DuraBlue Adhesive Melters Model DK25, DK25H, DK50, DK100

DuraBlueR
Adhesive Melters
Model DK25, DK25H, DK50, DK100
Manual P/N 7105986H
− English −
Issued 04/11
NORDSON ENGINEERING GMBH D LÜNEBURG D GERMANY
Note
This document is for products with the following P/N:
8063430
8063436
8063442
8063431
8063437
8063443
8063432
8063438
8063444
8063433
8063439
8063434
8063440
8063435
8063441
Order number
P/N = Order number for Nordson products
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.
No part of this document may be photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained in this publication is subject to
change without notice.
E 2011 All rights reserved.
Trademarks
AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve,
CleanSpray, Color-on-Demand, ColorMax, Control Coat, Coolwave, Cross-Cut, cScan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,
DuraPail, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI-stylized,
Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli-flow, Helix,
Horizon, Hot Shot, iControl, iDry, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, JR, KB30, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March,
Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OptiMix, Package of
Values, PatternView, PermaFlo, PicoDot, PluraFoam, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue,
Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, Seal Sentry, Select
Charge, Select Coat, Select Cure, Signature, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt,
SureBead, Sure Clean, Sure Coat, Sure-Max, Sure Wrap, Tela-Therm, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UniScan,
UpTime, u-TAH, Vantage, Veritec, VersaBlue, Versa-Coat, VersaDrum, VersaPail, Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect
more. are registered trademarks − ® − of Nordson Corporation.
Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, Artiste, ATS, Auto-Flo, AutoScan, Axiom, Best Choice,
BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt,
ContourCoat, Controlled Fiberization, Control Weave, CPX, cSelect, Cyclo-Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, e.dot+,
E-Nordson, Easy Clean, EasyOn, EasyPW, Eclipse, Equalizer, Equi=Bead, Exchange Plus, FillEasy, Fill Sentry, Flow Coat, Fluxplus, G-Net, G-Site, Get
Green With Blue, Gluie, Ink-Dot, IntelliJet, iON, Iso-Flex, iTrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge,
Minimeter, MonoCure, Multifil, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI,
Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PurTech, Quad Cure, Ready Coat, RediCoat, Royal
Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand,
SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, Trade Plus, Trlogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart,
Universal, ValueMate, Versa, Viper, Vista, WebCure, 2 Rings (Design) are trademarks − T − 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.
P/N 7105986H
D_K
E 2011 Nordson Corporation
Table of Contents
I
Table of Contents
Nordson International . . . . . . . . . . . . . . . . . . . . . . . . .
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-1
O-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Responsibilities of the Equipment Owner . . . . . . . . . . . .
1-1
1-1
1-2
Distributors in Eastern & Southern Europe . . . . . . . . . .
Outside Europe / Hors d’Europe / Fuera de Europa . . .
Africa / Middle East . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Asia / Australia / Latin America . . . . . . . . . . . . . . . . . . . .
Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions, Requirements, and Standards . . . . . . . . . .
User Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicable Industry Safety Practices . . . . . . . . . . . . . . . .
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . .
Instructions and Safety Messages . . . . . . . . . . . . . . . . . .
Installation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair Practices . . . . . . . . . . . . . . . . .
Equipment Safety Information . . . . . . . . . . . . . . . . . . . . . .
Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving System Hydraulic Pressure . . . . . . . . . . . . .
De-energizing the System . . . . . . . . . . . . . . . . . . . . . . .
Disabling the Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Warnings and Cautions . . . . . . . . . . . . .
Other Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E 2011 Nordson Corporation
D_K
O-1
O-2
O-2
O-2
O-2
O-2
1-2
1-2
1-3
1-4
1-4
1-4
1-5
1-5
1-6
1-7
1-7
1-7
1-7
1-8
1-9
1-12
1-12
P/N 7105986H
II
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Area of Use (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . .
Unintended Use − Examples − . . . . . . . . . . . . . . . . . . . . .
Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Melter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . .
Material Flow with Two Pumps . . . . . . . . . . . . . . . . . . . . .
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Scan (Normal Mode) . . . . . . . . . . . . . . . . . .
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Tower (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . .
ID Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P/N 7105986H
D_K
2-1
2-1
2-1
2-1
2-1
2-2
2-3
2-4
2-5
2-5
2-5
2-5
2-5
2-5
2-6
2-7
2-8
2-8
2-8
2-8
2-8
2-8
2-9
E 2011 Nordson Corporation
Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting (Unpacked Melter) . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . .
Required Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detaching Protective Panels . . . . . . . . . . . . . . . . . . . . . .
Exhausting Material Vapors . . . . . . . . . . . . . . . . . . . . . . . .
Experience of Installation Personnel . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Observe when Using Residual Current Circuit Breakers
Laying Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Control and Switching Circuits . . . . . . . . . . . . .
Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Melter Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Set up an Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Melter Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .
To Set up an Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up Melter Communications . . . . . . . . . . . . . . . . .
Connecting Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Open-jawed Wrench . . . . . . . . . . . . . . . . . . . .
Disconnecting Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Speed Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Up the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Operating Parameters . . . . . . . . . . . . . . . . .
Reading or Editing Operating Parameters . . . . . . . . .
Setpoint Temperature of the Tank, Hoses, and Guns .
Save and Restore Melter Settings . . . . . . . . . . . . . . . . . .
Review Parameter and Setpoint Temperature Changes
Removing Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposing of Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E 2011 Nordson Corporation
D_K
III
3-1
3-1
3-1
3-2
3-2
3-2
3-2
3-2
3-3
3-3
3-4
3-4
3-4
3-4
3-4
3-5
3-6
3-6
3-6
3-7
3-7
3-10
3-11
3-12
3-13
3-13
3-14
3-14
3-14
3-14
3-15
3-15
3-16
3-17
3-17
3-21
3-21
3-22
3-24
3-26
3-27
3-29
3-29
P/N 7105986H
IV
Table of Contents
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging Test Material out of Melter . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Confirm that the Melter is Operating Correctly . . . . . . .
Monitor Component Temperatures . . . . . . . . . . . . . . . . .
Monitor Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor the Service Interval . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Component Temperatures . . . . . . . . . . . . . . . .
Recommended Temperatures . . . . . . . . . . . . . . . . . . . . .
Enter Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven-day Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standby Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting Down the Melter . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P/N 7105986H
D_K
4-1
4-1
4-2
4-2
4-2
4-3
4-3
4-4
4-4
4-5
4-8
4-8
4-9
4-11
4-17
4-18
4-18
4-23
4-24
4-24
4-25
4-25
4-26
4-27
4-28
4-29
E 2011 Nordson Corporation
Table of Contents
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important when Using Cleaning Agents . . . . . . . . . . . . .
Processing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Inspection for External Damage . . . . . . . . . . . . . .
Changing Type of Material . . . . . . . . . . . . . . . . . . . . . . . . .
Purging with Cleaning Agent . . . . . . . . . . . . . . . . . . . . . . .
Detaching Protective Panels . . . . . . . . . . . . . . . . . . . . . . .
Detaching Insulation Blanket . . . . . . . . . . . . . . . . . . . . . . .
Fan and Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-2
5-2
5-3
5-4
5-4
5-4
5-5
5-5
5-5
5-6
5-7
Checking for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retighten Gland Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pump Shaft Seal . . . . . . . . . . . . . . . . . . . . . . .
Tightening Fixing Screws . . . . . . . . . . . . . . . . . . . . . . . . .
Motor / Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling and Cleaning . . . . . . . . . . . . . . . . . . . . . .
Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . .
Installing Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . .
Installing Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Tank by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Fixing Screws . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Record Form . . . . . . . . . . . . . . . . . . . . . . . .
5-7
5-7
5-7
5-7
5-8
5-8
5-8
5-9
5-9
5-10
5-10
5-10
5-10
5-11
5-12
5-12
5-12
5-12
5-13
5-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Helpful Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . .
Melter not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .
One Channel (Heating Zone) does not Heat . . . . . . . . .
Control Panel does not Function . . . . . . . . . . . . . . . . . . .
No Material (Motor does not Rotate) . . . . . . . . . . . . . . . .
No Material (Motor Rotating) . . . . . . . . . . . . . . . . . . . . . .
Too Little Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Pressure too High . . . . . . . . . . . . . . . . . . . . . . . .
Material Pressure too Low . . . . . . . . . . . . . . . . . . . . . . . .
Material Residue in Tank . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Hardens in Tank . . . . . . . . . . . . . . . . . . . . . . . . . .
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEDs of Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . .
E 2011 Nordson Corporation
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6-2
6-2
6-2
6-2
6-3
6-4
6-4
6-5
6-5
6-5
6-6
6-6
6-7
P/N 7105986H
VI
Table of Contents
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Observe Before Performing Repairs . . . . . . . . . . . . . . . .
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Motor Controller . . . . . . . . . . . . . . . . . . . . . . . .
Replace Standard I/O Module of Motor Controller . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detaching Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Regarding Coupling . . . . . . . . . . . . . . . . . . .
Replacing Variseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Heater Connection Insulation . . . . . . . . . . . .
Replacing Temperature Sensor . . . . . . . . . . . . . . . . . . . .
Installing Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-3
7-3
7-3
7-3
7-4
7-5
7-6
7-6
7-7
7-8
7-8
7-8
7-9
7-10
7-10
7-11
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use Illustrated Parts List . . . . . . . . . . . . . . . . . . . .
8-1
8-1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-2
9-3
General Instructions Regarding Working with
Application Materials . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . .
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vapors and Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A-1
A-1
A-1
A-1
A-2
A-2
A-2
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Designation . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P/N 7105986H
7-1
7-1
7-1
7-1
7-2
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8-1
9-4
E 2011 Nordson Corporation
Table of Contents
E 2011 Nordson Corporation
VII
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . .
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven-day Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
B-2
B-10
B-15
B-16
B-23
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
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Table of Contents
P/N 7105986H
D_K
E 2011 Nordson Corporation
Introduction
O-1
Nordson International
http://www.nordson.com/Directory
Country
Phone
Fax
Austria
43-1-707 5521
43-1-707 5517
Belgium
31-13-511 8700
31-13-511 3995
Czech Republic
4205-4159 2411
4205-4124 4971
Denmark
Hot Melt
45-43-66 0123
45-43-64 1101
Finishing
45-43-200 300
45-43-430 359
Finland
358-9-530 8080
358-9-530 80850
France
33-1-6412 1400
33-1-6412 1401
Erkrath
49-211-92050
49-211-254 658
Lüneburg
49-4131-8940
49-4131-894 149
Nordson UV
49-211-9205528
49-211-9252148
EFD
49-6238 920972
49-6238 920973
Italy
39-02-216684-400
39-02-26926699
Netherlands
31-13-511 8700
31-13-511 3995
47-23 03 6160
47-23 68 3636
Poland
48-22-836 4495
48-22-836 7042
Portugal
351-22-961 9400
351-22-961 9409
Russia
7-812-718 62 63
7-812-718 62 63
Slovak Republic
4205-4159 2411
4205-4124 4971
Spain
34-96-313 2090
34-96-313 2244
Sweden
46-40−680 1700
46-40-932 882
Switzerland
41-61-411 3838
41-61-411 3818
Hot Melt
44-1844-26 4500
44-1844-21 5358
Industrial
Coating
Systems
44-161-498 1500
44-161-498 1501
49-211-92050
49-211-254 658
Europe
Germany
Norway
United
Kingdom
Hot Melt
Distributors in Eastern & Southern Europe
DED, Germany
E 2011 Nordson Corporation
All rights reserved
NI_EN_O-0211-MX
O-2
Introduction
Outside Europe / Hors d’Europe / Fuera de Europa
S For your nearest Nordson office outside Europe, contact the Nordson
offices below for detailed information.
S Pour toutes informations sur représentations de Nordson dans votre
pays, veuillez contacter l’un de bureaux ci-dessous.
S Para obtener la dirección de la oficina correspondiente, por favor
diríjase a unas de las oficinas principales que siguen abajo.
Contact Nordson
Phone
Fax
DED, Germany
49-211-92050
49-211-254 658
Pacific South Division,
USA
1-440-685-4797
−
Japan
81-3-5762 2700
81-3-5762 2701
Canada
1-905-475 6730
1-905-475 8821
Hot Melt
1-770-497 3400
1-770-497 3500
Finishing
1-880-433 9319
1-888-229 4580
Nordson UV
1-440-985 4592
1-440-985 4593
Africa / Middle East
Asia / Australia / Latin America
Japan
North America
USA
NI_EN_O-0211-MX
E 2011Nordson Corporation
All rights reserved
Safety
1-1
Section 1
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation,
operation, and maintenance (hereafter referred to as “use”) of the product
described in this document (hereafter referred to as “equipment”).
Additional safety information, in the form of task-specific safety alert
messages, appears as appropriate throughout this document.
WARNING: Failure to follow the safety messages, recommendations, and
hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.
Safety Alert Symbols
The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all 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 potentially
hazardous situation that, if not avoided, can result in damage to equipment
or property.
E 2011 Nordson Corporation
A1EN−01−[XX−SAFE]−10
1-2
Safety
Responsibilities of the Equipment Owner
Equipment owners are responsible for managing safety information,
ensuring that all instructions and regulatory requirements for use of the
equipment are met, and for qualifying all potential users.
Safety Information
S 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, and
this document.
S Make safety information available to equipment users in accordance
with governing regulations. Contact the authority having jurisdiction for
information.
S Maintain safety information, including the safety labels affixed to the
equipment, in readable condition.
Instructions, Requirements, and Standards
S Ensure that the equipment is used in accordance with the information
provided in this document, governing codes and regulations, and best
industry practices.
S If applicable, receive approval from your facility’s engineering or safety
department, or other similar function within your organization, before
installing or operating the equipment for the first time.
S Provide appropriate emergency and first aid equipment.
S Conduct safety inspections to ensure required practices are being
followed.
S Re-evaluate safety practices and procedures whenever changes are
made to the process or equipment.
A1EN−01−[XX−SAFE]−10
E 2011 Nordson Corporation
Safety
1-3
User Qualifications
Equipment owners are responsible for ensuring that users:
S Receive safety training appropriate to their job function as directed
by governing regulations and best industry practices
S Are familiar with the equipment owner’s safety and accident
prevention policies and procedures
S Receive, equipment- and task-specific training from another qualified
individual
NOTE: Nordson can provide equipment-specific installation,
operation, and maintenance training. Contact your Nordson
representative for information
S Possess industry- and trade-specific skills and a level of experience
appropriate to their job function
S Are physically capable of performing their job function and are not
under the influence of any substance that degrades their mental
capacity or physical capabilities
E 2011 Nordson Corporation
A1EN−01−[XX−SAFE]−10
1-4
Safety
Applicable Industry Safety Practices
The following safety practices apply to the use of the equipment in the
manner described in this document. The information provided here is not
meant to include all possible safety practices, but represents the best safety
practices for equipment of similar hazard potential used in similar industries.
Intended Use of the Equipment
S Use the equipment only for the purposes described and within the limits
specified in this document.
S Do not modify the equipment.
S Do not use incompatible materials or unapproved auxiliary devices.
Contact your Nordson representative if you have any questions on
material compatibility or the use of non-standard auxiliary devices.
Instructions and Safety Messages
S Read and follow the instructions provided in this document and other
referenced documents.
S Familiarize yourself with the location and meaning of the safety warning
labels and tags affixed to the equipment. Refer to Safety Labels and
Tags (if available) at the end of this section.
S If you are unsure of how to use the equipment, contact your Nordson
representative for assistance.
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Safety
1-5
Installation Practices
S Install the equipment in accordance with the instructions provided in this
document and in the documentation provided with auxiliary devices.
S Ensure that the equipment is rated for the environment in which it will be
used and that the processing characteristics of the material will not
create a hazardous environment. Refer to the Material Safety Data
Sheet (MSDS) for the material.
S If the required installation configuration does not match the installation
instructions, contact your Nordson representative for assistance.
S Position the equipment for safe operation. Observe the requirements for
clearance between the equipment and other objects.
S Install lockable power disconnects to isolate the equipment and all
independently powered auxiliary devices from their power sources.
S Properly ground all equipment. Contact your local building code
enforcement agency for specific requirements.
S Ensure that fuses of the correct type and rating are installed in fused
equipment.
S Contact the authority having jurisdiction to determine the requirement for
installation permits or inspections.
Operating Practices
S Familiarize yourself with the location and operation of all safety devices
and indicators.
S Confirm that the equipment, including all safety devices (guards,
interlocks, etc.), is in good working order and that the required
environmental conditions exist.
S Use the personal protective equipment (PPE) specified for each task.
Refer to Equipment Safety Information or the material manufacturer’s
instructions and MSDS for PPE requirements.
S Do not use equipment that is malfunctioning or shows signs of a
potential malfunction.
E 2011 Nordson Corporation
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1-6
Safety
Maintenance and Repair Practices
S Perform scheduled maintenance activities at the intervals described in
this document.
S Relieve system hydraulic and pneumatic pressure before servicing the
equipment.
S De-energize the equipment and all auxiliary devices before servicing the
equipment.
S Use only new or factory-authorized refurbished replacement parts.
S Read and comply with the manufacturer’s instructions and the MSDS
supplied with equipment cleaning compounds.
NOTE: MSDSs for cleaning compounds that are sold by Nordson are
available at www.nordson.com or by calling your Nordson
representative.
S Confirm the correct operation of all safety devices before placing the
equipment back into operation.
S Dispose of waste cleaning compounds and residual process materials
according to governing regulations. Refer to the applicable MSDS or
contact the authority having jurisdiction for information.
S Keep equipment safety warning labels clean. Replace worn or
damaged labels.
A1EN−01−[XX−SAFE]−10
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Safety
1-7
Equipment Safety Information
This equipment safety information is applicable to the following types of
Nordson equipment:
S hot melt and cold adhesive application equipment and all related
accessories
S pattern controllers, timers, detection and verification systems, and all
other optional process control devices
Equipment Shutdown
To safely complete many of the procedures described in this document, the
equipment must first be shut down. The level of shut down required varies
by the type of equipment in use and the procedure being completed. If
required, shut down instructions are specified at the start of the procedure.
The levels of shut down are:
Relieving System Hydraulic Pressure
Completely relieve system hydraulic pressure before breaking any hydraulic
connection or seal. Refer to the melter-specific product manual for
instructions on relieving system hydraulic pressure.
De-energizing the System
Isolate the system (melter, hoses, guns, and optional devices) from all
power sources before accessing any unprotected high-voltage wiring or
connection point.
1. Turn off the equipment and all auxiliary devices connected to the
equipment (system).
2. To prevent the equipment from being accidentally energized, lock and
tag the disconnect switch(es) or circuit breaker(s) that provide input
electrical power to the equipment and optional devices.
NOTE: Government regulations and industry standards dictate specific
requirements for the isolation of hazardous energy sources. Refer to
the appropriate regulation or standard.
E 2011 Nordson Corporation
A1EN−01−[XX−SAFE]−10
1-8
Safety
Disabling the Guns
All electrical or mechanical devices that provide an activation signal to the
guns, gun solenoid valve(s), or the melter pump must be disabled before
work can be performed on or around a gun that is connected to a
pressurized system.
1. Turn off or disconnect the gun triggering device (pattern controller, timer,
PLC, etc.).
2. Disconnect the input signal wiring to the gun solenoid valve(s).
3. Reduce the air pressure to the gun solenoid valve(s) to zero; then
relieve the residual air pressure between the regulator and the gun.
A1EN−01−[XX−SAFE]−10
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Safety
1-9
General Safety Warnings and Cautions
Table 1-1 contains the general safety warnings and cautions that apply to
Nordson hot melt and cold adhesive equipment. Review the table and
carefully read all of the warnings or cautions that apply to the type of
equipment described in this manual.
Equipment types are designated in Table 1-1 as follows:
HM = Hot melt (melters, hoses, guns, etc.)
