Bulk Melters AltaPail

Transcription

1 Bulk Melters AltaPail Manual - English - Edition 02/12 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document is for products with the following P/N: Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 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 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, Fibrijet, 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, Micromedics, MicroSet, Millenium, Mini Squirt, Moist Cure, Mountaingate, MultiScan, Nordson, Optimum, 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, Active Nozzle, 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, OptiMix, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, 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, YESTECH, 2 Rings (Design) are trademarks - - of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights.

3 Table of Contents I Table of Contents Nordson International... O 1 Europe... O 1 Distributors in Eastern & Southern Europe... O 1 Outside Europe / Hors d'europe / Fuera de Europa... O 2 Africa / Middle East... O 2 Asia / Australia / Latin America... O 2 Japan... O 2 North America... O 2 Safety Safety Alert Symbols Responsibilities of the Equipment Owner 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 Applicators General Safety Warnings and Cautions Other Safety Precautions First Aid Safety Signs and Labels

4 II Table of Contents Introduction Intended Use Unintended Use - Examples Area of Use Residual Risks ID Plate Note on Manual Definition of Term(s) Drum / Pail / Container Valves Key to line Symbols Description of the Bulk Melter Electrical Cabinet Button Two hand Control and Selector Raise/Lower Platen 2 6 Control Panel and Motor Control Panel Main Switch Fan with Filter Door Lock Function / Concepts Raising and Lowering Platen Deaerating Container Aerating Container Platen Position Heating and Temperature Control Overtemperature shutdown Undertemperature Interlock Standby Melting Process and Material Flow Safety Valve Material Pressure Pressure Control Valve Modes Normal Mode (Auto Scan) Standby Setup Fault

5 Table of Contents III Installation Installation Personnel's Experience Transport Storage Unpacking Lifting (Unpacked Bulk Melter) Setting Up Exhausting Material Vapors Electrical Connections - General Information Observe when Using Residual Current Circuit Breakers Laying Cable Power Supply Connecting Hose Second Open end Wrench Electrical connection Connecting Disconnecting Relieving pressure Connecting Assembly Handguns Connecting Compressed Air Pneumatic Plate Pressure Control Valves Adapting the Bulk Melter to the Container Used Platen Position: Adjusting Switches Installing Inputs and Outputs Connecting Line Speed Voltage Terminal Block XL Information on I/O Expansion Board Standard Inputs Standard Outputs Overview Initial Startup Removing Bulk Melter Bulk Melter Disposal Operation Control Panel Description Serial Interface Component Keys/LEDs Function Keys Heater Key Pump Key (Control Panel) Motor Key (Motor Control Panel) Setup Key Seven day Clock Key (Abbreviated: Clock) Standby Key LEDs Fault LED Container is Empty LED Service LED Switching Bulk Melter ON/OFF Daily Startup Daily Switchoff Switching Off in an Emergency

6 IV Table of Contents Initial Startup Function diagram: Enabling and Switching On Settings When Using Handguns Purging Bulk Melter Initial Maintenance Setting Up the Bulk Melter Quick Setup Operating Parameters Reading or Editing Operating Parameters Setting Up an Input Setting Up an Output Saving and Restoring Settings To Save Current Settings Restoring Saved Settings Review Parameter and Setpoint Temperature Changes Review the Change History Log Adjusting Component Temperatures Preliminary Information To Adjust the Setpoint Temperature Using the Global Method 4 22 To Adjust the Setpoint Temperature Using the Global by component Group Method To Adjust the Setpoint Temperature of an Individual Component Entering Password Inserting and Replacing Container Raising Platen No Container in the Bulk Melter Container in the Bulk Melter Lowering Platen Setting Platen Pressure Setting Material Pressure Output Quantity SN0773 (Formerly PR25m2) Output Quantity SN0371 (Formerly PR12m2) Setting the Pump Speed Monitoring the System Confirm that the Bulk Melter is Operating Correctly Container is Empty LED Monitor Component Temperatures To Check Component Temperatures in Normal Mode To Manually Check a Component's Temperature Monitoring Faults F1, F2 and F3 Faults F4 Fault Resetting System Fault Log Fault Log Examples Settings Record

7 Table of Contents V Maintenance Risk of Burns Relieving Pressure Important when Using Cleaning Agents Processing Materials Preventive Maintenance Initial Maintenance External Cleaning Visual Inspection for External Damage Changing Type of Material Purging with Cleaning Agent Cleaning Melting Plate Fan and Air Filter Motor / Gear Box Change lubricant Lubricant Changing Interval Capacity Lubricant Selection Gear Pump Checking for Leakage Troubleshooting Some Tips Troubleshooting Tables Fault Codes Motor controller fault Bulk Melter does not Function One Channel (Heating Zone) does not Heat No Material (Motor Rotating) No Material (Motor does not Rotate) Too Little Material or Irregular Feeding Material Pressure too High Material Pressure too Low Others LEDs of Motor Controller Calibrating Pump Speed Display Changing Motor Control Parameters Flow Chart Platen Control Repair Observe Before Performing Repairs Risk of Burns Relieving Pressure Replacing Gear Pump Detaching Gear Pump Attaching Gear Pump Replacing Motor Replacing Safety Valve Replacing O rings Replacing Coupler Component Replacing Motor Controller Replacing Standard I/O Board of Motor Controller Replacing Melting Plate and/or Sealing Ring Replacing Temperature Sensor or Thermostat Replacing Control Panel Installing Service Kit

8 VI Table of Contents Parts How to Use Illustrated Parts List Fasteners Component Designation Technical Data General Data Air Consumption Suitable Containers (Customer's) Exhaust Hood Temperatures Electrical Data Rated Current / Operating Voltage Dimensions and Weights General Instructions Regarding Working with Application Materials... A 1 Definition of Terms... A 1 Manufacturer Information... A 1 Liability... A 1 Risk of Burns... A 1 Vapors and Gases... A 2 Substrate... A 2 Processing Temperature... A 2 Operating Parameters... B 1 Restore Bulk Melter Default Settings... B 1 Standard... B 2 Temperature Control... B 7 Input Setup... B 11 Output Setup... B 16 Seven day Clock... B 18 Setting Internal Clock (Realtime Clock)... B 18 Creating Schedule... B 18 Example 1... B 19 Example 2... B 19 Example 3... B 19 Miscellaneous... B 28 PID Selection... B 28 Glossary... C 1

9 Introduction O 1 Nordson International Europe Country Phone Fax Austria Belgium Czech Republic Denmark Hot Melt Finishing Finland France Germany Erkrath Lüneburg Nordson UV EFD Italy Netherlands Norway Hot Melt Poland Portugal Russia Slovak Republic Spain Sweden Switzerland United Kingdom Hot Melt Industrial Coating Systems Distributors in Eastern & Southern Europe DED, Germany Nordson Corporation All rights reserved NI_EN_O 0211 MX

10 O 2 Introduction Outside Europe / Hors d'europe / Fuera de Europa For your nearest Nordson office outside Europe, contact the Nordson offices below for detailed information. Pour toutes informations sur représentations de Nordson dans votre pays, veuillez contacter l'un de bureaux ci dessous. Para obtener la dirección de la oficina correspondiente, por favor diríjase a unas de las oficinas principales que siguen abajo. Contact Nordson Phone Fax Africa / Middle East DED, Germany Asia / Australia / Latin America Pacific South Division, USA Japan North America Japan Canada USA Hot Melt Finishing Nordson UV NI_EN_O 0211 MX 2011Nordson Corporation All rights reserved

11 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 Nordson Corporation Safe_PPA1011LUE_EN

12 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 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. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. 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. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re evaluate safety practices and procedures whenever changes are made to the process or equipment. Safe_PPA1011LUE_EN 2011 Nordson Corporation

13 Safety 1 3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner's safety and accident prevention policies and procedures 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 possess industry and trade specific skills and a level of experience appropriate to their job function 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 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 Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non standard auxiliary devices Nordson Corporation Safe_PPA1011LUE_EN

14 1 4 Safety Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used. This equipment has not been certified for compliance with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments. Ensure that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. 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. Do not use equipment that is malfunctioning or shows signs of a potential malfunction. Safe_PPA1011LUE_EN 2011 Nordson Corporation

15 Safety 1 5 Maintenance and Repair Practices Equipment Safety Information Allow only personnel with appropriate training and experience to operate or service the equipment. Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De energize the equipment and all auxiliary devices before servicing the equipment. Use only new Nordson authorized refurbished or replacement parts. 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 or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. 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. Keep equipment safety warning labels clean. Replace worn or damaged labels. This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices 2011 Nordson Corporation Safe_PPA1011LUE_EN

16 1 6 Safety 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, applicators, 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. Disabling the Applicators NOTE: Adhesive dispensing applicators are referred to as guns in some previous publications. All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected to a pressurized system. 1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. Safe_PPA1011LUE_EN 2011 Nordson Corporation

17 Safety 1 7 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, applicators, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and applicators) Equipment Type Table 1 1 General Safety Warnings and Cautions 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 applicators 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. Continued Nordson Corporation Safe_PPA1011LUE_EN

18 1 8 Safety General Safety Warnings and Cautions (contd.) Equipment Type Table 1 1 General Safety Warnings and Cautions (contd) Warning or Caution 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. HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator's triggering device and remove the air supply to the applicator's solenoid valve(s). Failure to disable the applicator'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 has not been cerfified for the ATEX directive or as nonincendive. In addition, this equipment 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. Continued... Safe_PPA1011LUE_EN 2011 Nordson Corporation

19 Safety 1 9 Equipment Type Table 1 1 General Safety Warnings and Cautions (contd) Warning or Caution 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. HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of applicators, 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 Nordson Corporation Safe_PPA1011LUE_EN

20 1 10 Safety Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First 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. Safe_PPA1011LUE_EN 2011 Nordson Corporation

21 Safety 1 11 Safety Labels and Tags Figure 1 1 illustrates the location of the safety labels and warning tags affixed to the equipment. Table 1 2 provides an illustration of the hazard identification symbols that appear on the safety labels and tags, the meaning of the symbols and the exact wording of the safety message Fig. 1 1 Safety Labels and Tags Table 1 2 Safety Labels and Tags Position P/N Description WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage WARNING: Hot surface. Failure to observe can cause burns WARNING: Risk of pinching parts of the body between platen and container. Ensure that, during operation, no one else is near the system. 4, 5, TAGS, SHEET OF, VERSA/DURABLUE LG, CE LANG

22 1 12 Safety

23 Introduction 2 1 Section 2 Introduction Intended Use Bulk melters of the series AltaPail - hereafter also referred to as melter - may only be used to melt and feed suitable materials. When in doubt, seek permission from Nordson. 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. Unintended Use - Examples - The bulk melters may not be used under the following conditions: In defective condition With electrical cabinet door open In a potentially explosive atmosphere With unsuitable operating/processing materials When the values stated under Technical Data are not complied with. The systems may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products. Do not use the platen As a press To lift loads To heat objects. Area of Use The bulk melter is designed for use in industrial areas. When using in industrial areas and in small businesses, the system may cause interference in other electrical units, e.g. radios.

