Durablue II

DuraBlue II Adhesive Melters
Models 20 and 45
Customer Product Manual
Part 1126931_01
Issued 08/18
This document contains important safety information.

Be sure to read and follow all safety information in this
document and any other related documentation.
NORDSON CORPORATION  DULUTH, GEORGIA  USA

www.nordson.com
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2018.
Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written
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Part 1126931_01 2018 Nordson Corporation

All rights reserved
Table of Contents i
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
Responsibilities of the Equipment Owner . . . . . . . . . . . . . . . . . . . . . . . 1‐2
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
Instructions, Requirements, and Standards . . . . . . . . . . . . . . . . . . 1‐2
User Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Applicable Industry Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Instructions and Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Installation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
Maintenance and Repair Practices . . . . . . . . . . . . . . . . . . . . . . . . . 1‐5
Equipment Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐5
Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Relieving System Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . 1‐6
De‐energizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
Disabling the Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐6
General Safety Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . 1‐7
Other Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐10
Safety Labels and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Examples of Unintended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Key Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐3
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐4
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐5
Tank Isolation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐6
Pressure Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐6
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Automatic Scan (Normal Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Gear‐to‐Line Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐7
Melter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐8
2018 Nordson Corporation Part 1126931_01

ii Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Installation Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Experience of Installation Personnel . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐2
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐4
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐4
Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐5
Unpacking the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Moving the Unpacked Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Contents of the Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Customer‐Supplied Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Configuring the Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Residual Current Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Connecting the Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐7
Connecting Hoses and Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Connect Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐12
Setting Up the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐13
Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐13
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐15
Selecting Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 3‐15
Reading or Editing Operating Parameters . . . . . . . . . . . . . . . . . 3‐16
Set‐point Temperature of the Tank, Hoses, and Applicators . . . . 3‐20
Save and Restore Melter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐22
Review Parameter and Set‐point Temperature Changes . . . . . . . 3‐23
Setting Up Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐25
Wire Inputs/Outputs to the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐26
Set Up Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐27
Setting Up Gear‐to‐Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐31
Setting Up Motor Run Status Monitoring . . . . . . . . . . . . . . . . . . . . . . . 3‐32
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐32
Keypad Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐32
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐33
Installing Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐34
Connecting an Applicator Driver, Pattern Controller, or Timer . . . . . 3‐34
Flushing the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐34
Disposing of Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐1
Filling the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐2
About Heated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐2
Starting the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐3
Manually Adjusting the Pump Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
Adjust the Motor Speed for Manual Operation . . . . . . . . . . . . . . . . 4‐6
Adjusting Material Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐7
Monitoring the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐8
Confirm that the Melter is Operating Correctly . . . . . . . . . . . . . . . . 4‐8
Monitor Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . 4‐9
Monitor Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐11
Monitor the Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐17

Table of Contents iii
Adjusting Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐18

Entering a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐22
Using Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐23
Heater Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐23
Master Pump Enable Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐23
Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐24
Seven‐Day Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐24
Standby Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐25
Shutting Down the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐26
Record of Melter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐27
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Relieving System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Through the Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Through the Melter Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐2
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐3
Changing the Material Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Detaching the Exterior Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Fan and Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐4
Motor and Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐5
Changing the Motor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐5
Replacing a Motor or Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐6
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐8
Tightening the Pump Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐8
Replacing a Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐9
Replacing the Adhesive Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐13
Replace the Adhesive Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐14
Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐15
Replace the Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . 5‐15
Pressure/Circulation Control Valve Service Kit . . . . . . . . . . . . . . . . . . 5‐16
Cleaning the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐17
Draining Material from the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐17
Cleaning the Tank by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐17
Tightening the Fixing Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐17
Main PCA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐18
Replace the Main PCA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐18
Maintenance Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐1
Troubleshooting Quick‐Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐2
Returning the Melter Setup to Factory Settings . . . . . . . . . . . . . . . . . . 6‐2
Melter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐3
Motor Control Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐5
Changing a Motor Control Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐6
Motor Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐8
LED Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐9
Motor Drive Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐10
Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐10
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐12

iv Table of Contents
Changing a Motor Drive Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐15

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐15
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐15
Favorites Group Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐17
Saving the Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐18
Navigation Group 1‐7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐19
Saving the Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐19
Motor Drive Parameter Factory Settings . . . . . . . . . . . . . . . . . . . . . 6‐20
Calibrating the Pump Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐21
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐22
Melter Not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐22
One Channel (Heating Zone) Does Not Heat . . . . . . . . . . . . . . . . . 6‐22
Control Panel Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐22
No Material (Motor Does not Rotate) . . . . . . . . . . . . . . . . . . . . . . . . 6‐23
No Material (Motor Rotating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐24
Too Little Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐24
Material Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐25
Material Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐25
Material Residue in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐26
Material Hardens in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐26
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐1
Melter Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐2
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐3
Melter Frame Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐3
Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐4
1‐Single Stream Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7‐4
Hopper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐6
Melter Hopper Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐6
Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐8
Drive Module Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐8
Single‐Stream Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐9
Safety Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐10
Control Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐11
Control Valve Module Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐11
Filter Cartridge Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐12
Pressure Control Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐13
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐14
Electrical Enclosure Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 7‐16
Melter Left Panel Parts ‐ 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐16
........................................................ 7‐16
Melter Back Panel Parts ‐ 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐18
Melter Right Panel Parts ‐ 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐20
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐24
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐25
Optional Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐26
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐27

Table of Contents v
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐1
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐1
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐2
Mechanical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐2
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8‐4
Calculating Melter Power Requirements . . . . . . . . . . . . . . . . . . . . . A-1

Evaluate Hose/Applicator Power Requirements . . . . . . . . . . . . . . A‐2
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B‐2
Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B‐9
Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B‐12
Seven‐day Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B‐13
PID Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B‐19
Melter Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Software Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C‐1
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C‐1
Installing the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C‐2
Removing the Software from Your PC . . . . . . . . . . . . . . . . . . . . . . . C‐4
Connecting the PC and the Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . C‐5
Using Nordson Configuration Manager . . . . . . . . . . . . . . . . . . . . . . . . . C‐6
Saving and Restoring Melter Settings . . . . . . . . . . . . . . . . . . . . . . . C‐6
Upgrading or Restoring Melter Firmware . . . . . . . . . . . . . . . . . . . . . C‐7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C‐10
Using Nordson Configuration Manager . . . . . . . . . . . . . . . . . . . . . . C‐10

vi Table of Contents
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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.
2018 Nordson Corporation Issued 4-15

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.
Issued 4−15 2018 Nordson Corporation

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.

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 Safety Data Sheet (SDS) 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 SDS for PPE requirements.
Do not use equipment that is malfunctioning or shows signs of a potential
malfunction.

Safety 1-5
Maintenance and Repair Practices

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 SDS
supplied with equipment cleaning compounds.
NOTE: SDSs for cleaning compounds that are sold by Nordson are
available at www.nordson.com 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 SDS or
contact the authority having jurisdiction for information.
Keep equipment safety warning labels clean. Replace worn or damaged
labels.
Equipment Safety Information

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

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.

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)
Table 1‐1General Safety Warnings and Cautions

Equipment
Type Warning or Caution
WARNING! Hazardous vapors! Before processing any polyurethane

reactive (PUR) hot melt or solvent‐based material through a compatible
HM Nordson melter, read and comply with the material's SDS. 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
SDS requirements can cause personal injury, including death.
WARNING! Reactive material! Never clean any aluminum component

or flush Nordson equipment with halogenated hydrocarbon fluids.
HM 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.
WARNING! System pressurized! Relieve system hydraulic pressure

HM, CA 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...

1-8 Safety
Table 1‐1General Safety Warnings and Cautions (contd)

Equipment
WARNING! Molten material! Wear eye or face protection, clothing that

HM 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.
WARNING! Equipment starts automatically! Remote triggering devices

are used to control automatic hot melt applicators. Before working on
HM, PC 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.
WARNING! Risk of electrocution! Even when switched off and

electrically isolated at the disconnect switch or circuit breaker, the
HM, CA, PC 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.
WARNING! Risk of fire or explosion! Nordson adhesive equipment is

not rated for use in explosive environments and has not been certified
for the ATEX directive or as nonincendive. In addition, this equipment
HM, CA, PC should not be used with solvent‐based adhesives that can create an
explosive atmosphere when processed. Refer to the SDS 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.
WARNING! Allow only personnel with appropriate training and

HM, CA, PC 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.

Safety 1-9
Equipment
CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of
HM 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.
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
HM
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.
CAUTION! Before using any cleaning or flushing compound on or in

the equipment, read and comply with the manufacturer's instructions
HM, CA and the SDS supplied with the compound. Some cleaning compounds
can react unpredictably with hot melt or cold adhesive, resulting in
damage to the equipment.
CAUTION! Nordson hot melt equipment is factory tested with Nordson

Type R fluid that contains polyester adipate plasticizer. Certain hot melt
HM 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.

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 SDS for the hot melt
to the medical personnel providing treatment.

Safety 1-11
Safety Labels and Tags

Figure 1‐1 illustrates the location of the product safety labels and tags affixed
to the equipment. Table 1‐2 provides an illustration of the hazard
identification symbols that appear on each safety label and tag, the meaning
of the symbol, or the exact wording of any safety message.
2 3
Figure 1‐1 Safety labels and tags
Table 1‐2 Safety Labels and Tags

Item Part Description
1. 1025795 [Tag, warning, hazardous volts]
WARNING: Hazardous voltage.
Disconnect all power supply
connections before servicing.
2. 224906
[Tag, warning, electrical shock]
3. 224905
[Tag, warning, hot]
4. 1025326 [Tag, caution, hot surface]

5. 1021983 [Tag, warning, hot adh/hyd press]

1-12 Safety

Introduction 2-1
Section 2
Introduction
Intended Use
DuraBlue II adhesive melters may be used only to melt and convey suitable
materials, e.g. thermoplastic hot melt adhesives.
Any other use is considered to be unintended. Nordson will not be liable for
personal injury or property damage resulting from unintended use.
Intended use includes the observance of Nordson safety instructions.

Nordson recommends obtaining detailed information on the materials to be
used.
Electromagnetic Compatibility (EMC)

In regard to electromagnetic compatibility (EMC), the melter is intended for
use in industrial applications.
When operated in residential or commercial areas, the melter may cause

interference in other electrical units, e.g. radios.

2-2 Introduction
Examples of Unintended Use

The melter may not be used under the following conditions:
In defective condition
Without insulation blanket and protective panels
With electrical cabinet door open
With tank lid open
In a potentially explosive atmosphere
When the values stated under Technical Data are not complied with.
The melter may not be used to process the following materials:
Polyurethane hot melt adhesive (PUR)

Explosive and flammable materials
Erosive and corrosive materials
Food products
Residual Risks
In the design of the unit, every measure was taken to protect personnel from
potential danger. However, some residual risks can not be avoided:
Risk of burns from hot material.

Risk of burns when filling the tank, from the tank lid, and from the tank lid
supports.
Risk of burns when conducting maintenance and repair work for which
the melter must be heated up.
Risk of burns when attaching and removing heated hoses.
Material fumes can be hazardous. Avoid inhalation.
Risk of damage to cables/lines belonging to the customer, if they were
installed such that they come into contact with hot or rotating parts.
The safety valve may malfunction due to hardened or charred material.

Introduction 2-3
Key Components
Figure 2‐1 provides the name and the location of key melter components.
1 3
4 11
10
7
2
6
2 5
Figure 2‐1 Key melter components

1 Control panel (see Figure 2‐3) 5 Motors/pumps 9 Hose receptacles
2 Protective panel, removable 6 Drain valve 10 ID plate
3 Tank lid 7 Pressure control valve 11 Tank
4 Main power switch 8 Manifold

2-4 Introduction
Electrical Components
4 6
9
2
2
3
5
11
10
Figure 2‐2 Key electrical components

1 Main board 5 Motor controller 9 Main switch
2 Circuit breakers 6 Signal conditioner 10 Distribution block
3 Solid state relay 7 Expansion board 11 Contactor
4 Fan 8 Power module
Note: The central processing unit is not shown in this illustration. Refer to Section 7, Parts.