PC = Process control
CA = Cold adhesive (dispensing pumps, pressurized container, and
guns)
Table 1-1 General Safety Warnings and Cautions
Equipment
Type
Warning or Caution
HM
WARNING: Hazardous vapors! Before processing any polyurethane
reactive (PUR) hot melt or solvent-based material through a
compatible Nordson melter, read and comply with the material’s
MSDS. Ensure that the material’s processing temperature and
flashpoints will not be exceeded and that all requirements for safe
handling, ventilation, first aid, and personal protective equipment are
met. Failure to comply with MSDS requirements can cause personal
injury, including death.
HM
WARNING: Reactive material! Never clean any aluminum component
or flush Nordson equipment with halogenated hydrocarbon fluids.
Nordson melters and guns contain aluminum components that may
react violently with halogenated hydrocarbons. The use of
halogenated hydrocarbon compounds in Nordson equipment can
cause personal injury, including death.
HM, CA
WARNING: System pressurized! Relieve system hydraulic pressure
before breaking any hydraulic connection or seal. Failure to relieve
the system hydraulic pressure can result in the uncontrolled release of
hot melt or cold adhesive, causing personal injury.
HM
WARNING: Molten material! Wear eye or face protection, clothing
that protects exposed skin, and heat-protective gloves when servicing
equipment that contains molten hot melt. Even when solidified, hot
melt can still cause burns. Failure to wear appropriate personal
protective equipment can result in personal injury.
Continued...
E 2011 Nordson Corporation
A1EN−01−[XX−SAFE]−10
1-10 Safety
General Safety Warnings and Cautions
(contd)
Table 1-1 General Safety Warnings and Cautions (contd)
Equipment
Type
Warning or Caution
HM, PC
WARNING: Equipment starts automatically! Remote triggering
devices are used to control automatic hot melt guns. Before working
on or near an operating gun, disable the gun’s triggering device and
remove the air supply to the gun’s solenoid valve(s). Failure to
disable the gun’s triggering device and remove the supply of air to the
solenoid valve(s) can result in personal injury.
HM, CA, PC
WARNING: Risk of electrocution! Even when switched off and
electrically isolated at the disconnect switch or circuit breaker, the
equipment may still be connected to energized auxiliary devices.
De-energize and electrically isolate all auxiliary devices before
servicing the equipment. Failure to properly isolate electrical power to
auxiliary equipment before servicing the equipment can result in
personal injury, including death.
HM, CA, PC
WARNING: Risk of fire or explosion! Nordson adhesive equipment is
not rated for use in explosive environments and should not be used
with solvent-based adhesives that can create an explosive
atmosphere when processed. Refer to the MSDS for the adhesive to
determine its processing characteristics and limitations. The use of
incompatible solvent-based adhesives or the improper processing of
solvent-based adhesives can result in personal injury, including death.
HM, CA, PC
WARNING: Allow only personnel with appropriate training and
experience to operate or service the equipment. The use of untrained
or inexperienced personnel to operate or service the equipment can
result in injury, including death, to themselves and others and can
damage to the equipment.
Continued...
A1EN−01−[XX−SAFE]−10
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Safety
1-11
Equipment
Type
Warning or Caution
HM
CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces
of guns, hoses, and certain components of the melter. If contact can
not be avoided, wear heat-protective gloves and clothing when
working around heated equipment. Failure to avoid contact with hot
metal surfaces can result in personal injury.
HM
CAUTION: Some Nordson melters are specifically designed to
process polyurethane reactive (PUR) hot melt. Attempting to process
PUR in equipment not specifically designed for this purpose can
damage the equipment and cause premature reaction of the hot melt.
If you are unsure of the equipment’s ability to process PUR, contact
your Nordson representative for assistance.
HM, CA
CAUTION: Before using any cleaning or flushing compound on or in
the equipment, read and comply with the manufacturer’s instructions
and the MSDS supplied with the compound. Some cleaning
compounds can react unpredictably with hot melt or cold adhesive,
resulting in damage to the equipment.
HM
CAUTION: Nordson hot melt equipment is factory tested with
Nordson Type R fluid that contains polyester adipate plasticizer.
Certain hot melt materials can react with Type R fluid and form a solid
gum that can clog the equipment. Before using the equipment,
confirm that the hot melt is compatible with Type R fluid.
E 2011 Nordson Corporation
A1EN−01−[XX−SAFE]−10
1-12 Safety
Other Safety Precautions
S Do not use an open flame to heat hot melt system components.
S Check high pressure hoses daily for signs of excessive wear, damage,
or leaks.
S Never point a dispensing handgun at yourself or others.
S Suspend dispensing handguns by their proper suspension point.
First Aid
If molten hot melt comes in contact with your skin:
1. Do NOT attempt to remove the molten hot melt from your skin.
2. Immediately soak the affected area in clean, cold water until the hot melt
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 MSDS for the hot
melt to the medical personnel providing treatment.
A1EN−01−[XX−SAFE]−10
E 2011 Nordson Corporation
Introduction
2-1
Section 2
Introduction
Intended Use
DuraBlueR adhesive melters may be used only to melt and convey suitable
materials, e.g. thermoplastic hot melt adhesives.
Any other use is considered to be unintended. Nordson will not be liable for
personal injury or property damage resulting from unintended use.
Intended use includes the observance of Nordson safety instructions.
Nordson recommends obtaining detailed information on the materials to be
used.
Area of Use (EMC)
In regard to electromagnetic compatibility (EMC), the melter is intended for
use in industrial applications.
Operating Restrictions
When operated in residential or commercial areas, the melter may cause
interference in other electrical units, e.g. radios.
Unintended Use − Examples −
The melter may not be used under the following conditions:
S
S
S
S
S
S
In defective condition
Without insulation blanket and protective panels
With electrical cabinet door open
With tank lid open
In a potentially explosive atmosphere
When the values stated under Technical Data are not complied with.
The melter may not be used to process the following materials:
S
S
S
S
E 2011 Nordson Corporation
Polyurethane hot melt adhesive (PUR)
Explosive and flammable materials
Erosive and corrosive materials
Food products.
D_K
P/N 7105986H
2-2
Introduction
Residual Risks
In the design of the unit, every measure was taken to protect personnel
from potential danger. However, some residual risks can not be avoided:
S Risk of burns from hot material.
S Risk of burns when filling the tank, from the tank lid, and from the tank
lid supports.
S Risk of burns when conducting maintenance and repair work for which
the melter must be heated up.
S Risk of burns when attaching and removing heated hoses.
S Material fumes can be hazardous. Avoid inhalation.
S Risk of damage to cables/lines belonging to the customer, if they were
installed such that they come into contact with hot or rotating parts.
S The safety valve may malfunction due to hardened or charred material.
P/N 7105986H
D_K
E 2011 Nordson Corporation
2-3
Introduction
Melter Description
1
3
2
4
11
5
6
12
18
7
17
16
15
14
13
8
9
10
Fig. 2-1
1
2
3
4
5
6
Example DK25H
Control panel
Main switch
ID plate
Light tower (accessory)
Hose receptacles
Tank lid
E 2011 Nordson Corporation
7
8
9
10
11
12
Protective panel, removable
Pressure control valve
Filter cartridge
Electrical cabinet
Hopper
Tank
D_K
13
14
15
16
17
18
Motor
Coupling
Pump
Safety valve plate
Manifold
Insulation blanket
P/N 7105986H
2-4
Introduction
Control Panel
1
2
3
4
9
8
5
6
7
Fig. 2-2
1
2
3
Control panel
Fault LED
Ready LED
Component keys / LEDs
P/N 7105986H
4
5
6
Keypad
Serial port
Right display and scroll keys
D_K
7
8
9
Left display and scroll key
Function keys
Service LED
E 2011 Nordson Corporation
Introduction
2-5
Safety Valve Plate
Tank Isolation Valve
1
The tank isolation valve (1) enables replacement of the pump without first
emptying the tank.
2
Safety Valve
The safety valve (2) is fixed at
8.5 MPa
85 bar
1235 psi.
When the pressure is exceeded, the safety valve opens, allowing the
material to circulate within the safety valve plate.
Fig. 2-3
Tank
The tank is divided into grid (low melt) and reservoir (high melt) sections. An
insulating seal (2) provides a temperature barrier between the two sections.
The temperature barrier allows the material in the grid section (1) to be
gently melted at a low temperature. The material is then melted to
processing temperature in the reservoir (3).
1
2
Hopper
3
The tank of the model DK25H is equipped with a 35 cm high tank extension
(hopper); the hopper increases the tank volume from 20 l to 45 l. The
hopper is not heated.
Fig. 2-4
Pressure Control Valve
1
The pressure control valves (3) can be manually adjusted from
0.5 to 9 MPa
5 to 90 bar
72.5 to 1305 psi
2
3
Fig. 2-5
1
2
3
Hose connection
Filter cartridge
Pressure control valve
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2-6
Introduction
Material Flow with Two Pumps
The connecting locations on the melter are labeled with numbers.
2.1 on the manifold means motor/pump 2, 1st hose
2
1
2.1
2.2
2.3
1.1
1.2
1.3
Motor 2
Motor 1
Fig. 2-6
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Introduction
2-7
Electrical Cabinet
3
2
1
4
9
8
7
2
6
5
Fig. 2-7
1 Main board
2 Circuit breakers
3 Control panel board
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4 Terminal blocks speed setpoint
5 Fan with filter
6 Motor controller
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7 Power supply 24VDC
8 Mains terminals
9 I/O terminal block
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2-8
Introduction
Modes of Operation
DuraBlue melters operate in the following modes:
Automatic Scan (Normal Mode)
The melter automatically checks and displays the current temperature of the
tank, hoses, and guns to confirm that they are within their pre-defined
temperature range. By default, the melter is always in the automatic scan
mode unless it is placed into another operating mode.
Standby
The temperatures of the tank, hoses, and guns are reduced down from their
operating temperature (hereafter referred to as set-point temperature) by a
pre-set number of degrees.
Setup
The setup mode is used to configure melter control options and features
and to review stored operating data. To prevent unauthorized changes to
the melter’s configuration, the melter can be password-protected.
Fault
The melter alerts the operator when an abnormal event occurs.
Light Tower (Accessory)
The light tower shows of the unit operating mode.
White
Switched on
Green
Ready for operation
Yellow
Tank empty
Red
General alarm
Also refer to Troubleshooting and Installation.
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Introduction
2-9
ID Plate
DuraBlue
2
1
ADHESIVE
MELTER
3
4
Serial No:
UL
C
US
LISTED
63U1
Year
5
2003
Nordson Engineering GmbH
Lilienthalstr. 6
D 21337 Lüneburg − Germany
www.nordson.com
Fig. 2-8
1
Melter designation
2
Order number
3
4
Electrical connection, operating voltage, line voltage frequency, melter fuse protection
5
Serial number
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2-10 Introduction
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Installation
3-1
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
Transport
1
2
3
S Refer to section Technical Data for weight. Use only suitable transport
devices.
S If possible, use the pallet (3) that came with the melter and use angle
brackets (2) to fasten the melter.
S Use sturdy cardboard (1) to protect from damage.
S Protect from humidity and dust.
S Avoid jolts and vibrations.
Fig. 3-1
Principle drawing
Storage
CAUTION: Do not store melter outside! Protect from humidity, dust and
extreme temperature fluctuations (formation of condensation).
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3-2
Installation
Unpacking
Unpack carefully and check for damage caused during transport. Save
pallet, angle brackets and box for later use, or dispose of properly according
to local regulations.
Fig. 3-2
Lifting (Unpacked Melter)
Refer to the section Technical Data for weight. Lift melter only at the chassis
using suitable lifting equipment or a forklift.
Installation Requirements
Set up only in an environment that corresponds to the stated Degree of
Protection (Refer to section Technical Data). Do not mount in a potentially
explosive atmosphere! Protect from vibration.
Required Space
Refer to section Technical Data, Dimensions
Detaching Protective Panels
Open the protective panels with a 4 mm Allan key.
On the inside
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Installation
3-3
Exhausting Material Vapors
Ensure that material vapors do not exceed the prescribed limits. Observe
the safety data sheet (MSDS) for the material to be processed.
If necessary, exhaust material vapors and/or provide sufficient ventilation of
the location of the system.
Fig. 3-3
Experience of Installation Personnel
The instructions provided in this section are intended to be used by
personnel who have experience in the following subjects:
S
S
S
S
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Hot melt application processes
Industrial power and control wiring
Industrial mechanical installation practices
Basic process control and instrumentation
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Installation
Electrical Connections
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or melter damage.
Observe when Using Residual Current Circuit Breakers
Local regulations in some geographic areas or industrial branches may
require residual current circuit breakers.
Then observe the following points:
S Permanent installation is required (fixed line voltage connection)
S The residual current circuit breaker is to be installed only between the
power supply and the melter.
S Only residual current circuit breakers sensitive to pulsating current or
universal current (> 30 mA) may be used.
Laying Cable
WARNING: Use only temperature resistant cable in the heating part of the
melter. Ensure that cables do not touch rotating and/or hot melter
components. Do not pinch cables and check regularly for damage. Replace
damaged cables immediately!
Operating Voltage
WARNING: Operate only at the operating voltage shown on the ID plate.
NOTE: Permitted deviation from the rated line voltage is 10%.
NOTE: The power cable cross-section must comply with the maximum
power consumption (refer to section Technical Data).
External Control and Switching Circuits
WARNING: Connect external control and switching circuits using suitable
NEC class I cables. In order not to cause short circuits lay cables such that
they do not touch any printed circuit boards.
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3-5
Power Supply Connection
NOTE: The melter must be installed securely (permanent power supply
connection).
Terminals
Line voltage
L1
L2
L3
N
200 VAC 3-phase without neutral
(Delta)
D
D
D
D
230 VAC 3-phase without neutral
(Delta)
D
D
D
D
400 VAC 3-phase with neutral
(star − WYE)
D
D
D
400 VAC 3-phase without neutral
(Delta)
D
D
D
D
480 VAC 3-phase without neutral
(Delta)
D
D
D
D
D
PE
Mains terminals in
electrical cabinet
D
Refer to wiring diagram for connecting arrangement.
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3-6
Installation
Accessories
The following components can also be installed later as accessories:
Mains Filter
Installing Kit
WARNING: Disconnect the unit from the line voltage.
1. Disconnect the customer’s power supply from the mains terminals in the
electrical cabinet. Extract power cable.
2. Replace the cable gland on the electrical cabinet with the EMC cable
gland on the shielded cable (1).
3. Screw on mains filter on electrical cabinet.
4. Connect shielded cable (1) to mains terminals in electrical cabinet.
5. Connect customer’s power cable (2) to the terminals in the mains filter
casing.
1
6. Fasten casing cover again.
2
Fig. 3-4
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3-7
Light Tower
Installing Kit
WARNING: Disconnect the system from the line voltage.
3
4
5
1
2
Fig. 3-5
CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must be
set to the default.
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3-8
Installation
Installing Kit (contd.)
1. Break out the plate from the top of the tower (1, Fig. 3-5) along the
punched lines and remove.
2. Swivel tower open.
3. Guide cable through the resulting hole.
4. Use the two screws M5 to fasten the light tower.
5. Guide the cable through the top opening of the tower and to the inside
wall of the electrical cabinet.
6. Release knurled nut (4) from the bracket Cable duct (3). Slide bracket
up in the slot.
6
7. Guide the cable through the resulting opening to the terminal blocks
(6, Fig. 3-6) in the electrical cabinet door.
8. Place wire ends and bridges according to their designations (e.g. no. 5
to terminal 5). Refer to wiring diagram.
9. Use a cable tie to fasten the cable to one of the metal teeth (5) below
the bracket Cable duct.
10. Slide the bracket down and tighten knurled nut.
11. Close tower.
Fig. 3-6
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Installation
3-9
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3-10 Installation
Installing Melter Inputs
DuraBlue melters are equipped with four inputs.
Fig. 3-7
XL2
Each input is customer-wired to the melter and then set up to provide one of
the following control options:
S
S
S
S
Place the melter into the standby mode
Turn the heaters on and off
Enable or disable a specific hose or gun
Turn the motor(s) on and off
The inputs can be activated with the 24VDC signal (terminal 20) via the
external relay contact.
WARNING: The operator can override the melter inputs by using the
control panel function keys. Ensure that the control logic for any external
device that sends an input signal to the melter is programmed to prevent the
creation of an unsafe condition in the event that the operator overrides an
external input to the melter.
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3-11
To Set up an Input
Set up the parameter control option for each input that you connected to the
melter. Table 3-1 lists the available control options. Refer to Setting Up the
Melter, for information about how to select operating parameters and edit
parameter control options.
Tab. 3-1 Input Data
Input
Terminals
XL2
Operating Parameter
Control Option
Note
Standard inputs
NOTE: Terminals 9, 11, 13, 14, 18, 19 (0VDC) are jumpered at the factory. Refer to wiring diagram
0 - Input Disabled
1 - Standby On/Off
2 - Heaters On/Off
3 - Pump 1 Enable/Disable
A
4 - Hose/Gun 1 Enable/Disable
5 - Hose/Gun 2 Enable/Disable
1
8 and 9
30
6 - Hose/Gun 3 Enable/Disable
7 - Hose/Gun 4 Enable/Disable
8 - Hose/Gun 5 Enable/Disable
9 - Hose/Gun 6 Enable/Disable
10 – Automatic standby (Default)
B
11 - Pump 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
0 - Input Disabled
1 - Standby On/Off (Default)
2 - Heaters On/Off
3 - Pump 1 Enable/Disable
A
4 - Hose/Gun 1 Enable/Disable
5 - Hose/Gun 2 Enable/Disable
2
10 and 11
31
6 - Hose/Gun 3 Enable/Disable
7 - Hose/Gun 4 Enable/Disable
8 - Hose/Gun 5 Enable/Disable
9 - Hose/Gun 6 Enable/Disable
11 - Pump 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
3
12 and 13
32
Same as parameter 31 (Default=2)
4
7 and 14
33
Same as parameter 31 (Default=4)
NOTE
A:
If control option 3 is selected, the motor will not turn on—even if you press the pump key—if voltage is
not present on the input’s contacts.
B:
If control option 10 is selected for input 1, a time must be set in parameter 24.
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3-12 Installation
Installing Melter Outputs
The melter has three outputs on terminal block XL2 of which outputs 1 and
3 are user-configurable. Output 2 may not be changed. Outputs are used to
communicate with user-supplied production equipment or control hardware,
such as a programmable logic controller.
Fig. 3-8
XL2
The customer wires each output and then configures it in the melter’s
firmware for one of the following control options:
S
S
S
S
The melter is ready
The melter is ready and the motor is on
A fault has occurred
The service LED is on.
The terminals 33, 36 and 39 as well as 34 and 37 can be bridged with two
bridges from the Ship-With-Kit.
Also refer to wiring diagram for connecting arrangement.
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3-13
Installation
To Set up an Output
Set up the parameter control option for each output that you connected to
the melter. Table 3-2 lists the available control options. Refer to Setting Up
the Melter, for information about how to select operating parameters and
edit parameter control options.
CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must be
set to the default.
Tab. 3-2 Output Data
Terminals
XL2
Output
Operating
Parameter
Control Options
Note
Standard outputs
NOTE: Terminals 1, 3, 5, 15, 20 (24VDC) are jumpered at the factory. Refer to wiring diagram
0 - Output Disabled
1 - Ready (Default)
Refer to
wiring
diagram,
pages
132a, 132b
and 132c
1
2 - Ready and Motor ON
40
3 - Fault
4 - Tank level low (not available)
5 - Service LED ON
6 - Alarm
2
41
Like parameter 40 (default = 3, may not be
modified)
3
42
Like parameter 40 (default = 4)
NOTE
A:
−
B:
−
C
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.
Setting up Melter Communications
1
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With a computer connected to the system’s serial interface (1), all settings
can be displayed and changed, settings can be transferred between
systems and the system’s operating firmware can be up- and downgraded.
