA−01

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Troubleshooting6-24


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Troubleshooting6-26


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le 6

-1.

Doe

s re

plac

ing

the

com

pone

nt(s

) lis

ted

unde

r th

ere

spec

tive

faul

t cod

e, a

nd th

enre

setti

ng th

e m

elte

r cl

ear

the

faul

t?

+

Is a

n F

4 fa

ult i

ndic

ated

in th

e rig

htdi

spla

y?

Sto

p.

Go

to T

.2.2

Go

to T

.2.1

Con

tinue

don

nex

tpa

ge...

.

Co

nta

ct N

ord

son

fo

r te

chn

ical

assi

stan

ce.

Troubleshooting6-28


Con

tinue

d fr

om p

revi

ous

page

....

Co

nfi

rm t

hat

th

e R

TD

has

faile

d.

Ref

er t

o D

P.2.

P/N

102

8320

.

+

−

Is th

e ta

nk k

ey L

ED

illu

min

ated

?

+

−

+

−

Is th

e rib

bon

cabl

e fr

om th

e6-

hose

exp

ansi

on b

oard

conn

ecte

d to

the

mai

n bo

ard,

alig

ned

and

func

tioni

ng p

rope

rly?

(J5

to J

1)

+

−

Are

all

of th

e gu

n-to

-hos

e an

dho

se-t

o-m

elte

r el

ectr

ical

cor

dset

sse

cure

ly c

onne

cted

? (

The

gun

or

hose

key

LE

D is

illu

min

ated

)

Doe

s th

e fa

ult r

e-oc

cur

if yo

um

ove

the

faul

ting

hose

/gun

pai

r to

a kn

own

good

hos

e/gu

n m

odul

e?

Rep

lace

th

e h

ose

or

gu

n R

TD

.

Ref

er t

o t

he

ho

se o

r g

un

man

ual

.

Co

nn

ect

secu

rely

or

rep

lace

.

Sec

ure

th

e el

ectr

ical

con

nec

tors

an

d t

hen

pre

ss t

he

rese

t ke

y.

Co

nta

ct N

ord

son

fo

r te

chn

ical

assi

stan

ce.

Sta

rtin

g C

ondi

tion:

Fau

lt LE

D is

illu

min

ated

T.2



Res

et t

he

mel

ter

and

tu

rn t

he

hea

ters

bac

k o

n.

Allo

w t

he

un

it t

o c

om

e to

tem

per

atu

re.

Sta

rtin

g C

ondi

tions

:

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

T.2.

1

Con

t.on ne

xtpa

ge

+

−

+

−

Is th

e po

wer

cab

le th

at c

onne

cts

to J

6 co

nnec

ted

secu

rely

?

+

−

Is th

e ta

nk k

ey L

ED

illu

min

ated

?

Was

hot

mel

t rec

ently

add

ed to

the

tank

?

Allo

w t

he

un

it t

o r

each

set-

po

int

tem

per

atu

re.

Sec

ure

or

rep

air

the

loo

seco

rdse

t th

en p

ress

th

e R

eset

key.

Ref

er t

o t

he

ho

se o

r g

un

man

ual

.

+

−

Is th

e af

fect

ed g

un o

r ho

seco

rdse

t loo

se, o

r ar

e th

e pi

nsbe

nt, l

oose

or

corr

oded

? (

the

gun

or h

ose

key

LED

is il

lum

inat

ed.)

Co

nn

ect

secu

rely

.

Co

nn

ect

secu

rely

.

+

−

Are

the

wire

s to

the

elec

tric

alco

nnec

tor

into

TB

1 se

cure

?

Sec

ure

or

rep

lace

.

+

−

Is th

e po

wer

lead

con

nect

ing

the

6-ho

se e

xpan

sion

boa

rd to

the

mai

n bo

ard

loos

e or

dam

aged

?(J

10 to

J2)

(P

10 o

nly)

Go

toT.

2.3

Ver

ify

that

th

e m

anif

old

hea

ter

has

fai

led

an

d r

epla

ce.

Ref

er t

o D

P.5.

P/N

101

7723

.

+

−

Doe

s th

e m

anifo

ld fa

il to

com

eto

tem

pera

ture

?