24 2 2 Introduction Residual Risks In the design of the melter, every measure was taken to protect personnel from potential danger. However, some residual risks can not be avoided. Personnel should be aware of the following: Risk of burns from hot material Risk of burns from hot bulk melter components Risk of burns when conducting maintenance and repair work for which the system must be heated up Risk of burns when attaching and removing heated hoses Material fumes can be hazardous. Avoid inhalation. If necessary, exhaust material vapors and/or provide sufficient ventilation of the location of the bulk melter (Refer to page 3 2, Exhausting Material Vapors) Risk of pinching parts of the body between platen and container. Ensure that, during operation, no one else is near the system The safety valve may malfunction due to hardened or charred material. ID Plate System designation Order number AltaPail Electrical connection Operating voltage Operating voltage frequency Rated current Serial no. Serial number Year Year of construction

25 Introduction 2 3 Note on Manual Some of the illustrations in this manual may deviate from the actual equipment due to ongoing technical development or a different configuration. Operating side (= front) Definition of Term(s) Drum / Pail / Container The term Container is used regardless of size. Valves Depending on their function and use, valves have different designations in Nordson documentation, for example: Safety valve and Pressure restrictor valve: Valves that limit pressure for safety reasons. The term Safety valve is usually used in conjunction with material pressure. Pressure control valve: A valve used to set or control pressure. Depending on the model, the pressure can be set manually, electrically or pneumatically. Key to line Referred to in Nordson literature as either Key to line (KTL) or Automatic mode. In key to line the motor/pump speed is proportional to the speed of the parent machine. Symbols Original state Additional information

26 2 4 Introduction Description of the Bulk Melter AltaPail bulk melters are designed to accommodate 20 liter containers Fig Electrical cabinet 2 Platen 3 Pump 4 Sealing ring 5 Melting plate 6 Aeration and air relief valve 7 Pressure control valve Material pressure 8 Hose fitting

27 Introduction 2 5 Electrical Cabinet Back wall of electrical cabinet Fig Display Platen pressure 2 Pressure control valve Platen pressure 3 Control panel 4 Door lock 5 Air filter / fan with filter 6 Button Two hand control 7 Selector Raise/lower platen 8 Main switch 9 Motor control panel 10 Cable gland Inputs/outputs 11 Cable gland Power supply

28 2 6 Introduction Button Two hand Control and Selector Raise/Lower Platen Used to raise and lower the platen. WARNING: The two hand control may only be operated by one person using both hands! Control Panel and Motor Control Panel Refer to page 4 1, Control Panel Description. Main Switch The main switch is used to switch the bulk melter on and off. Position 0/OFF = Bulk melter is switched off. Position I/ON = Bulk melter is switched on. Padlocks can be used to protect the main switch from being turned on by unauthorized personnel. Fan with Filter The fan reduces the temperature inside of the electrical cabinet. The filter must be serviced regularly. Refer to page 5 6, Fan and Air Filter. Door Lock The electrical cabinet can be opened for installation, maintenance and repair. Store the included key such that it is accessible only to qualified and authorized personnel. The bulk melter may not be operated when the electrical cabinet is open. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect the bulk melter from the line voltage.

29 Introduction 2 7 Function / Concepts Raising and Lowering Platen Air The pneumatic cylinders raise and lower the platen. When lowering the platen, a two hand control must be operated for safety reasons until the platen is in the container. The selector Raise/lower platen then lights up green. Deaerating Container The air relief valve must be opened manually to allow air to escape when the platen is lowered into the container. Deaerate Compressed air Aerating Container To prevent a vacuum from forming when the platen is lifted out of the container, the container must be aerated manually. Aerating Platen Position WARNING: Risk of squash! Ensure that switch 1 is not actuated until the platen is inside of the container. 1 A switch rod activates the switches (1 and 2) one after the other, triggering the following switching functions: Switching functions when lowering: Switches from two hand lowering mode to normal lowering mode when the platen sealing ring is completely submerged in the container (switch 1) Activates the Container empty indication (switch 2). 2 Switching functions when raising: Switches off container aeration (switch 1).

30 2 8 Introduction Heating and Temperature Control The bulk melter electronically controls the temperature of various components of the bulk melter itself (e.g. heating punch) as well as connected components of an entire application system. Overtemperature shutdown The overtemperature shutdown feature protects the bulk melter and the material from overheating. For overtemperature shutdown, the heater and motor are switched off. Undertemperature Interlock The undertemperature interlock prevents the bulk melter motor from being switched on as long as the material is too cold and thus too thick. This could damage the pumps. Standby Standby serves to protect the hot melt material and to save energy during breaks in production. The temperature setpoints are reduced by a standby value. Melting Process and Material Flow 1 2 The material is melted only directly below the melting plate. A pump feeds the melted material to the hose connection. Safety Valve A safety valve (2) limits the material pressure generated by the pump (1). The standard safety valve (2) is fixed at 100 bar kpa 1450 psi When the pressure is exceeded, the safety valve opens, allowing the material to circulate within the adapter plate. Principle drawing Material Pressure Pressure Control Valve The mechanical pressure control valve can be manually adjusted up to 75 bar 7500 kpa 1100 psi Also refer to page 4 30, Setting Material Pressure.

31 Introduction 2 9 Modes AltaPail bulk melters operate in the following modes: Normal Mode (Auto Scan) When the bulk melter is first switched on, it is in normal mode. In normal mode the bulk melter checks the current temperature of the platen, the hoses and the guns to verify that they are within the set temperature ranges. Standby The temperatures of the platen, the hoses and the guns are lowered from their operating temperature (hereafter referred to as setpoint temperature) by a set number of degrees. Setup Setup mode (configuration) is used to configure the control options and features of the bulk melter as well as to check the saved operating data. The bulk melter is protected by password from unauthorized changes to the configuration. Fault The bulk melter alerts the user when a fault occurs, e.g. a sensor fault (RTD) or a temperature that is not within the permitted range.

32 2 10 Introduction

33 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. Installation Personnel's Experience The instructions contained in this section are intended for personnel with experience/authorization in the following fields: Application methods with hot melt adhesive or similar materials Industrial electrical wiring of power and control lines Industrial mechanical installation General knowledge of process control. Transport Refer to page 9 3, Dimensions and Weights for weight. Use only suitable transport devices (lift truck or forklift). Do not lift with a crane. If possible, use the pallet on which the bulk melter was delivered, and fasten the bulk melter to the pallet. Protect from damage, moisture and dust with suitable packing material. Avoid jolts and vibrations. Storage Do not store the bulk melter outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation).

34 3 2 Installation Unpacking Unpack carefully and check for damage caused during transport. Save pallet and fastening and packing material for later use, or dispose of properly according to local regulations. Lifting (Unpacked Bulk Melter) Refer to page 9 3, Dimensions and Weights for weight. Lift only with a suitable floor conveyor (lift truck or forklift). Do not lift with a crane. Setting Up Set up only in an environment that corresponds to the stated Degree of Protection. Refer to page 9 1,Technical Data. Do not set up in a potentially explosive atmosphere! Protect from vibration. Remove transport protection (if present). Ensure that there is sufficient clearance around the system, especially above it. Refer to page 9 3, Dimensions and Weights for dimensions. Observe the minimum hose bending radius (Refer to the hose manual). Exhausting Material Vapors Customer's Ensure that material vapors do not exceed the prescribed limits. Always 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 equipment. Fig. 3 1 Principle drawing

35 Installation 3 3 Electrical Connections - General Information WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Connect external control and signal circuits with suitable cable in accordance with the NEC, class 1. To prevent short circuiting, lay the cables such that they do not touch printed circuits on PCBs. Observe when Using Residual Current Circuit Breakers Local regulations in some industrial branches require residual current circuit breakers. Then observe the following points: Permanent installation is required (fixed line voltage connection) The residual current circuit breaker is to be installed only between the power supply and the bulk melter. 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 bulk melter. Ensure that cables do not touch rotating and/or hot parts. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Power Supply WARNING: Operate only at the operating voltage shown on the ID plate. Permitted deviation from the rated line voltage is 10%. CAUTION: The power cable cross section must comply with the rated current (Refer to ID plate) The bulk melter must be installed securely (permanent power supply connection). Mains terminal (example)

36 3 4 Installation Connecting Hose Also refer to the hose manual. WARNING: Hot! Risk of burns. Wear heat protective gloves. Second Open end Wrench Use a second open end wrench when connecting and disconnecting the hose. This prevents the hose connection from turning. Electrical connection 1 Up to two hoses can be attached to the platen. Guide the hoses through the hose holders to the platen and initially connect them electrically to interfaces XS10 and XS11 (1). Electrically connect additional hose/gun pairs (or other heated components) to the following interfaces. -XS15 -XS14 -XS13 -XS12

37 Installation 3 5 Connecting If cold material can be found in the hose connection (1), the components (2, 3) must be heated until the material softens (approx. 70 C / 158 F, depending on material). 1. First connect the hose (3) electrically to the unit. 2. Heat the bulk melter and hose to approx. 70 C / 158 F. 3. Screw the hose onto the unit. NOTE: Close unused hose ports with Nordson port plugs. Disconnecting WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. Relieving pressure 1. Switch off motor. 2. Set selector Raise/lower platen to 0/stop. 3. Place a container under the nozzle(s) of the gun/assembly handgun. 4. Guns: 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. 5. Properly dispose of material according to local regulations. Connecting Assembly Handguns 1 Connect the assembly handgun switches to receptacles XS18 and XS19 (1, Switch receptacles). When the assembly handgun is triggered (switch closed), the pump is switched on.