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3-14 Installation
Connecting Hose
Also refer to the hose manual.
Connecting Electrically
1. First connect the hose (1) electrically to the unit.
Use the hose receptacles XS10 to XS15 (2b) for the plugs (2a) of the
hoses. The connections are protected with a clamp.
NOTE: For more than one hose: Every hose connection is allocated to a
corresponding receptacle. Do not mistakenly exchange!
Refer to wiring diagram for connecting arrangement.
2b
1
2a
2a
Fig. 3-9
Electrical connection
Connecting
Second Open-jawed Wrench
Use a second open-jawed wrench when connecting and disconnecting the
hose. This prevents the hose connection from turning.
MXHH002S033A0295
Fig. 3-10
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Installation
Connecting
3-15
(contd.)
WARNING: Hot! Risk of burns. Wear heat-protective gloves.
2 3
Fig. 3-11
1
If cold material can be found in the hose connection, the components (2, 3)
must be heated until the material softens (approx. 70 ° C (158 ° F),
depending on material).
Connecting
2. Heat the melter and hose to approx. 70 ° C (176 ° F).
3. Connect the hoses in the order of the numbers on the manifold. This
prevents the creation of dead space that would otherwise result from
unused connections.
NOTE: Close unused hose connections with Nordson port plugs.
Disconnecting Hose
WARNING: System and material pressurized. Relieve system pressure
before disconnecting hoses. Failure to observe can result in serious burns.
Relieving Pressure
1. Switch off the motor(s) (Refer to section Operation).
2. Place a container under the nozzle(s) of the gun / assembly handgun.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly handgun. Repeat this procedure until no more material
flows out.
4. Properly dispose of the material according to local regulations.
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3-16 Installation
Setting Speed Setpoint
WARNING: Disconnect melter from line voltage before opening the
electrical cabinet.
The speed is set with the terminal blocks (1) in the electrical cabinet.
1
1
Fig. 3-12
Terminal 1
Terminal 3
Speed
Output capacity per pump
DK25 / DK25H / DK50
in
out
in
out
out
in
in
out
DK100
50
min−1
35 kg/h
77 lb / hr
50 kg/h
110 lb / hr
65
min−1
45 kg/h
99 lb / hr
65 kg/h
143 lb / hr
min−1
90 kg/h
198 lb / hr
130 kg/h
286 lb / hr
0 kg/h
0 lb / hr
0 kg/h
0 lb / hr
129
0
min−1
NOTE: The setting 0 min−1 is not meant to shut down the melter. To shut
down the melter set the main switch to 0/OFF.
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Setting Up the Melter
After physically installing the melter, it must be set up to support your
manufacturing process. Melter setup consists of enabling or making
changes to factory-set operating parameters that affect the use and function
of the melter. The operating temperature (set-point) of the tank and each
hose and gun is also established during melter setup.
The melter is shipped from the factory with the most commonly used
operating parameters already set up. The factory setup can be modified at
any time to suit your manufacturing process.
Quick Setup
Table 3-3 describes the most commonly used operating parameters and
their factory settings. Review the table to determine if the factory settings for
each parameter will support your manufacturing process. If the default
values for each of these operating parameters are appropriate for your
manufacturing process, then no melter setup is required. Go directly to
Set-point Temperature of the Tank, Hoses, and Guns later in this section to
complete the installation process.
If you need to make changes to the factory setup or if you want to learn
about other operating parameters, go to the next part in this section,
Operating Parameters.
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3-18 Installation
Tab. 3-3 Common Operating Parameters
Parameter
Parameter Name
Purpose
Default Value
0
Enter password
0 to 9999
4000
1
Total hours with
heaters on
(noneditable)
9999
0
2
Fault log
(noneditable)
—
_-F0 (log entry
not used)
3
Change history log
(noneditable)
—
P-_ (log entry not
used)
Ready Delay Time
A timer that delays the activation of the ready LED for a
pre-defined time period after the tank, hoses, and guns
are at the desired set-point temperature. The ready
delay timer will only activate if the temperature of the
tank, at the time the melter is turned on, is below its
assigned set-point temperature by 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 the timer equals the number of hours that the
heaters have been on. The service LED is used to
signal the need for maintenance.
500 hours
7
Motor Off Delay
Not being used, only displayed.
−
8
Automatic Pump On
Allows the pump to start automatically when system
ready is reached, provided that the pump has been
enabled by pressing the pump key.
Enabled
11
Create Password
Sets a password that must be entered before any
melter operating parameter or set-point temperature
can be changed.
5000
4
12
Change hose 1 output to electric activation
0 (disabled) or 1 (enabled)
0 (disabled)
13
Change hose 2 output to electric activation
0 (disabled) or 1 (enabled)
0 (disabled)
14
Safety interlock for
external communication
0 or 1
0 (disabled)
20
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Temperature Units
Sets the units of the temperature display to degrees
Celsius (C) or to degrees Fahrenheit (F).
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Parameter
Parameter Name
Purpose
Default Value
21
Over Temperature
Delta
Sets the number of degrees that any heated
component can exceed its assigned set-point
temperature before an over temperature fault occurs.
15 °C (25 °F)
22
Under Temperature
Delta
Sets the number of degrees that any heated
component can drop below its assigned set-point
temperature before an under temperature fault occurs.
25 °C (50 °F)
23
Standby Delta
Sets the number of degrees that the temperature of all
heated components will be decreased when the melter
is placed into the standby mode.
50 °C (100°F)
26
Manual Standby Time
Sets the amount of time the melter will remain in the
standby mode after the standby key is pressed.
Disabled
30
Standard input 1
31
Standard input 2
32
Standard input 3
33
Standard input 4
3-19
0–8 and 10−14
10 (Automatic
standby)
0−8 and 11−14
1 (Enter/exit
standby)
0−8 and 11−14
2 (Heaters on/off)
0−8 and 11−14
4 (Hose/gun 1
enable/disable)
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)
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Parameter
Parameter Name
Purpose
Default Value
Seven-day clock
50
Current Day
1 to 7 (1 = Monday)
—
51
Current Time
0000 to 2359
—
55
Schedule 1 Heaters On
0000 to 2359
06:00
56
Schedule 1 Heaters Off
0000 to 2359
17:00
57
Schedule 1
Enter Standby
0000 to 2359
—:—
58
Schedule 1
Exit Standby
0000 to 2359
—:—
60
Schedule 2 Heaters On
0000 to 2359
—:—
61
Schedule 2 Heaters Off
0000 to 2359
—:—
62
Schedule 2
Enter Standby
0000 to 2359
—:—
63
Schedule 2
Exit Standby
0000 to 2359
—:—
65
Schedule 3 Heaters On
0000 to 2359
—:—
66
Schedule 3 Heaters Off
0000 to 2359
—:—
67
Schedule 3
Enter Standby
0000 to 2359
—:—
68
Schedule 3
Exit Standby
0000 to 2359
—:—
71 − 77
Schedules for the days
of the week
(71 = Monday)
0−7
0
78
Automatic Fill interruption
0−99 seconds
0 (disabled)
79
Reverse fault logic
0 or 1
0 (open when fault
condition)
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3-21
Operating Parameters
The melter uses operating parameters to store noneditable and editable
values. Noneditable values are those that provide information about the
historical performance of the melter. Editable values are either a numeric
set-point or a control option setting. Control options settings affect the
display of information or the function of the melter.
Operating parameters are stored in the melter’s firmware in the form of a
sequentially numbered list. The list is organized into the logical groups
described in Table 3-4.
Tab. 3-4 Parameter Groups
Group
Standard
Parameter
Number
0 to 8 and
11 to 14
Description
Noneditable and other frequently used
parameters
Temperature
Control
20 to 26
Control heaters
Input Setup
30 to 33
Configure the inputs
Output Setup
40 to 42
Configure the outputs
Seven-day Clock
50 to 77
Configure the clock feature
Automatic Fill
timer
78
Configures external motor control switch
Reverse fault logic
79
Configures fault logic to open when fault
condition
In addition to the ability to read and edit parameter values, you can also
save and restore the current value of every operating parameter and review
a log of the last ten changes that were made to editable parameters.
Selecting Operating Parameters
Refer to Appendix B, Operating Parameters, for detailed information about
each parameter. Appendix B contains a complete description of each
parameter, including its affect on the melter, default value, and format.
NOTE: Parameters that are used to configure optional equipment or that
are otherwise reserved in the firmware are excluded from Appendix B.
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Reading or Editing Operating Parameters
Regardless of whether a parameter’s value is editable or not, the procedure
for accessing each parameter in order to read or edit its current value is the
same.
To read or edit a parameter
1. Switch the melter on.
The melter performs a start-up check.
2. Press the Setup key.
The left display flashes parameter 1.
3. Use the numeric keypad to enter the number of the desired parameter.
Refer to Appendix B for a complete list of parameters.
Setup key
NOTE: If you incorrectly enter the parameter number, press the
Clear/Reset key to return to parameter 1 and then re-enter the correct
parameter number.
When you have finished entering the one- or two-digit parameter
number, the right display indicates the parameter’s current value.
4. Do one of the following:
S If the value is noneditable, refer to Monitor the Melter in Section 4,
Clear/Reset key
Operation.
S If the value is editable go to step 5.
5. Press the Enter key.
The right display flashes.
Enter key
6. Use the keypad to enter the desired numeric set-point or control option
into the right display. Refer to Appendix B, Operation Parameters, for
information about the numeric value or control option choices for each
parameter.
NOTE: If the keypad has no affect on the right display, the melter is
password protected. You must enter a valid password before you can
edit parameters. Refer to Enter the Melter Password in Section 4,
Operation.
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To read or edit a parameter (contd.)
7. Press the Enter key.
The melter checks that the new value or control option is acceptable.
S If the numeric set-point or control option is accepted, the left and
right displays index to the next sequential parameter number and
value.
S If the numeric set-point or control option is not accepted, the right
display will indicate dashes (----) for three seconds and then it will
change back to the original value.
8. Repeat step 5 through step 7 to read or change the next sequential
parameter number or press the Setup key to exit the setup mode.
You can exit the setup mode at any
time by pressing the Setup key.
Parameter numbers that are not
applicable are skipped when you
scroll through the operating
parameter list in the left display.
When the right display is flashing,
you can quickly set the value of the
current parameter to it’s lowest
possible value by simultaneously
pressing both of the right-display
scroll keys.
While in the setup mode, if no key is
pressed for two minutes, the melter
will return to the automatic scan
mode.
You can also use the right-display
scroll keys to enter or change a
parameter’s value or control option.
After entering the parameter’s
number in the left display, press
either of the right-display scroll keys
to change the value or control
option.
If password protection is enabled,
the melter will return to the password
protected mode whenever you exit
the setup mode.
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3-24 Installation
Setpoint Temperature of the Tank, Hoses, and Guns
The melter is shipped from the factory with the tank set-point temperature at
175 °C (350 °F) and the hose and gun set-point temperatures at 0 degrees
(turned off).
Before the melter can be used, a set-point temperature must be assigned to
the tank, hoses, and guns. Assign set-point temperatures using any of the
following methods:
S Global—The tank and all hoses and guns are set to the same set-point
temperature.
S Global-by-component group—All of the hoses or all of the guns are
set to the same set-point temperature.
S Individual Component—The set-point temperature of the tank and
each hose and gun is set individually.
Since most manufacturing processes will require the tank, hoses, and guns
to be set to the same temperature, only the global method of assigning
set-point temperatures is described in this section. For information about the
other two methods of assigning set-point temperatures, refer to Section 4,
Adjusting Component Temperatures.
As with operating parameters, you can also save and restore set-point
temperatures and review past changes that were made to set-point
temperatures.
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Installation
3-25
To Assign a Global Setpoint Temperature
1. Press and hold the Tank key for three seconds.
The left display flashes 1.
Tank key
2. Scroll the left display to 0.
The right display indicates all dashes (----) and the LEDs on the tank,
hose, and gun keys turn green.
3. Press the Enter key.
The right display flashes.
Left display and
scroll key
4. Use the numeric keypad to enter the set-point temperature
recommended by the manufacturer of the hot melt.
Refer to the technical data sheet provided by the manufacturer of the
hot melt to determine the optimal set-point temperature.
5. Press the Tank key.
Each component begins to heat or cool to the new global set-point
temperature and the melter returns to the automatic scan mode.
Enter key
When all of the components reach the global set-point temperature, the
ready LED turns on (green).
Ready LED
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3-26 Installation
Save and Restore Melter Settings
The current value of all editable operating parameters and the set-point
temperature of each component can be saved and, if necessary, restored at
a later time. When saved settings are restored, they overwrite the settings
that are presently in use.
This save-restore feature is useful in instances where the settings that are
in use are deliberately or accidentally changed and you need to return the
melter to its pre-change setup.
To save current settings
With the melter in the automatic scan mode, simultaneously press the
number 1 key and the Setup key.
+
Saving current settings
S-1 appears momentarily in the right display.
To restore saved settings
CAUTION: All melter settings will be deleted! Before restoring saved
settings, ensure that use of the restored settings will not disrupt the current
process or create an unsafe operating condition.
+
With the melter in the automatic scan mode, simultaneously press the
number 2 key and the Setup key.
S-2 appears momentarily in the right display.
Restoring saved settings
If you use the restore feature before the
save feature is used for the very first
time, the factory default set-point
temperatures will be restored. This will
cause the hoses and guns to stop
heating.
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Installation
3-27
Review Parameter and Setpoint Temperature Changes
The melter stores in a change history log, a record of the last ten changes
that were made to either operating parameters or set-point temperatures.
Since the log only stores ten changes, old log entries are overwritten
beginning with the first log entry, by the eleventh and following log entries.
To Review the Change History Log
1. Press the Setup key.
Setup key
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:
S If the last change was to an editable parameter, all of the component
key LEDs remain off.
Left display and
scroll key
or
S If the last change was to a set-point temperature, the LED on the
associated component key(s) turns on.
and
S The right display indicates the four-digit log entry associated with the
last change that was made.
Table 3-5 provides the meaning, from left to right, of each digit in the
log entry. Following the table are two example log entries.
Component key LEDs
3. Press a right-display scroll key to review each of the remaining nine log
entries. Each press of a scroll key displays a progressively older log
entry.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the log
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3-28 Installation
Tab. 3-5 Change history log
First digit
Second
digit
P
Third and fourth digit
Indicates the number of the parameter that was changed
(Parameter)
Are used in conjunction with the LEDs on the component keys to indicate the
location and method of a set-point temperature change.
−
S (Set-point)
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When this LED is
on..
And the Fourth
Digit Indicates..
The change was
to..
And the Method
of Change was..
Tank Key
1
The tank
Individual
Hose Key
1– 6
A single hose
Individual
Gun Key
1– 6
A single gun
Individual
All Keys
0
All components
Global
Hose Key
0
All hoses
Global-bycomponent
Gun Key
0
All guns
Global-bycomponent
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Installation
3-29
Change History Log Examples
Example 1:
Parameter 4 (ready delay) was changed.
Example 2:
If the LED on the gun key is on, then this display would
indicate that the global-by-component method was used to change the
temperature of the guns.
Unused log entries in the change history log
are indicated by “P-_” in the right display.
To view how many heater hours have
elapsed since a specific change (displayed)
was made, simultaneously press both of the
right-display scroll keys.
Removing Melter
Run the melter until empty, separate all connections from the melter, and
allow the melter to cool down.
Disposing of Melter
When your Nordson product has exhausted its purpose, dispose of it
properly according to local regulations.
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Operation
4-1
Section 4
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
This section provides information about the following operator-level tasks:
S
S
S
S
S
S
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 the
control panel. Refer to Melter Description in Section 2, Introduction, for
the location of the controls and indicators described in this section.
Additional Information
This section presents operating procedures in their most commonly used
form. Procedural variations or special considerations are explained in the
additional information table that follows most procedures. Where applicable,
some table entries also contain cross-reference information. Additional
information tables are indicated by the symbol shown to the left.
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4-2
Operation
Initial Startup
After the melter has been properly installed, initial startup can take place.
Purging Test Material out of Melter
The melter was subjected to extensive testing prior to shipment. In doing so,
the tank was filled with a special test material. Material residue may still be
present in the melter. To remove the residue, melt and feed several
kilograms of material before starting production.
WARNING: Risk of burns! The test liquid may splash if it comes out at high
pressure. Before purging the melter, set the pressure control valve to low
pressure.
Pump
After initial startup check the pump for leakage; tighten the gland bolt if
necessary.
X
Before retightening for the first time, the space between the gland and the
front block (dimension X, Fig. 4-1) should be 8 − 9 mm on a PR100/SN1710
gear pump. The distance must be 4 mm for all other pumps used in
DuraBlue.
Fig. 4-1
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Operation
4-3
Filling the Tank
Manually
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment. Tank and tank lid are hot. When filling, hot material may
splash out of the tank. Use caution when filling tank with material.
WARNING: Do not operate melter with open tank. When the tank is open,
hot material vapors can escape; vapors may contain potentially hazardous
substances.
CAUTION: Before filling the tank, ensure that tank and material are clean
and free of foreign substances. Foreign substances can hinder functioning
or even cause damage to the melter or accessories.
Fig. 4-2
CAUTION: Cease operation before the tank is completely empty. If there is
too little material in the tank, the material can overheat. Overheated material
can char, collect on surfaces and cause malfunctioning.
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4-4
Operation
25 mm
Maximum Level
Fig. 4-3
The maximum level should not exceed 25 mm (1 inch) under the rim of the
tank.
Cross-section of
tank
Heated Components
The melter contains three groups of heated components. These are the
tank group, which contains the tank and the pump, the hose group, and the
gun group. Component groups are represented on the control panel by the
component keys shown to the left.
Component keys
(tank, hose, and gun)
Heated components within each group are identified by their position
number. The position of the tank and pump is fixed at 1. Hose and gun
position numbers are automatically assigned based on the hose/gun
receptacle they are connected to. For example, the position numbers of a
hose/gun pair that is connected to the second receptacle would be hose
position 2 and gun position 2.
NOTE: In some installations, auxiliary devices (such as a heated air
manifold) may be connected to a hose/gun receptacle. In such cases, you
should label (or otherwise identify) the auxiliary device as to the hose or gun
position number that represents the device. The control panel will identify
such devices as a hose or gun, regardless of what the device actually is.
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Operation
4-5
Starting the Melter
Before starting the melter for the first time, confirm that the
S melter is fully installed including any required inputs and outputs,
gun drivers, pattern controllers, or timers.
S melter’s operating parameters are set up to support the
current manufacturing process.
Refer to Section 3, Installation, if any of the items listed above are
not complete.
To Start the Melter
1. Switch the melter on.
The melter:
S Tests the control panel LEDs
S Turns on the heaters (the heaters LED turns green)
S Begins to automatically scan through and display the
actual temperature of the tank and each hose and gun that has a
set-point temperature that is greater than zero degrees. The
sequence of the automatic scan is: tank, each hose and gun pair,
and then back to the tank.
Heaters LED
S Turns on the ready LED (green) when the tank and all of the
hoses and guns are within 3 _C (5 _F) of their assigned
set-point temperature.
Automatic scan sequence
Ready LED
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4-6
Operation
CAUTION: Do not operate Nordson pumps without material. Before
switching on the motor, ensure that the tank is filled.
2. Press one of the two pump keys (1 or 2) to enable the pump.
S If the system has not reached the system-ready state at the time that
the pump key is pressed, the LED on the pump key will turn yellow,
indicating that the pump is enabled, but not started. The pump will
start automatically when the system-ready state is reached.
S If the system has reached the system-ready state at the time that the
1
Pump keys
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2
pump key is pressed, the pump will start and the LED on the pump
key will turn green, indicating that the pump is running.
S If the melter is set up for manual pump activation, the pump LED will
not turn on and the pump will not start until the pump is manually
started using the switching device.
NOTE: You can change the way the pump key operates by changing
parameter 8 (automatic pump on). Refer to Appendix B, Operating
Parameters.