Introduction 2-5
Control Panel
1 2
10 11 12 13
3 4 14 15 16 17
Figure 2‐3 Control panel (melter control panel and two motor control panels shown)
1 Pump speed arrow keys 7 Heaters key/LED 13 Control switch
2 Pump speed display (rpm) 8 Clock key/LED 14 Left display and arrow key
3 Pump mode key/LED 9 Setup key/LED 15 Right display and arrow keys
4 Pump enable key/LED 10 Fault light 16 Numeric keypad
5 Standby key/LED 11 Ready light 17 Serial port
6 Master pump enable key/LED 12 Component keys/LEDs

2-6 Introduction
Tank Isolation Valve

The tank isolation valve allows replacement of the pump without first
emptying the tank.
Figure 2‐4 Location of the tank isolation valve
Pressure Control Valves

The manual pressure control valves can be adjusted from 0-90 bar.
Figure 2‐5 Location of the pressure control valves

Introduction 2-7
Modes of Operation
DuraBlue II adhesive melters operate in the following modes.
Automatic Scan (Normal Mode)

The melter automatically checks and displays the current temperature of the
tank, hoses, and guns to confirm that they are within their pre‐defined
temperature range. By default, the melter is always in the automatic scan
mode unless it is placed into another operating mode.
Standby
The temperatures of the tank, hoses, and guns are reduced down from their
operating temperature (hereafter referred to as set‐point temperature) by a
pre‐set number of degrees.
Setup
The setup mode is used to configure melter control options and features and
to review stored operating data. To prevent unauthorized changes to the
melter's configuration, the melter can be password‐protected.
Fault
The melter alerts the operator when an abnormal event occurs.
Gear‐to‐Line Capability
The melter is capable of delivering an adhesive output that is geared to the
production line speed. The gear‐to‐line capability is enabled or disabled
through the motor control system. A line‐speed signal generator must be
installed if you want to use the gear‐to‐line capability.
NOTE: The gear‐to‐line mode of operation is also known as automatic mode

or key‐to‐line mode.

2-8 Introduction
Melter Identification
You will need the model and part number of your melter when requesting
service or ordering spare parts and optional equipment. The model and part
number are indicated on the equipment identification plate that is located on
the front of the melter.
Figure 2‐6 Location of the melter identification plate

Installation 3-1
Section 3
Installation
WARNING! Allow only qualified personnel to perform the following tasks.

Follow the safety instructions in this document and all other related
documentation.
Overview
DuraBlue‐II adhesive melters are factory‐configured for each order and
require only the assembly and set up tasks described in this section.
The melter is shipped from the factory with an installation kit that contains
components that must be assembled onto the melter by the customer. Some
additional materials must also be supplied by the customer to complete the
installation.
If optional equipment was ordered with the melter, refer to the documentation
provided with the optional equipment for installation and operating
instructions.
The illustrations accompanying the procedures in this section depict a

dual‐motor dual‐stream melter.
Additional Information
This section presents installation procedures in their most commonly used
form. Procedural variations or special considerations are explained in the
additional information table that follows most procedures. Where applicable,
some table entries also contain cross‐reference information. Additional
information tables are indicated by the symbol shown to the left.

3-2 Installation
Installation Tasks
The installation sequence is as follows:
1. Verify that the required environmental conditions and utilities exist.

2. Unpack and inspect the melter.
3. Configure the electrical service.
4. Connect hot melt hoses and applicators.
5. (Optional) Configure key-to-line.
6. (Optional) Connect to the pressure control transducer.
7. Set up the melter to work with the manufacturing process.
8. (Optional) Install inputs and outputs.
9. Install optional equipment.
10. Connect an applicator driver, pattern controller, or timer.
11. Flush the melter.
Experience of Installation Personnel

The instructions provided in this section are intended to be used by
personnel who have experience in the following subjects:
Hot melt application processes

Industrial power and control wiring
Industrial mechanical installation practices
Basic process control and instrumentation
Installation Requirements
Before installing the melter, ensure that the desired installation location
provides the required clearances, environmental conditions, and utilities.
Clearances
Figure 3‐1 illustrates the minimum clearances that are required between the
melter and surrounding objects.

Installation 3-3
Minimum Installation Clearances
118 in. (3000 mm) OPERATION SPACE
41.5 in. (1054.5 mm)
(1000 mm)
39.2 in.
6.6 in.
(167 mm)
OPERATION SPACE
38.3 in. (973 mm)
(973 mm)
(247 mm)
(600 mm)
38.3 in.
9.7 in.
23.6 in.
102 in. (2600 mm)

(1000 mm)
39.2 in.
1278 in. (50.3 mm)

48.4 in. (1230 mm)
(130 mm) 36.5 in. (928 mm)

5.1 in.
Figure 3‐1 Melter minimum installation clearances

3-4 Installation
Ventilation
DuraBlue II melters are cooled by forced air. Air is drawn in through by the
ventilation fan and is exhausted out of the ventilation slots at the top of the
melter.
CAUTION! Do not block the fan air intake openings or the exhaust ventilation
slots.
Figure 3‐2 Location of the ventilation openings
Electrical Power
Before installing the melter, ensure that the melter will not be overloaded and
that the plant's electrical service is rated to handle the power required by the
melter and the hoses and applicators that you plan to use.
Refer to Appendix A, Calculating Melter Power Requirements, for information

about how to calculate the maximum allowable hose lengths and applicator
wattages that can be used in your manufacturing application.
WARNING! Risk of electrocution! Install a lockable power disconnect switch

between the electrical service and the melter. Failure to install or properly
use the disconnect switch when servicing the melter can result in personal
injury, including death.

Installation 3-5
Other Considerations
Consider the following additional factors when evaluating where to install the
melter.
The maximum distance between the melter and each applicator is

dictated by the power requirement of each hose. Refer to Appendix A,
Calculating Melter Power Requirements, for information about how to
determine the maximum allowable length.
The operator must be able to safely reach the control panel and
accurately monitor the control panel indicators.
The operator must be able to safely observe the level of hot melt inside
the tank.
The melter must be installed away from areas with strong drafts or where
sudden temperature changes occur.
The melter must be installed where it will be in conformance with the
ventilation requirements specified in the Safety Data Sheet for the hot
melt being used.
The melter should not be exposed to excessive vibration.

3-6 Installation
Unpacking the Melter

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

When moving the melter, always support the melter by placing any lifting
device under the chassis.
Contents of the Installation Kit

The installation kit contains a package of safety label overlays that are
printed in variety of languages. If required by local regulations, the
appropriate language overlay should be applied over the English version of
the same label. Refer to Safety Labels and Tags in Section 1, Safety, for the
location of each safety label.
Customer‐Supplied Materials
The following additional materials are also required to install the melter.
A power cable. Rigid or flexible electrical conduit will be required.

(Optional) Gear‐to‐line input signal wiring
(Optional) Input/output signal wiring

Installation 3-7
Configuring the Electrical Service

DuraBlue II melters are shipped from the factory without an attached power
cable. To configure the melter to function in your facility, you must connect a
properly rated power cable.
The maximum power draw of the melter for any supported service code is
86 A.
Residual Current Circuit Breakers

Local regulations in some geographic areas or industrial branches may
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 melter.
Only residual current circuit breakers sensitive to pulsating current or
universal current (> 30 mA) may be used.
Connecting the Electrical Service

NOTE: The melter must be installed securely (permanent power supply
connection).
WARNING! Operate only at the operating voltage shown on the ID plate.
NOTE: Permitted deviation from the rated line voltage is 10%.
NOTE: The power cable cross‐section must comply with the maximum
power consumption (refer to Section 8, Technical Data).
WARNING! Ensure that cables do not touch rotating and/or hot melter
components. Do not pinch cables and check regularly for damage. Replace
damaged cables immediately!
1. See Figure 3‐3. Route the power cable into the electrical cabinet through
the strain relief on the side of the base.
NOTE: Do not route any input/output wiring through this strain relief.
2. Connect the power cable to the service terminal block as indicated in

table Table 3‐1 and illustrated in Figure 3‐3.
3. Connect the service ground lead to the ground terminal located on the
DIN rail at XL0:PE.

3-8 Installation
Connecting the Electrical Service (contd)
Table 3‐1 Electrical Service Wiring

Terminals
Line voltage
1 2 3 N PE
400 VAC 3‐phase with neutral (star ‐ WYE)
400V-XL0
Figure 3‐3 Location of service wiring strain relief and terminal block

Installation 3-9
Connecting Hoses and Applicators

WARNING! Risk of fire or equipment damage. Before connecting hoses and
applicators to the melter, confirm that the power required by each
hose/applicator pair and each hose/applicator module, does not exceed the
maximum wattages specified in Appendix A, Table A‐2, Maximum Allowable
Wattages.
Connect Hoses
See Figure 3‐4 to properly connect the hose hydraulic fittings based on the
manifold configuration. If hoses are not connected properly, the melter will
not operate correctly.
See Figure 3‐5 to connect hose cordsets.
Observe the following guidelines:
For information about choosing the correct Nordson hot melt hose for
your manufacturing process, refer to the latest edition of Nordson's hot
melt dispensing equipment Replacement Parts Catalog or contact your
Nordson representative.
Refer to the user's guide provided with each Nordson hose. The guide
contains important information about routing and installing the hose.
Save all of the port plugs removed from the manifold. A port plug will
need to be reinstalled into the manifold if a hose is later removed.

3-10 Installation
Connect Hoses (contd)
Pump 1: Output port 1
Pump 1: Output port 2
Figure 3‐4 Connecting hoses

Installation 3-11
Connect Hoses (contd)
HC−H6 HC−H5 HC−L4 HC−L3 HC−L2 HC−L1
Figure 3‐5 Connecting a hose cordset

3-12 Installation
Connect Applicators
Observe the following guidelines:
DuraBlue II melters with 120‐ohm nickel sensors support all Nordson

T‐style applicators. DuraBlue‐II melters with 100‐ohm platinum sensors
support all Nordson M‐style applicators.
For information about choosing the most appropriate Nordson hot melt
applicator for your manufacturing process, refer to the latest edition of
Nordson's hot melt dispensing equipment Replacement Parts Catalog or
contact your Nordson representative. Refer to Appendix A, Calculating
Melter Power Requirements, for information about how to calculate the
power required by Nordson hot melt applicators.
Refer to the user's guide that is shipped with each applicator for
information about installing the applicator and connecting a hose to the
applicator.
NOTE: DuraBlue II adhesive melters are shipped with a 0.2 mm hot melt
filter installed in the manifold. Order the appropriate applicator nozzle based
on this filter mesh size.

Installation 3-13
Setting Up the Melter

After physically installing the melter, it must be set up to support your
manufacturing process. Melter setup consists of enabling or making changes
to factory‐set operating parameters that affect the use and function of the
melter. The operating temperature (set‐point) of the tank and each hose and
applicator is also established during melter setup.
The melter is shipped from the factory with the most commonly used
operating parameters already set up. The factory setup can be modified at
any time to suit your manufacturing process.
Quick Setup
Table 3‐2 describes the most commonly used operating parameters and their
factory settings. Review the table to determine if the factory settings for each
parameter will support your manufacturing process. If the default values for
each of these operating parameters are appropriate for your manufacturing
process, then no melter setup is required. Go directly to Set‐point
Temperature of the Tank, Hoses, and Applicators later in this section to
complete the installation process.
If you need to make changes to the factory setup or if you want to learn about
other operating parameters, go to the next part in this section, Operating
Parameters.