38 3 6 Installation Connecting Compressed Air 1 Connect dry, clean and nonlubricated compressed air to the compressed air connection (1). Dirt particles in the air may not exceed 30 m in size. Air pressure Min 3 bar 0,3 MPa 43,5 psi Max 8 bar 0,8 MPa 116 psi NOTE: A pressure restrictor valve behind the compressed air connection limits the air pressure to 8 bar / 0.8 MPa / 116 psi Pneumatic Plate Also refer to pneumatics diagram. 2 3 Pressure Control Valves CAUTION: Do not change the setting: A lower pressure makes it difficult to raise the platen. Raise pneumatic cylinder (2) 1.6 bar / 0.16 MPa / 23.2 psi Aerate container (3): 1 bar / 0.1 MPa / 14.5 psi NOTE: A pressure restrictor valve prevents higher, unpermitted pressure. Pneumatic plate

39 Installation 3 7 Adapting the Bulk Melter to the Container Used Platen Position: Adjusting Switches WARNING: Risk of squash! Ensure that switch 1 is not actuated until the platen is inside of the container. 1 A switch rod activates the two switches (1 and 2) one after the other, triggering the following switching functions: Switching functions when lowering: Switches from two hand lowering mode to normal lowering mode when the platen sealing ring is completely submerged in the container (switch 1) Activates the Container empty indication (switch 2). 2 Switching functions when raising: Switches off container aeration (switch 1). 2mm Installing Inputs and Outputs The inputs and outputs are used to exchange data with the customer's production equipment and control hardware such as a PLC. 1. Pass the power cable through the smaller of the two glands (Fig. 3 2) on the back of the electrical cabinet. 2. Connect the cable as shown in the wiring diagram. The connection points are located in the left door of the electrical cabinet (Fig. 3 3). 3. When connecting to XT7, observe Information on I/O Expansion Board. Fig. 3 2 Back of electrical cabinet

40 3 8 Installation A XL1 190U1 XT Fig. 3 3 Connecting points - left door of electrical cabinet Connecting Line Speed Voltage To be able to use automatic mode, a signal generator, e.g. an encoder, must be provided by the customer and installed to measure the production line speed. The motor controller accepts an analog 0-10 V DC input signal. Connect to coupler component 190U1; ensure correct polarity - refer to wiring diagram. Terminal Block XL1 Terminals XL1 Designation / feature Note Input: Motor 1 on (contact for motor control panel: connect edge controlled) Input: Motor 1 off (contact for motor control panel: wire as make contact) A Output: Motor 1 running B NOTE A: Switching off via the input takes precedence over the Motor key. This means that the motor cannot be switched on with the Motor key, if the motor was switched off via this input. B: Make contact. Contact closed when motor is running.

41 Installation 3 9 Information on I/O Expansion Board Standard Inputs The inputs are activated by a constant signal of 10 to 30 V DC. The polarity is not important for the inputs. WARNING: The operator can override the inputs via the function keys on the control panel. Ensure that the control unit for external devices that transmit a signal to the bulk melter is programmed such that unsafe conditions can not occur when the operator overrides an external input on the bulk melter. Refer to Appendix B for all possible control options. Input (standard) Operating parameter Control option (default value) Plug connector and terminal 10: Automatic Standby P/N A time has to be set in parameter and 9 1: Standby on/off P/N and 11 2: Heaters on/off P/N and 13 4: Activate/deactivate hose/gun 1 P/N and P/N

42 3 10 Installation Standard Inputs (contd.) NOTE: Connector P/N is physically keyed to prevent it from being used in place of connector P/N , which has terminals numbered 1 through 7. XT7 P/N P/N Fig. 3 4 I/O expansion board - installing inputs

43 Installation 3 11 Standard Outputs All of the output contacts are intended for 240 V AC 2 A or 30 V DC 2 A. All contacts are open when the system is switched off. Refer to Appendix B for all possible control options. Output (standard) Operating parameter Control option Plug connector and (default value) terminal 1: Ready P/N and 2 3: Fault P/N and 4 4: Container is empty P/N and 6 NOTE: Connector P/N is physically keyed to prevent it from being used in place of connector P/N , which has terminals numbered 8 through 14. XT P/N Fig. 3 5 I/O expansion board - installing outputs

44 3 12 Installation Overview Observe for edge controlled signals (example) If standby is switched on via an input (rising edge), it can be switched off with the seven day clock or by the operator on the control panel. If standby is then to be switched on again via the input, it must first be switched off (falling edge) then on again via the interface. Terminal (comp. des.) Input Inputs Function 81A1 XT7:8/9 0 V 24 V Rising edge: Enter Automatic standby 24 V Falling edge: Exit Automatic standby 0 V 81A1 XT7:10/11 0 V 24 V Rising edge: IN standby 24 V Falling edge: OUT of standby 0 V 81A1 XT7:12/13 0 V 24 V Rising edge: Heaters ON (main contactor closes) 24 V Falling edge: Heaters OFF (main contactor opens) 0 V 81A1 XT7:7/14 0 V 24 V Rising edge: Activate hose/gun 1 24 V Falling edge: Deactivate hose/ gun 1 0 V Digital outputs Terminal (comp. des.) Contact Function 81A1 XT7:1 24 V DC External (to be supplied by customer) XT7:2 Make contact 24 V: Ready 0 V: Unit not ready 81A1 XT7:3 24 V DC External (to be supplied by customer) XT7:4 Make contact 24 V: Fault 0 V: No fault 81A1 XT7:5 24 V DC External (to be supplied by customer) XT7:6 Make contact 24 V: Container is empty 0 V: Container not empty

45 Installation 3 13 Initial Startup After the bulk melter has been correctly installed, initial startup may begin. Refer to page 4 8, Initial Startup. Removing Bulk Melter Bulk Melter Disposal 1. Remove the container. 2. When the bulk melter will not be used for longer periods of time, purge with cleaning agent if necessary. Refer to page 5 6, Purging with Cleaning Agent. 3. Wipe off sealing ring and clean melting plate. Refer to page 5 6, Cleaning Melting Plate. 4. Disconnect all lines to the bulk melter, and allow bulk melter to cool. When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations.

46 3 14 Installation

47 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. Control Panel Description Fig. 4 1 Control Panel and Motor Control Panel 1 Fault LED 6 Right display and scroll keys 2 Ready LED 7 Container is empty LED 3 Component keys/leds 8 Left display and scroll key 4 Keypad 9 Service LED 5 Serial interface 10 Function keys 11 Arrow keys Pump speed 12 Display Pump speed [min 1 ] 13 Key Pump mode/led 14 Key Motor/LED NOTE: The function key "Pump 2" on the control panel has no function.

48 4 2 Operation Serial Interface 1 With a computer connected to the bulk melter's serial interface (1), settings can be transferred between bulk melters and the bulk melter's operating firmware can be upgraded and downgraded. The required software, Nordson Configuration Manager, and the respective instruction sheet can be downloaded from Component Keys/LEDs Component keys (platen, hose and gun) The bulk melter contains three groups of heated components: Platen Hoses Guns. Component groups are represented on the control panel by the component keys shown to the left. They are used e.g. to set temperatures. The LEDs on each component key will change from green to yellow if any component in the group drops more than 3 C (5 F) below its assigned setpoint temperature. Function Keys The control panel provides the following standard and special function keys: Standard function keys Heater Pump Setup Special function keys Standby Seven day clock CAUTION: Unintentionally activating function keys can have undesirable effects on the bulk melter or the manufacturing process. Only personnel familiar with the bulk 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.

49 Operation 4 3 Heater Key Heater key Use the Heater key to manually turn the component heaters on and off. Pressing the key overrides the heater control by the seven day clock feature or a remote input. The LED on the key is illuminated when the heaters are on. Most faults (Refer to section Troubleshooting) cause the heaters to switch off. The Heater key is used to turn the heaters back on after correcting a fault condition. Switching the pump on or off has no effect on the heater control. Pump Key (Control Panel) Motor Key (Motor Control Panel) Enabling is requested with the Pump key. If the bulk melter is ready, the Motor key is enabled and the motor can be started with the Motor key. Refer to Enabling and Switching On in this section. Meaning of the LED on the Pump key: Pump key 1 LED off... LED yellow... LED green... LED flashing green Key was not pressed Motor/pump enabled; system not ready Motor/pump enabled; system ready Motor/pump running when the LED on the Motor key is also green No signal from standard input Meaning of the LED on the Motor key: LED off... LED green... Key was not pressed, or pressing was ignored Motor/pump running Motor key Setup Key The Setup key is used to enter and exit setup mode. In setup mode the automatic scan stops. The left and right displays are used to select, read and edit operating parameters. Setup key

50 4 4 Operation Seven day clock key Seven day Clock Key (Abbreviated: Clock) Use the Seven day clock key to turn the clock features 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. Four clock schedules are available to accommodate daily shift work and non working days. Three of the schedules are used to specify when the heaters should turn on or when the bulk melter should enter and exit standby mode. The fourth schedule determines the days on which the bulk melter should be switched off. When the heaters switch on as dictated by the schedule, they are regulated to their assigned setpoint temperatures. When the clock activates the standby mode, the setpoint temperatures are all temporarily reduced by a preset standby delta. Also refer to page B 18, Seven day Clock. If the bulk melter is switched off while the clock is on, the clock will automatically turn back on the next time the bulk melter is switched on. If the heaters are manually turned off during 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 bulk melter is malfunctioning or in setup mode. If F4 appears in the right display when the Clock key is pressed, the clock function has failed. Contact Nordson customer service to remedy the fault.

51 Operation 4 5 Standby key Standby Key The Standby key is used to enter and exit standby mode. Using the standby mode during periods when no material is being fed helps to conserve energy and allows heated components to quickly return to their setpoint temperatures when the bulk melter is once again needed. When the bulk melter enters standby mode, the temperatures of all components are reduced from their setpoint temperatures by a preset standby delta. The bulk melter remains in standby mode until the key is pressed or one of the operating parameters causes the bulk melter to exit standby mode. If the bulk melter was set up to use the manual standby timer (parameter 26), pressing the key places the bulk melter in standby mode for the period of time specified by the timer. After the manual standby time has expired, the bulk melter once again begins heating all of the components to their assigned setpoint temperatures. Using the key overrides the control of the bulk melter (on or off) by the seven day clock or a remote input. The bulk melter may be set up to automatically enter standby mode using a variety of operating parameters. Whenever manual standby is enabled, the LED on the key flashes. Appendix B, parameters 25, 26, 30 33, 57, 62 and 67 Appendix B, parameter 26

52 4 6 Operation LEDs Heater LED Automatic scan sequence When the bulk melter is switched on: The bulk melter Tests the control panel LEDs Turns on the heaters (the LED in the Heater key turns green) Begins to automatically scan through and display the actual temperature of the platen, hoses and guns. The sequence of the automatic scan is: platen, each hose/gun pair and then back to the platen. Turns on the Ready LED (green) when the platen and all of the hoses and guns are within 3 C (5 F) of their assigned setpoint temperature. Ready LED Fault LED The Fault LED lights up when a fault occurs. Refer to page 4 38, Monitoring Faults. Fault LED (red) Container is empty LED Container is Empty LED The Container is empty LED (yellow) lights up when the platen is lowered far enough that a switch on the pneumatic cylinder closes. Refer to page 3 7, Platen Position: Adjusting Switches. Service LED The LED lights up after a preset time to signal that maintenance is due. When maintenance is completed, the LED must be reset. Service LED (yellow) Resetting LED Press the Clear/Reset key to turn off the Service LED and reset the service interval. Clear/reset key The default setting for the service interval is 500 hours. Appendix B, parameter 5

53 Operation 4 7 Switching Bulk Melter ON/OFF CAUTION: Before initial startup, read and observe the instructions in the section Initial Startup. Start up only as described in this section. Refer to page 4 8 Initial Startup. NOTE: The main switch must be set to I/ON (switched on) when using the seven day clock. Daily Startup NOTE: Do not operate Nordson pumps without material. Before switching on the motor, ensure that a container that is not empty is in the bulk melter and that the platen has contact with the material. 1. Set the main switch to I/ON. 2. Set selector Raise/lower platen to Lower Press the Pump key. Pump key 4. Wait until the bulk melter is ready. WARNING: Depending on the set parameters, the motor can start automatically when the bulk melter is ready. Refer to Enabling and Switching On for more information. Daily Switchoff Pump key 1 1. Switch off the motor/pump. 2. Set the main switch to 0/OFF and protect from unauthorized access with padlocks if necessary. 3. Set selector Raise/lower platen to 0/stop. 4. Perform daily maintenance. Switching Off in an Emergency WARNING: Immediately switch off the bulk melter in any emergency situation. 1. Set the main switch to 0/OFF. 2. Set selector Raise/lower platen to 0/stop. 3. After standstill and before switching the system back on, have the fault remedied by qualified personnel.