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Operation
If the melter is switched on when the
temperature of the tank is 27 _C (50 _F) or
greater below its assigned set-point
temperature (cold start condition), the ready
LED will not turn on until the ready delay
(defined when the melter was set up) has
elapsed.
Appendix B, parameter 4
The time remaining on the ready delay (in
minutes) appears in the right display at the
end of every scan cycle. When only one
minute remains in the ready delay time, the
right display counts down in seconds.
Appendix B, parameter 4
4-7
You can by-pass the ready delay time by
pressing the Heaters key twice.
The appearance of F4 in the right display
immediately after the melter is switched on
indicates a problem with the melter’s
processor or main board.
Monitor Melter Faults
The appearance of F1 in the right display
immediately after starting the melter indicates
that a hose or gun cordset may be loose or
disconnected.
Section 6, Troubleshooting
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 and
turned on when the melter was last switched
off, the clock will automatically turn on the next
time the melter is switched on.
Function Keys
If a power failure occurs, the melter will restart
in it’s normal heat-up cycle, even if the heaters
were off or the melter was in standby prior to
the power failure. If the seven-day clock was
on prior to the power failure, the melter will
restart in the mode dictated by the clock
schedule at the time the melter restarts.
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4-8
Operation
Monitoring the Melter
The melter provides indicators that allow you to:
S Quickly confirm that the melter is operating correctly
S Monitor the actual temperature of the tank group and each hose
and gun
S Identify melter faults
S Determine when service is required
The melter automatically determines the number and receptacle of all
hoses and guns that are connected to it. Refer to Heated Components,
earlier in this section, for information on identification of heated
components.
Confirm that the Melter is Operating Correctly
The ready LED turns on (green) when all of the heated components
are within 3 _C (5 _F) of their set-point temperature.
The ready LED will not turn on, or will turn off, if any of the following events
occur:
Ready LED
S The ready delay is still counting down.
S The operator or a remote input places the melter in the standby
mode.
S The seven-day clock places the melter in the standby mode.
S There is a fault (the fault LED will turn on).
Refer to Monitor Melter Faults and Function Keys in this section for
information about melter faults and using the seven-day clock and standby
functions. Refer to Appendix B, Parameter 4, for information about the
ready delay.
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Operation
4-9
Heated components with a set-point
temperature of zero degrees are skipped
during the automatic scan cycle.
The set-point temperature of the tank and
the pump cannot be set independently.
The time remaining on the ready delay
appears in the right display at the end of each
scan cycle.
Appendix B, parameter 4
You can override the seven-day clock at any
time. If the clock has turned the heaters off,
pressing the heaters key will turn the heaters
back on. If the clock has placed the melter into
the standby mode, pressing the standby key
will return the heated components to their
assigned set-point temperature.
Function Keys
Monitor Component Temperatures
The actual temperature of each heated component − tank and each hose
and gun − can be checked via normal mode or by manually selecting and
checking each component.
By default, the melter remains in the automatic scan mode except when:
S The melter is placed into the setup mode
S The set-point temperature of all hoses and guns is set to zero
degrees
S 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 component
group (tank, hose, or gun) turns on, observe the left display until it
indicates the position number of the specific component you want to
check.
LEDs on component keys
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3. When the position number of the desired component appears in the
left display, observe the right display to determine the component’s
actual temperature.
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4-10 Operation
To Manually Check a Component’s Temperature
1. Press the key (tank, hose, or gun) that represents the component
group you want to check.
The automatic scan stops and the left display indicates the number
of the first sequential component in the selected component group. The
right display indicates the component’s actual temperature.
Left display and
scroll key
NOTE: When the tank key is pressed, the left display does not
indicate a component number (blank display).
2. If the first sequential component is not the component you want
to check, use the left-display scroll key to change to the correct
component number.
The right display indicates the actual temperature of the
selected component.
Component temperature display
3. Press the Setup key twice to return to the automatic scan mode.
When you scroll the left display past the
number of the last sequential component in a
component group, the number of the first
sequential component in the next component
group appears in the left display.
The melter will return to the automatic scan
mode two minutes after the last key is
pressed.
When you press the Tank key, it is the pump
temperature that is actually indicated in the
right display. To check the actual temperature
of the tank, simultaneously press the Tank
key and the left-display scroll key.
The default unit for temperature display is
degrees Celsius (C). This may be changed to
degrees Fahrenheit using operating
parameter 20.
Appendix B, Parameter 20
The LEDs on each component key will change
from green to yellow if any component in the
component group drops more than 3 _C (5 _F)
below its assigned set-point temperature.
You can check the set-point temperature of a
component at any time, by pressing the
right-display UP scroll key. Holding down the
scroll key while the melter is in the automatic
scan mode reveals the set-point of each
component that is scanned.
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Operation
4-11
Monitor Melter Faults
The melter alerts the operator to the faults listed in Table 4-2.
When a fault occurs, you must diagnose and correct the fault condition and
then place the melter back into operation. You can use the fault log to
determine the type, order, and relative time of the last ten faults.
Tab. 4-1 Melter Faults
Display
Code/Sub-code
Name
Affect on the
Melter
Cause
F1/None
RTD
Heaters turn off
The RTD for the component indicated has failed or
the component was disconnected from the melter.
F2/None
Under temperature
Heaters turn off
The actual temperature of the component
indicated has dropped below the under
temperature delta, which was set using parameter
22.
F3/None
Over temperature
Heaters turn off
The actual temperature of the component
indicated has increased beyond the over
temperature delta, which was set using parameter
21.
F4/1
RAM test
Melter stops functioning
Internal RAM failure
F4/2
Internal Clock time
F4/3
Internal Clock time
F4/4
Internal clock battery
backed RAM
F4/5
Internal clock failure
Heaters remain on, but
fault condition persists
Internal clock time faulty
Internal clock battery
Heaters remain on, but
fault condition persists
Battery-backed RAM battery dead
F4/6
Analog-to-digital
Melter stops functioning
RTD analog-to-digital converter failed
F4/7
Analog-to-digital
calibration
Melter stops functioning
RTD analog-to-digital converter could not be
calibrated
F4/8
Main board feedback
Melter stops functioning
Communication failure between main board and
CPU
F4/A
Thermostat
Melter stops functioning
Tank or pump thermostat is open
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Battery-backed RAM failure
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4-12 Operation
F1, F2 and F3 Faults
When the melter detects an F1, F2, or an F3 fault:
1. The automatic scan stops and the melter begins to monitor the potential
fault for up to two minutes. The ready and heater LEDs remain on during
the 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 will
return to the automatic scan mode.
2. The LED on the affected component key (tank, hose, or gun) turns on 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.
S If the LED on the tank key is on, the left display will indicate either 1
for the tank or 2 for the pump.
S If the LED on the hose or gun key is on, the left display will indicate
the number of the affected hose or gun.
Fault LED (red)
5. If the fault condition still exists at the end of the two-minute monitoring
period, the ready LED will turn off, the red fault LED will turn on, the
heaters turn off, and the melter records the fault in the fault log. Refer to
Fault log in this part.
To be able to put the melter back into operation, the fault must be remedied
and the melter reset (reset key). Refer to section 6, Troubleshooting, for
information about diagnosing and correcting fault conditions. Also refer to
Resetting Melter.
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Operation
4-13
To view the temperature of a heated component
when an F2 or F3 fault exists, simultaneously
press and hold both of the right-display scroll
keys.
You can temporarily dismiss an F1 fault (RTD)
and return to the automatic scan mode by
pressing the Clear/Reset key. The heaters will,
however, remain off. If the fault condition still
exists two minutes after pressing the clear/reset
key, the fault LED will turn back on.
When an F1 fault code appears, you can
determine whether the fault was caused by an
open or a shorted RTD by simultaneously
pressing both of the right-display scroll keys. If
the right display indicates OP, the RTD is open, if
it indicates SH, the RTD has shorted.
If, for any reason, a component reaches 235 _C
(458 _F), an immediate F3 fault will occur (no
two-minute monitoring period).
F4 Fault
When the melter detects an F4 fault:
1. The ready LED turns off and the red fault LED turns on.
2. All of the component key LEDs (tank, hose, and gun) turn off.
3. The right display indicates F4.
4. The left display indicates a sub-code. Sub-codes classify the fault as
being fatal or nonfatal. The affect on the melter of each of these two
classes of F4 faults is:
Fatal—The fault LED turns on and stays on and the melter stops
functioning completely.
Nonfatal—The fault LED turns on for five seconds, but the heaters and
pump continue to operate normally. Nonfatal faults affect the internal
clock.
5. The melter records the fault in the fault log. Refer to Fault Log in this
part.
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4-14 Operation
Resetting Melter
1. Diagnose and correct the fault condition. Refer to Section 6,
Troubleshooting, for information about diagnosing and correcting fault
conditions.
2. Return the melter to the automatic scan mode by pressing the Setup
key twice.
Clear/Reset key
3. Press the Clear/Reset key.
4. Press the Heater key to turn on the heaters.
Heater key
If F4 appears in the right display when you press the
clock key, the internal clock function has failed.
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Operation
4-15
Fault Log
1. Press and hold the Setup key.
The automatic scan stops and operating parameter 1 appears in the
left display.
2. Scroll the left display to parameter 2 (the fault log).
The right display indicates the last fault that occurred as follows:
Setup Key
S If the last fault was an F1, F2, or F3 fault, then the LED on
the affected component key turns yellow.
S If the last fault to occur was an F4 fault, then the LEDs on all of
the component keys turn off.
S The right display indicates the log entry for the last fault to
occur. Table 4-2 provides the meaning of each digit in the log
entry. Following the table are two example fault log entries.
Left display and scroll key
3. Press the right-display scroll key to review each of the remaining
nine log entries. Each press of the scroll key displays a progressively
older log entry.
NOTE: The fault log only stores the last ten faults. After ten faults
occur, the existing log entries are overwritten, beginning with the oldest
entry, by the eleventh and following log entries.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the fault log
Tab. 4-2 Fault Log
First Digit
Second and Third Digits
Fourth Digit
Component:
Type of fault:
1 = Tank or hose/gun 1
0 = Unused log entry
2 = Pump or hose/gun 2
3 = Hose 3 or gun 3
4 = Hose 4 or gun 4
-F
1 = RTD (open or short)
2 = Component under temperature
3 = Component over temperature
4 = Processor or electrical failure
5 = Hose 5 or gun 5
6 = Hose 6 or gun 6
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4-16 Operation
Fault Log Examples
Example 1:
An unused log entry.
Example 2:
If the LED on the tank key were on, this log entry
would indicate that the tank is under temperature. If the LED on the hose
key were on, this log entry would indicate that hose 1 is under temperature.
To view the number of heater hours that have
elapsed since a log entry was created,
simultaneously press both of the right-display
scroll keys. The hours are indicated in the right
display.
The melter will return to the automatic scan
mode if the fault log is left open for a period of
two minutes without any key being pressed.
When an F1 fault is the result of a hose/gun pair
being disconnected from the melter, two fault log
entries are created. The first entry is for the gun
and the second entry is for the hose.
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Operation
4-17
Monitor the Service Interval
The melter can be set up so that the service LED located on the left side
of the control panel turns on after a customer-defined time period has
elapsed. The service LED may be used to signal the need to change the
hot melt filter or to complete any other customer-specified maintenance
activity. Once the specified maintenance is performed, the service LED must
be reset.
To Reset the Service LED
Service LED (yellow)
With the melter in the scan mode, press the Clear/Reset key to turn off the
service LED and reset the service interval time.
Clear/Reset key
The default setting for the service interval time is
500 hours.
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Appendix B, parameter 5
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4-18 Operation
Adjusting Component Temperatures
You can adjust the set-point temperature of heated components using the
following methods:
S Global—The tank and all hoses and guns are set to the same
set-point temperature.
S Global-by-component group—All of the hoses or all of the guns
are set to the same set-point temperature.
S Individual Component—The set-point temperature of the tank
and each hose and gun is adjusted independently.
Before adjusting set-point temperatures, confirm that each hose/gun pair
is connected to the correct hose/gun receptacle. For example,
hose/gun pair 1 should be connected to the receptacle 1. Refer to Heated
Components earlier in this section for information about hose/gun positions.
Recommended Temperatures
The temperature setting is determined by the processing temperature
prescribed by the material supplier. The maximum operating temperature for
the melter and heated components described here may not be exceeded.
CAUTION: Nordson will grant no warranty and assume no liability for
damage resulting from incorrect temperature settings.
Tank
Prescribed processing temperature
(Material quantity used <50 g/min: 0 to 10 ° C (18 ° F) below prescribed
processing temperature
Undertemperature value
(warning)
10 ° C (18 ° F) below set processing temperature
Undertemperature value
(fault)
15 ° C (27 ° F) below set processing temperature
Overtemperature value
(warning)
10 ° C (18 ° F) above set processing temperature
Overtemperature value (fault)
15 ° C (27 ° F) above set processing temperature
Gun (accessory)
Prescribed processing temperature(s)
Hose (accessory)
Prescribed processing temperature
P/N 7105986H
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Operation
4-19
To Adjust the Setpoint Temperature Using the Global Method
1. Press and hold the Tank key for three seconds.
Tank key
The left display flashes 1.
2. Scroll the left display to 0 (flashing).
The right display indicates all dashes (----) and the LEDs on all of
the component keys turn green.
3. Press the Enter key.
Left display and
scroll key
The right display flashes.
4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt.
Enter key
NOTE: If the keypad or the right-display scroll keys have no affect
on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter Password in this section.
5. Press the Tank key.
All components begin to heat or cool to the new global
set-point temperature. When all of the components reach their
set-point temperature, the ready LED turns on (green).
Ready LED
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P/N 7105986H
4-20 Operation
To Adjust the Setpoint Temperature Using the Global-by-component
Method
1. Press and hold the Hose or Gun key for three seconds.
The left display indicates the number of the first sequential hose or
gun. The right display indicates the current set-point temperature of the
hose or the gun.
2. Scroll the left display to 0.
Tank, hose, and gun keys
The right display indicates all dashes (- - - -).
3. Press the Enter key.
The right display flashes.
4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt.
NOTE: If the keypad or the right-display scroll keys have no affect
on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter Password in this section.
5. Press the Enter key.
The hoses or the guns begin to heat or cool to their new
set-point temperature.
P/N 7105986H
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Operation
4-21
To Adjust the Setpoint Temperature of an Individual Component
1. Press and hold the Tank, Hose, or Gun key for three seconds.
If the tank key was pressed, the left display indicates 1 (Flashing). If a
hose or gun key was pressed, the left display indicates the number of
the first sequential hose or gun (Flashing). The right display indicates
the current set-point temperature of the component indicated in the left
display.
2. Scroll the left display to the number of the desired component.
The right display indicates the current set-point temperature of the
component that you selected in the left display.
3. Press the Enter key.
The right display flashes.
4. Use the keypad to enter the set-point temperature recommended by
the manufacturer of the hot melt. Refer to the technical data
sheet provided by the manufacturer of the hot melt to determine the
optimal set-point temperature.
NOTE: If the keypad or the right-display scroll keys have no affect
on the right display, the melter is password protected. You must enter
a valid password before you can change set-point temperatures. Refer
to Enter Password in this section.
5. Do one of the following:
S To register the new set-point temperature and then move on to
change the set-point temperature of the next sequential component,
press the Enter key and then repeat steps 4 and 5.
S To register the new set-point temperature and return to the automatic
scan mode, go to step 6.
6. Press any component key (tank, hose, or gun).
The selected component begins to heat or cool to its new
set-point temperature.
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P/N 7105986H
4-22 Operation
If you enter a valid set-point temperature for a
hose/gun that is not connected to the melter or if you
enter a set-point temperature that is out of range, the
right display will indicate dashes (----) for three
seconds and then change back to the original
set-point temperature.
When the right display is flashing, you can quickly
change the current set-point temperature to 0 degrees
(off) by simultaneously pressing both of right-display
scroll keys.
After removing a hose or a gun, use the individual
component method of set-point temperature
adjustment to set the component’s temperature to zero
degrees (off). This will avoid causing an F1 fault. When
a hose or gun is added, use the individual component
method to set the desired temperature.
The factory set-point temperature of the tank is 175 _C
(350 _F). The factory set-point temperature of all
others components is zero degrees (off).
When the units of temperature is set to degrees
Celsius, the minimum and maximum set-point
temperatures are 40 _C and 230 _C. When the units of
temperature are set to degrees Fahrenheit, the
minimum and maximum set-point temperatures are
100 _F and 450 _F.
When using the right-display scroll keys to adjust a
set-point temperature, the right display automatically
increments between 0, 175, and 230 _C or between 0,
350, and 450 _F.
If you make a mistake while you are changing a
set-point temperature, but you have not yet pressed
the enter key, press the Clear/Reset key to reset the
right display to the original temperature.
The melter will exit the setup mode and return to the
automatic scan mode two minutes after the last key is
pressed.
A global set-point temperature of zero degrees
(Celsius or Fahrenheit) turns all components off.
When scrolling through component numbers in the left
display, component numbers that are associated
with unused hose/gun receptacles are skipped.
P/N 7105986H
The melter stores a record of the last ten changes
made to the set-point temperatures (and operating
parameters) in the change history log.
Section 3, Installation, Review
Parameter and Set-point
Temperature Changes
You can save set-point temperature changes by
simultaneously pressing the 1 key and the Setup key.
Section 3, Installation, Save and
Restore Melter Setting
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Operation
4-23
Enter Password
If the melter is password protected, a valid password must be
entered before any set-point temperature or melter parameter can be
changed.
To Enter a Melter Password
1. Press the Setup key.
The left display indicates parameter 0 (flashing) and the right
display indicates 4000.
2. Press the Enter key.
The right display begins flashing.
3. Use the keypad to enter the melter password.
4. Press the Enter key.
One of the following occurs:
S If the password is correct, the left display indicates parameter 1.
S If the password is incorrect, the left display remains at 0 and the
right display momentarily indicates dashes (----) and then returns to
4000.
If the password is incorrect, re-enter it and then press the Enter key.
The melter will automatically revert back to the
password-protected mode two minutes after
the last key press (any key). To force the
melter back into the password protected mode
before two minutes has elapsed, press the
Setup key twice.
The melter password is created and
enabled/disabled during system setup.
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Setting Up the Melter in Section 3,
Installation
P/N 7105986H
4-24 Operation
Function keys
The control panel provides the following standard and special function keys:
Standard function keys
S Heater
S Pump (1 and 2)
S Setup
Special function keys
S Seven-day clock
S Standby
CAUTION: Unintentionally activating function keys can, under the
correct circumstances, have undesirable effects on the melter or the
manufacturing process. Only personnel who are familiar with the melter’s
setup and its connection with the manufacturing process should use the
function keys. Improper use of the function keys can result in erratic process
behavior or personal injury.
Heater Key
Use the heater key to manually turn the component heaters on and
off. Pressing the heater key overrides the control (on or off) of the heaters
by either the seven-day clock feature or a remote input. The LED on the
heater key illuminates when the heaters are on.
Heater key
When a fault occurs (refer to Monitor Melter Faults in this section) the
heaters automatically turn off. The heater key is used to turn the
heaters back on after correcting a fault condition.
P/N 7105986H
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Operation
4-25
Pump Keys
Pump key
1
Press the pump keys (1 resp. 2) to enable, start or stop the pump. The LED
on the pump key is yellow when the pump is enabled (not yet running) and
green when the pump is running. Switching the pump on or off has no effect
on the heater control.
2
If the automatic pump on feature (parameter 8) is disabled, then the
pump key must be used to start the pump when the melter is ready.
If any of the inputs are set up to use the pump enable/disable control option
(option 3 and option 11), the pump motor will not start until the pump is
enabled and the correct voltage is applied to the input contacts. If the pump
is enabled, but the input voltage is not present, the pump LED will flash
green.