3-14 Installation
Quick Setup (contd)
Table 3‐2 Common Operating Parameters

Parameter Parameter Name Purpose Default Value
A timer that delays the activation of the ready LED for

a pre‐defined time period after the tank, hoses, and
applicators are at the desired set‐point temperature.
4 Ready Delay Time The ready delay timer will only activate if the 0 minutes
temperature of the tank, at the time the melter is turned
on, is below its assigned set‐point temperature by
27 C (50 F) or more.
A timer that turns on a service LED when the value set

Service Interval for the timer equals the number of hours that the
5 500 hours
Time heaters have been on. The service LED is used to
signal the need for maintenance.
If the switch receptacle is used, this parameter

7 Motor Off Delay determines the amount of time the motor will remain 0 seconds
on after the switched device is turned off.
Allows the pump to start automatically when system

8 Automatic Pump On ready is reached, provided that the pump has been Enabled
enabled by pressing the pump key.
Sets a password that must be entered before any

11 Create Password melter operating parameter or set‐point temperature 5000
can be changed.
Sets the units of the temperature display to degrees

20 Temperature Units C
Celsius(C) or to degrees Fahrenheit (F).
Sets the number of degrees that any heated

Over Temperature
21 component can exceed its assigned set‐point 15 C (25 F)
Delta
temperature before an over temperature fault occurs.
Sets the number of degrees that any heated

Under Temperature
22 component can drop below its assigned set‐point 25 C (50 F)
Delta
temperature before an under temperature fault occurs.
Sets the number of degrees that the temperature of all

23 Standby Delta heated components will be decreased when the melter 50 C (100F)
is placed into the standby mode.
Manual Standby Sets the amount of time the melter will remain in the
26 Disabled
Time standby mode after the standby key is pressed.
A group of parameters that control the melter's clock.

50 to 77 Seven‐day Clock The clock is used to automatically turn the heaters on Disabled
and off and to place the melter into the standby mode.

Installation 3-15
Operating Parameters
The melter uses operating parameters to store non‐editable and editable
values. Non‐editable values are those that provide information about the
historical performance of the melter. Editable values are either a numeric
set‐point or a control option setting. Control options settings affect the display
of information or the function of the melter.
Operating parameters are stored in the melter's firmware in the form of a

sequentially numbered list. The list is organized into the logical groups
described in Table 3‐3.
Table 3‐3 Parameter Groups

Parameter
Group Group Description
Numbers
0 to 8 and Noneditable and other frequently used

Standard
10-14 parameters
Temperature
20 to 29 Control heaters
Control
Configure the standard and optional

Input Setup 30 to 39
inputs
Configure the standard and optional

Output Setup 40 to 46
outputs
Seven‐day Clock 50 to 77 Configure the clock feature
In addition to the ability to read and edit parameter values, you can also save
and restore the current value of every operating parameter and review a log
of the last ten changes that were made to editable parameters.
Selecting Operating Parameters

Table 3‐4 provides a complete list of the operating parameters. Review the
list to determine which operating parameters would best support your
manufacturing process. Refer to Appendix B, Operating Parameters, for
detailed information about each parameter. Appendix B contains a complete
description of each parameter, including its affect on the melter, default
value, and format.
NOTE: Parameters that are used to configure optional equipment or that are
otherwise reserved in the firmware are excluded from Table 3‐4 and
Appendix B.

3-16 Installation
Reading or Editing Operating Parameters

Regardless of whether a parameter's value is editable or not, the procedure
for accessing each parameter in order to read or edit its current value is the
same.
To read or edit a parameter
1. Place the main power and control switches on the ON position.

The melter performs a start‐up check.
2. Press the Setup key.

The left display flashes parameter 1.
3. Use the numeric keypad to enter the number of the desired parameter.
Refer to Table 3‐4 for a complete list of parameters.
NOTE: If you incorrectly enter the parameter number, press the

Setup key Clear/Reset key to return to parameter 1 and then re‐enter the correct
parameter number.
When you have finished entering the one‐ or two‐digit parameter number,
the right display indicates the parameter's current value.
4. Do one of the following:

If the value is noneditable, refer to Monitoring the Melter in Section4,
Operation.
Clear/Reset key
If the value is editable go to step 5.
5. Press the Enter key.

The right display flashes.
6. Use the keypad to enter the desired numeric set‐point or control option
into the right display. Refer to Appendix B, Operating Parameters, for
information about the numeric value or control option choices for each
Enter key parameter.
NOTE: If the keypad has no affect on the right display, the melter is
password protected. You must enter a valid password before you can
edit parameters. Refer to Entering a Password in Section 4, Operation.

The melter checks that the new value or control option is acceptable.
If the numeric set‐point or control option is accepted, the left and right
displays index to the next sequential parameter number and value.

Installation 3-17
If the numeric set‐point or control option is not accepted, the right

display will indicate dashes (‐‐‐‐) for three seconds and then it will
change back to the original value.
8. Repeat step 5 through step 7 to read or change the next sequential

parameter number or press the Setup key to exit the setup mode.
Table 3‐4 Operating Parameters

Parameter Name Range of Values Default Value
Standard
0 Enter Password 0 to 9999 4000
1 Total Hours with Heaters On
0 to 9999 0
(noneditable)
2 Fault Log (noneditable) — _‐F0 (empty)
3 Change History Log (noneditable) — P‐_ (empty)
4 Ready Delay Time 0 to 60 minutes 0 minutes
5 Service Interval Time 0 to 8736 hours 500 hours
6 Service LED Heater Hours 0 to 9999hours 0
81 Automatic Pump On 0 (disabled) or 1(enabled) 1 (enabled)
10 Enable or Disable Password 0 (disabled) or 1(enabled) 0 (disabled)
11 Create Password 0 to 9999 5000
Change Hose 1 Output to Electric
121 0 (disabled) or 1 (enabled) 0 (disabled)
Applicator Activation
Change Hose 2 Output to Electric
131 0 (disabled) or 1 (enabled) 0 (disabled)
Applicator Activation
14 External Communications Lock‐out 0 or 1 0 (disabled)
Temperature Control
20 Temperature Units (degrees C or F) C (degrees Celsius) or F
C (degrees Celsius)
(degrees Fahrenheit)
21 Over Temperature Delta 5 C (10 F) to 60C(110 F) 15 C (25 F)
22 Under Temperature Delta 5 C (10 F) to 60C(110 F) 25 C (50 F)
23 Standby Delta 25 C (50 F) to 190C (350 F) 50 C (100 F)
24 Automatic Standby Timeout 0 to 1440minutes 0 (disabled)
25 Automatic Heaters Off Time 0 to 1440minutes 0 (disabled)
26 Manual Standby Time 0 to 180 minutes 0 (disabled)
27 Hose Standby Delta 1 C (1 F) to 190C (350 F) 0 (disabled)
28 Applicator Standby Delta 1 C (1 F) to 190C (350 F) 0 (disabled)
29 Internal Zone Temperate Offset 0 C (0 F) to ‐15C (‐30 F) 0 (disabled)
30 Standard Input 1 10 (Automatic
0–8 and 10-14
Standby)
31 Standard Input 2 0–8 and 10-14 1 (Standby on/off)
32 Standard Input 3 0–8 and 10-14 2 (Heaters on/off)
33 Standard Input 4 4 (Hose/applicator 1
0–8 and 10-14
enable/disable)
34 Optional Input 5 0–8 and 10-14 0 (disabled)
1Not used with DuraBlue II melters.

3-18 Installation
To read or edit a parameter (contd)

Input Setup
Output Setup
40 Standard Output 1 0–6 1 (Ready)
41 Standard Output 2 0–6 3 (Fault)
42 Standard Output 3 0–6 4 (Not used)
43 Optional Output 4 0–6 0 (disabled)
Seven‐day Clock
50 Current Day 1 to 7 (1 = Monday) —
51 Current Hour 0000 to 2359 —
55 Schedule 1 Heaters On 0000 to 2359 06:00
56 Schedule 1 Heaters Off 0000 to 2359 17:00
57 Schedule 1 Enter Standby 0000 to 2359 —:—
58 Schedule 1 Exit Standby 0000 to 2359 —:—
60 Schedule 2 Heaters On 0000 to 2359 —:—
61 Schedule 2 Heaters Off 0000 to 2359 —:—
65 Schedule 3 Heaters On 0000 to 2359 —:—
66 Schedule 3 Heaters Off 0000 to 2359 —:—
Continued…

Installation 3-19

71 Schedule for Monday 0-7 0
72 Schedule for Tuesday 0-7 0
73 Schedule for Wednesday 0-7 0
74 Schedule for Thursday 0-7 0
75 Schedule for Friday 0-7 0
76 Schedule for Saturday 0-7 0
77 Schedule for Sunday 0-7 0
You can exit the setup mode at any time by

pressing the Setup key.
Parameter numbers that are not applicable are

skipped when you scroll through the operating
parameter list in the left display.
When the right display is flashing, you can

quickly set the value of the current parameter
to its lowest possible value by simultaneously
pressing both of the right‐display scroll keys.
While in the setup mode, if no key is pressed

for two minutes, the melter will return to the
automatic scan mode.
You can also use the right‐display scroll keys

to enter or change a parameter's value or
control option. After entering the parameter's
number in the left display, press either of the
right‐display scroll keys to change the value or
control option.
Using a personal computer that is connected Refer to Appendix C, Melter

to the melter through the serial port, you can Communications
view and change all of the operating
parameters from a single computer screen.
If password protection is enabled, the melter Appendix B, Parameter 10

will return to the password protected mode
whenever you exit the setup mode.

3-20 Installation
Set‐point Temperature of the Tank, Hoses, and Applicators

The melter is shipped from the factory with the tank set‐point temperature at
175 C (350 F) and the hose and applicator set‐point temperatures at 0
degrees (turned off).
Before the melter can be used, a set‐point temperature must be assigned to

the tank, hoses, and applicators. Assign set‐point temperatures using any of
the following methods:
Global—The tank and all hoses and applicators are set to the same
set‐point temperature.
Global‐by‐component group—All of the hoses or all of the applicators
are set to the same set‐point temperature.
Individual Component—The set‐point temperature of the tank and each
hose and applicator is set individually.
Since most manufacturing processes will require the tank, hoses, and
applicators to be set to the same temperature, only the global method of
assigning set‐point temperatures is described in this section. For information
about the other two methods of assigning set‐point temperatures, refer to
Adjusting Component Temperatures in Section 4, Operation.
As with operating parameters, you can also save and restore set‐point
temperatures and review past changes that were made to set‐point
temperatures.

Installation 3-21
To assign a global set‐point temperature
1. Press and hold the Tank key for three seconds.

The left display flashes 1.
Tank key 2. Scroll the left display to 0.

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

4. Use the numeric keypad to enter the set‐point temperature

Left display and recommended by the manufacturer of the hot melt.
scroll key
Refer to the technical data sheet provided by the manufacturer of the hot
melt to determine the optimal set‐point temperature.
5. Press the Tank key.

Each component begins to heat or cool to the new global set‐point
temperature and the melter returns to the automatic scan mode.
Enter key When all of the components reach the global set‐point temperature, the
ready LED turns on (green).
Ready LED

3-22 Installation
Save and Restore Melter Settings

The current value of all editable operating parameters and the set‐point
temperature of each component can be saved and, if necessary, restored at
a later time. When saved settings are restored, they overwrite the settings
that are presently in use.
This save‐restore feature is useful in instances where the settings that are in
use are deliberately or accidentally changed and you need to return the
melter to its pre‐change setup.
To save current settings

With the melter in the automatic scan mode, simultaneously press the
number 1 key and the Setup key.
+ S‐1 appears momentarily in the right display.
Saving current settings

To restore saved settings
CAUTION! All melter settings will be deleted! Before restoring saved

settings, ensure that use of the restored settings will not disrupt the current
process or create an unsafe operating condition.
+ With the melter in the automatic scan mode, simultaneously press the
number 2 key and the Setup key.
S‐2 appears momentarily in the right display.

Restoring saved settings
If you use the restore feature before the save

feature is used for the very first time, the
factory default set‐point temperatures will be
restored. This will cause the hoses and
applicators to stop heating.
You can transfer melter settings from one Refer to Appendix C, Melter
melter to another using the Nordson Communications
Configuration Manager software utility.

Installation 3-23
Review Parameter and Set‐point Temperature Changes

The melter stores in a change history log, a record of the last ten changes
that were made to either operating parameters or set‐point temperatures.
Since the log only stores ten changes, old log entries are overwritten
beginning with the first log entry, by the eleventh and following log entries.
To review the change history log
Setup key 1. Press the Setup key.