Troubleshooting6-30


Con

tinue

d fr

om p

revi

ous

page

....

+

−

+

−

Are

the

hose

and

gun

RT

Dfu

nctio

ning

cor

rect

ly?

+

−

Are

the

indi

cato

rs D

S5

or D

S6

onth

e af

fect

ed h

ose/

gun

mod

ule

illum

inat

ed?

See

Fig

ure

6-1.

Doe

s th

e fa

ult r

e-oc

cur

if yo

ure

plac

e th

e af

fect

ed h

ose/

gun

mod

ule

with

a k

now

n go

odm

odul

e?

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

102

8323

.

Rep

lace

th

e h

ose

or

gu

n R

TD

.

Rep

lace

th

e af

fect

ed h

ose

/gu

nm

od

ule

.

P/N

102

8328

.

Rep

lace

fu

se p

airs

F1/

F2

or

F3/

F4

on

th

e af

fect

ed h

ose

/gu

nm

od

ule

.

P/N

102

8331

.

See

Fig

ure

6-1

.+

−

Is in

dica

tor

DS

2 on

the

mai

nbo

ard

or D

S5

and

DS

6 on

any

hose

/gun

mod

ule

illum

inat

ed?

Ch

eck

the

op

erat

ion

of

the

po

wer

rel

ay o

r th

erm

ost

at.

Ref

er t

o D

P.3.

+

−

Co

rrec

t th

e h

ou

se v

olt

age

or

rep

lace

th

e h

ose

/gu

n w

ith

ap

rop

erly

rat

ed h

ose

/gu

n.

Sta

rtin

g C

ondi

tions

:

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

T.2.

1Is

ther

e 24

0 V

AC

acr

oss

fuse

sF

1/F

2 or

F3/

F4

on th

e af

fect

edho

se/g

un m

odul

e, a

nd is

the

hose

/gun

wat

tage

pro

perly

rate

d?



Res

et t

he

mel

ter

and

tu

rn t

he

hea

ters

bac

k o

n.

Allo

w t

he

un

it t

o c

om

eto

tem

per

atu

re.

Sta

rtin

g co

nditi

ons:

Fau

lt LE

D is

illu

min

ated

>

F3

faul

t exi

sts

T.2.

2

+

−

Is m

ore

than

one

com

pone

ntov

erhe

atin

g? (

Che

ck th

e ac

tual

tem

pera

ture

of t

he fa

ultin

gco

mpo

nent

.)

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

102

8323

.

+

−

+

−

Is th

e ta

nk k

ey L

ED

illu

min

ated

?

Are

the

tank

/man

ifold

TR

IAC

sop

erat

ing

prop

erly

?

Ref

er to

DP.

4.

Rep

lace

th

e ta

nk/

man

ifo

ld R

TD

.

P/N

102

8320

.

Ref

er t

o D

P.2.

+

−

Doe

s re

plac

ing

the

hose

or

gun

RT

D s

olve

the

prob

lem

?

+

−

Is D

S1,

DS

2, D

S3

or D

S4

on th

eho

se/g

un m

odul

e ill

umin

ated

cont

inuo

usly

?

Sto

p.

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

102

8323

.

Rep

lace

th

e h

ose

/gu

n

P/N

102

8328

.

Con

tinue

d on

next

pag

e

Troubleshooting6-32


Con

tinue

d fr

om p

revi

ous

page

....

Sta

rtin

g co

nditi

ons:

Fau

lt LE

D is

illu

min

ated

>

F3

faul

t exi

sts

T.2.

2

+

−

Doe

s in

stal

ling

an R

C s

nubb

er o

nth

e D

C d

rive

and

rese

tting

the

mel

ter

clea

r th

e fa

ult?

P/N

332

182.

+

−

Is th

ere

a D

C d

rive

near

the

mel

ter?

Sto

p.

+

−

Is th

e re

sist

ance

bet

wee

n th

egr

ound

leg

and

eart

h gr

ound

on

the

pow

er c

able

gre

ater

than

zero

?

+

−

Is th

e po

wer

cab

le g

roun

ded

toth

e m

elte

r’s c

hass

is?

Co

rrec

t o

r es

tab

lish

ear

thg

rou

nd

co

nn

ecti

on

wit

h t

he

mel

ter.