Setup Key
Use the setup key to place the melter into and take the melter out of
the setup mode. When the melter is placed into the setup mode, the
automatic scan stops and the left and right displays are used to select and
read or edit operating parameters.
Setup key
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P/N 7105986H
4-26 Operation
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 is
automatically regulated based on a set of user-defined schedules.
Seven-day clock key
To accommodate daily shift work and non-working days, four
clock schedules are available. Schedules 1, 2, and 3 are used to specify
when the heaters should turn on and off or when the melter should enter
and exit the standby mode. Schedule 0 is used to keep the melter in the last
condition dictated by the clock (heaters on or off, or standby).
When a clock schedule calls for the heaters to be on, the heaters
are regulated at their pre-assigned set-point temperatures. When the
clock activates the standby mode, the set-point temperature of each
component is temporarily reduced by a pre-set standby delta.
Refer to Appendix B, Operating Parameters, for information 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 next
time the melter is switched back on.
If the heaters are manually turned off at the time
that a clock schedule calls for the heaters to be
on, the heaters will not turn back on until the next
clock schedule calls for them to be on.
The clock will still operate when the melter
is faulting or is in the setup mode.
If F4 appears in the right display when you press
the clock key, the internal clock function has
failed.
P/N 7105986H
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Section 7, Troubleshooting
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Operation
4-27
Standby Key
Use the standby key to manually place the melter into, and take it out of, the
standby mode. Using the standby mode during periods of time when the
melter is inactive helps conserve energy and allows heated components to
quickly return to their set-point temperatures when the melter is once again
needed.
Standby key
When the melter is placed into the standby mode, the temperatures of all
components are reduced down from their set-point temperature by a pre-set
standby delta. The melter will remain in the standby mode until the standby
key is pressed or the function of one of the operating parameters takes 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 the standby mode for the
period of time specified by the timer. After the manual standby time has
elapsed, the melter will once again begin heating all of the components to
their assigned set-point temperature.
Using the standby key overrides the control of the melter (on or off) by the
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 and
the standby timer.
E 2011 Nordson Corporation
The melter may also be set up to automatically
enter the standby mode using a variety of
operating parameters.
Appendix B, Parameters 25, 26, 57,
30–33, 62, and 67
Whenever manual standby is enabled, the
standby LED blinks.
Appendix B, Parameter 26
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P/N 7105986H
4-28 Operation
Shutting Down the Melter
Shut the melter down when it will not be used for an extended period of
time.
To Shut the Melter Down
1. Set the main switch to 0/OFF.
2. Disable the guns as follows:
S Air-operated guns: Turn off the air supply to the guns.
S Electric guns: Turn off the gun driver, pattern controller, or timer.
P/N 7105986H
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Operation
4-29
Settings Record
Production information:
Manufacturer
Material:
Processing Temperature
Viscosity
Manufacturer
Cleaning agent:
Flash point
High melt/reservoir (factory-set)
Reference channel:
Processing temperatures (Setpoint temperatures):
Grid (low melt)
Reservoir (high melt)
Hose
(accessory)
1)
2)
3)
4)
5)
6)
Gun
(accessory)
1)
2)
3)
4)
5)
6)
Air heater
(accessory)
1)
2)
3)
4)
5)
6)
Pump speeds:
Pump
1)
2)
Air pressures at gun (accessories):
Control air
1)
2)
3)
4)
5)
6)
Spray air
1)
2)
3)
4)
5)
6)
Notes:
Name
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Date
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P/N 7105986H
4-30 Operation
Settings Record - Spare Copy
Production information:
Manufacturer
Material:
Processing Temperature
Viscosity
Manufacturer
Cleaning agent:
Flash point
High melt/reservoir (factory-set)
Reference channel:
Processing temperatures (Setpoint temperatures):
Grid (low melt)
Reservoir (high melt)
Hose
(accessory)
1)
2)
3)
4)
5)
6)
Gun
(accessory)
1)
2)
3)
4)
5)
6)
Air heater
(accessory)
1)
2)
3)
4)
5)
6)
Pump speeds:
Pump
1)
2)
Air pressures at gun (accessories):
Control air
1)
2)
3)
4)
5)
6)
Spray air
1)
2)
3)
4)
5)
6)
Notes:
Name
P/N 7105986H
Date
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Maintenance
5-1
Section 5
Maintenance
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
NOTE: Maintenance is an important preventive measure for maintaining
operating safety and extending the lifetime of the unit. It should not be
neglected under any circumstances.
Risk of Burns
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
Some maintenance work can only be done when the melter is heated up.
Relieving Pressure
WARNING: System and material pressurized. Relieve system of pressure
before disconnecting hoses, guns and hot melt handguns. Failure to
observe can result in serious burns.
1. Switch off the motor(s) (Refer to section Operation).
2. Place a container under the nozzle(s) of the gun / assembly handgun.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly handgun. Repeat this procedure until no more material
flows out.
4. Properly dispose of material according to local regulations.
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P/N 7105986H
5-2
Maintenance
Important when Using Cleaning Agents
S Use only a cleaning agent recommended by the hot melt material
manufacturer. Observe the Material Safety Data Sheet for the cleaning
agent.
S Properly dispose of cleaning agent according to local regulations.
Processing Materials
Designation
Order number
Use
High temperature grease
S
Can
10 g
P/N 394 769
S
Tube
250 g
P/N 783 959
S
Cartridge
400 g
P/N 402 238
To be applied to O-rings and
threads
NOTE: The grease may not be
mixed with other lubricants.
Oily/greasy parts must be cleaned
before application.
Sealing paste Stucarit 203:
S
Tube
100 ml
Applied to sealing surfaces
P/N 255 369
Temperature-resistant
adhesive Loctite 640
S
50 ml
Secures screw connections
P/N 230 359
Heat transfer compound
NTE303
S
1g
P/N 7105986H
To improve heat conducting of
temperature sensors
P/N 1023441
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Maintenance
5-3
Preventive Maintenance
The maintenance intervals are general guidelines based on experience.
Depending on the operating environment, production conditions and melter
hours of operation, other scheduled maintenance tasks may prove
necessary.
Melter part
Complete melter
Activity
Interval
Refer to page
External cleaning
Daily
5-4
Inspect for external
damage
Daily
5-4
Purge with cleaning
agent
When material is changed
5-5
Fan and air filter
Check filter, clean or
replace if necessary
Clean fan screen
Depending on dust
accumulation; daily if necessary
5-6
Power cable
Inspect for damage
Every time the melter is serviced
−
Pump
(beginning 12/2008,
model with Varisealr)
Pumps with gland:
Check for leakage,
tighten gland bolt if
necessary
Dependent on hours of
operation, pump speed and
pump temperature
Recommendation: Monthly
Tighten fixing screws
Every 500 hours of operation
Air hoses
Inspect for damage
Every time the melter is serviced
−
Motor / gear box
Clean fan cover
Depending on dust
accumulation; daily if necessary
−
Change lubricant
Every 15 000 hours of operation
or every 4 years
5-8
Pressure control valve
Disassemble and clean
Every six months
5-9
Filter cartridge
Replace filter cartridge
Disassemble and clean
filter cartridge
Depending on degree of material
pollution
Recommendation: Every 1000
hours of operation
5-10
Tank
Clean tank by hand
When there is material residue in
tank
5-12
Tighten fixing screws
Every 500 hours of operation
Activating the piston
Monthly
Safety valve
5-7
5-13
NOTE: Coupling and motor controller are maintenance-free.
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P/N 7105986H
5-4
Maintenance
External Cleaning
External cleaning prevents impurities created during production from
causing the melter to malfunction.
CAUTION: Observe the unit’s Degree of Protection when cleaning (Refer
to section Technical Data).
CAUTION: Do not damage or remove safety labels. Damaged or removed
safety labels must be replaced by new ones.
Remove material residue only with a cleaning agent recommended by the
material supplier. Heat with an air heater if necessary.
Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.
Nordson recommends the orange cleaning agent P/N 771 192 (12 spray
bottles, 0.5 l each).
Visual Inspection for External Damage
WARNING: When damaged parts pose a risk to the operational safety of
the melter and/or safety of personnel, switch off the melter and have the
damaged parts replaced by qualified personnel. Use only original Nordson
spare parts.
Changing Type of Material
1. Run the melter until empty.
2. Determine whether the new material may be mixed with the old material.
S May be mixed: Remaining old material can be flushed out using the new
material.
S May not be mixed: Thoroughly purge the unit with a cleaning agent
recommended by the material supplier.
NOTE: Properly dispose of the old material according to local regulations.
P/N 7105986H
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Maintenance
5-5
Purging with Cleaning Agent
CAUTION: Use only a cleaning agent recommended by the hot melt
material manufacturer. Observe the Material Safety Data Sheet for the
cleaning agent.
Cleaning agent residue can be flushed out of the unit with new material
before production begins again.
NOTE: Properly dispose of cleaning agent according to local regulations.
Detaching Protective Panels
Open the protective panels with a 4 mm Allan key.
On the inside
Fig. 5-1
Detaching Insulation Blanket
1. Release Velcro and clamps.
2. Take insulation blanket out of hooks.
2
1
Fig. 5-2
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P/N 7105986H
5-6
Maintenance
Fan and Air Filter
The air filters must be cleaned (knocked out) or replaced, depending on
dust accumulation.
Refer to section Parts for filter order number.
2
1
Fig. 5-3
1 Fan with filter
P/N 7105986H
2 Air filter, air outlet
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Maintenance
5-7
Pump
All melters delivered in December 2008 and later have pumps with a
Varisealr seal instead of a gland.
Checking for Leakage
The pump is equipped with a shaft seal. Material may seep out along the
shaft at irregular intervals.
S Pumps with Varisealr: Replacing Pump Shaft Seal
S Pumps with gland: Retighten gland bold.
Retighten Gland Bolt
NOTE: Retighten only when melter is warm.
Retighten the gland approx. ¼ of a revolution in the operating direction of
the pump. If tightening is no longer possible, the gear pump must be
replaced.
Fig. 5-4
Replacing Pump Shaft Seal
When the pump shaft seal needs to be replaced, Nordson recommends
replacing the pump and sending the old one in to be repaired. Only trained
personnel can replace the pump shaft seal.
Tightening Fixing Screws
Normal heat cycling (heating and cooling) can cause the fixing screws to
become loose.
NOTE: Tighten fixing screws only using a torque wrench (25 Nm / 220 Ibin)
and when the melter is cold.
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P/N 7105986H
5-8
Maintenance
Motor / Gear Box
The only motor maintenance required is cleaning the fan cap.
Changing Lubricant
NOTE: Use only the stated lubricant or one that has proven to be
equivalent (Refer to Lubricant Selection). Using any other lubricant can
result in premature wear and/or damage to the gear box.
NOTE: Drain lubricant when warm.
Remove gear box from the motor to change lubricant. Wash out casing with
suitable cleaning agent and remove lubricant residue.
NOTE: Properly dispose of the old lubricant according to local regulations.
Lubricant Changing Interval
Operating temperature < 100 ° C / 212 ° F:
Every 15 000 hours of operation or at least every 4 years.
Capacity
The lubricant quantity is indicated on the ID plate. Ensure that the upper
gears and rolling bearings are properly lubricated.
NOTE: Never mix different types of lubricants.
Lubricant Selection
Lubricant manufacturer
Mineral oil CLP 220
AGIP
Blasia 220
ARAL
Degol BMB 220 or Degol BG 220
BP
Energol GR-XP 220
DEA
Falcon CLP 220
ESSO
Spartan EP 220 or GP 90
KLÜBER
Klüberoil GEM 1-220
OPTIMOL
Optigear 220
SHELL
Omala Oil 220
TEXACO
Geartex EP-A SAE 85 W-90
P/N 7105986H
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Maintenance
5-9
Pressure Control Valve
Disassembling and Cleaning
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
WARNING: System and material pressurized. Relieve system pressure.
Failure to observe can result in serious burns.
Measure and make a note of the insertion depth of the setting screw
(dimension X). This way the insertion depth can be replicated after
reassembly.
Fig. 5-5
X
Fig. 5-6
Pressure control valve
NOTE: Screw in only when valve and pump are warm and material is soft.
1. Apply high temperature grease to all threads and O-rings. For
information on high temperature grease refer to Processing Materials.
2. Slide the valve into the hole and tighten with torque wrench
(15 Nm / 133 lbin).
3. Adjust the setting screw to the recorded dimension X.
− +
S Turning to the right increases material pressure.
S Turning to the left decreases material pressure.
Fig. 5-7
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P/N 7105986H
5-10 Maintenance
Filter Cartridge
Replacing Filter Cartridge
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
WARNING: System and material pressurized. Relieve system pressure.
Failure to observe can result in serious burns.
Removing Filter Cartridge
NOTE: Remove filter cartridge only when the melter is hot and not under
pressure.
M10
SW 24
Fig. 5-8
Installing Filter Cartridge
NOTE: Install filter cartridge only when melter is hot.
1. Apply high temperature grease to all threads and O-rings.
Refer to Processing Materials.
2. Insert filter cartridge and tighten somewhat (approx. 1 Nm).
3. Feed material by allowing the pump to run until the material comes out
of the hose connection or gun free of bubbles.
4. Properly dispose of material according to local regulations.
Fig. 5-9
P/N 7105986H
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Maintenance
5-11
Installing Service Kit
Each kit contains three O-rings, filter sheath, filter screen and
high-temperature grease.
Fig. 5-10
Service kit P/N: 394590
Required tools:
Open-jawed wrench, size 24 and size 13
Size 24
1.
Disassemble the filter cartridge when hot.
2.
Replace filter sheath (1), O-rings (2) and filter screen (3).
3.
Clean all other parts.
4.
Apply grease to all threads and O-rings.
2
2
1
3
Size 13
2
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P/N 7105986H
5-12 Maintenance
Tank
Draining Material
Pump material out of the melter.
CAUTION: Do not feed charred material though the gun. Particles can
block the gun. Instead unscrew hose (Refer to section Installation).
Cleaning Tank by Hand
Cold material can usually be peeled off of the sides of the tank (Refer to
Fig. 5-11). If necessary, first heat tank to material softening temperature,
usually approx. 70 ° C / 158 ° F.
NOTE: The inside of the tank is release coated. Do not use metallic tools to
clean. Do not use wire brushes! This could damage the release coating.
MXTK007S050A0495
Fig. 5-11
Tightening Fixing Screws
Heating and cooling that occurs during daily operation can cause the fixing
screws to loosen. Tighten screw as indicated in the table.
NOTE: Tighten fixing screws only using a torque wrench and when the
melter is cold.
Fig. 5-12
Connection
Thread
Torque
Tank / melter chassis
M8
25 Nm / 220 lbin
Grid (low melt) / reservoir
(high melt)
M8
20 Nm / 177 lbin
P/N 7105986H
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Maintenance
5-13
Safety Valve
Activate the safety valve piston. This prevents the material from blocking the
safety valve.
Procedure:
1. Relieve pressure as described in section Installation.
2. Disconnect all hoses.
3. Close hose connections with Nordson port plugs (Fig. 5-13).
Fig. 5-13
X
4. Mechanical pressure control valves: Measure insertion depth of
setting screw (Fig. 5-14, dimension X) and make a note. This ensures
that insertion depth can be reproduced. Then close pressure control
valve.
Pneumatic pressure control valves: Set the compressed air supply to
6 bar.
5. Operate the melter at maximum motor speed and with hose connections
closed. Switch the motor on and off several times.
Fig. 5-14
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P/N 7105986H
5-14 Maintenance
Maintenance Record Form
Melter part
Date / Name
Date / Name
Date / Name
Pump
Motor / gear box
Fixing screws on pump and
tank
Air filter
Tank
Pressure control valve
Filter cartridge
P/N 7105986H
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Troubleshooting
6-1
Section 6
Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
WARNING: Troubleshooting activities may sometimes have to be carried
out when the melter is energized. Observe all safety instructions and
regulations concerning energized unit components (active parts). Failure to
observe may result in an electric shock.
Helpful Tips
Before starting systematic troubleshooting, check the following:
S Is the seven-day clock set correctly?
S Are all parameters set correctly?
S Is the interface wired correctly?
S Do all plug connections have sufficient contact?
S Have circuit breakers been activated?
S Could the fault have been caused by an external PLC?
S Provide recovery diodes for external, inductive loads (e.g. solenoid
valves)
Light Tower
S White = Switched ON. After switching on and during the heatup phase,
at first only the white indication lamp is lit (normal condition). A fault has
only occurred when the temperature does not increase (observe
temperature display) and when the green indication lamp is not lit after
the heatup phase has ended (1 hour and longer).
S Green = Ready. The green indication lamp lights when all channels have
reached their setpoint temperatures.
S Orange = Tank empty.
S Red = General alarm.
E 2011 Nordson Corporation
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P/N 7105986H
6-2
Troubleshooting
Troubleshooting Tables
Melter not Functioning
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
No line voltage
−
Connect line voltage
2.
Main switch not
switched on
−
Switch on main switch
3.
Main switch defective
−
Replace main switch
4.
Main circuit breaker
activated
−
Switch on main circuit breaker
5.
Main circuit breaker
activated again
Check for short circuit in melter or
accessories
−
6.
24 VDC power supply
defective
−
Replace
7.
Frequent melter
shutdown
Electromagnetic compatibility
disruptions
Add mains filter
One Channel (Heating Zone) does not Heat
Possible Cause
1.
Channel is disabled /
switched off
Possible Fault / Troubleshooting
−
Corrective Action
Enable / switch on
Control Panel does not Function
Problem
1.
Display is blank
P/N 7105986H
Possible Cause
SPS broad-band cable not
connected
D_K
Corrective Action
Connect
E 2011 Nordson Corporation
Troubleshooting
6-3
No Material (Motor does not Rotate)
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
Melter not yet ready
for operation (heatup
phase)
−
Wait until the melter has heated up
and the green indication lamp is lit
2.
Melter at present not
ready for operation
(Undertemperature
during operation)
Material was refilled
Wait until the melter has heated up
and the green indication lamp is lit
3.
Motor not switched
on
−
Switch on motor
4.
Speed (rpm) not set
−
Set speed (rpm)
5.
Standby entered
−
Exit or wait until standby period has
expired
6.
Motor overheated
Ambient temperature too high
Decrease ambient temperature by
cooling or airing out
Fan cap dirty
Clean
Pump blocked by foreign matter
Replace pump
Pump operates too sluggish
Replace pump
Material too cold
Set temperature accordingly
7.
Motor defective
−
Replace
8.
Motor not supplied
with voltage
−
Technical inspection
9.
Motor controller fault
−
Switch melter off and on again with
main switch
Motor overheated
See above
Motor controller overheated
Decrease ambient temperature by
cooling or airing out
Clean cooling section of motor
controller
10. Motor controller
defective
E 2011 Nordson Corporation
Short circuit
Check motor cable
Overload (pump blocked by
foreign matter, pump too sluggish,
material too cold)
Refer to 6.
−
Replace
D_K
P/N 7105986H
6-4
Troubleshooting
No Material (Motor Rotating)
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
Tank empty
−
Fill tank
2.
Filter cartridge
clogged
−
Clean or replace filter screen
3.
Material supply hole
to pump or pump
suction hole clogged
−
Detach pump and clean supply hole
or suction hole
Too Little Material
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
Material supply hole
to pump or pump
suction hole partially
clogged
−
Detach pump and clean supply hole
or suction hole
2.
Filter cartridge partly
clogged
−
Clean or replace filter screen
3.
Pressure control
valve defective
−
Clean or replace
4.
Processing
temperature set too
low
−
Correct temperature setting
5.
Pump block is worn
−
Replace pump
P/N 7105986H
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Troubleshooting
6-5
Material Pressure too High
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
Safety valve or
pressure control
valve dirty and thus
blocked
−
Disassemble and clean or replace
2.
Safety valve or
pressure control
valve defective
−
Replace
3.