Operating parameter 1 flashes in the left display.
2. Press the left‐display scroll key to change the display to parameter 3 (the
change history log).
The following occurs:
If the last change was to an editable parameter, all of the component
key LEDs remain off.
or
Left display and
scroll key If the last change was to a set‐point temperature, the LED on the
associated component key(s) turns on.
and
The right display indicates the four‐digit log entry associated with the
last change that was made.
Table 3‐5 provides the meaning, from left to right, of each digit in the
log entry. Following the table are two example log entries.
Component key LEDs
3. Press a right‐display scroll key to review each of the remaining nine log
entries. Each press of a scroll key displays a progressively older log
entry.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the log

3-24 Installation
Review Parameter and Set‐point Temperature Changes (contd)
Table 3‐5 Change History Log

Second
First Digit Third and Fourth Digits
Digit
P (Parameter) Indicates the number of the parameter that was changed
Are used in conjunction with the LEDs on the component keys to indicate the
location and method of a set‐point temperature change.
When this LED is And the Fourth The change was And the Method
on.. Digit Indicates.. to.. of Change was..
Tank Key 1 The tank Individual
- Hose Key 1– 6 A single hose Individual
S (Set‐point) A single
Applicator Key 1– 6 Individual
applicator
All Keys 0 All components Global
Global‐by‐
Hose Key 0 All hoses
component
Global‐by‐
Applicator Key 0 All applicators
component
Change History Log Examples
Example 1:
Parameter 4 (ready delay) was changed.
Example 2:
If the LED on the applicator key is on, then this display would
indicate that the global‐by‐component method was used to change the
temperature of the applicators.

Installation 3-25
Unused log entries in the change history log are

indicated by “P‐_” in the right display.
To view how many heater hours have elapsed

since a specific change (displayed) was made,
simultaneously press both of the right‐display
scroll keys.
Setting Up Inputs/Outputs
DuraBlue II adhesive melters are equipped with four standard inputs. Each
input is customer‐wired to the melter and then set up to provide one of the
following control options:
Place the melter into the standby mode

Turn the heaters on and off
Enable or disable a specific hose or applicator
Enable the motor
The input contacts use a constant 10 to 30 VDC signal voltage. The inputs
are not polarity sensitive.
WARNING! The operator can override the melter inputs by using the control
panel function keys. Ensure that the control logic for any external device that
sends an input signal to the melter is programmed to prevent the creation of
an unsafe condition in the event that the operator overrides an external input
to the melter.
The melter is also equipped with three user‐configurable outputs. Outputs

are used to communicate with user‐supplied production equipment or control
hardware, such as a programmable logic controller.
Each output is customer‐wired and then set up in the melter's firmware to

provide one of the following outputs:
The melter is ready

The melter is ready and the motor is enabled
A fault has occurred
The hot melt level is low (only if the optional level switch is installed)
The service LED is on
All outputs contacts are rated at 240 VAC 2 A or 30 VDC 2 A. All contacts are
normally open when the melter is turned off.

3-26 Installation
Wire Inputs/Outputs to the Melter

See Figure 3‐6.
1. Route a 2‐, 4, 6, or 8‐conductor signal cable from the control equipment

to the melter and through the PG‐16 penetration on side of the base. Use
rigid or flexible conduit or a suitable strain relief to protect the cable from
the sharp edge of the conduit penetration.
NOTE: Use a signal cable suitable for NEC class1 remote control and
signaling circuits. To reduce the possibility of electrical shorting, route the
cable so that it does not touch nearby circuit boards.
2. Connect each pair of input and output wires to the appropriate terminals
on terminal block XI. Refer to Table 3‐6 for the terminal numbers that
correspond to each input.
Figure 3‐6 Location of the XI terminal block for connecting input/output wiring

Installation 3-27
Set Up Inputs/Outputs
Set up the parameter control option for each input and output that you
connected to the melter. Table 3‐6 lists the available control options. Refer to
Setting Up the Melter earlier in this section for information about how to
select operating parameters and edit parameter control options.
With the exception of the motor Input Setup in Appendix B

enable/disable control option (Table 3‐6,
Input/Output Data), All inputs are
transition‐based.
The input capacity of the melter may be Section 7, Parts

increased from four inputs to a total of
ten inputs by adding an optional I/O
expansion card that is available from
Nordson Corporation.
The output capacity of the melter may Section 7, Parts

be increased from three outputs to
seven outputs by adding an optional I/O
expansion card that is available from
Nordson Corporation.
Table 3‐6 Input/Output Data

Operating
Item Description Control Options Terminals Notes
Parameter
1 Standard input 1 30 0 - Input Disabled XI:1, XI:2 A, B
1 - Standby On/Off
2 - Heaters On/Off
3 - Motor 1 Enable/Disable C
4 - Hose/Applicator 1
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
D
10 – Automatic standby (Default)
C
11 - Motor 2 Enable/Disable
Continued...

3-28 Installation
Set Up Inputs/Outputs (contd)

Operating
Parameter
2 Standard input 2 31 0 - Input Disabled XI:3, XI:4
1 - Standby On/Off (Default)
2 - Heaters On/Off
3 - Motor 1 Enable/Disable C
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
Enable/Disable
C
3 Standard input 3 32 Same as parameter 31 XI:5, XI:6
(Default=2)
4 Standard input 4 33 Same as parameter 31 XI:7, XI:8
(Default=4)
5 Standard output 1 40 0 - Output Disabled XI:9, XI:10 F
1 - Ready (Default) F
2 - Ready and the Motor is On F
3 - Fault G
4 - Tank Low Level
5 - Service LED is On
6 - Alert H
NOTE A: Parameter 30 has 12 control options. parameters 31, 32, and 33 each have only 11 control options.
B: Parameters 34 through 39 are reserved for the six inputs created when the optional I/O expansion card is installed. The
six optional inputs have the same control options as parameter 31.
C: Parameters are disabled in DuraBlue II adhesive melters. Refer to parameters 9-12 in this table.
D: If control option 10 is selected for input 1, a time must be set in parameter 24.
E: Refer to the instruction sheet provided with the optional I/O expansion card for wiring information.
F: When control option condition occurs, contacts close. Contacts are normally open when power is off.
G: When control option condition occurs, contacts open. Contacts are normally open when power is off.
H: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used, then
both a fault output and an alert output signal will be present when the fault LED turns on.
I: For wiring information, refer to the instruction sheet that is provided with the optional I/O expansion card
Continued...

Installation 3-29
Table 3‐6 Input/Output Data (contd)

Operating
Parameter
6 Standard output 2 41 Same as parameter 40 XI:11, XI:12
(Default=3)
7 Standard output 3 42 Same as parameter 40 XI:13, XI:14
(Default=4)
8 Key‐to‐line — XI:15 (+), Refer to Setting
0-10V input XI:16 (-) Up Gear‐to‐Line
Operation
9 Motor 1 — XI:17, XI:18 Connect a
remote start momentary,
normally open
contact to the
terminals.
remote stop momentary,
normally open
contact to the
terminals.
normally open
contact to the
terminals.
normally open
contact to the
terminals.
Continued...

3-30 Installation
Set Up Inputs/Outputs (contd)
Table 3‐6 Input/Output Data (contd)

Operating
Parameter
(See Note J) normally open
contact to the
terminals.
contact to the
terminals.
contact to the
terminals.
contact to the
terminals.
17 Motor drive 1 — XI:25, XI:26 Refer to Setting
running (optional) Up Motor Run
Status Monitoring.
18 Motor drive 2 — XI:27, XI:28
running (optional)
19 Motor drive 3 — XI:37, XI:38 Refer to Setting
running (optional) Up Motor Run
(See Note J) Status Monitoring.
20 Motor drive 4 — XI:39, XI:40

running (optional)
(See Note J)
J: Motors 3 and 4 are present only on three/four pump or 100L melters.

Installation 3-31
Setting Up Gear‐to‐Line Operation

If you want to use the gear‐to‐line capability, install a (customer‐supplied)
line‐speed signal generator to measure the speed of the production line. The
AltaBlue motor control accepts a 0-10 VDC analog input signal.
NOTE: Nordson offers a 0-10 VDC line‐speed signal generator. Refer to

Optional Accessories in Section7, Parts, for the part number.
To use the gear‐to‐line capability, connect a 0-10 VDC signal from a

customer‐supplied line‐speed signal generator to the appropriate terminals
on terminal block XI inside the electrical enclosure. See Figure 3‐6 for the
location of terminal block XI. Refer to Table 3‐6 for the terminal numbers that
correspond to each input/output.

3-32 Installation
Setting Up Motor Run Status Monitoring

If desired, you can set up the melter to allow remote monitoring of the run
status (running or not running) of the pump motors.
Wiring
To use the motor run status monitoring capability, connect wiring from the
parent machine to the appropriate terminals on terminal block XI inside the
electrical enclosure. See Figure 3‐6 for the location of terminal block XI.
Refer to Table 3‐6 for the terminal numbers that correspond to each
input/output.
NOTE: The relay contact between terminals XI:25/XI:26 and XI:27/XI:28 is

normally open. When the motor is running, these contacts should close.
Keypad Buttons
The motor driver keypad is not shipped with the melter, in order to use the
keypad you will need to order the keypad service kit (P/N 7411739)
separately.
An explanation of the keypad button functions is given in the following table.
Keypad Buttons Description

Menu navigation (UP/Down).
Adjust parameter values.
Analog Input 1 Enter (sub-) menu/parameter.
PAR 430 Confirm parameter.
REM AUTO SET 8
Exit (sub-) menu/parameter.
Stop inverter
Release inverter

Installation 3-33
Programming
This parameter comes pre‐set at the factory.
Analog Input 1 Use the service kit motor drive keypad, PN 7411739 to set up the motor run
PAR 430 SET 8
status monitoring for each motor. Refer to Changing a Motor Drive Parameter
REM AUTO
in Section 6, Troubleshooting, for a detailed procedure for changing a motor
drive parameter.
1. Press (ENT) until the Group Screen is displayed.

DuraBlue‐II service kit motor drive
keypad 2. Press (UP) until Group 4 is displayed.
3. Press (ENT) to access I/O parameters.
4. Press (UP) to select the parameter until “P420.00” is displayed.
5. Press (ENT) to select the sub parameter.
6. Press (UP) to select P420.01.
7. Press (ENT) to set parameter.
8. Press (UP) to change parameter until 51 is displayed.
9. Press (ENT) >3S to save parameters to memory.

3-34 Installation
Installing Optional Equipment

Each item of optional equipment is shipped with instructions for installing and
operating the equipment. Refer to Section 7, Parts, for equipment part
numbers.
Connecting an Applicator Driver, Pattern

Controller, or Timer
If applicable, complete the melter installation by connecting the applicators to
the desired applicator driver, pattern controller, or timer. Refer to the product
manual provided with the device for information about installing and
operating the equipment.
Flushing the Melter

Before using the melter for production, it should be flushed to remove any
residue left over from factory‐testing. Flushing the melter is accomplished by
processing a minimum of one tank volume of hot melt through the melter,
hoses, and applicators.
Refer to Section 4, Operation, for information about filling the tank and
operating the melter.
Disposing of Melter
When your Nordson product has reached the end of its useful life, dispose of
it in accordance with local regulations.

Operation 4-1
Section 4
Operation

documentation.
This section provides information about the following operator‐level tasks:
Filling the melter tank

Starting the melter
(Optional) Adjusting the speed of the motor(s)
(Optional) Adjusting material pressure
Monitoring melter operation
Adjusting the operating temperature of heated components
Using the melter function keys
Shutting the melter down
Most of the controls described in this section are located on the
control panel. Refer to Key Components in Section 2, Introduction, for
the location of the controls and indicators described in this section.
Additional Information
This section presents operating procedures in their most commonly used
form. Procedural variations or special considerations are explained in the
additional information table that follows most procedures. Where applicable,
some table entries also contain cross‐reference information. Additional
information tables are indicated by the symbol shown to the left.