+

−

Doe

s in

stal

ling

an R

C s

nubb

er o

nth

e m

elte

r cl

ear

the

faul

t?

P/N

332

182.

Gro

un

d t

he

po

wer

cab

lep

rop

erly

to

th

e ch

assi

s.

Sto

p.

Co

nta

ct N

ord

son

fo

r te

chn

ical

assi

stan

ce.



Sta

rtin

g co

nditi

ons:

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

>

Tank

key

LE

D is

illu

min

ated

>

Hot

mel

t has

not

bee

n ad

ded

T.2.

3

+

−

+

−

Is th

e po

wer

har

ness

into

J6

conn

ecte

d se

cure

ly?

+

−

Is in

dica

tor

DS

2 in

the

mai

n bo

ard

illum

inat

ed?

Is th

e vo

ltage

acr

oss

the

dow

nstr

eam

sid

e of

fuse

s F

1/F

2or

F3/

F4

on th

e m

ain

boar

dbe

twee

n 17

0 an

d 26

5 V

AC

?

See

Fig

ure

6-1.

Co

nn

ect

secu

rely

.

Ch

eck/

corr

ect

the

ho

use

volt

age.

+

−

Doe

s re

plac

ing

fuse

s F

1 an

d F

2on

the

mai

n bo

ard

and

then

rese

tting

the

mel

ter

clea

r th

efa

ult?

P/N

102

8329

.

+

−

Are

indi

cato

rs D

S5

or D

S6

illum

inat

ed o

n an

y ho

se/g

unm

odul

e?

See

Fig

ure

6-1.

Sto

p.

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

102

8323

.

Ch

eck

the

op

erat

ion

of

the

po

wer

rel

ay o

r th

erm

ost

at.

Co

nn

ect

secu

rely

. R

efer

to

DP.

3

Con

tinue

don

nex

tpa

ge

Troubleshooting6-34


Con

tinue

d fr

om p

revi

ous

page

....

+

−

+

−

Are

the

tank

and

the

man

ifold

TR

IAC

s fu

nctio

ning

pro

perly

?

Ref

er to

DP.

4.

+

−

Is th

e re

sist

ance

cor

rect

for

the

tank

and

the

man

ifold

hea

ters

?

Ref

er to

DP.

5.

Doe

s re

plac

ing

the

mal

func

tioni

ngta

nk o

r m

anifo

ld R

TD

sol

ve th

epr

oble

m?

P/N

102

8320

.

Ref

er to

DP.

2.

Sto

p.

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

/10 −

P/N

102

8323

Rep

lace

th

e m

anif

old

hea

ter,

tan

k, o

r th

e p

ow

er h

arn

ess.

Man

ifo

ld h

eate

r −

P/N

101

7723

.Ta

nk −

P/N

101

8379

.P

ow

er h

arn

ess −

P/N

102

4529

.

Co

nta

ct N

ord

son

fo

r te

chn

ical

assi

stan

ce.

Sta

rtin

g co

nditi

ons:

Fau

lt LE

D is

illu

min

ated

>

F2

faul

t exi

sts

>

Tank

key

LE

D is

illu

min

ated

>

Hot

mel

t has

not

bee

n ad

ded

T.2.

3



Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is n

ot il

lum

inat

ed

T.3

+

−

Is th

e he

ater

key

LE

Dill

umin

ated

?

+

−

Is th

e cl

ock

sche

dule

prog

ram

med

cor

rect

ly?

+

−

Is th

e cl

ock

LED

illu

min

ated

?

Th

e cu

rren

t cl

ock

sch

edu

le h

asth

e h

eate

rs t

urn

ed o

ff.

+

−

Is a

rem

ote

inpu

t bei

ng u

sed

toco

ntro

l the

hea

ters

?

Rep

lace

th

e o

per

ato

r p

anel

.

P4/

P7 −

P/N

102

8326

.P

10 −

P/N

102

8327

.

+

−

Doe

s pr

essi

ng th

e he

ater

key

turn

the

heat

ers

on?

Sto

p.

Go

toT.

3.1

Con

t. on

next

pag

e

Qui

ck c

heck

: S

ave

setti

ngs

and

rese

t the

mel

ter

to fa

ctor

y de

faul

t set

tings

. If

the

mel

ter

func

tions

nor

mal

ly, i

sola

te th

e in

put o

r ou

tput

pro

blem

.