Pressure control
valve set incorrectly
−
Set to default
Material Pressure too Low
Possible Cause
Possible Fault / Troubleshooting
Corrective Action
1.
Pump is worn
−
Replace pump
2.
Safety valve does not
close any more
−
Replace
3.
Pressure control
valve dirty and thus
clogged
−
Disassemble and clean or replace
4.
Pressure control
valve defective
−
Replace
5.
Pressure control
valve set incorrectly
−
Set to default
Material Residue in Tank
Possible Cause
1.
Tank setpoint
temperature set too
high
E 2011 Nordson Corporation
Possible Fault / Troubleshooting
Corrective Action
−
Correct temperature setting
Material of low quality or not
appropriate for application
(temperature resistance poor)
Consult material supplier
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P/N 7105986H
6-6
Troubleshooting
Material Hardens in Tank
Possible Cause
1.
Tank setpoint
temperature set too
high
Possible Fault / Troubleshooting
−
Corrective Action
Correct temperature setting
Others
Problem
1.
Possible Cause
Corrective Action
Leakage at pump
shaft seal
Pump shaft seal is worn
Pumps with gland: tighten
−
Replace pump
2.
Material pressure too
low, output quantity
too low
Pump is worn
Replace pump
3.
Pump blocked
Processed material too cold
Correct temperature setting (observe
data sheet of material manufacturer)
Foreign material in pump
Replace pump
Safety valve does not open
(expansion pressure)
Replace safety valve
4.
Leakage at gun
during heatup phase
P/N 7105986H
D_K
E 2011 Nordson Corporation
Troubleshooting
6-7
LEDs of Motor Controller
During operation the operating mode of the motor controller is displayed by
two LED’s on the front of the unit.
Fig. 6-15
LEDs
LED display
Green
Operating mode
Red
On
Off
Motor controller enabled
On
On
Mains switching and automatic start blocked
Flashing
Off
Motor controller blocked
Off
Flashing (every 1 s)
Fault message
Off
Flashing (every 0.4 s)
Over- or undervoltage shutdown
Off
Off
Missing voltage supply
E 2011 Nordson Corporation
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P/N 7105986H
6-8
Troubleshooting
P/N 7105986H
D_K
E 2011 Nordson Corporation
Repair
7-1
Section 7
Repair
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
Risk of Burns
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
Some melter components can only be detached when the melter is heated
up.
Observe Before Performing Repairs
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or melter damage.
WARNING: Disconnect melter from line voltage before any repairs.
Relieving Pressure
WARNING: System and material pressurized. Relieve system pressure
before disconnecting hoses. Failure to observe can result in serious burns.
1. Switch off the motor(s) (Refer to section Operation).
2. Place a container under the nozzle(s) of the gun / assembly handgun.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly handgun. Repeat this procedure until no more material
flows out.
4. Properly dispose of material according to local regulations.
E 2011 Nordson Corporation
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P/N 7105986H
7-2
Repair
Replacing Motor Controller
CAUTION: The connection terminals may only be connected or
disconnected when the melter is de-energized. The motor controller is still
energized after switching off. Wait at least 3 minutes before beginning any
work!
Use only original Nordson motor controllers. They are parameterized and
guarantee the required function.
Replace Standard I/O Module of Motor Controller
1. Disconnect motor controller from power supply and wait at least
3 minutes.
2. Disconnect standard I/O connections
3. Use a screwdriver to pry away the male connector (1) first and then the
standard I/O module (2).
4. Remove protective cap (3) of the new Standard I/O module.
5. Insert Standard I/O module into the serial port of the motor controller.
6. Insert male connector (1) into female connector of the standard I/O
module.
7. Connect standard I/O module according to cable designation.
NOTE: The DIP-switch of the standard I/O module is factory-set and need
not be changed.
3
1
1
2
Fig. 7-1
P/N 7105986H
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Repair
7-3
Pump
Nordson recommends replacing the pump and sending the old one in to be
repaired.
Replacing Pump
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
Tank Isolation Valve
Tank side
NOTE: Operate the tank isolation valve only when the melter is heated to
operating temperature.
Pin in position 0: Closed
0
Pin in position 1: Open
1
Pump side
Fig. 7-2
Detaching Pump
NOTE: Detach the pump only when the material is soft
(approx. 70 ° C/158 ° F, depending on material).
WARNING: The motor is precisely aligned and may not be be slid back
with the bracket in the slot.
Fig. 7-3
1. Remove protective panel.
2. Turn the coupling until the screws of the coupling half shells are
accessible.
3. Release the screws (2) of the coupling half shells on the pump side.
4. Remove the coupling half shell carefully from the pump side to prevent
the coupling from falling apart.
2
Fig. 7-4
E 2011 Nordson Corporation
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P/N 7105986H
7-4
Repair
5. Place a container under the pump (3) to collect any material left.
3
6. Slide coupling part off of the pump shaft.
7. Detach pump.
8. Clean sealing surface on the plate (4). If necessary, heat material
residue with a hot air fan, then remove.
9. Allow melter to cool to room temperature.
4
Fig. 7-5
Attaching Pump
NOTE: The pump may only be screwed on when the melter is cold.
1
NOTE: The sealing surfaces on the plate and the pump must be clean.
Always replace all O-rings.
1
1. Apply sealing paste (Refer to section Maintenance, Processing
Materials) to the new pump.
2. Apply high temperature grease to the fixing screws of the pump, then
tighten screws crosswise using a torque wrench; the tank must be cold
when screws are tightened. Starting torque: 25 Nm / 220 lbin
3. Refer to Important Regarding Coupling.
2
4
3
The axial offset, meaning the sum of the four gaps (4, Fig. 7-6), must
result in at least 2 mm (0.08 in) of air to accommodate the heat
expansion during operation.
Permitted radial offset: 1 mm (0.04 in)
Permitted angle offset: 1 °
4. Slide coupling half onto the shaft of the new pump.
5. Center the coupling disks (1) to one another and allow the coupling links
(2) to hang vertically (Refer to Fig. 7-6). Turn the coupling half on the
motor shaft to its position by hand.
6. Tighten coupling screws (3).
1
2
1
7. Heat melter to operating temperature and open tank isolation valve
again.
Fig. 7-6
P/N 7105986H
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E 2011 Nordson Corporation
Repair
7-5
Important Regarding Coupling
=
1
1
1
2
1
=
Fig. 7-7
S The coupling half shells (1) such that the diagonal surfaces of the pump
shaft (2) rest on those of the coupling half shells (Refer to Fig. 7-7).
S The coupling half shells must be tightened such that the gaps are the
same size (Refer to Fig. 7-7).
Extract from manufacturer’s installation and operating instructions:
S The drive shaft and output shaft should be parallel* to one another. If the
axes lean towards one another, excess load is applied to the edges of
the bearings, causing premature wear.
S The coupling may not be twisted axially. Intermediate disk should move
freely.
S The coupling should not be disassembled. Interchanging of coupling
links and disks, damaged sealing rings, polluted bearings, etc. can
cause premature malfunctioning.
S All three coupling disks must be aligned to the dimension** of the shaft
offset. If the intermediate disk is extremely off-center − meaning that the
coupling links are no longer parallel − the coupling may be destroyed
upon startup.
* = axially aligned
** = within the permitted shaft offset
E 2011 Nordson Corporation
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P/N 7105986H
7-6
Repair
Replacing Variseal
NOTE: When the pump shaft seal needs to be replaced, Nordson
recommends replacing the pump and sending the old one in to be repaired.
Only trained personnel can replace the pump shaft seal.
NOTE: Nordson cannot provide a guarantee for Variseals that have been
replaced by anyone besides a Nordson employee.
1. Remove the gear pump from the melter but do not disassemble it!
Refer to Replacing Pump in this section.
2. Have a new seal and a suitable assembly tool ready.
Assembly Tool
The assembly tool is used to slide new seals over the shaft journal and the
pump shaft pulley key groove without damaging the seals.
CAUTION: The seal must be put into place using the tool; otherwise the
seal will be destroyed.
1. Follow the instructions Assembly Tools for Sealing Kits with Variseal
Seals (P/N 7146229) to proceed.
2. Put the gear pump back into place.
P/N 7105986H
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Repair
7-7
Replacing Motor
NOTE: Perform work only when the material is soft (approx. 70 ° C/158 ° F,
depending on material); otherwise the coupling can not be turned.
1. Disconnect motor power cable in the electrical cabinet.
2. Detach plug connector from motor controller.
3. Turn the coupling until the screws of the coupling half shells are
accessible.
4. Release the screws of the coupling half shells on the motor side.
5. Remove the coupling half shell carefully from the motor side to prevent
the coupling from falling apart.
WARNING: The bracket may not be slid back in the slot or unscrewed.
6. Unscrew motor from bracket (1).
7. If necessary, remove protective varnish from the shaft of the new motor.
8. Attach the coupling to the shaft without using force (no jolts or
pounding). If necessary, sand pulley keys and shaft with emery cloth.
Lubricate pulley keys and shaft if needed.
1
Fig. 7-8
9. Install new motor in the bracket.
10. Attach coupling (Refer to Important Regarding Coupling)
Reconnect motor electrically.
11. Secure power cable with strain relief. Ensure that cable shield and
clamp have contact.
12. Verify that the connection effects the desired direction of rotation (see
arrow).
Fig. 7-9
Direction of pump
rotation
E 2011 Nordson Corporation
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P/N 7105986H
7-8
Repair
Replacing Filter Cartridge
Proceed as described in chapter Maintenance to replace filter cartridge.
Replacing Safety Valve
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
WARNING: System and material pressurized. Relieve system pressure
before removing the safety valve. Failure to observe can result in serious
burns.
NOTE: Screw in/out only when valve (1) and pump are warm and material
is soft (approx. 70 ° C, depending on material).
1. Unscrew old valve.
2. New valve: Apply mounting paste to all threads and the O-rings.
3. To prevent damage to the O-rings, carefully guide the new valve into the
hole when the melter is warm.
1
4. Tighten valve with a torque wrench. Starting torque: 15 Nm (133 lbin)
Fig. 7-10
Tank
WARNING: The electrical cover (1) of the heater connections is linked to
ground conductors. The ground conductor (2) must be reconnected after
every repair.
2
1
Fig. 7-11
P/N 7105986H
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Repair
7-9
Replacing Heater Connection Insulation
WARNING: The melter may not be operated without properly insulated
heater connections. Use only Nordson spare parts for insulation.
The heater connection insulation may be damaged when maintenance and
repair work is performed.
Fig. 7-13 shows the Nordson spare parts kit for insulating heater
connections as well as properly attached heater insulation.
Spare parts kit order no.: P/N 263 274
1. Remove nut (4), washers (3 and 5) and insulating cylinder (2).
2. Remove all of the ceramic powder from the heater connection.
Fig. 7-12
3. Guide new insulating cylinder (1) into the heater connection.
4. Attach new insulating cylinder (2), washer (3) and nut (4). Tighten nut
carefully until the insulating cylinder (2) is tight and has contact with the
heater connection.
5. Attach heater cable, spring washer (5) and nut (4) and tighten nut.
5
3
4
2
1
MCTK020L050A0497
Fig. 7-13
Spare parts kit
1 Insulating cylinder, small
2 Insulating cylinder, large
E 2011 Nordson Corporation
3 Washer
4 Hexagonal nut
D_K
5 Spring washer
P/N 7105986H
7-10 Repair
Replacing Temperature Sensor
Installing Service Kit
The kit contains a temperature sensor and heat transfer compound.
Service kit P/N: 394597 (Ni120)
Required tools:
Pliers
Side cutting pliers
1.
Remove electrical equipment cover.
2.
Disconnect connecting wires and extract old temperature sensor by the
connecting wires or with the aid of a pliers.
P/N 7105986H
3.
Apply heat transfer compound to new sensor.
4.
Insert sensor and reconnect electrically.
5.
Attach electrical equipment cover again.
D_K
E 2011 Nordson Corporation
Repair
7-11
Replacing Thermostat
1. Remove electrical equipment cover.
2. Release fixing screws and remove thermostat.
3. Connect connecting wires to the new thermostat.
4. Apply heat transfer compound to the bottom of the thermostat (Refer to
Processing Materials in section Maintenance), then fasten it to the tank
again.
5. Attach electrical equipment cover again.
Fig. 7-14
E 2011 Nordson Corporation
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P/N 7105986H
7-12 Repair
P/N 7105986H
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Parts
8-1
Section 8
Parts
How to Use Illustrated Parts List
The parts lists in the separate document Parts List are divided into the following columns:
Item— Identifies parts that can be obtained from Nordson.
Part— Nordson part number for each spare part shown in the
illustration. A row of hyphens in the column Part (- - - - -) indicates that
this part can not be ordered separately.
Description— This column contains the name of the part and, when
appropriate, its dimensions and other properties. The points in the
column Description show the relationship between assemblies,
subassemblies and single parts.
Quantity— The quantity needed per unit, assembly or subassembly.
The abbreviation AR (as required) is used when this item is a bulk item
or when the quantity per assembly depends on the product version or
model.
Unit — Identifies the melter of which the spare part is a component.
NOTE: Refer to the separate document Parts List, P/N 7146488.
Fasteners
Fasteners are shown as Fx in every illustration, whereby ”x” indicates the
number of the fastener in the list Schedule of Fasteners at the end of the
separate document Parts List.
Component Designation
The electrical components are labeled in accordance with DIN 40719,
part 2.
E 2011 Nordson Corporation
D_K
P/N 7105986H
8-2
Parts
P/N 7105986H
D_K
E 2011 Nordson Corporation
Technical Data
9-1
Section 9
Technical Data
General Data
Type Designation
Storage temperature
Max. operating height
Type of heating
Temperature sensor
− Measuring precision
Material pressure
Melting capacity
Degree of protection
Noise emission
Motor type
Gear box type
Motor/pump speeds
Heatup time
DK25
− 45° C to + 75 ° C
DK25H
DK50
DK100
− 49 ° F to + 167 ° F
3000 m
9840 ft
Cast-in electrical resistance heating elements
Ni120 " 1 ° C
5 to 85 bar
0.5 to 8.5 MPa
72.5 to 1 233 psi
The pressure control valve is preset at the factory. Default:
35 bar
3.5 MPa
508 psi
1 tankfull per hour
IP 54
1 motor:
60 dBA
−
−
2 motors: 62 dBA
3 ph AC motor
Helical gear
50 min-1, 65 min-1, 129 min-1
<45 min
Temperatures
Min. ambient temperature
Max. ambient temperature
Humidity
Min. operating temperature
(setpoint)
Max. operating
temperatures
Overtemperature shutdown
by thermostat
E 2011 Nordson Corporation
- 5 °C
40 ° C
10 to 95 %, not condensing
40 ° C
23 °F
104 °F
230 ° C
450 °F
260 ° C
500 °F
D_K
100 °F
P/N 7105986H
9-2
Technical Data
Electrical Data
WARNING: The unit is designed for only one operating voltage. Operate
only at the operating voltage shown on the ID plate.
Available operating voltages 200 VAC 3-phase without neutral (Delta)
230 VAC 3-phase without neutral (Delta)
400 VAC 3-phase with neutral (star − WYE)
400 VAC 3-phase without neutral (Delta)
480 VAC 3-phase without neutral (Delta)
Mains filter
P/N 394908 for
200 VAC 3-phase without neutral
230 VAC 3-phase without neutral
P/N 394907 for
400 VAC 3-phase with neutral
400 VAC 3-phase without neutral
480 VAC 3-phase without neutral
Operating voltage
frequency
50/60 Hz
Fuse protection
Refer to ID plate
Max. load per hose
receptacle (2 channels)
P/N 7105986H
1 000 W per single hose or gun
1 200 W per hose/gun pair
2 000 W total, hose/gun pairs 1 and 2
2 000 W total, hose/gun pairs 3 and 4
2 000 W total, hose/gun pairs 5 and 6
D_K
E 2011 Nordson Corporation
Technical Data
9-3
Mechanical Data
Typenbezeichnung
DK25
DK25H
Weight
Refer to consignment note
Tank opening [mm]
242 x 284
DK50
DK100
306 x 685
Length & width
Tank volume [liters]
Approx. 25
Approx. 45
Approx. 50
Approx. 100
Maximum number of
single stream pumps
1
1
2
2
Number of hose connections
One pump: 6
Two pumps:
3 per pump
Two pumps:
3 per pump
−
−
Assignment of hose
connections with two pumps
P1
Pump 2 (P2)
2.1
2.2
2.3
Pump 1 (P1)
1.1
1.2
1.3
P2
E 2011 Nordson Corporation
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P/N 7105986H
9-4
Technical Data
1382
1711
Dimensions
1382
1361
DK25H
DK25
1270
*)
174,5
400
452
245
835
582
121
366
210
1224
885
Fig. 9-1
*) For minimum bending radius refer to the hose manual
P/N 7105986H
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E 2011 Nordson Corporation
Technical Data
1661
(contd.)
1381
Dimensions
9-5
DK50
1585
*)
658
175
245
1000
1129
600
782
121
543
212
1516
Fig. 9-2
*) For minimum bending radius refer to the hose manual
E 2011 Nordson Corporation
D_K
P/N 7105986H
Technical Data
(contd.)
1381
Dimensions
1585
9-6
DK100
*)
1935
1837
121
212
751
245
1306
1246
911
175
1101
Fig. 9-3
*) For minimum bending radius refer to the hose manual
P/N 7105986H
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E 2011 Nordson Corporation
General Instructions Regarding Working with Application Materials
A-1
Appendix A
General Instructions Regarding Working with
Application Materials
Definition of Terms
Application materials can be e.g. thermoplastic hot melt materials, adhesives, sealants, liquid adhesives and similar application materials. They are
referred to as materials.
NOTE: The materials that may be processed with your Nordson product
are described in the manual under Intended Use and Unintended Use.
When in doubt, please contact your Nordson representative.
Manufacturer Information
Materials may be processed only when the manufacturer’s product descriptions and Safety Data Sheets (MSDS) are observed.
They provide information, amongst other things, on correct processing of
the product, transport, storage and disposal. Information regarding reactivity
and potentially hazardous decomposition products, toxic properties, flash
points, etc. can also be found there.
Liability
Nordson is not be liable for danger or damage resulting from the materials.
Risk of Burns
There is a risk of burns when handling heated materials. Work carefully and
wear appropriate protective clothing/equipment.
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P/N 7105986H
A-2
General Instructions Regarding Working with Application Materials
Vapors and Gases
Ensure that vapors and gases do not exceed the prescribed limits. If necessary, exhaust vapors and gases and/or provide sufficient ventilation of the
work space.
Substrate
The substrate should be free of dust, grease and moisture. The suitable material, optimum working conditions, and possible pre-treatment of the substrate must be determined by testing.
Processing Temperature
When materials require heating, adherence to the prescribed processing
temperature is imperative to ensure the quality of the application. It may not
be exceeded! Overheating can cause material coking or cracking, resulting
in malfunctioning or unit failure.
Material should always be melted gently. Extended, unnecessary temperature load should be avoided. The temperature should be reduced during
breaks in work. The temperature in the tank should be attuned to the material consumption. Thus it is close to the prescribed processing temperature
for high material consumption and lower for lower consumption.
When materials are processed cold, take into consideration the shear heat
and the ambient temperature; cool if necessary.
P/N 7105986H
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Operating Parameters
B-1
Appendix B
Operating Parameters
Operating parameters are organized in this appendix according to the
logical groups listed in Table B-1. For information about selecting and
editing operating parameters, refer to Section 3, Installation, Setting Up the
Melter.
NOTE: Parameter numbers that are reserved or that are not used do not
appear in this appendix.