54 4 8 Operation Initial Startup The following instructions are valid for Nordson parameter defaults. When using a handgun refer additionally to Settings When Using Handguns. NOTE: Before initial startup and every time the container is replaced, remove residue and lubricate the platen sealing ring (Refer to page 5 2, Processing Materials for lubricant). Do not use sharp tools. 1. Set selector Raise/lower platen to Set the main switch to I/ON. The heaters are switched on. 3. Set up the bulk melter. Refer to page 4 11, Setting Up Bulk Melter. 4. Set temperatures. Refer to page 4 20, Adjusting Component Temperatures. 5. Insert container. Refer to page 4 27, Inserting and Replacing Container. 6. Wait until the bulk melter has heated up and is ready for operation (Ready LED on the control panel lights up green). Pump key Pump mode key 1 7. Switch on the motor/pump: a. Press the Pump key. For the initial startup select manual mode: b. Press the Pump mode key to select manual mode (LED on) or automatic mode (LED off). Manual mode - If the system is ready (LED in the Pump key is green) when the Motor key is pressed, the motor starts. If the system is not ready (LED in the Pump key is yellow) when the Motor key is pressed, wait until the LED is green and press the Motor key again. Automatic mode - If the system is ready (LED in the Pump key is green) when the Motor key is pressed, the motor starts. If the system is not ready (LED in the Pump key is yellow) when the Motor key is pressed, the motor starts automatically as soon as the system is ready. c. Press the Motor key on the motor control panel to start the motor. d. Press the Pump speed arrow keys to set the pump speed. Refer also to Setting the pump speed in this section. Motor key 8. Optimize settings and record in settings record form. Refer to page 4 43, Settings Record.

55 Operation 4 9 Function diagram: Enabling and Switching On 1 1 e.g. Operating parameter 33:3 0V/24V DC Srt:1 Srt:0 0V 24V XL1:17/18 Motor ON Fig. 4 2 Conditions for motor/pump running (function diagram) NOTE: If terminal XL1:19/20 (not shown) is bridged, the motor stops and/or cannot be started. Settings When Using Handguns Starting the motor with the Motor key is unwanted when using a handgun. 1. Therefore set Srt from 0 to 1 (refer to section Troubleshooting / Changing Motor Control Parameters). 2. Press Pumpe key. LED yellow. 3. The trigger of the handgun will start the motor.

56 4 10 Operation Purging Bulk Melter Initial Maintenance All features were tested before the bulk melter left the factory. Special test material was used. There may be residue from this material on the melting plate, in the pump, etc. To remove such residue, melt and feed several kilograms of material before starting production. Heating and cooling that occur during daily operation can cause screwed parts to loosen, resulting in leakage. Thus initial maintenance should be performed after the first day. Refer to page 5 4, Initial Maintenance.

57 Operation 4 11 Setting Up the Bulk Melter The bulk melter can be set up to suit your manufacturing process, meaning that the settings can deviate from the factory setup. Bulk melter setup consists of enabling or making changes to default operating parameters that affect the use and function of the bulk melter. The operating temperature (setpoint) of the platen, each hose and each gun is established during setup. The bulk 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 4 1 describes the most commonly used operating parameters and their factory settings. Review the table to determine whether the factory settings for each parameter will support your manufacturing process. If the default values for the operating parameters are appropriate for your manufacturing process, then no bulk melter setup is required. If changes to the default settings are required: Refer to page 4 13, Reading or Editing Operating Parameters. Tab. 4 1 Common operating parameters Parameters Parameter name Purpose Default value 4 Ready delay time A timer that delays readiness for a pre defined time period after the platen, hoses and guns have reached the desired setpoint temperature. The ready delay timer will only enable if the temperature of the platen, at the time the bulk melter is turned on, is below its assigned setpoint temperature by 27 C (50 F) or more. The ready delay feature gives a pump heated by the platen more time to heat up. 0 minutes 5 Service Interval When the number of hours of operation (heaters on) exceeds the set value, the Service LED lights up to indicate that service is due. 500 hours Continued...

58 4 12 Operation Parameters Parameter name Purpose Default value 7 Motor off delay If the switch receptacle (XS18 or XS19) is used, this parameter determines the amount of time the motor will remain on after the switched device is turned off. 0 seconds 8 Automatic pump on Switches the pump on automatically as soon as the bulk melter is ready. Prerequisite: The pump has been enabled by pressing the pump key. For melters with motor control panel only used in conjunction with Srt: / Activated:1 11 Create password Sets a password that must be entered before any operating parameter or setpoint temperature can be changed Temperature units Sets the units of the temperature display to degrees Celsius (C) or degrees Fahrenheit (F). C 21 Overtemperature delta Sets the number of degrees that any heated component can exceed its assigned setpoint temperature before an overtemperature fault occurs. 15 C (25 F) 22 Undertemperature delta Sets the number of degrees that any heated component can drop below its assigned setpoint temperature before an undertemperature 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 bulk melter enters the standby mode. 50 C (100 F) 26 Manual standby time Sets the amount of time that the bulk melter will remain in the standby mode after the Standby key is pressed. Deactivated 50 to 77 Seven day clock A group of parameters that control the bulk melter's clock. The clock is used to automatically turn the heaters on and off and to enter standby. Deactivated

59 Operation 4 13 Operating Parameters The bulk melter uses operating parameters to store noneditable and editable values. Noneditable values are those that provide information about the historical performance of the bulk melter. Editable values are either a numeric setpoint or a control option setting. Control option settings affect the display of information or the function of the bulk melter. Operating parameters are stored in the bulk melter's firmware in the form of a sequentially numbered list. 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. Refer to page B 1, Operating Parameters, for detailed information about each parameter. Appendix B contains a complete description of each parameter, including its effect on the bulk melter, default value and format. Reading or Editing Operating Parameters NOTE: 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. 1. Switch on the bulk melter. The bulk melter performs a startup check. 2. Press the Setup key. Parameter 1 flashes in the left display. Setup key Clear/reset key 3. Use the keypad to enter the number of the desired parameter. NOTE: If you incorrectly enter the parameter number, press the Clear/Reset key to return to parameter 1, 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: If the value is noneditable, refer to 4 35, Monitoring the System. If the value is editable, proceed to step 5.

60 4 14 Operation 5. Press the Enter key. The right display flashes. Enter key 6. Use the keypad to enter the desired numeric setpoint or control option in the right display. Refer to page B 1, Operating 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 bulk melter is password protected. You must enter a valid password before parameters can be edited. Refer to page 4 26, Entering Password. 7. Press the Enter key. The bulk melter checks that the new value or control option is acceptable. If the numeric setpoint or control option is accepted, the left and right displays show the next parameter number and value. If the numeric setpoint or control option is not accepted, the right display shows dashes ( ) for three seconds and then changes back to the original value. 8. Repeat steps 5 to 6 to read or change the next 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 scrolling through the operating parameter list in the left display. When the right display is flashing, you can set the value of the current parameter to its lowest possible value by simultaneously pressing both of the right display scroll keys. If no key is pressed for two minutes while in setup mode, the bulk melter will return to normal 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 number in the left display, press either of the right display scroll keys to change the value or control option. If password protection is activated, the bulk melter will return to the password protected mode whenever you exit the setup mode. Appendix B, Parameter 10

61 Operation 4 15 Setting Up an Input Table 4 2 shows the control options available. Refer to page 4 13, Reading or Editing Operating Parameters for information on how to select operating parameters and edit parameter control options. Tab. 4 2 Input Parameters Control options Note 0 Input deactivated 1 Enter/exit standby 2 Heaters on/off 3 Enable/disable motor 1 A Activate/deactivate hose/gun 1 5 Activate/deactivate hose/gun 2 6 Activate/deactivate hose/gun 3 7 Activate/deactivate hose/gun 4 8 Activate/deactivate hose/gun 5 9 Activate/deactivate hose/gun 6 10 Automatic standby (default) B 0 Input deactivated 1 Enter/exit standby (default) 2 Heaters on/off 3 Enable/disable motor 1 A Activate/deactivate hose/gun 1 5 Activate/deactivate hose/gun 2 6 Activate/deactivate hose/gun 3 7 Activate/deactivate hose/gun 4 8 Activate/deactivate hose/gun 5 9 Activate/deactivate hose/gun Like parameter 31 (default = 2) 4 33 Like parameter 31 (default = 4) Note A: If there is no voltage supplied to the input contacts, the motor does not start up when control option 3 is selected. B: When control option 10 is selected for the input, a time must be set in parameter 24.

62 4 16 Operation Setting Up an Output Table 4 3 shows the control options available. Refer to page 4 13, Reading or Editing Operating Parameters for information on how to select operating parameters and edit parameter control options. Tab. 4 3 Output Parameters Control options Note Output deactivated 1 Ready (Default) 2 Ready and Motor ON 3 Fault 4 Container is empty 5 Service LED ON 6 Alarm A 2 41 Like parameter 40 (default = 3) 3 42 Like parameter 40 (default = 4) Note A: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used, the illuminated Fault LED indicates a fault signal as well as an alarm signal.

63 Operation 4 17 Saving and Restoring Settings The current value of all editable operating parameters and the setpoint temperature of each component can be saved and, if necessary, restored at a later time. When saved settings are restored, they override 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 the bulk melter is to be returned to its original state. + To Save Current Settings With the bulk melter in normal mode, simultaneously press the number key 1 and the Setup key. S 1 appears briefly in the right display. Saving current settings Restoring Saved Settings CAUTION: All settings will be deleted! Before restoring saved settings, ensure that use of the restored settings will not disrupt the current process or create unsafe operating conditions. + With the bulk melter in normal mode, simultaneously press the number key 2 and the Setup key. S 2 appears briefly in the right display. Restoring saved settings If the restore feature is used before the save feature is used for the first time, the factory default setpoint temperatures will be restored. This will cause the hoses and guns to stop heating. Settings can be transferred from one bulk melter to another using the Nordson Configuration Manager software utility. Refer to page 4 2 Serial Interface.