Qui

ck c

heck

: M

anua

lly a

ctiv

atin

g th

e he

ater

key

or

the

pum

p ke

y w

ill o

verr

ide

and

elim

inat

e re

mot

e in

puts

as

the

caus

e of

a d

own

cond

ition

.

Troubleshooting6-36


Con

tinue

d fr

om p

revi

ous

page

....

Th

e m

elte

r is

in t

he

stan

db

ym

od

e.

Ref

er t

o S

ecti

on

4, S

tan

db

yK

ey.

+

−

Is th

e st

andb

y LE

D o

n?

+

−

Is th

e re

ady

dela

y co

untin

gdo

wn?

Wai

t fo

r th

e re

ady

del

ay t

oco

un

t d

ow

n.

Ref

er t

o A

pp

end

ix B

, par

amet

er4.

Co

nfi

rm t

hat

th

e ta

nk

hea

ter

has

fai

led

an

d r

epla

ce t

he

tan

k.

Tan

k −

P/N

101

8379

.

Ref

er t

o D

P.5.

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is n

ot il

lum

inat

ed

T.3



Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is n

ot il

lum

inat

ed >

Rem

ote

inpu

t is

bein

g us

ed

T.3.

1

+

−

+

−

Is th

ere

a si

gnal

at t

he in

put o

nth

e m

ainb

oard

or

on th

e I/O

boar

d?

Is th

e pr

ogra

mm

ing

for

the

inpu

tco

rrec

t?

Wai

t fo

r th

e in

pu

t to

init

iate

th

eh

eate

rs o

r u

se t

he

hea

ter

key

tom

anu

ally

tu

rn t

he

hea

ters

on

.

Rep

rog

ram

th

e in

pu

t.

+

−

+

−

Is th

ere

pow

er a

cros

s th

e w

ires

from

the

pare

nt m

achi

ne to

the

inpu

ts o

n th

e m

ain

boar

d or

I/O

boar

d?

+

−

Is th

ere

a si

gnal

at t

he p

aren

tm

achi

ne?

Doe

s pr

essi

ng th

e he

ater

s ke

ytu

rn th

e he

ater

s on

?

Rep

lace

th

e I/O

exp

ansi

on

bo

ard

kit

.

P/N

103

6607

.

Insp

ect

the

wir

es f

or

dam

age

or

corr

osi

on

an

d r

epla

ce if

nee

ded

.

Ver

ify

that

th

e p

aren

t m

ach

ine

is w

ork

ing

pro

per

ly.

Ref

er t

oth

e ap

pro

pri

ate

man

ual

.

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

102

8323

.

Troubleshooting6-38


Thi

s pa

ge in

tent

iona

lly le

ft bl

ank



Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns

T.4

+

−

Has

the

pum

p st

oppe

d?

+

−

+

−

Is th

e pu

mp

cycl

ing

fast

?

Is th

ere

suffi

cien

t air

pres

sure

toth

e pu

mp

(gre

ater

than

0.7

bar

/10

psi)?

Lo

cate

an

d r

epai

r th

e le

ak.

+

−

Is h

ot m

elt l

eaki

ng fr

om th

esy

stem

som

ewhe

re b

etw

een

the

man

ifold

and

the

guns

?

Ad

just

th

e ai

r p

ress

ure

.

Th

e p

um

p p

isto

n b

all v

alve

isst

uck

op

en.

Ref

er t

o A

pp

end

ix D

.

Con

tinue

d on

next

pag

e

Go

to T

.4.1

Qui

ck c

heck

: M

anua

lly a

ctiv

atin

g th

e he

ater

key

or

the

pum

p ke

y w

ill o

verr

ide

and

elim

inat

e re

mot

e in

puts

as

the

caus

e of

a d

own

cond

ition

.

Qui

ck c

heck

: S

ave

setti

ngs

and

rese

t the

mel

ter

to fa

ctor

y de

faul

t set

tings

. If

the

mel

ter

func

tions

nor

mal

ly, i

sola

te th

e in

put o

r ou

tput

pro

blem

.