Tab. B-1 Parameter Groups
Group
0 to 8 and
Group Description
11 to 14
Noneditable and other frequently used
parameters
Temperature
Control
20 to 29
Control heaters
Input Setup
30 to 33
Configure the inputs
Output Setup
40 to 42
Configure the outputs
Seven-day Clock
50 to 77
Configure the clock feature
Standard
E 2011 Nordson Corporation
Parameter
Number
Automatic Fill
timer
78
Configures external motor control switch
Reverse
Fault Logic
79
Configures fault logic to open when fault
condition
PID selection
80 to 91
D_K
Change the default PID settings
P/N 7105986H
B-2
Operating Parameters
Standard
0
Enter Password
Description: A user-defined password that prevents unauthorized changes to set-point
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 11 and
then enabled using parameter 10.
NOTE: The melter remains in the password-protected mode for two minutes
after the last key press. After exiting the setup mode, attempting to re-enter the
setup mode, even before two minutes has elapsed, will require you to re-enter
the password.
1
Total Hours with Heaters On
Description: A non editable value that indicates the total number of hours that the heaters
have been on.
Value: 9999 (control panel) and 999,999 on the web browser
Resolution: 1 hour
Default Value: 0
Format: —
Use: The display registers up to 9999 hours and then rolls over to 0000.
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 ten faults.
Empty log entries are indicated by “_-F0.” Refer to Monitor the Melter in Section
4, Operation.
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Operating Parameters
Standard
B-3
(contd.)
3
Change History Log
(Noneditable)
Description: Records the last ten changes made to either the set-point temperatures or the
operating parameters.
Value: —
Resolution: —
Default Value: P-_ (unused log entry)
Format: Refer to Section 3, Installation. Review Parameter and Set-point Temperature
Changes.
Use: Use the right-display key to review the log entries for the last ten changes that
were made to the operating parameters or the set-point temperatures. Empty
log entries are indicated by “P-_.”
4
Ready Delay Time
Description:
Value:
Resolution:
Default Value:
Format:
Use:
The amount of time that will elapse after all of the components have reached
their set-point temperature before the ready LED will turn on. The ready delay
time only functions when the temperature of the tank, at the time the melter is
turned on, is more than 27 °C (50 °F) from its set-point temperature. The
ready delay time begins when all components are within 3 °C (5 °F) of their
respective set-point temperature.
0 to 60 minutes
1 minute
0 minutes
—
The ready delay allows the contents of the tank an additional amount of time
to heat before pump turns on.
NOTE: The time remaining on the ready delay is indicated in minutes in the
right display at the end of every automatic scan cycle. When the delay time
reaches 1 minute, the time remaining appears in seconds.
5
Service Interval Time
Description: 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 or
maintenance event, such as changing the filter. The service LED will turn on
after the pre-set time elapses. With the melter in the scan mode, press the
Clear/Reset key to turn off the service LED and reset the time.
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P/N 7105986H
B-4
Operating Parameters
Standard
(contd.)
6
Service LED Heater Hours
Description: A timer indicates how many more hours the heaters need to remain on before
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 this parameter
will work.
Note: Heater hours accumulate whenever the heaters LED is illuminated.
7
Motor Off Delay
Description:
8
Not being used, only displayed.
Automatic Pump On
Description: Determines if the pump can be enabled before the melter is ready.
Value: 0 = disabled or 1 = enabled
Resolution: —
Default Value: 1 (enabled)
Format: —
Use: If enabled, the pump can be enabled before the melter is ready. Once enabled,
the pump will start automatically when the melter is ready.
If disabled, the pump must be started by pressing the pump key(s) after 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.
P/N 7105986H
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Operating Parameters
Standard
B-5
(contd.)
10
Enable or Disable the Melter Password
Description: Activates or deactivates the melter password. When password protection is
activated, component set-point temperatures or melter operating parameters
cannot be changed until a valid password is entered using parameter 0.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default Value: 0
Format: —
Use: A password must first be created using parameter 11 before it can be enabled
or disabled using parameter 10.
11
Create Password
Description: A user-defined password that prevents unauthorized changes to operating
parameters or set-point temperatures.
Value: 0 to 9999
Resolution: 1
Default Value: 5000
Format: —
Use: Refer to Section 4, Operation, Enter Password.
NOTE: When the password is created and enabled, parameter 10 will not
appear again in the right display until the password is entered.
12
Change Hose 1 Output to Electric Gun Activation
Description: Changes the proportioned 240 VAC current that is provided to the hose 1
heater to a switched 240 VAC current that is used to activate a
manifold−mounted electric gun.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default Value: 0 (disabled)
Format: —
Use: Use only when a Nordson manifold-mounted electric gun is installed and a
switching device is connected to the melter’s switch receptacle. Refer to the
electric gun manual for information on mounting and using the gun.
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P/N 7105986H
B-6
Operating Parameters
Standard
(contd.)
13
Change Hose 2 Output to Electric Gun Activation
Description: Changes the proportioned 240 VAC current that is provided to the hose 1
heater to a switched 240 VAC current that is used to activate a
manifold−mounted electric gun.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default Value: 0 (disabled)
Format: —
Use: Use only when a Nordson manifold-mounted electric gun is installed and a
switching device is connected to the melter’s switch receptacle. Refer to the
electric gun manual for information on mounting and using the gun.
14
External Communications Lock-out
Description:
Value:
Used as a safety feature when performing maintenance on the melter.
Prevents external control of the melter through standard or optional
inputs/outputs or network communications (optional).
0 (disabled)
or
1 (enabled)
Resolution:
Default Value:
Format:
Use:
20
—
0 (disabled)
—
Set parameter to 1 (enabled) before performing any maintenance on the
melter. When enabled, all external control of the melter stops until the
parameter is once again set to 0 (disabled).
Temperature Units
Description:
Value:
Resolution:
Sets the units for temperature display.
C (degrees Celsius) or F (degrees Fahrenheit)
0 = Celsius
1 = Fahrenheit
Default Value:
P/N 7105986H
0
Format:
—
Use:
—
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Operating Parameters
Standard
B-7
(contd.)
21
Over Temperature Delta
Description: The number of degrees that the temperature of any component can increase
over its assigned set-point temperature before an over temperature 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 Delta
Description: The number of degrees that the temperature of any component can decrease
from its set-point temperature before an under temperature fault (F2) occurs.
Value: 5 _C (10 _F) to 60 _C (110 _F)
Resolution: 1_C
1_F
Default Value: 25 _C (50 _F)
Format: —
Use: —
23
Standby Delta
Description: The number of degrees by which all heated components will be decreased
when the melter is placed into the standby mode.
Value: 25_C to 190_C (50_F to 350_F)
Resolution: 1_C
1_F
Default Value: 50 _C (100 _F)
Format: —
Use: A standby delta should be selected that results in a balance between melter
energy savings during periods of inactivity, the amount of time and energy
required to bring the melter back up to set-point temperature, and a
temperature at which the hot melt can be held in the tank for extended periods
of time without charring. Refer to Section 4, Operation, Function Keys.
NOTE: The standby delta does not affect the under temperature delta
(parameter 22).
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P/N 7105986H
B-8
Operating Parameters
Standard
(contd.)
24
Automatic Standby Timeout
Description: The amount of time that must elapse after the last signal (gun driver) is sent to
input 1 before the melter will enter the standby mode. The automatic standby
timeout feature saves energy by allowing the melter to automatically go into the
standby mode if the melter detects that the guns are no longer firing.
Value: 0 to 1440 minutes (24 hours)
Resolution: 1 minute
Default Value: 0 (disabled)
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 is connected
to input 1. If there is no voltage on the input contacts when the melter is ready,
the melter will enter the standby mode after the automatic standby time.
25
Automatic Heaters Off Time
Description: 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)
Resolution: 1 minute
Default Value: 0 (disabled)
Format: —
Use: Set parameter 24 (automatic standby timeout) to the desired value before
setting parameter 25.
26
Manual Standby Time
Description: The amount of time that the melter will remain in the standby mode after the
standby key is pressed.
Value: 0 to 180 minutes
Resolution: 1 minute
Default Value: 0
Format: —
Use: Set the standby time when you want the operator to be able to place the melter
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 setting
parameter 26.
Note: When a time value equal to or greater than 1 minute is entered, the
standby LED will flash to indicate that the manual standby timer is counting
down.
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Operating Parameters
Standard
B-9
(contd.)
27
Standby delta (all hoses)
Software version 2.023 and higher
Description: A standby value that applies only to the hoses.
Value: 1_C to 190_C (1_F to 350_F)
Resolution: 1_C
1_F
Default: 0 (disabled)
Format: —
Use: If this parameter is deactivated, the standby value of parameter 23 Standby
delta (global) applies instead.
NOTE: For control purposes, the hopper is hose 5.
28
Standby delta (all guns)
Software version 2.023 and higher
Description: A standby value that applies only to the guns.
Value: 1_C to 190_C (1_F to 350_F)
Resolution: 1_C
1_F
Default: 0 (disabled)
Format: —
Use: If this parameter is deactivated, the standby value of parameter 23 Standby
delta (global) applies instead.
29
Temperature offset
Software version 2.023 and higher
Description: The grid and reservoir may be assigned different temperature setpoints.
The setpoint temperature entered on the control panel is that of the reservoir.
The grid setpoint temperature is lowered internally by the value set here.
Value: 0_C to −15_C (0_F to −30_F)
Resolution: 1_C
1_F
Default: 0
Format: —
Use: In case different temperatures for grid and reservoir are needed.
Setpoint Reservoir + Temperature offset = Setpoint Grid
Example: 150 _C + (−15 _C) = 135 _C
NOTE: For control purposes, the hopper is hose 5. To ensure a steadily
increasing temperature hopper − grid − reservoir, its setpoint temperature must
be taken into consideration when setting the temperature offset.
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P/N 7105986H
B-10 Operating Parameters
Input Setup
30
Input 1
Description: Control options that determine the function of input 1.
Value: 0 − Input Disabled
1 – Standby On/Off
2 – Heaters On/Off
3 – Motor 1 Enable/Disable
4 – Hose/Gun 1 Enable/Disable
5 – Hose/Gun 2 Enable/Disable
6 – Hose/Gun 3 Enable/Disable
7 – Hose/Gun 4 Enable/Disable
8 – Hose/Gun 5 Enable/Disable
9 – Hose/Gun 6 Enable/Disable
10 – Automatic standby
11 − Motor 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
Resolution: 1
Default Value: 10
Format:
Use: If Motor Enable/Disable (3) is selected, the motor will turn on whenever voltage
is present on the input contacts. To require that the pump key be pressed
(pump enabled) and that there be voltage on the input contacts before the
motor can turn on, set the value of parameter 8, Automatic Pump On to 0
(disabled).
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: Only Input 1 offers control option 10.
Multiple inputs can be set to the same input value. After one or more inputs that
have the same input value are energized, the input functionality will not be
considered inactive (off) until all of the inputs with the same input value are
de-energized (Multiple inputs set to the same input value are logical ORed.).
NOTE: To be able to use option 13 or 14, set parameter 78 (Automatic Fill
timer) to equal or greater than 1. Output option 6 (alarm) can be used to signal
when Automatic Fill time expires.
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Operating Parameters
Input Setup
31
B-11
(contd.)
Input 2
Description: Control options that determine the function of input 2.
Value: 0 − Input Disabled
1 – Standby On/Off
2 – Heaters On/Off
3 – Motor 1 Enable/Disable
4 – Hose/Gun 1 Enable/Disable
5 – Hose/Gun 2 Enable/Disable
6 – Hose/Gun 3 Enable/Disable
7 – Hose/Gun 4 Enable/Disable
8 – Hose/Gun 5 Enable/Disable
9 – Hose/Gun 6 Enable/Disable
11 − Motor 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
Resolution: 1
Default Value: 1
Format: —
Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless the
pump is enabled and the correct voltage is present on the input contacts.
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: Multiple inputs can be set to the same input value. After one or more
inputs that have the same input value are energized, the input functionality will
not be considered inactive (off) until all of the inputs with the same input value
are de-energized (Multiple inputs set to the same input value are logical
ORed.).
NOTE: To be able to use option 13 or 14, set parameter 78 (Automatic Fill
timer) to equal or greater than 1. Output option 6 (alarm) can be used to signal
when Automatic Fill time expires.
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P/N 7105986H
B-12 Operating Parameters
Input Setup
32
(contd.)
Input 3
Description: Control options that determine the function of input 3.
Value: 0 − Input Disabled
1 – Standby On/Off
2 – Heaters On/Off
3 – Motor 1 Enable/Disable
4 – Hose/Gun 1 Enable/Disable
5 – Hose/Gun 2 Enable/Disable
6 – Hose/Gun 3 Enable/Disable
7 – Hose/Gun 4 Enable/Disable
8 – Hose/Gun 5 Enable/Disable
9 – Hose/Gun 6 Enable/Disable
11 − Motor 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
Resolution: 1
Default Value: 2
Format: —
Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless the
pump is enabled and the correct voltage is present on the input contacts.
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: Multiple inputs can be set to the same input value. After one or more
inputs that have the same input value are energized, the input functionality will
not be considered inactive (off) until all of the inputs with the same input value
are de-energized (Multiple inputs set to the same input value are logical
ORed.).
NOTE: To be able to use option 13 or 14, set parameter 78 (Automatic Fill
timer) to equal or greater than 1. Output option 6 (alarm) can be used to signal
when Automatic Fill time expires.
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Operating Parameters
Input Setup
33
B-13
(contd.)
Input 4
Description: Control options that determine the function of input 4.
Value: 0 − Input Disabled
1 – Standby On/Off
2 – Motor 1 On/Off
3 – Pump Enable/Disable
4 – Hose/Gun 1 Enable/Disable
5 – Hose/Gun 2 Enable/Disable
6 – Hose/Gun 3 Enable/Disable
7 – Hose/Gun 4 Enable/Disable
8 – Hose/Gun 5 Enable/Disable
9 – Hose/Gun 6 Enable/Disable
11 − Motor 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
Resolution: 1
Default Value: 4
Format: —
Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless the
pump is enabled and the correct voltage is present on the input contacts.
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: Multiple inputs can be set to the same input value. After one or more
inputs that have the same input value are energized, the input functionality will
not be considered inactive (off) until all of the inputs with the same input value
are de-energized (Multiple inputs set to the same input value are logical
ORed.).
NOTE: To be able to use option 13 or 14, set parameter 78 (Automatic Fill
timer) to equal or greater than 1. Output option 6 (alarm) can be used to signal
when Automatic Fill time expires.
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P/N 7105986H
B-14 Operating Parameters
Input Setup
34 – 39
(contd.)
Optional Inputs 5, 6, 7, 8, 9, and 10
Description: Control options that determine the function of the six optional inputs provided
when the optional I/O expansion card is installed on the main board.
Value: 0 − Input Disabled
1 – Standby On/Off
2 – Motor 1 On/Off
3 – Pump Enable/Disable
4 – Hose/Gun 1 Enable/Disable
5 – Hose/Gun 2 Enable/Disable
6 – Hose/Gun 3 Enable/Disable
7 – Hose/Gun 4 Enable/Disable
8 – Hose/Gun 5 Enable/Disable
9 – Hose/Gun 6 Enable/Disable
11 − Motor 2 Enable/Disable
13 − Automatic Fill timer no. 1
14 − Automatic Fill timer no. 2
Resolution: 1
Default Value: 0 (Disable)
Format: —
Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless the
pump is enabled and the correct voltage is present on the input contacts.
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: When more than one input is set to the same value, the controller
follows the state of the active input.
NOTE: To be able to use option 13 or 14, set parameter 78 (Automatic Fill
timer) to equal or greater than 1. Output option 6 (alarm) can be used to signal
when Automatic Fill time expires.
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Operating Parameters
B-15
Output Setup
40 − 42
Outputs 1, 2, and 3
Description: Determines the function of the output.
Value: 0 = Output Disabled
1 = Ready
2 = Ready and Pump is on
3 = Fault
4 = Low level (not available)
5 = Service LED is on
6 = Alert
Resolution: 1
Default Value: Output 1 = 1
Output 2 = 3
Output 3 = 4
Format: —
Use: Refer to Installing Melter Outputs in Section 3, Installation, for information on
setting up outputs.
When control option 6, Alert is selected, the output is active whenever the
melter enters the two minute fault monitoring period. If the potential fault
condition clears before the end of the two minute period, the output signal ends.
Refer to Section 4, Operation, Monitor Melter Faults, for information about fault
monitoring.
43 − 46
Optional Outputs 4, 5, 6, and 7
Description: Control options that determine the function of the four optional outputs provided
when the optional I/O expansion card is installed on the main board.
Value: 0 = Output Disabled
1 = Ready
2 = Ready and Pump is on
3 = Fault
4 = Low level (not available)
5 = Service LED is on
6 = Alert (Potential fault)
Resolution: 1
Default Value: 1 (all optional outputs)
Format: —
Use: Refer to the instruction sheet provided with the optional I/O expansion card for
information about wiring and setting up the optional outputs.
When control option 6, Alert is selected, the output is active whenever the
melter enters the two minute fault monitoring period. If the potential fault
condition clears before the end of the two minute period, the output signal ends.
Refer to Section 4, Operation, Monitor Melter Faults, for information about fault
monitoring.
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P/N 7105986H
B-16 Operating Parameters
Seven-day Clock
Before setting up the clock, refer to Function Keys in Section 4, Operation,
to familiarize yourself with the function and use of the clock feature.
If you are unfamiliar with the procedure for accessing and editing operating
parameters, refer to Section 3, Installation, Setting Up the Melter.
To Set the Clock
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 heaters
should turn on and off.
b. Setting parameters 57 and 58 to the time of the day that the melter
should enter and exit the standby mode.
4. Using parameters 60 through 68, create schedules 2 and 3 by repeating
step 3.
5. Use parameters 71 through 77 to assign which of the four schedules
should be used on each day of the week. Up to three schedules may be
assigned each day (to support three work shifts). Each of the eight
control options (0 to 7) that is available in parameters 71 through 77
assigns a different combination of the three schedules. Option 0 is used
hold the melter in the state dictated by the last clock transition until the
next clock transition occurs.
In order for the clock to operate continuously
throughout the week, a valid schedule must
be assigned to every day of the week
(parameters 71 through 77).
To prevent unintentional activation of the clock
the default setting for parameters 71 through
77 is schedule 0. which has no time values
assigned to it. With the default set to schedule
0, unintentionally pressing the clock key will
have no affect on the melter.
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Operating Parameters
Seven-day Clock
50
B-17
(contd.)
Current Day
Description: 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, Function Keys, for information about the use and
affects of the seven-day clock feature.
51
Current Time
Description: Used to set the local time of the day.
Value: 0000 to 2359 (European time format)
Resolution: 1 minute
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 On
Description: Used to set the time that the clock will turn on the heaters during schedule 1.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: 0600
Format: Hours, Hour: Minute, Minute
Use: Set the desired time for the heaters to turn on.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
56
Schedule 1 Heaters Off
Description: Used to set the time that the clock will turn off the heaters during schedule 1.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: 1700
Format: Hours, Hour: Minute, Minute
Use: To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
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P/N 7105986H
B-18 Operating Parameters
Seven-day Clock
57
(contd.)
Schedule 1 Enter Standby
Description: Used to set the time that the melter will enter the standby mode during
schedule 1.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will enter the standby mode during schedule 1.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an enter standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
58
Schedule 1 Exit Standby
Description: Used to set the time that the melter will exit the standby mode during schedule
1.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will exit the standby mode during schedule 1.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an exit standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
60
Schedule 2 Heaters On
Description: Used to set the time that the clock will turn on the heaters during schedule 2.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hours, Hour: Minute, Minute
Use: Set the desired time for the heaters to turn on.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
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Operating Parameters
Seven-day Clock
61
B-19
(contd.)
Schedule 2 Heaters Off
Description: Used to set the time that the clock will turn off the heaters during schedule 2.