64 4 18 Operation Review Parameter and Setpoint Temperature Changes The bulk melter stores in a change history log a record of the last ten changes that were made to either operating parameters or setpoint temperatures. Review the Change History Log Setup key 1. Press Setup key. Operating parameter 1 flashes in the left display. 2. Press the left display scroll key to change the display to parameter 3 (change history log). Left display and scroll key Component key LEDs The following occurs: If the last change was to an editable parameter, all of the component key LEDs remain off. or If the last change was to a setpoint temperature, the LED on the associated component key(s) turns on. and The right display shows the four digit log entry associated with the last change that was made. Table 4 4 indicates the meaning, from left to right, of each digit in the log entry. Two sample log entries are shown following the table. 3. Press the right display scroll key to review each of the remaining nine log entries. Each time a scroll key is pressed, a progressively older log entry appears. 4. Press the Setup key to return to normal mode. Scrolling through the log

65 Operation 4 19 First digit P (Parameter) S (Setpoint) Second digit - Tab. 4 4 Change History Log Third and fourth digit Indicates the number of the parameter that was changed Used in conjunction with the LEDs on the component keys to indicate the location and method of a setpoint temperature change. LED illuminated on... And the fourth digit indicates... The change was to... And the method of change was... Platen key 1 Platen Individual Hose key 1 6 A single hose Individual Gun key 1 6 A single gun Individual All keys 0 All components Global Hose key 0 All hoses Gun key 0 All guns Global bycomponent Global bycomponent Change History Log Examples Example 1: Example 2: Parameter 4 (ready delay) was changed. If the LED on the Gun key is illuminated, 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 the last change, simultaneously press both of the right display scroll keys.

66 4 20 Operation Adjusting Component Temperatures The temperature setting is determined by the processing temperature prescribed by the material supplier. The maximum operating temperature for the system 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. Preliminary Information The bulk melter is shipped from the factory with the platen setpoint temperature at 175 C (350 F) and the hose and gun setpoint temperature at 0 degrees (turned off). Before the bulk melter can be used, a setpoint temperature must be assigned to the platen, hoses and guns. Setpoint temperatures are assigned with any of the following methods: Global The platen and all hoses and guns are set to the same setpoint temperature. Global by component group All of the hoses or all of the guns are set to the same setpoint temperature. Individual component The setpoint temperature of the platen and each hose/gun is set individually. In some installations, auxiliary devices (such as a heated air manifold) may be connected to a hose/gun receptacle. The control panel will identify such devices as a hose or gun, regardless of what the device actually is As with operating parameters, setpoint temperatures can be saved and restored, and past changes that were made to setpoint temperatures can be reviewed. Page 4 17, Saving and Restoring Settings, and page 4 18, Review Parameter and Setpoint Temperature Changes.

67 Operation 4 21 If the bulk melter is switched on when the temperature of the platen is 27 C (50 F) or more below its assigned setpoint temperature (cold start condition), the Ready LED will not turn on until the ready delay (defined when the bulk melter was set up) has elapsed. The time remaining on the ready delay (in minutes) appears in the right display at the end of every scan cycle. When less than one minute remains in the ready delay time, the right display counts down in seconds. Appendix B, parameter 4 Appendix B, parameter 4 You can bypass the ready delay time by pressing the Heater key twice. The appearance of F4 in the right display immediately after the system is switched on indicates a problem with the bulk melter's processor or main board. The appearance of F1 in the right display immediately after starting the bulk melter indicates that a hose or gun cordset may be loose or disconnected. If the bulk melter is set up for manual pump activation and the parameter 7 (motor off delay) has been changed from the default, the pump will not stop until a user specified amount of time has elapsed. The (logical) state of one or more inputs may prevent the heaters from being turned on. Page 4 38, Monitoring Faults Section 6, Troubleshooting Appendix B, parameter 7 Page 4 15, Setting Up an Input If the seven day clock feature was set up and turned on when the bulk melter was last switched off, the clock will automatically turn on the next time the bulk melter is switched on. If a power failure occurs, the bulk melter will restart in its normal heat up cycle, even if the heaters were off or the bulk melter was in standby prior to the power failure. If the seven day clock was on prior to the power failure, the bulk melter will restart in the mode dictated by the clock schedule at the time the bulk melter restarts.

68 4 22 Operation To Adjust the Setpoint Temperature Using the Global Method Set the platen and all hoses and guns to the same setpoint temperature: 1. Press and hold the Platen key for three seconds. The left display flashes 1. Platen key 2. Scroll the left display to 0 (flashing). The right display shows dashes ( ) and the LEDs on all components turn green. Left display and scroll key Enter key 3. Press the Enter key. The right display flashes. 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the material. Refer to the data sheet provided by the manufacturer of the material for the optimal setpoint temperature. NOTE: If the keypad or the right display scroll keys have no effect on the right display, the bulk melter is password protected. Enter a valid password before changing the setpoint temperatures. Refer to page 4 26, Entering Password. Ready LED 5. Press the Platen key. All of the components begin to heat or cool to the new global setpoint temperature. When all of the components have reached their setpoint temperatures, the Ready LED lights up (green).

69 Operation 4 23 To Adjust the Setpoint Temperature Using the Global by component Group Method Set all hoses and guns to the same setpoint temperature: 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 setpoint temperature of the hose or gun. Platen, hose and gun keys 2. Scroll the left display to 0. The right display indicates all dashes ( ). 3. Press the Enter key. The right display flashes. 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the material. Refer to the data sheet provided by the manufacturer of the material for the optimal setpoint temperature. NOTE: If the keypad or the right display scroll keys have no effect on the right display, the bulk melter is password protected. Enter a valid password before changing the setpoint temperatures. Refer to page 4 26, Entering Password. 5. Press the Enter key. The hoses or guns begin to heat or cool to the new global setpoint temperature.

70 4 24 Operation To Adjust the Setpoint Temperature of an Individual Component NOTE: Heated components within each group are identified by their position number. The position number of the platen is fixed at 1. Hose and gun position numbers are automatically assigned based on the hose/gun receptacle they are connected to: Receptacle XS 10 XS 11 XS 12 XS Position number Set the setpoint temperature of the platen and each hose/gun individually 1. Press and hold the Platen, Hose or Gun key for three seconds. If the Platen 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 setpoint temperature of the component indicated in the left display. 2. Scroll the left display to the number of the desired component. The right display then indicates the current setpoint temperature of the component selected in the left display. 3. Press the Enter key. The right display flashes. 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the material. Refer to the data sheet provided by the manufacturer of the material for the optimal setpoint temperature. NOTE: If the keypad or the right display scroll keys have no effect on the right display, the bulk melter is password protected. Enter a valid password before changing the setpoint temperatures. Refer to page 4 26, Entering Password. 5. Do one of the following: To register the new setpoint temperature and then move on to change the setpoint temperature of the next sequential component, press the Enter key. Then repeat steps 4 and 5. To register the new setpoint temperature and return to normal mode, go to step Press any component key (platen, hose or gun). The selected component begins to heat or cool to its new setpoint temperature.

71 Operation 4 25 If you enter a valid setpoint temperature for a hose/gun that is not connected to the bulk melter or if you enter a setpoint temperature that is out of range, the right display will indicate dashes ( ) for three seconds and then change back to the original setpoint temperature. When the right display is flashing, you can change the current setpoint temperature to 0 degrees by simultaneously pressing both of the right display scroll keys. If the global or global by component method is used to set the setpoint temperature and then a hose or gun is added or removed later, the setpoint temperature of the hose or gun must be adapted or adjusted. If a hose or gun is removed, use the individual component method to set the setpoint temperature of the removed component to 0 degrees. This will avoid an F1 fault. When a hose or gun is added, use the individual component method to set the desired temperature. The factory setpoint temperature of the platen is 175 C (350 F). The factory setpoint temperatures of all other components is zero degrees (off). When the units of temperature is set to degrees Celsius, the minimum and maximum setpoint temperatures are 40 C and 230 C. When the units of temperature are set to degrees Fahrenheit, the minimum and maximum setpoint temperatures are 100 F and 450 F. When a setpoint temperature is set with the right scroll keys, the right display automatically jumps from 0 to 175 or 230 C or from 0 to 350 or 450 F. If you make a mistake while changing a setpoint temperature but have not yet pressed the Enter key, press the Clear/Reset key to reset the right display to the original temperature. The bulk melter exits setup mode and returns to normal mode two minutes after the last key is pressed. A global setpoint temperature of zero degrees (Celsius or Fahrenheit) turns all components off. When scrolling through component numbers in the left display, component numbers assigned to unused hose/gun receptacles are skipped. The bulk melter stores a record of the last ten changes made to setpoint temperatures (and operating parameters) in a change history log. Changes to setpoint temperatures can be saved by simultaneously pressing the keys 1 and Setup. Page 4 18, Review Parameter and Setpoint Temperature Changes Page 4 17, Saving and Restoring Settings

72 4 26 Operation Entering Password If a bulk melter is password protected, a valid password must be entered before any setpoint temperature can be entered or any parameter changed. 1. Press the Setup key. Parameter 0 flashes in the left display, and the right display shows Setup key 2. Press the Enter key. The right display begins to flash. 3. Enter the password with the keypad. NOTE: The password is created and activated/deactivated during bulk melter setup. 4. Press the Enter key. Then the following occurs: If the password is correct, the left display indicates parameter 1. If the password is incorrect, the left display remains at 0, while the right display briefly indicates dashes ( ) then returns to If the password is incorrect, reenter it and then press the Enter key. The bulk melter reverts to password protected mode two minutes after the last key (any key) is pressed. To return to password protected mode before 2 minutes have elapsed, press the Setup key twice. The password is created and activated/deactivated during bulk melter setup. Page 4 11 Setting up the Bulk Melter

73 Operation 4 27 Inserting and Replacing Container CAUTION: Place only undamaged, suitable containers in the bulk melter; otherwise the platen sealing ring will be damaged. Refer to page 9 1, Suitable Containers. Always keep the base plate of the bulk melter clean so that the container is positioned straight. WARNING: Risk of pinching parts of the body between platen and container. Ensure that, during operation, no one else is near the system. 1. Raise the platen. Refer to page 4 27, Raising Platen. 2. Set selector Raise/lower platen to 0/Stop. 3. Insert or replace container. 4. Lubricate sealing ring. Refer to page 5 2, Processing Materials. 5. Lower platen. Refer to page 4 29, Lowering Platen. 6. Properly dispose of empty container according to local regulations. Raising Platen WARNING: Risk of burns! Hot material can splash out when the platen exits the container. Hot material may flow out of the air relief valve. Wear goggles and heat protective gloves. No Container in the Bulk Melter 1. Set selector Raise/lower platen to Raise. 2. Press both buttons on the two hand control at the same time (within 0.5 seconds).