4-2 Operation
Filling the Tank

CAUTION: Before filling the tank, ensure that tank and material are clean
and free of foreign substances. Foreign substances can hinder functioning or
even cause damage to the melter or accessories.
CAUTION: Cease operation before the tank is completely empty. If there is

too little material in the tank, the material can overheat. Overheated material
can char, collect on surfaces and cause malfunctioning.
1. Use a scoop to pour material into the tank, leaving a minimum of

2.54 cm (1 in.) of space between the top of the material and the top of the
tank.
2. Close the lid after filling the tank.
Filling the tank
About Heated Components

The melter contains three groups of heated components. These are the tank
group, which contains tank, the grid, and the reservoir; the hose group; and
the applicator group. Component groups are represented on the control
panel by the component keys shown to the left.
Heated components within each group are identified by their position

number. The position of the tank group is fixed at 1. Hose and applicator
position numbers are automatically assigned based on the hose/applicator
receptacle they are connected to.
Component keys
(tank, hose, and applicator) NOTE: In some installations, auxiliary devices (such as a heated air
manifold) may be connected to a hose/applicator receptacle. In such cases,
you should label (or otherwise identify) the auxiliary device as to the hose or
applicator position number that represents the device. The control panel will
identify such devices as a hose or applicator, regardless of what the device
actually is.

Operation 4-3
Starting the Melter

Before starting the melter for the first time, confirm that the
melter is fully installed including any required inputs and outputs,

applicator drivers, pattern controllers, or timers.
melter's operating parameters are set up to support the
current manufacturing process.
Refer to Section 3, Installation, if any of the items listed above are
not complete.
To start the melter

1. Place the main power switch in the ON position.
2. Place the control switch in the ON position.
The melter:
Tests the control panel LEDs
Turns on the heaters (the heaters LED turns green)
Begins to automatically scan through and display the
actual temperature of the tank and each hose and applicator that has
a set‐point temperature that is greater than zero degrees. The
sequence of the automatic scan is: tank, each hose and
Control switch
applicator pair, and then back to the tank.
Turns on the ready LED (green) when the tank and all of the
hoses and applicators are within 3 C (5 F) of their assigned
Heaters LED
Automatic scan sequence
Ready LED

4-4 Operation
Starting the Melter (contd)
CAUTION! Do not operate Nordson pumps without material. Before enabling

the motor(s), ensure that the tank is filled.
3. Press the master pump enable key to enable the pump(s).

The LED on the key turns yellow to indicate that a pump is enabled, but
not running.
Master pump enable key/LED

4. Melters equipped with the optional motion switch: Place the motion
switch in the ON position.
5. Press the pump mode key(s) to select the manual (LED on) or automatic
(LED off) mode.
Pump mode key and LED
6. Press the pump enable key(s) on the motor control panel(s) to enable the
motor(s). The LEDs turn on when a motor is enabled:
Manual Mode—If the system is at ready status (master pump enable key
LED is green) at the time a pump enable key is pressed, then the
motor(s) will start. If the system is not at ready status (master pump
enable key LED is yellow), wait until the LED is green, and then repress
the pump enable key(s).
Automatic Mode—If the system is at ready status (master pump enable
key LED is green) at the time a pump enable key is pressed, then the
Motor start/stop key and LED motor(s) will start. If the system is not at ready status (master pump
enable key LED is yellow), the motor(s) will start automatically when the
system reaches ready.
NOTE: If any one of standard inputs 1-4 (Parameters 30-33) are being
used and if either control option 3 (Motor 1 Enable/Disable) or control
option 11 (Motor2 Enable/Disable) is selected, the pump enable keys
have no effect. Refer to Setting Up Inputs/Outputs in Section 3,
Installation, for information on connecting and setting up inputs/outputs.

Operation 4-5
If the melter is switched on when the Appendix B, Parameter 4

temperature of the tank is 27 C (50 F) or
greater below its assigned set‐point
temperature (cold start condition), the ready
LED will not turn on until the ready delay
(defined when the melter was set up) has
elapsed.
The time remaining on the ready delay (in Appendix B, Parameter 4

minutes) appears in the right display at the end
of every scan cycle. When only one minute
remains in the ready delay time, the right
display counts down in seconds.
You can by‐pass the ready delay time by

pressing the Heaters key twice.
The appearance of F4 in the right display Monitor Melter Faults

immediately after the melter is switched on
indicates a problem with the melter's
processor or main board.
The appearance of F1 in the right display Section 6, Troubleshooting

immediately after starting the melter indicates
that a hose or applicator cordset may be loose
or disconnected.
The condition of one or more inputs, may Installing Melter Inputs in Section 3,
prevent the heaters from turning on. Installation
If the seven‐day clock feature was set up and Function Keys

turned on when the melter was last switched
off, the clock will automatically turn on the next
time the melter is switched on.
If a power failure occurs, the melter will restart

in its normal heat‐up cycle, even if the heaters
were off or the melter was in standby prior to
the power failure. If the seven‐day clock was
on prior to the power failure, the melter will
restart in the mode dictated by the clock
schedule at the time the melter restarts.

4-6 Operation
Manually Adjusting the Pump Speed

When the motor control is set to manual operation, the pump speed can be
adjusted from 0-94 rpm.
NOTE: When the motor control is set to automatic operation, pressing the
motor speed arrow keys will alter the ratio of the line speed reference signal
to allow for fine‐tuning of the adhesive output rate.
Adjust the Motor Speed for Manual Operation

CAUTION! To ensure adequate motor control and cooling, the
recommended minimum pump speed is 18 rpm or greater. To prevent
excessive wear on the pump, avoid prolonged operation of the pump at
speeds greater than 80 rpm.
1. Use the following formula to determine the best pump speed:
desiredflowrate[gńmin]
pumpspeed[rpm] +
adhesivedensity[gńcc] pumpoutputrate[ccńrev]
2. Press the pump speed arrow keys to adjust the motor(s) to the desired
speed (rpm). Each press of an arrow key increases/decreases the motor
speed by 1 rpm.
The current motor speed is indicated on the display.
NOTE: You can change the amount by which the motor speed increases
or decreases (1%, 1 rpm, 0.5 rpm, etc.) upon each press of an arrow key
by changing the value of the motor control SEt parameter. Refer to
Changing a Motor Control Parameter in Section 6, Troubleshooting.
Pump speed arrow keys

Operation 4-7
Adjusting Material Pressure

The pressure of each material stream can be independently adjusted from
0-103 bar (0-1500 psi).
To adjust the pressure, loosen the set screw, and then turn the pressure
adjustment screw clockwise. When the pressure adjustment is set to its full
counterclockwise position, 100% of the material is re‐circulated.
Pressure control valves

4-8 Operation
Monitoring the Melter

The melter provides indicators that allow you to:
Quickly confirm that the melter is operating correctly

Monitor the actual temperature of the tank group and each hose
and applicator
Monitor the speed of the motor(s)
Identify melter faults
Determine when service is required
The melter automatically determines the number and receptacle of all
hoses and applicators that are connected to it. Refer to Heated Components,
earlier in this section, for information on identification of heated components.
Confirm that the Melter is Operating Correctly

The ready LED turns on (green) when all of the heated components
are within 3 C (5 F) of their set‐point temperature.
The ready LED will not turn on, or will turn off, if any of the following events
occur:
Ready LED The ready delay is still counting down.

The operator or a remote input places the melter in the standby
mode.
The seven‐day clock places the melter in the standby mode.
There is a fault (the fault LED will turn on).
Refer to Monitor Melter Faults and Using Function Keys in this section for
information about melter faults and using the seven‐day clock and standby
functions. Refer to Parameter 4 in Appendix B, Operating Parameters, for
information about the ready delay.
Heated components with a set‐point

temperature of zero degrees are skipped
during the automatic scan cycle.
The set‐point temperature of the tank and

the pump cannot be set independently.
The time remaining on the ready delay Appendix B, Parameter 4

appears in the right display at the end of each
scan cycle.
You can override the seven‐day clock at any Function Keys

time. If the clock has turned the heaters off,
pressing the heaters key will turn the heaters
back on. If the clock has placed the melter into
the standby mode, pressing the standby key
will return the heated components to their
assigned set‐point temperature.

Operation 4-9
Monitor Component Temperatures

The actual temperature of each heated component—the tank and each hose
and applicator—can be checked via normal mode or by manually selecting
and checking each component.
By default, the melter remains in the automatic scan mode except when:
The melter is placed into the setup mode

The set‐point temperature of all hoses and applicators is set to zero
degrees
A fault occurs
To check component temperatures using the automatic scan mode
1. When the ready LED is on, observe the LEDs on the component keys.
2. When the LED on the key that represents the desired component
group (tank, hose, or applicator) turns on, observe the left display until it
indicates the position number of the specific component you want to
check.
3. When the position number of the desired component appears in the
left display, observe the right display to determine the component's
actual temperature.
LEDs on component keys
To manually check a component's temperature

1. Press the key (tank, hose, or applicator) that represents the component
group you want to check.
The automatic scan stops and the left display indicates the number of the
first sequential component in the selected component group. The right
display indicates the component's actual temperature.
Left display and NOTE: When the tank key is pressed, the left display does not indicate a
scroll key component number (blank display).
2. If the first sequential component is not the component you want to check,
use the left‐display scroll key to change to the correct
component number.
The right display indicates the actual temperature of the
selected component.
Component temperature display
3. Press the Setup key twice to return to the automatic scan mode.

4-10 Operation
To manually check a component's temperature (contd)
When you scroll the left display past the

number of the last sequential component in a
component group, the number of the first
sequential component in the next component
group appears in the left display.
The melter will return to the automatic scan

mode two minutes after the last key is pressed.
When you press the Tank key, it is the pump

temperature that is actually indicated in the
right display. To check the actual temperature
of the tank, simultaneously press the Tank key
and the left‐display scroll key.
The default unit for temperature display is Appendix B, Parameter 20

degrees Celsius (C). This may be changed to
degrees Fahrenheit using operating Parameter
20.
The LEDs on each component key will change

from green to yellow if any component in the
component group drops more than 3 C (5 F)
below its assigned set‐point temperature.
You can check the set‐point temperature of a

component at any time, by pressing the
right‐display UP scroll key. Holding down the
scroll key while the melter is in the automatic
scan mode reveals the set‐point of each
component that is scanned.

Operation 4-11
Monitor Melter Faults

The melter alerts the operator to the faults listed in Table 4‐1.
When a fault occurs, you must diagnose and correct the fault condition and
then place the melter back into operation. You can use the fault log to
determine the type, order, and relative time of the last ten faults.
Table 4‐1 Melter Faults

Display
Name Affect on Melter Cause Corrective Action
Code/Sub‐code
The RTD for the
Replace RTD
component indicated
has failed or the
F1/None RTD Heaters turn off Check hose/applicator
component was
connections
disconnected from
the melter.
The actual temperature
of the component Check for conditions
indicated has dropped that may cause a drop
Under
F2/None Heaters turn off below the under in ambient temperature
temperature
temperature delta,
which was set using Replace RTD
parameter22.

of the component
indicated has increased
F3/None Over temperature Heaters turn off beyond the over Replace RTD
temperature delta,
which was set using
parameter21.
Melter stops
F4/1 RAM test Internal RAM failure Replace CPU
functioning
Heaters remain on,

Internal Clock
F4/2 but fault condition Internal clock failure Replace CPU
time
persists
RAM backup Clock does not Insufficient voltage from
F4/3 Replace CPU
battery function RAM backup battery
Internal clock Heaters remain on,

Battery‐backed RAM
F4/4 battery backed but fault condition Replace CPU
failure
RAM persists
Heaters remain on,
Internal clock Battery‐backed RAM
F4/5 but fault condition Replace CPU
battery battery dead
persists
Melter stops RTD analog‐to‐digital Replace main board or
F4/6 Analog‐to‐digital
functioning converter failed CPU
Continued...