Value: 0000 to 2359, - - - Resolution: 1 e
Default Value: - - - Format: Hours, Hour: Minute, Minute
Use: To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
62
Schedule 2 Enter Standby
Description: Used to set the time that the melter will enter the standby mode during
schedule 2.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will enter the standby mode during schedule 2.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an enter standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
63
Schedule 2 Exit Standby
Description: Used to set the time that the melter will exit the standby mode during schedule
2.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will exit the standby mode during schedule 2.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an exit standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
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P/N 7105986H
B-20 Operating Parameters
Seven-day Clock
65
(contd.)
Schedule 3 Heaters On
Description: Used to set the time that the clock will turn on the heaters during schedule 3.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hours, Hour: Minute, Minute
Use: Set the desired time for the heaters to turn on.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
66
Schedule 3 Heaters Off
Description: Used to set the time that the clock will turn off the heaters during schedule 3.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hours, Hour: Minute, Minute
Use: To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
67
Schedule 3 Enter Standby
Description: Used to set the time that the melter will enter the standby mode during
schedule 3.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will enter the standby mode during schedule 3.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an enter standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
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Operating Parameters
Seven-day Clock
68
B-21
(contd.)
Schedule 3 Exit Standby
Description: Used to set the time that the melter will exit the standby mode during schedule
3.
Value: 0000 to 2359, - - - Resolution: 1 minute
Default Value: - - - Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will exit the standby mode during schedule 3.
To disable this parameter, set the parameter’s value to “- - - -” by
simultaneously pressing both of the right-display scroll keys.
Note: Do not set an exit standby time that is outside of the time period defined
by the schedule’s heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
71 - 77
Schedules for the Days of the Week
Description: Used to select which schedule(s) should be used on a specific day of the week.
Value: 0 – Remain at last clock transition
1 – Use just schedule 1
2 – Use just schedule 2
3 – Use just schedule 3
4 – Use schedule 1 and 2
5 – Use schedule 2 and 3
6 – Use schedule 1 and 3
7 – 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 on again until
the next scheduled heaters on time arrives.
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B-22 Operating Parameters
Seven-day Clock
78
(contd.)
Automatic Fill Timer
Description: A counting down timer for a switch that can be connected to an input.
Value: 0 to 90 seconds
Resolution: 1
Default Value: 0 (disabled)
Format: —
Use: Used together with input control option 13 or 14. Activate output control
option 6 (alarm) to be able to send a signal when the filling time expires.
NOTE: If the filling process is not ended within the specified
time, a message runs up and the melter stops. In this case,
check why the filling process was not ended and fix the cause.
hen press the Clear/Reset key to reset the melter to normal
mode.
79
Reverse Fault Logic
Description: Used to reverse the logic of the fault output from Open when fault
condition to Close when fault condition.
Value: 0 or 1
Resolution: —
Default Value: 0 (open when fault condition)
Format: —
Use: Use extreme caution when reversing the fault logic. Ensure that the fault
signal to the parent machine does not create an unsafe condition.
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Operating Parameters
B-23
PID Selection
80−91
PID Selection for Receptacles, Hose/Gun 1, 2, 3 and 4
Description: Used to change the preset PID selections. Use parameter 80 to select the
value for hose 1, parameter 81 to select the value for gun 1, and so on.
Value: 0 = Hose
1 = Standard gun
2 = Large gun
3 = Air heater
Resolution: —
Default Value: 0 or 1 depending on the channel type (hose or gun)
Format: —
Use: Consult your Nordson representative before changing PID settings.
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B-24 Operating Parameters
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Glossary
C-1
Appendix C
Glossary
Advance Distance
Distance between initiator and gun/application head.
Angel Hair
Fine threads of adhesive that are created when adhesive is incorrectly
transferred from the nozzle to the substrate. This could be caused e.g. by
poor shaving of high viscosity material at the nozzle.
Application Head
Refer to Gun.
Application System, Hot Melt
An arrangement of units and components that melt, feed, meter and apply
hot melt adhesive, e.g. bulk melter, melter, gear metering pump station, gun,
coating stand and heated hoses.
Application Weight
The weight (grammage) of the application material applied to a surface unit
of the substrate.
Determining the application weight: A circle cutter is used to cut several
100 mm2 sized circles from the uncoated substrate. The cut out sections
should be evenly distributed on the substrate. The samples are each
weighed to exactly 0.01 g, and the average weight is calculated. The same
is done with the coated substrate. The number of samples taken depends
on how much the weights of the samples differ. The application weight is the
difference between the coated and uncoated substrate. The application
weight is usually stated in g/m2.
Assembly Handgun
Manually operated system component used to apply material as a bead,
dot, surface or spray application.
bar
Legal unit for pressure. The SI unit is Pascal (Pa). The unit commonly used
in the USA is psi. Refer to Conversions.
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C-2
Glossary
Bd (Baud)
Rate of data transfer: Bit/s.
Bead Size
The width of a bead of material applied to a substrate. The size refers to the
bead before it is compressed by the two parts.
CAN Bus
The Controller Area Network is an internationally standardized serial bus
system. With Nordson melters, control components such as temperature
controllers, motor controllers (frequency converters) and pressure sensors
exchange data with the industrial PC via the CAN bus. The CAN bus is used
as an internal network for Nordson unit control and is not intended to be an
interface for the customer’s control units.
Cast-in Heater
A resistance heating element that is cast into a tank or melting plate. This
fixed connection provides optimal heat conducting.
Charring
Decomposition of a synthetic material, particularly through heat influence.
Can occur when processing temperature is too high.
Class of protection
Protective measures are required to ensure electrical safety of the units.
The measures prevent accessible metal parts from conducting voltage
when a fault occurs. Assignment of classes of protection indicates the
protective measures.
Class of
protection
Symbol
Precaution
1
All accessible metal parts are conductively connected to one another and
are linked to the mains ground conductor.
2
The unit is insulated such that there are no accessible metal parts that
could conduct voltage in the event of a fault. There is no ground
conductor.
3
The unit is operated with extra-low voltage up to 42 V from a safety
isolating transformer or a battery.
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Glossary
C-3
Component
1. System component:
This term designates a single unit (e.g. melter) that is part of an
application system.
2. Unit component:
This term designates a single part (e.g. coupling, EMERGENCY OFF
button) or a group of parts that forms a functional unit (e.g. inert gas
equipment).
Controller
Used to control proportional valves (pressure control unit) or solenoid valves
and guns/application heads (pattern controller) dependent on the speed of
the parent machine.
ControlNet
Internationally standardized serial field bus with scanner and adapter
subscribers. Nordson melters (adapter) with a ControlNet interface can be
controlled remotely by the customer’s control unit (scanner).
Control Voltage
Electrical cabinet internal voltage for electrical components such as
temperature controllers, PLC, etc. The control voltage in Nordson electrical
cabinets is usually 230 VAC or 24 VDC.
Conversions
In mesh
In mm
In mesh
In mm
2,5
8.0
50
0.30
3
6.73
60
0.25
5
4.0
80
0.18
8
2.38
100
0.149
10
2.0
140
0.105
14
1.41
170
0.088
18
1.0
200
0.074
20
0.84
270
0.053
30
0.59
325
0.044
40
0.42
400
0.037
Table: U.S. Bureau of Standards
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C-4
Glossary
Conversions
(contd.)
Multiplied by
Unit
Result
SI unit: [kg/m3]
Density
Kilograms per cubic meter
kg/m3 1.0 x 10−3
Kilograms per liter
kg/l
Kilograms per cubic meter
kg/m3 8.35 x 10−3
Pounds per gallon (US)
lb/gal
Kilograms per liter
kg/l
8.35
Pounds per gallon (US)
lb/gal
Pounds per gallon (US)
lb/gal
0.12
Kilograms per liter
kg/l
SI unit: [Nm]
Starting torque
Newtonmeter
Nm
8.85
Pound inch (US)
lbin
Newtonmeter
Nm
0.74
Pound foot (US)
lbft
Pound inch (US)
lbin
0.113
Newtonmeter
Nm
Pound foot (US)
lbft
1.36
Newtonmeter
Nm
SI unit: Pascal [Pa = N/m2]
Pressure
Pascal
Pa
1.0 x 10−5
Bar
bar
Pascal
Pa
0.69 x 10−6
Pounds per square inch (US)
psi
Bar
bar
14.5
Pounds per square inch (US)
psi
Pounds per square inch (US)
psi
0.069
Bar
bar
SI unit: [m/s]
Speed
Meters per second
m/s
196.89
Feet per minute
ft/min
Feet per minute
ft/min
5.1 x 10−3
Meters per second
m/s
SI basic unit: Meter [m]
Length
Meter
m
3.2808
Foot
ft
Foot
ft
0.3048
Meter
m
Centimeter
cm
0.3937
Inch
in
Inch
in
2.54
Centimeter
cm
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C-5
Glossary
Conversions
(contd.)
Multiplied by
Unit
Result
SI basic unit: Kilogram [kg]
Masse
Kilogram
kg
2.2046
Pound (US)
lb
Pound (US)
lb
0.4536
Kilogram
kg
Gram
g
0.0353
Ounce
oz
Ounce
oz
28.35
Gram
g
SI basic unit: Kelvin [K]
Temperature
Degrees Celsius
°C
(° C x 1.8) + 32
Degrees Fahrenheit
°F
Degrees Fahrenheit
°F
(° F − 32) 1.8
Degrees Celsius
°C
SI unit: Pascal second [Pas]
Viscosity, dynamic
Pascal second
Pas
1.0 x 103
CentipioseA
cP
CentipioseA
cP
1.0 x 10−3
Pascal second
Pas
SI unit: [m2/s]
Viscosity, kinematic
Square meters per second
m2/s
1.0 x 10−6
CentistokeA
cSt
CentistokeA
cSt
1.0 x 106
Square meters per second
m2/s
SI unit: [m3]
Volume
Cubic meter
m3
1. 0 x 103
Liter
l
Cubic meter
m3
264.2
Gallon (US)
gal
Liter
l
0.2642
Gallon (US)
gal
Gallon (US)
gal
3.7853
Liter
l
NOTE: A: Has not been a legal unit since 1986.
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C-6
Glossary
dB (A)
Unit for the sound intensity level, measured according to the internationally
standardized evaluation curve A, which measures sound in a way similar to
how it is perceived by the human ear.
Degree of Protection
According to IEC 529/DIN 40 050.
The degrees of protection of electrical components through metal protection
are stated as an abbreviation such as IP 54. The first numeral stands for the
contact and impurity protection, and the second numeral indicates water
protection. The third numeral, which indicates impact protection, is usually
not stated.
1. numeral
2. numeral
3. numeral
Contact and impurity
protection
Water protection
Impact protection
Protection from...
Protection from...
Protection from impact strength
up to...
0
−
−
1
Foreign object > 50 mm
Water dripping vertically
0,225 J = Impact of 150 g from a
height of 15 cm
2
Foreign object > 12 mm
Water dripping diagonally
0,375 J = Impact of 250 g from a
height of 15 cm
3
Foreign object > 2.5 mm
Spray water
0,5 J = Impact of 250 g from a
height of 20 cm
4
Foreign object > 1 mm
Splash water
−
5
Dust accumulation
Water stream
2,0 J = Impact of 500 g from a
height of 40 cm
6
Dust penetration
Upon flooding
−
7
−
When dipped
6,0 J = Impact of 1.5 kg from a
height of 40 cm
8
−
When submerged
9
−
−
IP
−
−
20 J = Impact of 5 kg from a height
of 40 cm
Drop-off Delay
1. The time between the signal to switch off the gun/application head and
the end of material application.
2. The time that a delay relay remains engaged after it has been switched
off.
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Glossary
C-7
Encoder
The encoder compiles the line speed of the parent machine. It supplies a
certain number of electrical pulses per revolution. The frequency is a
measure of line speed. Refer to Line Speed Signal.
Firmware
Internal software that cannot be changed by and that is not accessible to
the customer.
Flap Valve
A valve through which material can only flow in one direction. The valve
closes automatically when the flow direction changes.
Free-wheeling Diode
Electronic component that protects electronic assemblies from power
surges that occur when relays or solenoid valves are switched off.
Grammage
Refer to Application Weight.
Gun, Hot Melt
System component used to apply material as a bead, dot, surface or spray
application.
Heater Cartridge
A replaceable, cylindrical resistance heating element. It is inserted into a
hole in the component to be heated.
Hopper
Unheated tank extension, used to increase tank volume.
Host
Higher-order control unit.
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C-8
Glossary
Hot Melt
Synonym for hot melt adhesive.
Hot Melt Adhesive
Hot melt adhesives are thermoplastic synthetic materials. They are
processed in a liquid state. They bond by solidifying.
Inert gas
Gas (e.g. nitrogen) used to protect the adhesive from contact with humidity
and therefore from undesired reactions. Inert gas is also referred to as
protective gas.
Initiator
Component that generates a signal when an object is in a certain area of its
surroundings. Possible models are e.g. proximity initiators and light beam
photo cells.
Intermittent Mode
Mode of operation for guns/application heads. Instead of material
application being continuous, it occurs with pauses to create the desired
application pattern.
LED
Light Emitting Diode.
Line Speed Signal
A signal generated by the parent machine (voltage, current or frequency) to
control the melter.
Line Voltage
Voltage in the customer’s network. It may need to be converted to operating
voltage by a transformer.
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Glossary
C-9
Machine Enable
A control unit is enabled by a signal from the parent machine. In Nordson
literature the enable feature is also referred to as Parent Machine Interlock
or Security.
Master-Slave
The setup of two or more units in which one assumes control of one or more
slaves.
Example: Nordson melters on the PROFIBUS are slaves that are controlled
by the customer’s master.
Material
General Nordson term for application materials such as thermoplastic hot
melt adhesives, adhesives, sealants, cold glue, etc.
Melter
Melts and feeds hot melt adhesives or similar materials.
Menu
Branched program structure from which the operator selects the desired
functions/features.
min −1
min−1 = 1/min. Revolutions per minute (rpm).
MSDS
Material Safety Data Sheet.
Ni 120
Abbreviation for a nickle based resistance temperature sensor. At a
temperature of 0° C (32° F), it has an electrical resistance of 120 W.
Nm
Newtonmeter, SI unit for energy and starting torque. Refer to Conversions.
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C-10 Glossary
Noise Emission
Noise level that a unit produces in the immediate vicinity. The noise
emission is stated in dB (A).
Nominal Air Quantity
States suction volume of exhaust hoods. The pressure drop from the
exhaust hood to the customer’s fan must also be taken into consideration.
Nozzle
The component through which the material leaves the gun/application head.
The nozzle determines the volume, shape and direction of the material
outlet.
Open Time
The maximum time in which bonding can occur between application of the
material to the substrate and pressing on the second part. Factors such as
application temperature, substrate, adhesive properties and amount of
adhesive are relevant to open time.
Operating Air Pressure
The customer’s compressed air supply is usually reduced by pressure
controllers in the units. The operating air pressure is the reduced pressure
at which pneumatic components are operated.
Operating Voltage
The voltage used to operate the unit. The operating voltage is stated on the
ID plate. A transformer may be necessary to adapt the melter to the
customer’s line voltage.
Output Quantity
The material volume fed by the pump. Stated e.g. in cm3/min.
Pa
Pascal, SI unit for pressure. Refer to Conversions.
Parameters
Variably adjusted values that must be entered into a control unit, a PLC
control or the control system.
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Glossary
C-11
Parent Machine
The user’s machine that generates the line speed signal for key-to-line
mode. Refer to Line Speed Signal.
Pas
Pascal second, SI unit for dynamic viscosity.
PID Controller
A type of controller that combines different control characteristics of
proportional, integral and differential aspects.
The controller should be calibrated such that the controlled variable (output
variable) and the manipulating variable (input variable) fluctuate as little as
possible and the time needed for the manipulating variable to stabilize is as
short as possible.
PLC
Programmable Logic Controller.
Polyamide
A term used by Nordson to describe polyamide-based hot melt adhesives.
Other common designations are polyamide resin and polyamide hot melt
adhesive.
Polyurethane Hot Melt Adhesive
Moisture interlaced hot melt adhesive. Common abbreviations are PU and
PUR. When processing polyurethane adhesives, additional safety
instructions must be observed.
Power Consumption P
The electrical power consumption (wattage) of the unit (motor, heater and
the electrical components in the electrical cabinet).
Power Consumption Pmax
The maximum electrical power consumption (wattage) of the unit and the
connected accessories. It is calculated as the product of the connected
voltage and the maximum current protected by fuse.
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C-12 Glossary
Processing Temperature
The processing temperature is prescribed or recommended by the material
manufacturer. It can be found in the product information and/or in the
Material Safety Data Sheet (MSDS)
PROFIBUS
Internationally standardized serial field bus with master-slave subscribers.
Nordson melters (slave) with a PROFIBUS DP interface can be controlled
remotely by one of the customer’s control units (master).
Proper Disposal
Disposal of all types of waste in compliance with all local regulations.
Proportional Pressure Control Valve
Electropneumatic component that enables control of pneumatic pressure
with an electrical variable (usually control voltage).
Protective Gas
Refer to Inert Gas.
Pt 100
Abbreviation for a platinum based resistance temperature sensor. At a
temperature of 0° C (32° F), it has an electrical resistance of 100 W.
Pull-in Delay
1. The time between the signal to switch on the gun/application head and
the beginning of material application.
2. The time between when the voltage is turned on and when the delay
relay is actually engaged.
PUR
Refer to Polyurethane Hot Melt Adhesive.
Rated Current
The setpoint for current to a unit, determined by standards or as agreed
upon by the manufacturer and the customer.
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Glossary
C-13
Release Coating
Largely prevents hot melt adhesive from burning onto the surface and
makes it easier to clean the application system parts coming into contact
with the adhesive.
Residual Risks
Hazards that can pose a danger to the user, even when all safety
regulations for manufacturing a product are followed and when the unit is
used only as intended. Residual risks are noted - as extensively as the
manufacturer is aware of them - in the manual and/or with waning signs on
the unit.
Resistance Temperature Sensor
Component with an electrical resistance, the value of which changes as a
factor of the temperature. Nordson units use the models Pt 100 and Ni 120.
Reverse Mode
A pump motor operates counter to the direction of material feeding.
Prevents material from dripping.
RPM
Revolutions per minute, same as min−1 = 1/min.
Safety Valve
A valve that prevents the material pressure from exceeding a preset value.
Safety Valve Plate
A component in which material circulates when the installed safety valve is
open.
Set Time
The amount of time that the adhesive needs from application to complete
hardening.
SI
Système International d’ Unités (international standardization system).
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C-14 Glossary
Solenoid Valve
Usually part of the gun/application head. A control valve that is activated by
an electromagnetic coil.
Solid State Relay
Electronic assembly without mechanical parts but with the function of an
electromechanical relay.
Solvent
Solvents are liquid, organic materials and their compounds, used to clean
adhesive off of surfaces. Solvents are slightly volatile. Special regulations
must be followed when using solvents.
In Nordson literature, the solvent is always the substance prescribed by the
hot melt manufacturer.
Substrate
The product − fabric, foil, etc. − to which a material is applied.
Tach Generator
A component that generates electrical voltage (pilot voltage). The voltage is
proportional to the speed at which the tach generator is driven.
Temperature Sensor
A part of a temperature control system that compiles the temperature and
transmits it to the control system. Resistance temperature sensor are used
in Nordson units.
Thermostat
Component that regulates temperature. It is usually an electrical switch that
switches at a certain or set temperature. The difference between the
temperatures at which the unit switches on and off is called hysteresis.
Transformer
Voltage converter.
Used in Nordson units to convert the customer’s line voltage to the
operating voltage.
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Glossary
C-15
VAC
Abbreviation for Alternating Current. AC voltage.
VDC
Abbreviation for Direct Current. DC voltage.
Viscosity
Strength; an indication of the force that must be generated to move a liquid:
1. Viscosity (also called dynamic viscosity).
Unit: Pas (Refer to Conversions).
2. Kinematic viscosity (dynamic viscosity divided by material density).
Unit: m2/s (Refer to Conversions).
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C-16 Glossary
P/N 7105986H
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