74 4 28 Operation Container in the Bulk Melter CAUTION: Verify that the platen is heated up when it is raised. Otherwise the sealing rings could be damaged. Aerating Container WARNING: Risk of injury! Do not use an external source of compressed air for aeration. Excessive pressure could damage the container or cause the platen to jerk. If the platen is inside of the container, the container must be aerated to support raising. Aerating means that compressed air is forced under the platen. 1. Verify that the selector Raise/lower platen (2) is set to Screw the rod (4) out of the aeration connection. 3. Screw in the aeration tube (3). 4. Open the shutoff valve Compressed air to aerate container (1). 5. Set selector Raise/lower platen to Raise

75 Operation 4 29 Lowering Platen The container must always be deaerated when the platen is moved into the container. When the container is deaerated, the air that is under the platen escapes. 1. Set selector Raise/lower platen (1) to Lower. 2. Place a drip pan under the air relief valve (3). 3. Unscrew the rod (2) somewhat to open the air relief valve. 4. Press both buttons on the two hand control at the same time (within 0.5 seconds) until the platen is inside of the container. The downward motion continues on its own now. 5. Close air relief valve when material flows out free of bubbles: Screw the rod back into place. 6. Properly dispose of material according to local regulations Setting Platen Pressure 6 bar / 0.6 MPa / 87 psi The setting can be modified on the pressure control valve: Increase pressure for high viscosity (ropy) materials Decrease pressure for low viscosity (liquid) materials.

76 4 30 Operation Setting Material Pressure Pressure Control Mechanical control with manually adjustable pressure control valve (1) Actuator - + 1

77 Operation 4 31 Output Quantity SN0773 (Formerly PR25m2) The output quantity is a factor of the pump used. Output [ccm] *) *) Depending on application, consider influence of 800 type/density of hot melt material operating temperature hose length (longer hose lower output rate) input pressure (increasing input pressure increasing output rate) 5 bar ** 30 bar ** Test setup Test material: HS5100 Fuller Density: C Viscosity: approx C Temperature: 140 C (284 F) Hydrostatic input pressure **) Application pressure (measured at melter hose port) Range of recommended speed Speed [min -1 ]

78 4 32 Operation

79 Operation 4 33 Output Quantity SN0371 (Formerly PR12m2) The output quantity is a factor of the pump used. Output [ccm] *) *) Depending on application, consider influence of type/density of hot melt material operating temperature hose length (longer hose lower output rate) input pressure (increasing input pressure increasing output rate) Test setup Test material: HS5100 Fuller Density: C Viscosity: approx C Temperature: 140 C (284 F) Hydrostatic input pressure **) Application pressure (measured at melter hose port) 5 bar ** 30 bar ** Range of recommended speed Speed [min -1 ]

80 4 34 Operation Setting the Pump Speed The pump speed is set with the arrow keys in manual mode. Display in min 1. Setting the Pump Speed in Manual Mode CAUTION: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min 1 (rpm) or continuously exceed 80 min 1 (rpm). 1. Apply the following formula to determine the optimum pump speed: Pumpspeed[1min] desiredadhesivequantity[gmin] adhesivedensity[gccm] outputquantityofpump[ccmrev.] 2. Press the Pump speed arrow keys to set the pump speed to the desired value [min 1 ]. The current pump speed is shown in the display. Arrow keys Pump speed Setting the Pump Speed in Automatic Mode Pressing the arrows in automatic mode causes the proportion of the reference line speed signal to change. This allows calibration with the incoming signal and fine adjustment of the adhesive quantity fed. Values from 0.01 to 5.00 are possible. Example 1 Example 2 The bulk melter accepts a line speed signal from 0 to 10 V. A reference line speed signal of 10 V corresponds to a pump speed of 100 min 1. The parent machine runs at maximum speed and sends an input signal of 8 V. If the pump should run at maximum speed when the parent machine is at maximum speed, set the value to This results in a reference line speed signal of 10 V (8 x 1.25 = 10). The parent machine runs at maximum speed and sends an input signal of 10 V. If the pump should run at 80 min 1 when the parent machine is at maximum speed, set the value to 0.8. This results in a reference line speed signal of 8 V (10 x 0.8 = 8).

81 Operation 4 35 Monitoring the System The bulk melter has display elements that Quickly confirm that the bulk melter is operating correctly Monitor the actual temperature of the platen and each hose and gun Identify faults Alert the operator when service is required. Signal Container is empty. Confirm that the Bulk Melter is Operating Correctly Ready LED The ready LED turns on (green) when all of the heated components are within 3 C (5 F) of their assigned setpoint temperature. The ready LED will not light up, or will turn off, if any of the following events occur: The ready delay is still counting down. Refer to page B 3, Ready Delay Time. The operator or a remote input places the bulk melter in standby mode The seven day clock places the bulk melter in standby mode There is a fault (the fault LED will turn on). Refer to page 4 38, Monitoring Faults The container is empty. The bulk melter may be set up to automatically enter standby mode using a variety of operating parameters. Appendix B, parameters 25, 26, 30 33, 57, 62 and 67 Container is Empty LED The Container is empty LED (yellow) lights up when the platen is lowered far enough that a switch on the pneumatic cylinder closes. Refer to page 3 7, Platen Position: Adjusting Switches. Container is empty LED

82 4 36 Operation Heated components with a setpoint temperature of zero degrees are skipped during the automatic scan cycle (normal mode). The time remaining on the ready delay appears in the right display at the end of every 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 Heater key will turn the heaters back on. If the clock has placed the bulk melter in standby mode, pressing the Standby key will return the heated components to their assigned setpoint temperatures. Monitor Component Temperatures The actual temperature of each heated component - platen and each hose and gun - can be checked in normal mode or by manually selecting and checking each component. By default, the bulk melter remains in normal mode except when: The bulk melter is in setup mode The setpoint temperature of all hoses and guns is set to zero degrees A fault occurs. To Check Component Temperatures in Normal 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 (platen, hose or gun) lights up, observe the left display until it shows the position number of the specific component to be checked. LEDs on component keys 3. When the position number of the desired component appears in the left display, the right display shows the component's actual temperature.

83 Operation 4 37 To Manually Check a Component's Temperature 1. Press the key (platen, hose or gun) that represents the component group to be checked. Left display and scroll key The automatic scan (normal mode) stops and the left display indicates the number of the first sequential component in the selected component group. The right display shows the component's actual temperature. NOTE: When the Platen key is pressed, the left display does not show a component number (blank display). 2. If the first sequential component is not the component to be checked, use the left display scroll key to move to the correct component number. Component temperature display The right display shows the actual temperature of the selected component. 3. Press the Setup key twice to return to normal mode. When you scroll the left display past the number of the last sequential component in a component group, the number of the first component in the next group appears. The bulk melter returns to normal mode two minutes after the last key is pressed. The default for the temperature display is degrees Celsius (C). This may be changed to degrees Fahrenheit with parameter 20. Appendix B, parameter 20 The LEDs on each component key will change from green to yellow if any component in the group drops more than 3 C (5 F) below its assigned setpoint temperature. The setpoint temperature of a component can be checked at any time by pressing the right display UP scroll key. Holding down the scroll key while the bulk melter is in normal mode reveals the setpoint of each component that is scanned.

84 4 38 Operation Monitoring Faults The bulk melter alerts the operator to the faults listed in Table 4 5. Tab. 4 5 Fault Codes Fault code Type of fault Description F1 RTD (resistance temperature detector) The RTD for the component indicated has failed or the component was disconnected from the bulk melter. F2 F3 F4 Undertemperature Overtemperature Electrical or control failure The actual temperature of the component indicated has dropped below the undertemperature delta, which was set using parameter 21. The actual temperature of the component indicated has increased beyond the overtemperature delta, which was set using parameter 21. Problem with a board, cable harness or control component. The sub code in the left display shows the failed component or the cause of the fault. F1, F2 and F3 Faults When the bulk melter detects an F1, F2 or F3 fault: 1. The automatic scan (normal mode) stops and the bulk melter begins to monitor the potential fault for up to two minutes. The ready and heater LEDs remain on during the two minute period. If the bulk melter detects during this time that the fault condition no longer exists, the bulk melter returns to normal mode. 2. The LED on the affected component key (platen, 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). Typical error code display Fault LED (red) 4. The left display indicates the component that has, or is, failing. If the LED on the Platen key is illuminated, the left display shows either 1 for the platen or 2 for the pump. If the LED on the hose or gun key is illuminated, the left display shows the number of the affected hose or gun. 5. If the fault condition still exists after two minutes, the Ready LED turns off, the Fault LED lights up and the bulk melter records the fault in the fault log. Refer to page 4 41, Fault Log. To be able to put the bulk melter back into operation, the fault must be remedied and the bulk melter reset (reset key). Refer to section 6, Troubleshooting, for information about diagnosing and correcting fault conditions. Also refer to page 4 40, Resetting System.

85 Operation 4 39 To view the temperature of a heated component when an F2 or F3 fault exists, simultaneously press and hold down both of the right display scroll keys. An F1 fault (RTD) can be temporarily dismissed and the bulk melter returned to normal mode by pressing the Clear/Reset key. The heaters will remain off. If the fault condition still exists two minutes after pressing the Clear/Reset key, the Fault LED will light up again. When an F1 fault code appears, you can determine whether the fault was caused by an open or 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 bulk melter detects an F4 fault: 1. The Ready LED turns off and the red Fault LED lights up. Fault LED (red) 2. All of the component key LEDs (platen, hose and gun) turn off. 3. The right display indicates F4. 4. The left display indicates a subcode. The subcode classifies the fault as being fatal or nonfatal. Fatal -The Fault LED lights up and stays on; the bulk melter stops functioning completely. Nonfatal - The Fault LED lights up for five seconds, but the heaters and pumps continue to operate normally. Nonfatal F4 faults affect only the functions dependent on the seven day clock. 5. The bulk melter records the fault in the fault log. Refer to page 4 41, Fault Log. To be able to put the bulk melter back into operation, the fault must be remedied and the bulk melter reset (reset key). Refer to section 6, Troubleshooting, for information about diagnosing and correcting fault conditions. Also refer to page 4 40, Resetting System.

86 4 40 Operation Resetting System 1. Correct the fault. Refer to section 6, Troubleshooting for information on diagnosis and remedies. Clear/reset key 2. Return the bulk melter to normal mode by pressing the Setup key twice. 3. Press the Clear/reset key. 4. Press the Heater key to switch on the heaters. Heater key If F4 appears in the right display when the Seven day clock key is pressed, the internal clock (realtime clock) has failed.

87 Operation 4 41 Fault Log 1. Hold down Setup key. The automatic scan stops, and parameter 1 appears in the left display. 2. Scroll the left display to parameter 2 (fault log). Setup key Left display and scroll key The right display indicates the last fault as follows: If the last fault was an F1, F2 or F3 fault, then the LED on the affected component key turns yellow. If the last fault was an F4 fault, all of the component key LEDs turn off. The right display indicates the log entry for the most recent fault. Table 4 6 provides the meaning of each digit in the log entry. Two sample fault log entries are shown following the table. 3. Press a right display scroll key to review each of the remaining nine log entries. Each time a scroll key is pressed, a progressively older log entry is displayed. NOTE: The fault log only stores the last ten faults. After ten faults occur, the existing log entries are overwritten, beginning with the oldest entry, by the eleventh and subsequent log entries. 4. Press the Setup key to return to normal mode. Scrolling through the fault log

88 4 42 Operation Tab. 4 6 Fault Log First digit Second and third digit Fourth digit Component: Type of fault: 1 = Platen or hose/gun 1 0 = Unused log entry 2 = Pump or hose/gun 2 1 = RTD (open or short) 3 = Hose 3 or gun 3 2= Component undertemperature 4 = Hose 4 or gun 4 F 3 = Component overtemperature 5 = Hose 5 or gun 5 4 = Processor or electrical failure 6 = Hose 6 or gun 6 Subcode for fault type F4: Assigned by Nordson Fault Log Examples Example 1: Example 2: Unused log entry If the LED on the Platen key is illuminated, the log entry indicates platen undertemperature. If the LED on the Hose key is illuminated, the log entry indicates hose 1 undertemperature. To view the number of heater hours since the last log entry, simultaneously press both of the right display scroll keys. The hours appear in the right display. The bulk melter will return to normal 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 bulk melter, two fault log entries are created. The first entry is for the gun, the second for the hose.