Troubleshooting6-40


Con

tinue

d fr

om p

revi

ous

page

....

+

−

Is th

e ta

nk e

mpt

y?

Turn

off

th

e p

um

p. F

ill t

he

tan

k.W

ait

for

the

un

it t

o h

eat

the

adh

esiv

e to

op

erat

ing

tem

per

atu

re.

+

−

Is th

e is

olat

ion

valv

e (s

hut o

ffva

lve)

clo

sed?

See

Fig

ure

6-6.

Op

en t

he

valv

e.

+

−

Is h

ot m

elt r

etur

ning

to th

e ta

nkth

roug

h th

e re

turn

por

t loc

ated

behi

nd th

e ta

nk s

cree

n?

See

Fig

ure

6-3.

Rep

lace

th

e p

ress

ure

dis

char

ge

valv

e.

P/N

102

8308

.

Ch

eck

and

cle

an t

he

ou

tlet

of

the

tan

k an

d t

he

cro

sso

ver

tub

e o

r cl

ean

/rep

lace

th

em

anif

old

.

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns

T.4



+

−

+

−

Is th

e pu

mp

LED

illu

min

ated

?

Is th

e pu

mp

LED

flas

hing

?

+

−

Are

you

usi

ng a

n op

tiona

l inp

ut(p

aram

eter

s 5

thru

10)

toen

able

/dis

able

the

pum

p?

Sto

p.

+

−

Doe

s pr

essi

ng th

e pu

mp

key

turn

the

pum

p on

?

Sto

p.

+

−

Doe

s re

plac

ing

the

oper

ator

’spa

nel a

nd th

en r

esta

rtin

g th

em

elte

r co

rrec

t the

pro

blem

?

P4/

P7 −

P/N

102

8326

.P

10 −

P/N

102

8327

.

Rep

lace

th

e C

PU

bo

ard

.

P/N

102

8325

.

Go

toT.

4.2

Con

tinue

d on

nex

t pag

e

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns >

Pum

p ha

s st

oppe

d

T.4.

1

Qui

ck c

heck

: M

anua

lly a

ctiv

atin

g th

e he

ater

key

or

the

pum

p ke

y w

illov

errid

e an

d el

imin

ate

rem

ote

inpu

ts a

s th

e ca

use

of a

dow

n co

nditi

on.

Troubleshooting6-42


Con

tinue

d fr

om p

revi

ous

page

....

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns >

Pum

p ha

s st

oppe

d

T.4.

1

+

−

Are

the

inpu

ts p

rope

rlyfu

nctio

ning

? (

Ref

er to

tabl

e T.

3.1

for

diag

nost

ic p

roce

dure

s)

+

−

Is th

e po

wer

LE

D o

n th

e I/O

boar

d ill

umin

ated

?

Wai

t fo

r th

e sy

stem

co

ntr

olle

rto

sen

d a

pu

mp

sta

rt s

ign

al.

Rep

air

or

rep

lace

th

em

alfu

nct

ion

ing

inp

ut.

Rep

lace

th

e I/O

exp

ansi

on

bo

ard

kit

.

P/N

103

6607

.



Pro

ble

m

Turn

on

or

adju

st t

he

pla

nt

air

pre

ssu

re.

+

−

+

−

Is a

ir be

ing

supp

lied

to th

e to

p of

the

pum

p?

Is 2

4 V

DC

bei

ng s

uppl

ied

to th

eso

leno

id v

alve

(w

ire h

arne

ssle

ads

9 an

d 10

)?

Rep

lace

th

e p

neu

mat

icas

sem

bly

.

P/N

102

8307

.

+

−

+

−

Are

the

yello

w a

nd g

reen

air

lines

to th

e pn

eum

atic

ass

embl

yco

nnec

ted

prop

erly

?

See

Fig

ure

6-4.

Do

the

wire

s at

Pin

s 9

and

10 o

nth

e J7

wire

har

ness

lack

cont

inui

ty?

Con

nect

sec

urel

y. S

ee F

igur

e6-

2.

Rep

lace

th

e J7

wir

e h

arn

ess.

P/N

102

4600

.

Co

nn

ect

secu

rely

.

Rep

lace

th

e m

ain

bo

ard

.