4-12 Operation
Table 4‐1 Melter Faults (contd)

Display
Code/Sub‐code
Failed hose or
applicator Replace hose or
applicator. Note: Set
Analog‐to‐digital Melter stops setpoint to zero to avoid
F4/7 RTD analog‐to‐digital F1 fault.
calibration functioning
converter could not be Replace main board or
calibrated (grounded ribbon cable, or CPU
RTD in system)
Communication failure
Main board Melter stops Replace main board,
F4/8 between main board
feedback functioning ribbon cable, or CPU
and CPU
Check the ribbon cable
Expansion board Melter stops connections between
F4/9 between expansion
feedback functioning the expansion board
board and main board
and the main board.
Melter stops Tank or manifold Replace thermostat, J7

F4/A Thermostat
functioning thermostat is open harness, or main board
Communications Heaters remain on, Communication failure

Replace the I/O card or
F4/d with optional I/O but fault condition between CPU and the
CPU
card persists optional I/O card
Alert output (if output
Fieldbus
option 6 is selected) Replace the Fieldbus
F4/E communications Fieldbus card failure.
Melter continues to card
failure
operate normally.
F1, F2 and F3 Faults

When the melter detects an F1, F2, or an F3 fault:
1. The automatic scan stops and the melter begins to monitor the potential
fault for up to two minutes. The ready and heater LEDs remain on during
the two‐minute time period. If, at any time during the two‐minute period,
the melter detects that the fault condition no longer exists, the melter will
return to the automatic scan mode.
2. The LED on the affected component key (tank, hose, or applicator) 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).

Operation 4-13
4. The left display indicates, as follows, the component that has, or is,
failing.
If the LED on the tank key is on, the left display will indicate either 1
for the tank or 2 for the pump.
If the LED on the hose or applicator key is on, the left display will
indicate the number of the affected hose or applicator.
5. If the fault condition still exists at the end of the two‐minute monitoring
period, the ready LED will turn off, the red fault LED will turn on, the
Fault LED (red) heaters turn off, and the melter records the fault in the fault log. Refer to
Monitor Melter Faults in this section.
To be able to put the melter back into operation, the fault must be remedied
and the melter reset (reset key). Refer to Section 6, Troubleshooting, for
information about diagnosing and correcting fault conditions. Also refer to
Returning the Melter to Factory Settings.
To view the temperature of a heated component

when an F2 or F3 fault exists, simultaneously
press and hold both of the right‐display scroll
keys.
You can temporarily dismiss an F1fault (RTD)

and return to the automatic scan mode by
pressing the Clear/Reset key. The heaters will,
however, remain off. If the fault condition still
exists two minutes after pressing the clear/reset
key, the fault LED will turn back on.
When an F1 fault code appears, you can

determine whether the fault was caused by an
open or a shorted RTD by simultaneously
pressing both of the right‐display scroll keys. If
the right display indicates OP, the RTD is open, if
it indicates SH, the RTD has shorted.
If, for any reason, a component reaches 235 C

(458 F), an immediate F3 fault will occur (no
two‐minute monitoring period).

4-14 Operation
F4 Fault
When the melter detects an F4 fault:
1. The ready LED turns off and the red fault LED turns on.
2. All of the component key LEDs (tank, hose, and applicator) turn off.
3. The right display indicates F4.
4. The left display indicates a sub‐code. Sub‐codes classify the fault as
being fatal or nonfatal. The affect on the melter of each of these two
classes of F4 faults is:
Fatal—The fault LED turns on and stays on and the melter stops
functioning completely.
Nonfatal—The fault LED turns on for five seconds, but the heaters and
pump continue to operate normally. Nonfatal faults affect the internal
clock.
5. The melter records the fault in the fault log. Refer to Monitor Melter Faults
in this section.
Resetting the melter

1. Diagnose and correct the fault condition. Refer to Section 6,
Troubleshooting, for information about diagnosing and correcting fault
conditions.
2. Return the melter to the automatic scan mode by pressing the Setup key
twice.
Clear/Reset key 3. Press the Clear/Reset key.
4. Press the Heater key to turn on the heaters.
Heater key
If F4 appears in the right display when you press the clock key, the internal clock function
has failed.

Operation 4-15
Reviewing the Fault Log

1. Press and hold the Setup key.
The automatic scan stops and operating Parameter 1 appears in the
left display.
2. Scroll the left display to Parameter 2 (the fault log).
The right display indicates the last fault that occurred as follows:
Setup Key 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 to occur was an F4 fault, then the LEDs on all of
the component keys turn off.
The right display indicates the log entry for the last fault to
occur. Table 4‐2 provides the meaning of each digit in the log
entry. Following the table are two example fault log entries.
3. Press the right‐display scroll key to review each of the remaining nine log
entries. Each press of the scroll key displays a progressively older log
Left display and scroll key entry.
NOTE: The fault log only stores the last ten faults. After ten faults
occur, the existing log entries are overwritten, beginning with the oldest
entry, by the eleventh and following log entries.
4. Press the Setup key to return to the automatic scan mode.
Scrolling through the fault log
Table 4‐2 Fault Log

First Digit Second and Third Fourth Digit
Digits
Component: Type of fault:
1 = Tank or hose/applicator 1 0 = Unused log entry

2 = Pump or hose/applicator 2 1 = RTD (open or short)
3 = Hose 3 or applicator 3
‐F 2 = Component under temperature
3 = Component over temperature
5 = Hose 5 or applicator 5 4 = Processor or electrical failure

4-16 Operation
Fault Log examples

Example 1:
An unused log entry.
Example 2:
If the LED on the tank key were on, this log entry
would indicate that the tank is under temperature. If the LED on the hose key
were on, this log entry would indicate that hose 1 is under temperature.
To view the number of heater hours that have

elapsed since a log entry was created,
simultaneously press both of the right‐display
scroll keys. The hours are indicated in the right
display.
The melter will return to the automatic scan mode

if the fault log is left open for a period of two
minutes without any key being pressed.
When an F1 fault is the result of a

hose/applicator pair being disconnected from the
melter, two fault log entries are created. The first
entry is for the applicator and the second entry is
for the hose.

Operation 4-17
Monitor the Service Interval

The melter can be set up so that the service LED located on the left side
of the control panel turns on after a customer‐defined time period has
elapsed. The service LED may be used to signal the need to change the
hot melt filter or to complete any other customer‐specified maintenance
activity. Once the specified maintenance is performed, the service LED must
be reset.
To reset the service LED

With the melter in the scan mode, press the Clear/Reset key to turn off the
service LED and reset the service interval time.
Clear/Reset key
The default setting for the service interval time is 500 hours, refer to Parameter 5 in
Appendix B.

4-18 Operation
Adjusting Component Temperatures

You can adjust the set‐point temperature of heated components using the
following methods:
Global—The tank and all hoses and applicators are set to the same
Global‐by‐component group—All of the hoses or all of the
applicators are set to the same set‐point temperature.
Individual Component—The set‐point temperature of the tank
and each hose and applicator is adjusted independently.
Before adjusting set‐point temperatures, confirm that each hose/applicator

pair is connected to the correct hose/applicator receptacle. For example,
hose/applicator pair 1 should be connected to the receptacle 1. Refer to
Heated Components earlier in this section for information about
hose/applicator positions.
NOTE: For additional temperature control features, refer to

Parameters20-29 in Appendix B, Operating Parameters.
To adjust the setpoint temperature using the global method

1. Press and hold the Tank key for three seconds.
Tank key The left display flashes 1.
2. Scroll the left display to 0 (flashing).
The right display indicates all dashes (‐‐‐‐) and the LEDs on all of
the component keys turn green.

Left display and
scroll key 4. Use the keypad to enter the set‐point temperature recommended by
the manufacturer of the hot melt.
NOTE: If the keypad or the right‐display scroll keys have no affect on the
right display, the melter is password protected. You must enter a valid
password before you can change set‐point temperatures. Refer to
Entering a Password in this section.
Enter key
5. Press the Tank key.
All components begin to heat or cool to the new global

set‐point temperature. When all of the components reach their
set‐point temperature, the ready LED turns on (green).
Ready LED

Operation 4-19
To adjust the setpoint temperature using the global‐by‐component

method
1. Press and hold the Hose or Applicator key for three seconds.
The left display indicates the number of the first sequential hose or
applicator. The right display indicates the current set‐point temperature of
the hose or the applicator.
2. Scroll the left display to 0.
The right display indicates all dashes (‐ ‐ ‐ ‐).

Tank, hose, and applicator keys

4. Use the keypad to enter the set‐point temperature recommended by
the manufacturer of the hot melt.
The hoses or the applicators begin to heat or cool to their new


4-20 Operation
To adjust the setpoint temperature of an individual component

1. Press and hold the Tank, Hose, or Applicator key for three seconds.
If the tank key was pressed, the left display indicates 1 (Flashing). If a
hose or applicator key was pressed, the left display indicates the number
of the first sequential hose or applicator (Flashing). The right display
indicates the current set‐point temperature of the component indicated in
the left display.
2. Scroll the left display to the number of the desired component.
The right display indicates the current set‐point temperature of the

component that you selected in the left display.

4. Use the keypad to enter the set‐point temperature recommended by
the manufacturer of the hot melt. Refer to the technical data
sheet provided by the manufacturer of the hot melt to determine the
optimal set‐point temperature.

To register the new set‐point temperature and then move on to
change the set‐point temperature of the next sequential component,
press the Enter key and then repeat steps 4 and 5.
To register the new set‐point temperature and return to the automatic

scan mode, go to step 6.
6. Press any component key (tank, hose, or applicator).
The selected component begins to heat or cool to its new


Operation 4-21
If you enter a valid set‐point temperature for a

hose/applicator that is not connected to the melter or if
you enter a set‐point temperature that is out of range,
the right display will indicate dashes (‐‐‐‐) for three
seconds and then change back to the original
When the right display is flashing, you can quickly

change the current set‐point temperature to 0 degrees
(off) by simultaneously pressing both of right‐display
scroll keys.
After removing a hose or a applicator, use

the individual component method of set‐point
temperature adjustment to set the component's
temperature to zero degrees (off). This will
avoid causing an F1 fault. When a hose or applicator
is added, use the individual component method to set
the desired temperature.
The factory set‐point temperature of the tank is 175 C

(350 F). The factory set‐point temperature of all others
components is zero degrees (off).
When the units of temperature is set to degrees

Celsius, the minimum and maximum set‐point
temperatures are 40 C and 230 C. When the units of
temperature are set to degrees Fahrenheit, the
minimum and maximum set‐point temperatures are 100
F and 450 F.
When using the right‐display scroll keys to adjust a

set‐point temperature, the right display automatically
increments between 0, 175, and 230 C or between 0,
350, and 450 F.
If you make a mistake while you are changing a

set‐point temperature, but you have not yet pressed the
enter key, press the Clear/Reset key to reset the right
display to the original temperature.
The melter will exit the setup mode and return to the
automatic scan mode two minutes after the last key is
pressed.
A global set‐point temperature of zero degrees (Celsius

or Fahrenheit) turns all components off.
When scrolling through component numbers in the left

display, component numbers that are associated
with unused hose/applicator receptacles are skipped.
The melter stores a record of the last ten changes Section 3, Installation, Review
made to the set‐point temperatures (and operating Parameter and Set‐point
parameters) in the change history log. Temperature Changes
You can save set‐point temperature changes by Section 3, Installation, Save and
simultaneously pressing the 1 key and the Setup key. Restore Melter Setting

4-22 Operation
Entering a Password
If the melter is password protected, a valid password must be entered before
any set‐point temperature or melter parameter can be changed.
To enter a melter password

1. Press the Setup key.
The left display indicates Parameter 0 (flashing) and the right
display indicates 4000.
The right display begins flashing.
3. Use the keypad to enter the melter password.
One of the following occurs:
If the password is correct, the left display indicates Parameter 1.
If the password is incorrect, the left display remains at 0 and the
right display momentarily indicates dashes (‐‐‐‐) and then returns to
4000.
If the password is incorrect, re‐enter it and then press the Enter key.
The melter will automatically revert back to the

password‐protected mode two minutes after
the last key press (any key). To force the
melter back into the password protected mode
before two minutes has elapsed, press the
Setup key twice.
The melter password is created and Setting Up the Melter in Section 3,

enabled/disabled during system setup. Installation

Operation 4-23
Using Function Keys

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

Heater
Pump (1 and 2)
Setup
Special function keys
Seven‐day clock
Standby
CAUTION! Unintentionally activating function keys can, under the

correct circumstances, have undesirable effects on the melter or the
manufacturing process. Only personnel who are familiar with the melter's
setup and its connection with the manufacturing process should use the
function keys. Improper use of the function keys can result in erratic process
behavior or personal injury.
Heater Key
Use the heater key to manually turn the component heaters on and
off. Pressing the heater key overrides the control (on or off) of the heaters
by either the seven‐day clock feature or a remote input. The LED on the
heater key illuminates when the heaters are on.
Heater key
When a fault occurs (refer to Monitor Melter Faults in this section) the heaters
automatically turn off. The heater key is used to turn the heaters back on after
correcting a fault condition.
Master Pump Enable Key

Use the master pump enable key to enable and stop the pumps. The LED is
green when the pumps are enabled and the melter is ready.
If the automatic pump on feature (Parameter 8) is disabled, then the master

pump enable key must be used to start the pumps when the melter is ready.
Master pump enable key/LED
If any of the inputs are set up to use the pump enable/disable control option,
the pump motor will not start until the pump is enabled and the correct
voltage is applied to the input contacts. If the pump is enabled, but the input
voltage is not present, the master pump enable key LED will flash green.