89 Operation 4 43 Settings Record Production information: Material: Cleaning agent: Reference channel: Manufacturer Processing temperature Viscosity Manufacturer Flash point Factory set Processing temperatures (setpoint temperatures) Platen Hose (accessory) 1) 2) 3) 4) Gun (accessory) 1) 2) 3) 4) Assembly handgun (accessory) 1) 2) 3) 4) Air pressure: bar MPa psi Operating pressure Notes: Name Date

90 4 44 Operation

91 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 service life of the unit. It should not be neglected under any circumstances. Risk of Burns Some maintenance work can only be done when the bulk melter is heated up. WARNING: Hot! Risk of burns. Wear safety goggles and heat protective gloves. Relieving Pressure WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. 1. Switch off motor. 2. Set selector Raise/lower platen to Place a container under the nozzle(s) of the gun/assembly handgun. 4. Guns: 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. 5. Re use the material or properly dispose of it according to local regulations.

92 5 2 Maintenance Important when Using Cleaning Agents Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Properly dispose of cleaning agent according to local regulations. Processing Materials Before using, read the included EU safety data sheet. Designation Order number Use High temperature grease To be applied to O rings and Can 10 g P/N threads NOTE: The grease may not be Tube 250 g P/N mixed with other lubricants. Cartridge 400 g P/N Oily/greasy parts must be cleaned before application. Grease Centoplex H0 Lubricating platen sealing ring 1 kg P/N Sealing paste Stucarit 203 Tube 100 ml P/N Temperature resistant adhesive Loctite ml P/N Heat transfer compound 500 g P/N Applied to sealing surfaces Secures screw connections To improve heat conducting of temperature sensors

93 Maintenance 5 3 Preventive Maintenance The maintenance intervals are general guidelines based on experience. Depending on the operating environment, production conditions and hours of operation, other scheduled maintenance tasks may prove necessary. Interval Bulk melter part Activity Page After initial startup Various Initial maintenance 5 4 Every time the container is changed Melting plate Base plate Check melting plate for charred material, clean if necessary Check base plate for material residue or other impurities, clean if necessary Daily Complete bulk melter External cleaning 5 5 Inspect for external damage 5 5 Power cable Inspect for damage - Air hoses Daily, if dust accumulation is severe Electrical cabinet ventilation Clean fan screens, clean or replace filter 5 6 Depending on hours of operation, pump speed and pump temperature Recommendation: Monthly Every hours of operation or every 2 to 3 years Motor / gear box Clean fan cover - Various Like initial maintenance 5 4 Motor / gear box Change lubricant

94 5 4 Maintenance Initial Maintenance Heating and cooling that occur during daily operation can cause screwed parts to loosen, resulting in leakage. Retighten the following components with a torque wrench: Component Torque Example Pos. Designation [Nm] [lbin] Note 1 Plug A 2 Hose fitting A Pump: Fixing screws A, B 5 Safety valve A NOTE A: Retighten while the material is still soft (approx. 70 C/158 F, depending on the material) B: Retighten crosswise

95 Maintenance 5 5 External Cleaning External cleaning prevents pollution created by production from causing bulk melter malfunctions. CAUTION: Observe the unit's Degree of Protection when cleaning. Refer to page 9 2, Electrical 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. Visual Inspection for External Damage WARNING: When damaged parts endanger the operating safety and/or the safety of personnel, switch off the bulk melter and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. Changing Type of Material NOTE: Before changing the material type, determine whether the old and new material can be mixed. May be mixed: Remaining old material can be flushed out using the new material. May not be mixed: Purge thoroughly and clean melting plate with a cleaning agent recommended by the material manufacturer. Refer to page 5 6, Cleaning Melting Plate. NOTE: Properly dispose of the old material according to local regulations.

96 5 6 Maintenance Purging with Cleaning Agent Place a container of cleaning agent in the bulk melter to purge. Then feed the cleaning agent until it comes out free of material residue. CAUTION: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Before starting production again, flush out residue of the cleaning agent using the new material. NOTE: Properly dispose of cleaning agent according to local regulations. Cleaning Melting Plate The melting plate is standardly release coated. This makes it easy to clean. Cooled material can usually be pulled off of the melting plate; if necessary, first heat to approx. 60 C / 140 F. CAUTION: Do not use hard or metallic tools to clean. Do not use wire brushes! This could damage the release coating. Use only soft aids (wooden or PTFE spatula or soft brush). Fan and Air Filter Depending on dust accumulation, the air filters in the fan and for the air outlet must be cleaned (knocked out) or replaced. Refer to separate document Parts for filter order numbers. 2 1 Fig Fan 2 Air filter, air outlet

97 Maintenance 5 7 Motor / Gear Box Change lubricant Observe when changing lubricant: Drain lubricant when warm Use only the stated lubricant or one that has proven to be equivalent. Using any other lubricant can result in premature wear and/or damage to the gear box Properly dispose of the old lubricant according to local regulations. Remove gear box from the motor to change lubricant. Wash out casing with suitable cleaning agent and remove lubricant residue. Lubricant Changing Interval When lubricant temperature is below 100 C / 212 F: Every hours of operation or at least every 2 to 3 years. Capacity The lubricant quantity is indicated on the ID plate. 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 OPTIMOL Optigear 220 SHELL Omala Oil 220 TEXACO Geartex EP A SAE 85 W 90

98 5 8 Maintenance Gear Pump Checking for Leakage 1 Variseals are fixed in place on the pump with a flange (1). If material escapes along the shaft, the pump shaft seal must be replaced. NOTE: A special assembly tool is needed for replacement. Refer to the separate document Parts List. However, Nordson recommends replacing the pump and sending the old one in to be repaired. Refer to page 7 2, Replacing Gear Pump.

99 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 bulk melter is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. Some Tips Before starting systematic troubleshooting, check the following: Are all parameters set correctly? Do all plug connections have sufficient contact? Have circuit breakers been activated? Are external, inductive loads (e.g. solenoid valves) equipped with recovery diodes? The recovery diodes must be directly allocated to the inductive load. For more information on troubleshooting, refer to Page 6 12, Flow Chart Platen Control Separate document Pneumatics Diagram Separate document Wiring Diagram.

100 6 2 Troubleshooting Troubleshooting Tables The troubleshooting tables serve as an orientation for qualified personnel. They cannot, however, replace targeted fault location with the help of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. Fault Codes Display Code/subcode Name Effect on bulk melter Cause Corrective Action F1 / n.a. RTD (resistance temperature detector) The RTD for the component indicated has failed or the component was disconnected from the bulk melter. Replace RTD Check hose/gun connections F2 / n.a. Undertemperature Heaters turn off The actual temperature of the component indicated has dropped below the undertemperature delta, which was set using parameter 22. Check whether external factors have caused the ambient temperature to fall Replace RTD F3 / n.a. Overtemperature The actual temperature of the component indicated has increased beyond the overtemperature delta, which was set using parameter 21. Replace RTD F4/1 RAM (random access memory) test Bulk melter stops functioning Internal RAM failure Replace CPU F4/2 Realtime clock Time Heaters remain on, but fault condition persists Internal clock failure Replace CPU F4/3 RAM backup battery Clock does not work Insufficient voltage from RAM backup battery Replace CPU F4/4 F4/5 Realtime clock Batterybacked RAM Realtime clock Battery Heaters remain on, but fault condition persists Battery backed RAM failure Battery for battery-backed RAM dead Replace CPU Replace CPU Continued...

101 Troubleshooting 6 3 Display Code/subcode Name Effect on bulk melter Cause Corrective Action F4/6 Analog digital RTD analog digital converter failed Replace main board or CPU F4/7 Analog digital calibration RTD analog digital converter could not be calibrated Replace main board, ribbon cable or CPU F4/8 F4/9 Main board feedback Expansion board feedback Bulk melter stops functioning Communication failure between main board and processor Communication failure between expansion board and CPU Replace main board, ribbon cable or CPU Replace expansion board, ribbon cable or CPU F4/A Thermostat Open tank or manifold thermostat Replace thermostat, J7 cable harness or main board F4/C Connection to expansion board Faulty connection between expansion board and CPU Check/replace the four individual cable connections between the main board and expansion board F4/d Communication with optional I/O board Heaters remain on, but fault condition persists Communication failure between processor and optional I/O board Replace I/O board or CPU NOTE: Subcode F4/b does not exist. This is to prevent it from being confused with F4/6.

102 6 4 Troubleshooting Motor controller fault Table 6 7 shoes the motor controller faults and fault codes that may appear in the pump speed display. Display Pump speed Tab. 6 7 Motor controller faults Fault code / problem Possible fault Corrective Action no EnA Flashes when the Motor key is pressed No enable Press the Pump key on the control panel until the LED lights up hot Motor thermostat open Wait until the motor has cooled off; check that the pump speed is not set too low, then start the pump again. If the fault code hot continues to be displayed, go to the troubleshooting table No Material (Motor does not Rotate) / Motor Overheated The displayed speed is not the actual speed The motor controller does not function as expected The pump speed display is not calibrated Motor control parameters are not set properly Refer to Calibrating Pump Speed Display in this section Check the motor control parameters. Refer to Changing Motor Control Parameters in this section

103 Troubleshooting 6 5 Bulk Melter does not Function Possible Cause Possible Fault / Troubleshooting Corrective Action 1. No line voltage - Connect line voltage 2. Main switch not - Switch on main switch switched on 3. Main switch defective - Replace main switch 4. Main circuit breaker - Switch on main circuit breaker activated 5. Main circuit breaker Check for short circuit in bulk - activated again melter or accessories V DC power supply defective - Replace 7. Bulk melter has no pneumatic function There is no compressed air Connect compressed air. Refer to page 3 6, Connecting Compressed Air One Channel (Heating Zone) does not Heat Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Channel is disabled / switched off - Enable / switch on No Material (Motor Rotating) Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Material supply hole to pump or pump suction hole clogged 2. Pressure control valve malfunctioned due to hardened or charred material - Detach pump and clean supply hole or suction hole - Replace