P4/

P7 −

P/N

102

8322

.P

10 −

P/N

028

323.

+

−

Is th

e ai

r su

pply

to th

e m

elte

rtu

rned

off

or is

the

plan

t air

pres

sure

low

?

+

−

Is th

e op

erat

ing

air

pres

sure

set

corr

ectly

?

Ref

er to

Sec

tion

4.

Ad

just

th

e o

per

atin

g a

irp

ress

ure

fo

r th

e cu

rren

tm

anu

fact

uri

ng

pro

cess

.

Con

tinue

don

nex

tpa

ge...

.

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns >

Pum

p ha

s st

oppe

d >

Pum

p LE

D is

illu

min

ated

>

Tank

set

-poi

nt te

mpe

ratu

re is

OK

>

Pum

p is

not

con

trol

led

by a

rem

ote

inpu

t

T.4.

2

Troubleshooting6-44


Con

tinue

d fr

om p

revi

ous

page

....

Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

No

hot m

elt o

utpu

t fro

m a

ll gu

ns >

Pum

p ha

s st

oppe

d >

Pum

p LE

D is

illu

min

ated

>

Tank

set

-poi

nt te

mpe

ratu

re is

OK

>

Pum

p is

not

con

trol

led

by a

rem

ote

inpu

t

T.4.

2

+

−

Doe

s ad

hesi

ve fl

ow fr

om th

edr

ain

valv

e w

hen

it is

ope

n?

Cle

an o

r re

pla

ce t

he

man

ifo

ld.

P/N

102

2727

.

+

−

Is th

e fil

ter

clog

ged?

Ref

er to

Sec

tion

5.

Rep

lace

th

e fi

lter

.

P/N

102

8305

.

Rep

lace

or

rep

air

the

pu

mp

.

Ref

er t

o A

pp

end

ix D

.



Sta

rtin

g co

nditi

ons:

No

faul

ts >

Rea

dy L

ED

is il

lum

inat

ed >

Hot

mel

t out

put f

rom

som

e gu

ns

T.5

+

−

Is th

e di

spla

yed

tem

pera

ture

for

the

stop

ped

hose

/gun

cha

ngin

ger

ratic

ally

?

+

−

Is th

e se

t-po

int t

empe

ratu

reco

rrec

t for

the

hose

/gun

pai

r th

atha

s no

hot

mel

t out

put?

Ch

eck/

rep

lace

th

e h

ose

or

the

gu

n R

TD

.

Ref

er t

o t

he

ho

se o

r g

un

man

ual

.

+

−

+

−

Are

the

gun

sole

noid

, gun

driv

er,

or a

ir su

pply

to th

e gu

nfu

nctio

ning

pro

perly

?

Ad

just

th

e se

t-p

oin

tte

mp

erat

ure

.

WA

RN

ING

: R

elie

ve s

yste

mpr

essu

re b

efor

e co

ntin

uing

.

Is th

e gu

n no

zzle

or

an in

line

Sat

urn

filte

r bl

ocke

d?

Cle

an t

he

no

zzle

or

rep

lace

th

efi

lter

.

+

−

Rep

lace

/rep

air

the

sole

no

id/g

un

dri

ver

or

adju

stth

e ai

r su

pp

ly.

WA

RN

ING

: R

elie

ve s

yste

mpr

essu

re b

efor

e co

ntin

uing

.

Doe

s ho

t mel

t flo

w fr

om th

e gu

nbo

dy if

you

rem

ove

the

gun

mod

ule?

Rep

lace

th

e g

un

mo

du

le.

Ref

er t

o t

he

gu

n m

anu

al.

Rep

lace

th

e h

ose

.

+

−

WA

RN

ING

: R

elie

ve s

yste

mpr

essu

re b

efor

e co

ntin

uing

.

Doe

s ho

t mel

t flo

w fr

om th

e ho

seif

you

rem

ove

the

gun?

Rep

lace

th

e g

un

bo

dy,

hea

ter,

or

RT

D.

Ref

er t

o t

he

gu

n m

anu

al.

Troubleshooting6-46


Thi

s pa

ge in

tent

iona

lly le

ft bl

ank

Date post:	22-May-2018
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Section 6 Troubleshooting - Welcome to Nordson...

Documents