4-24 Operation
Setup Key
Use the setup key to place the melter into and take the melter out of
the setup mode. When the melter is placed into the setup mode, the
automatic scan stops and the left and right displays are used to select and
read or edit operating parameters.
Setup key
Seven‐Day Clock Key

Use the seven‐day clock key to turn the melter's clock feature on and off.
When the clock is on, the temperature of each heated component is
automatically regulated based on a set of user‐defined schedules.
To accommodate daily shift work and non‐working days, four

clock schedules are available. Schedules 1, 2, and 3 are used to specify
Seven‐day clock key when the heaters should turn on and off or when the melter should enter and
exit the standby mode. Schedule 0 is used to keep the melter in the last
condition dictated by the clock (heaters on or off, or standby).
When a clock schedule calls for the heaters to be on, the heaters
are regulated at their pre‐assigned set‐point temperatures. When the
clock activates the standby mode, the set‐point temperature of each
component is temporarily reduced by a pre‐set standby delta.
Refer to Appendix B, Operating Parameters, for information about setting up

the seven‐day clock and the standby delta.
If the melter is switched off while the clock is on,

the clock will automatically turn back on the next
time the melter is switched back on.
If the heaters are manually turned off at the time

that a clock schedule calls for the heaters to be on,
the heaters will not turn back on until the next clock
schedule calls for them to be on.
The clock will still operate when the melter

is faulting or is in the setup mode.
If F4 appears in the right display when you press Section 7, Troubleshooting

the clock key, the internal clock function has failed.

Operation 4-25
Standby Key
Use the standby key to manually place the melter into, and take it out of, the
standby mode. Using the standby mode during periods of time when the
melter is inactive helps conserve energy and allows heated components to
quickly return to their set‐point temperatures when the melter is once again
needed.
Standby key
When the melter is placed into the standby mode, the temperatures of all
components are reduced down from their set‐point temperature by a pre‐set
standby delta. The melter will remain in the standby mode until the standby
key is pressed or the function of one of the operating parameters takes the
melter out of the standby mode.
If the melter was set up to use the manual standby timer (Parameter 26),
pressing the standby key will place the melter in the standby mode for the
period of time specified by the timer. After the manual standby time has
elapsed, the melter will once again begin heating all of the components to
their assigned set‐point temperature.
Using the standby key overrides the control of the melter (on or off) by the
seven‐day clock or a remote input.
Refer to Section 3, Installation, Setting Up the Melter, and to Appendix B,

Operating Parameters, for information about setting the standby delta and
the standby timer.
The melter may also be set up to automatically Appendix B, Parameters 25, 26, 57,
enter the standby mode using a variety of 30–33, 62, and 67
operating parameters.
Whenever manual standby is enabled, the standby Appendix B, Parameter 26

LED blinks.

4-26 Operation
Shutting Down the Melter

Shut the melter down when it will not be used for an extended period of time.
To shut the melter down

1. Press the pump enable key(s) to disable the motor(s).
2. Place the control switch in the OFF position.
3. Place the main power switch in the OFF position.
4. Disable the applicators as follows:
Air‐operated applicators: turn off the air supply to the applicators.
Electric applicators: turn off the applicator driver, pattern controller, or
timer.

Operation 4-27
Record of Melter Settings

Production information:
Material: Manufacturer
Processing Temperature
Viscosity
Cleaning agent: Manufacturer

Flash point
Processing temperatures (Setpoint temperatures):

Tank/Grid/Reservoir
Hose 1) 2) 3) 4) 5) 6)
Applicator 1) 2) 3) 4) 5) 6)
Pump speeds:
Pump 1) 2)
Notes:
Name Date

4-28 Operation

Service 5-1
Section 5
Service

documentation.
Maintenance is an important preventive measure for maintaining operating

safety and extending the lifetime of the unit. It should not be neglected under
any circumstances.
Relieving System Pressure

WARNING! System and material pressurized. Relieve system of pressure
before disconnecting hoses, applicators and hot melt hand‐held applicator.
Failure to observe can result in serious burns.
Through the Applicators

1. Disable the motor(s). Refer to Section 4, Operation.
2. Place a container under the nozzle(s) of the applicator/assembly
hand‐held applicator.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly hand‐held applicator. Repeat this procedure until no
more material flows out.
4. Re‐use the material or properly dispose of it according to local
regulations.

5-2 Service
Through the Melter Drain Valves

1. Disable the motor(s). Refer to Section 4, Operation.
2. Place a container under the drain valve ports located on the bottom of the
manifold.
3. Open all the drain valves. Adhesive will drain from the valves.
4. When adhesive stops draining, close the drain valves.
5. Re‐use the material or properly dispose it of according to local
regulations.
Figure 5‐1 Location of the melter drain valves

Service 5-3
Preventive Maintenance Schedule

The maintenance intervals are general guidelines based on experience.
Depending on the operating environment, production conditions and melter
hours of operation, other scheduled maintenance tasks may prove
necessary.
Melter part Activity Interval Refer To

Complete melter External cleaning Daily External Cleaning
Inspect for external Daily
damage
Purge with cleaning agent When material is changed Changing the
Material Type
Fan and air filter Check filter, clean or Depending on dust accumulation; Fan and Air Filter
replace if necessary daily if necessary
Clean fan screen
Power cable Inspect for damage Every time the melter is serviced
Air hoses Inspect for damage Every time the melter is serviced
Pump Tighten the gland bolt (if After initial startup Pump
present)
Check for leakage, tighten Dependent on hours of operation,
gland bolt (if present) if pump speed and pump temperature
necessary Recommendation: Monthly
Tighten fixing screws Every 500 hours of operation
Motor / gear box / coupling Clean fan cover Depending on dust accumulation; Motor and Gear
daily if necessary Box
Change lubricant Every 15000 hours of operation or
every 2 to 3 years
Pressure control valve Disassemble and clean Every six months Pressure Control
Valve
Filter cartridge Replace filter cartridge Depending on degree of material Filter Cartridge
Disassemble and clean pollution
filter cartridge Recommendation: Every 1000
hours of operation
Tank Clean tank by hand When there is material residue in Cleaning the Tank
tank
Tighten fixing screws Every 500 hours of operation

5-4 Service
Changing the Material Type

1. Run the melter until empty.
2. Determine whether the new material may be mixed with the old material.
May be mixed: Remaining old material can be flushed out using the
new material.
May not be mixed: Thoroughly purge the unit with a cleaning agent
recommended by the material supplier.
NOTE: Properly dispose of the old material according to local regulations.
Detaching the Exterior Panels

Open the protective panels with a 4 mm Allen key.
On the inside
Fan and Air Filter

The air filters must be cleaned (knocked out) or replaced, depending on dust
accumulation.
Refer to Section 7, Parts, for the filter part number.

Service 5-5
Motor and Gear Box

Changing the Motor Lubricant
Remove the gear motor assembly from the melter.
Use only the stated lubricant or one that has proven to be equivalent
(refer to Lubricant Selection). Using any other lubricant can result in
premature wear and/or damage to the gear box.
Drain lubricant when warm.
Properly dispose of the old lubricant according to local regulations.
CAUTION! Never mix different types of lubricants.
Lubricant Changing Interval

Operating temperature < 100 C / 212 F:
Every 15000 hours of operation or at least every 4 years.
Lubricant Capacity
Ensure that the upper gears and rolling bearings are properly lubricated.
Lubricant Selection
Lubricant manufacturer Mineral oil CLP 220

AGIP Blasia 220
ARAL Degol BMB 220 or Degol BG 220
BP Energol GR‐XP 220
DEA Falcon CLP 220
ESSO Spartan EP 220 or GP 90
KLÜBER Klüberoil GEM 1‐220
OPTIMOL Optigear 220
SHELL Omala Oil 220
TEXACO Geartex EP‐A SAE 85 W‐90

5-6 Service
Replacing a Motor or Coupling

Follow this procedure to replace a motor or coupling. You will need the
following items:
appropriate tools
replacement motor or coupling
anti‐seize lubricant (if needed)
1. Disconnect and lock out electrical power to the melter.
2. Remove the hydraulic side covers and the left and right control cabinet
side covers. Refer to Detaching the Exterior Panels earlier in this section
as needed.
3. Disconnect the motor cable wires, noting their terminal positions.
4. See Figure 5‐2. Loosen the screws that secure the motor to the base of
the melter and then slide the motor back.
5. Slide the coupling sleeve (2) off of the coupling hubs (1 and 3), loosen
the hub set screws, and remove the hubs.

Service 5-7
1 2 3
Figure 5‐2 Coupling assembly components

1 Motor coupling hub 3 Pump coupling hub
2 Coupling sleeve
6. Remove the protective coating from the new motor shaft, slide the
replacement (if applicable) motor coupling hub onto the motor shaft, and
tighten the hub set screws.
7. Install the replacement (if applicable) pump coupling hub on the pump
shaft, ensure that it is flush with the pump shaft, and tighten the hub set
screws.
8. Loosely install the replacement motor assembly and slide the assembly,
including the motor coupling hub and sleeve, toward the pump until the
coupling sleeve engages with pump coupling hub.
9. Ensure that the coupling sleeve cannot move, then slide the motor
assembly back 4 mm (0.16 in.), as indicated in Figure 5‐3.

5-8 Service
Replacing a Motor or Coupling (contd)
4 mm (0.16 in.)
Figure 5‐3 Moving the motor assembly back 4 mm (0.16 in.)

10. Tighten the screws that secure the motor to the base of the melter
11. To ensure proper motor and pump shaft alignment, ensure that you can
freely slide the coupling sleeve back and forth by about 4 mm (0.16 in.)
each way.
12. Reconnect the motor cable wires to the same terminals from which they
were disconnected.
13. Reinstall the melter covers and restore the system to normal operation.
Pump
Tightening the Pump Screws
1. Ensure that the melter is turned off and that power has been
disconnected and locked out.
2. Ensure that the melter, tank, manifold, and pump are cold.
3. See Figure 5‐4. Tighten the screws to 25 Nm (222 in.‐lb).
Figure 5‐4 Tightening the pump screws

4. Restore the system to normal operation.

Service 5-9
Replacing a Pump
Follow this procedure to replace a pump. You will need the following items:
tool kit, including a torque wrench
drain pan
cleaning supplies
replacement pump
replacement pump O‐rings
O‐ring lubricant
anti‐seize lubricant
NOTE: To rebuild a pump, contact your Nordson representative for
assistance.
1. Ensure the melter is at operating temperature.
2. Relieve system pressure. Refer to Section 1, Safety.
3. See Figure 5‐5. Close the tank isolation valve.
Figure 5‐5 Location of the tank isolation valve

5-10 Service
Replacing a Pump (contd)

4. Remove the hydraulic side covers. Refer to Detaching the Exterior
Panels earlier in this section as needed.
5. Place a drain pan under the pump.
6. See Figure 5‐6. Loosen the screws that secure the motor to the base of
the melter and then slide the motor back.
7. Slide the coupling sleeve (2) off of the coupling hubs (1 and 3), loosen
the pump coupling hub set screws, and remove the pump coupling hub.
1 2 3
Figure 5‐6 Coupling assembly components

1 Motor coupling hub 3 Pump coupling hub
2 Coupling sleeve

Service 5-11
8. See Figure 5‐7. Remove the pump screws (3) and then remove the pump
(2) and O‐rings (1).
1 2
Figure 5‐7 Replacing a pump

1 O‐rings 2 Pump 3 Pump screw
9. Clean the surface of the manifold where the pump mates to it.
10. Allow the melter to cool to room temperature.
11. Install the pump coupling hub on the pump shaft, ensure that it is flush
with the pump shaft, and tighten the hub set screws.
12. Apply O‐ring lubricant to new pump O‐rings and install them on the pump.
13. Apply anti‐seize lubricant to the pump screws and secure the new pump
to the manifold with the screws. Use a torque wrench to tighten the
screws in a criss‐cross manner to 25Nm(222 in.‐lb).