104 6 6 Troubleshooting No Material (Motor does not Rotate) Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Bulk melter not yet ready for operation (heatup phase) 2. Motor not switched on 3. Switch Container is empty does not switch - Wait until the bulk melter is heated up. - Switch on motor. Refer to section Operation, Enabling and Switching On Cable pulled off Connect Switch defective Replace 4. Standby entered - Exit or wait until standby period has expired 5. Motor overheated Ambient temperature too high Decrease ambient temperature by cooling or airing out Fan cap dirty Clean Pump blocked by foreign material Replace pump. Refer to page 7 2, Replacing Gear Pump Pump operates too sluggish Replace pump. Refer to page 7 2, Replacing Gear Pump Material too cold Set temperature accordingly 6. Motor defective - Replace 7. Motor not supplied - Technical inspection with voltage 8. Motor controller fault - Switch the bulk melter off and on again with the main switch Motor overheated See above. Motor controller overheated Decrease ambient temperature by cooling or airing out Clean cooling section of motor controller Short circuit Check motor cable Overload (pump blocked by foreign Refer to 5. material, pump too sluggish, material too cold) 9. Motor controller defective - Replace

105 Troubleshooting 6 7 Too Little Material or Irregular Feeding Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Material supply hole to pump or pump suction hole partially clogged 2. Processing temperature set too low - Detach pump and clean supply hole or suction hole. Refer to page 7 2, Replacing Gear Pump - Correct temperature setting 3. Pump block is worn - Replace pump. Refer to page 7 2, Replacing Gear Pump 4. Pressure control valve malfunctioned due to hardened or charred material - Replace Material Pressure too High Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Safety valve dirty and thus clogged 2. Pressure control valve set incorrectly - Replace. Refer to page 7 3, Replacing Safety Valve - Adjust. Refer to page 4 30, Setting Material Pressure Material Pressure too Low Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Pump is worn - Replace pump. Refer to page 7 2, Replacing Gear Pump 2. Safety valve does not close any more 3. Pressure control valve set incorrectly - Replace. Refer to page 7 3, Replacing Safety Valve - Adjust. Refer to page 4 30, Setting Material Pressure

106 6 8 Troubleshooting Others Possible Cause Possible Fault / Troubleshooting Corrective Action 1. Leakage at pump shaft seal 2. Material pressure too low, output quantity too low Pump shaft seal is worn Replace seal. Refer to page 5 8, Gear Pump Replace pump. Refer to page 7 2, Replacing Gear Pump Pump is worn Replace pump. Refer to page 7 2, Replacing Gear Pump 3. Pump blocked Processed material too cold Correct temperature setting (observe data sheet of material manufacturer) Foreign material in pump Replace pump. Refer to page 7 2, Replacing Gear Pump 4. Leakage at gun during heatup phase 5. Container is not completely emptied 6. Container is empty is not indicated Safety valve does not open (expansion pressure) Switch Container is empty is maladjusted Replace safety valve. Refer to page 7 3, Replacing Safety Valve Refer to page 3 7, Platen Position: Adjusting Switches

107 Troubleshooting 6 9 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 1 LEDs LED display Operating mode Green Red On Off Motor controller enabled On On Mains switching and automatic start blocked Flashing Off Motor controller blocked Off Flashing (every 1 s) Fault message or motor controller is being parameterized Off Flashing (every 0.4 s) Overvoltage or undervoltage shutdown Off Off Missing voltage supply

108 6 10 Troubleshooting Calibrating Pump Speed Display The pump speed display is calibrated before the bulk melter is delivered to the customer. If calibration is required again, perform the following steps. 1. Operate the motor at maximum speed. 2. Measure the pump speed with strobe. 3. Press both arrow keys and hold them down. 4. Release the keys when CAL appears in the display. 5. Use the arrow keys to set the value to the pump speed measured. Arrow keys 6. Press the Pump mode key to save the setting and exit calibration mode. Pump mode key

109 Troubleshooting 6 11 Changing Motor Control Parameters The motor control parameters have been set at the factory (Refer to table 6 8) and can be changed via the motor control panel: 1. Switch off motor. 2. Set the main switch to 0/OFF. 3. Hold down both arrow keys and turn on the main switch again. As soon as SEt appears, release the keys. Arrow keys 4. Use the arrow keys to set a value for the parameter indicated by the pump speed display. Refer to Table 6 8 for the list of parameters. 5. Press the Pump mode key to save the value and move to the next parameter. 6. Repeat steps for each of the parameters to be changed. 7. To exit setup mode, press the Pump mode key again after the last parameter has been displayed. Pump mode key Tab. 6 8 Motor control parameters (defaults) Parameters Default value Designation Explanation SEt 100 Maximum pump speed In manual mode, this parameter determines the size of the step by which the speed is changed when one of the Pump speed arrow keys is pressed. To change the pump speed in steps of 1, set this parameter to the maximum pump speed. Srt 0 Type of motor start 0: Motor key is active. The enabled pump is switched on with the Motor key and switched off with the Motor key or the Pump key. 1: Motor key is not active. The pump is switched on and off with the Pump key or with the handgun trigger. LoS 0 Minimum speed in automatic mode If the bulk melter is operated in manual mode, enter 0. If the bulk melter is operated in automatic mode, a minimum speed can be entered. Then the speed does not fall below this value, even if the line speed signal falls to 0 V.

110 6 12 Troubleshooting Flow Chart Platen Control

111 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. Observe Before Performing Repairs WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from line voltage before any repairs. Risk of Burns WARNING: Hot! Risk of burns. Wear appropriate protective clothing/equipment. Some components can be detached only when the bulk melter is heated up. Relieving Pressure WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. 1. Switch off motor. 2. Set selector Raise/lower platen to 0/stop. 3. Place a container under the nozzle(s) of the gun/assembly handgun. 4. Guns: 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. 5. Properly dispose of material according to local regulations.

112 7 2 Repair Replacing Gear Pump WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. Refer to page 7 1, Relieving Pressure. WARNING: Hot! Risk of burns. Wear heat protective gloves. Detaching Gear Pump NOTE: Detach the gear pump only when the material is soft (approx. 70 C/158 F, depending on material). 1. Remove the cover and detach the Cardan joint (1) from the pump shaft. 2. Detach pump. 3. Allow the bulk melter to cool to room temperature Attaching Gear Pump 1. Clean the sealing surfaces on the plate and pump. If necessary, heat material residue with a hot air fan, then remove. 2. Put the pump in place. Ensure that the suction hole (2) is positioned properly. 3. Screw the pump into place: a. Apply high temperature grease (Refer to page 5 2, Processing Materials) and tighten by hand, such that the pump and plate have thermal contact b. Wait until the pump and plate are at the same temperature c. Tighten the fixing screws crosswise using a torque wrench. Torque: 25 Nm / 220 lbin. 4. Attach Cardan joint. Ensure that the marks (3) line up. 5. Put the cover into place.

113 Repair 7 3 Replacing Motor NOTE: Perform work only when the material is soft (approx. 70 C/158 F, depending on material); otherwise the Cardan joint can not be turned. Observe when replacing: Verify that the electrical connection effects the desired direction of rotation (see arrow). Replacing Safety Valve WARNING: For safety reasons, the safety valve may not be disassembled. The complete valve must be replaced every time. WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. Refer to page 7 1, Relieving Pressure. WARNING: Hot! Risk of burns. Wear heat protective gloves. Observe when replacing: Replace the valve only when the bulk melter is heated. Otherwise the sealing rings could be damaged by charred material Apply high temperature grease to all threads and O rings (Refer to page 5 2, Processing Materials) Tighten valve with a torque wrench. Torque: 15 Nm (133 lbin). Size 19

114 7 4 Repair Replacing O rings WARNING: System and material pressurized. Relieve bulk melter pressure before disconnecting pressurized components (e.g. hoses, pressure sensors). Failure to observe can result in serious burns. Refer to page 7 1, Relieving Pressure. WARNING: Hot! Risk of burns. Wear heat protective gloves. When leakage occurs, e.g. at the hose connections, the O rings must be replaced. Observe the following: Clean and lubricate O ring groove. Nordson recommends special high temperature grease; refer to page 5 2, Processing Materials. Also lubricate O ring Do not use removed O rings again. Tighten hose connection and blind covers with a torque wrench to 9.5 Nm. Replacing Coupler Component Always set the coupler component DIP switches to Input / Output: 0-10 V DC / 0-10 V DC (Refer to Fig. 7 1). S1 ON ON S Fig. 7 1 Coupler component

115 Repair 7 5 Replacing Motor Controller CAUTION: Connect or disconnect the terminals only when the bulk melter is deenergized. The motor controller is still energized after switching off. Wait at least three minutes before beginning any work! Use only original Nordson motor controllers. They are parameterized and guarantee the required function. Replacing Standard I/O Board 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 board (2). 4. Remove protective cap (3) of the new standard I/O board. 5. Set the DIP switch of the standard I/O board as indicated by the wiring diagram (Refer to Motor Controller). 6. Insert standard I/O board into the serial port of the motor controller. 7. Insert male connector (1) into female connector of the standard I/O board. 8. Connect standard I/O board according to cable designation Fig. 7 2

116 7 6 Repair Replacing Melting Plate and/or Sealing Ring WARNING: Hot! Risk of burns. Wear heat protective gloves Heat the platen until the material softens (approx. 70 C / 158 F, depending on the material). 2. Place a clean, hard, heat resistant resting surface (e.g. metal plate) on the container and lower the platen onto the surface. 3. Release all of the fixing screws (1). 4. Raise the platen approx. 10 cm. The melting plate remains on the resting surface. 5. Shut down the bulk melter. 6. Carefully extract the temperature sensor from the bore (4). 7. Replace the O rings (3). Clean and grease the grooves. Refer to page 5 2, Processing Materials for the type of grease to be used. The sealing ring (2) can now be replaced. Refer to page 5 2, Processing Materials for the type of grease to be used. 8. Apply heat transfer compound (Refer to page 5 2, Processing Materials) to the temperature sensor and insert it into the bore (4). 9. Screw the melting plate into place: a. Grease the fixing screws and screw in loosely such that the platen and melting plate have thermal contact b. Wait until the platen and melting plate are at the same temperature c. Tighten the fixing screws with 10 Nm. NOTE: The next time the platen is cold (e.g. weekend, factory vacation) tighten the fixing screws again with the stated torque.

117 Repair 7 7 Replacing Temperature Sensor or Thermostat WARNING: Hot! Risk of burns. Wear heat protective gloves. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage Disconnect the bulk melter from the line voltage. 2. Remove the cover (1) Thermostat (2) 1. Apply heat transfer compound (Refer to page 5 2, Processing Materials) to the new thermostat and replace. Temperature sensor (3) 1. Carefully pull the temperature sensor out of the melting plate by the connecting cable. If it cannot be pulled out easily, the melting plate must be removed. Refer to page 7 6, Replacing Melting Plate. 2. Apply heat transfer compound (Refer to page 5 2, Processing Materials) to the temperature sensor and insert/fasten. 4. Re attach the cover. 5. Start up the bulk melter again.