5-12 Service
Replacing a Pump (contd)

14. Slide motor assembly, including the motor coupling hub and sleeve,
toward the pump until the coupling sleeve engages with pump coupling
hub.
15. Ensure that the coupling sleeve cannot move, then slide the motor
assembly back 4 mm (0.16 in.), as indicated in Figure 5‐8.
4 mm (0.16 in.)
Figure 5‐8 Moving the motor assembly back 4 mm (0.16 in.)

16. Tighten the screws that secure the motor to the base of the melter.
17. To ensure proper motor and pump shaft alignment, verify that you can
freely slide the coupling sleeve back and forth by about 4 mm (0.16 in.)
each way.
18. Restore the system to normal operation.

Service 5-13
Replacing the Adhesive Filter

DuraBlue II melters are equipped with a 100-mesh (0.15-mm) disposable
hot melt adhesive filter. The adhesive filter removes debris and char from
the hot melt as it flows from the tank. Hot melt flows from the inside to the
outside of the filter, trapping contaminants inside the filter. There is no need
to back-flush or clean the filter.
When the filter reaches the end of its service life, it should be replaced. The
factors that determine the service life of the filter are:
the type, grade, and purity of the solid-form hot melt

the set point temperature of the tank
the period of time that the hot melt remains in the tank
The filter should also be replaced when making the change to a different type
or grade of hot melt.
To determine the optimal service life for the filter, monitor and compare the
total number of hours that the heaters are on with observations of:
the purity of the dispensed hot melt

increases in operating pressure
the frequency of applicator nozzle replacement or cleaning
As an aid to ensuring that the filter is replaced at the end of its service life, the
melter is equipped with a service LED that turns on at the end of a
Hot melt flow path customer-defined time period. Refer to Setting Up the Melter in Section 3,
Installation, for information about the service interval time.

5-14 Service
Replace the Adhesive Filter

1. Relieve the system pressure. Refer to Relieving System Pressure at the
beginning of this section.
2. Use an 8 mm (5/16-inch) hex-head wrench or an adjustable wrench to
loosen (counterclockwise) and then remove the adhesive filter.
3. Properly dispose of the old filter.
4. Confirm that the O-ring on the new adhesive filter is in good condition
(100-mesh filter is P/N 1028305).
NOTE: 50- and 150-mesh filters are also available (P/Ns 1021941 and
1034720).
5. Screw the filter into the pump body and then tighten the filter to 4.5 Nm
(40 in.-lb).
6. Resume normal operation.
Service Kit, for P/N refer to Section 7, Parts.
Figure 5‐9 Turning the adhesive filter counterclockwise to remove

Service 5-15
Pressure Control Valve

Replace the Pressure Control Valve
Figure 5‐10 Pressure control valve set screw insertion depth
NOTE: Screw in only when valve and pump are warm and material is soft.
1. Ensure the melter is at operating temperature.
2. Relieve system pressure. Refer to Section 1, Safety.
3. Measure and make a note of the insertion depth of the set screw
(dimension X). This way the insertion depth can be replicated after
reassembly.
4. To prevent adhesive from leaking into the valve bore, drain the tank.
Refer to Draining Material from the Tank later in this section as needed.
5. Remove the old pressure control valve.
6. Apply high temperature grease to all threads and O-rings.
7. Slide the valve into the hole and tighten with torque wrench
(15 N•m / 133 in.-lb).
8. Adjust the setting screw to the recorded dimension X.
Turning to the right increases material pressure.
*+
Turning to the left decreases material pressure.
Adjusting the set screw

5-16 Service
Pressure/Circulation Control Valve Service Kit

Each kit contains two O‐rings and high‐temperature grease.
Service kit P/N: 394600

Required tools:
Open‐jawed wrench, size 24
Pliers
Torque wrench
1. Heat melter to operating temperature.
WARNING: Hot! Risk of burns. Wear appropriate protective
clothing/equipment.
2. Relieve melter pressure.

3. Measure insertion depth. Refer to Pressure Control Valve.
4. Use an open‐jawed wrench to screw out the pressure control valve, then extract with a
pliers.
5. Remove old O‐rings and disassemble and clean pressure control valve. Refer to Section
7, Parts, for a detailed drawing.
NOTE: Disassemble valve only when warm.
6. Install new O‐rings. Apply grease to all threads and O‐rings.
7. Guide pressure control valve into the hole when the melter is warm and tighten with
torque wrench.
Starting torque: 15 Nm (133 in.‐lb)
8. Adjust set screw. Refer to Pressure Control Valve.

Service 5-17
Cleaning the Tank

Draining Material from the Tank
Pump material out of the melter.
CAUTION! Do not feed charred material though the applicator. Particles can
block the applicator. Instead unscrew hose (refer to Section 3, Installation).
Cleaning the Tank by Hand

Cold material can usually be peeled off of the sides of the tank. If necessary,
first heat tank to material softening temperature, usually approximately
70 ° C / 158 ° F.
NOTE: The inside of the tank is release coated. Do not use metallic tools to
clean. Do not use wire brushes! This could damage the release coating.
Tightening the Fixing Screws

Heating and cooling that occurs during daily operation can cause the fixing
screws to loosen. Tighten screws as indicated in the table below.
NOTE: Tighten fixing screws only using a torque wrench and when the
melter is cold.
Connection Thread Torque

Tank/manifold M6 6-8 Nm / 53-71 in.‐lb

5-18 Service
Main PCA Board

Replace the Main PCA Board
1. Disconnect power to the melter at the local disconnect switch.
2. Switch the melter off.
3. See Figure 5‐11. Open the electrical enclosure access panel and locate
the main PCA board.
Figure 5‐11 Location of the main PCA board

4. Disconnect all of the power and control cables from the board.
5. Remove the four fastening screws that hold the board on the mounting
studs and then remove the board.
NOTE: Before installing the new board, you must ensure that the board
is properly configured for the type of temperature sensors present on the
melter. If the melter uses 100‐ohm platinum sensors, the jumpers
connected to the JP1 terminal on the old board must be removed and
then installed on the new board. Figure 5‐12 shows the location of
terminal JP1 on the main PCA board. Figures 5‐13 and 5‐14 show the
jumpers installed and not installed, as appropriate for each type of melter.

Service 5-19
+ C35
RV13
RV12
RV10
RV11
C10
RV9
RV7
C8
C3
C4
C9
C5
C36
C23
C24
C25
C26
C27
C28
C29
R95
C56
C30
R71
C44 R85
R93 R5 R19 R17 R81 RV6 R20
C55
R80
C43 C1 R18
C50
R82
C54
R79
U16 R26 R22 J1
R86
R90
Q22
D17 R84 C60 C53 XP5
1
RN4 RN6 C31 Q20 C2233 51
C21 C20
L1 R63 R15 JP1
R88
R121
C74
R101 6 2
HSNK1 RN3 Q19
D16 C58
RN2
RN9
U2
C75
+ U3
D3 C7 R99
RN10
RN7
C45 C46 Q18
C37
C18
RN5
RN1
C42 C47 U7 R119
U4 Q17
C6
C41 U14
C19 R77
R120
RN11
T1
R96
R72
L4
DS4
L3
+ XP6 U1
JP2
R87
U17 C17
RV8
R134 R135 U5
C12 +
C16 C15
C63
R124
C52 R89
++ D8 DS15 +
F4 R92 C66 D4
D18 R133 Q26
2A R91 DS17 R127 D6
C48 C49 C57 R129 C2
D7
R33
K1 D1 R4 RV5
F3 L2 R128
R122 R3 C11
+
2A D2 R1 R2 RV4
XT1 DS16
R38 C76
D12 D10 D11 J2 1 D14
XP4
Q13 R130 C51
+
U22 C77 1
C40
C65
R75 U12 U23

R45 R44 RV3
R131 R132
+
C59 U25
XP1
C64 XP2 R46 R43 C78

R100
C84
C83
R68
R67
R66
U21
C61 R76
C32
R123
U26
R102 X6 R136 U9 R73
R69
D5 R74
+
C82
C80
R83 RV1
R37 C62
F1 X7
F2 XP3
10A
10A
F11 F7 C39 1
F6 F5 Q24
6.3A 6.3A U24 R40 R41 RV2
5A 5A F9 DS14 R42 R39 C67
R114
R115
F12 F8 F10 6.3A
6.3A 6.3A 6.3A R116
U15 Q14
DS10
R6
R8
R9
R59
R60
DS3 DS2
R7
R16
R12
R13
R10
R57
R11
R14 DS7 DS5 DS6

U18 Q16
12 12 DS11
R78
3 3 R53
R94
X4 X5 U13 Q7
X1 DS9
R54
R53
X2
X3 R51
1 1 U10 Q5
DS8
1
R48
R47
1
R35
U19 Q12
DS12
R113
R56
R62
R34
R97
R98
R50
R105
R112
R108
R117
R58
R65
R52
R36
R106
R110
C79 C70 C71 C69 C68C73 C72

R109
Q9
R118
R55
R49
R111
R70
R61
U20
DS13
R107
R103
R104
Q25 Q15 Q23 Q8 Q6 Q10 Q11
Figure 5‐12 Location of the JP1 terminal on the main PCA board

5-20 Service
Replace the Main PCA Board (contd)

6. If 100‐ohm platinum sensors are present on the melter:
a. Locate the JP1 terminal on the replacement board.
NOTE: For 120‐ohm nickel melters, temperature sensor jumpers are
not required in this location, as shown in Figure 5‐14.
b. Install one of the jumpers removed from the old board between
terminals 1 and 2.
c. Install the second jumper between terminals 5 and 6. Figure 5‐13
shows the jumpers installed.
Figure 5‐13 100‐ohm platinum melter—jumpers installed
Figure 5‐14 120‐ohm nickel melter—no jumpers installed

7. Install the replacement board inside the melter electrical enclosure using
the fastening screws removed previously.
8. Reconnect all of the power and control cables to the replacement board
and close the electrical access panel.
9. Restore power to the melter and switch the melter on. Verify that the
melter starts normally.

Service 5-21
Maintenance Record Form

Melter part Date / Name Date / Name Date / Name
Pump
Motor / gear box
Fixing screws on pump and

tank
Air filter
Tank
Pressure control valve
Filter cartridge

5-22 Service

Troubleshooting 6-1
Section 6
Troubleshooting

documentation.
WARNING! Troubleshooting activities may sometimes have to be carried out

when the melter is energized. Observe all safety instructions and regulations
concerning energized unit components (active parts). Failure to observe may
result in an electric shock.
Safety
Never disconnect cables from, or reconnect cables to, the main board
while the melter is energized.
Before breaking any hydraulic connection, always relieve system
pressure. Refer to Relieving System Pressure in Section 5, Service.
Refer to the safety information provided with optional equipment.
If the melter is removed from its sub‐base for diagnostic checks or
service, ensure that the ground lead between the chassis and the
sub‐base is re‐attached when the melter is reconnected to the sub‐base.

6-2 Troubleshooting
Troubleshooting Quick‐Checks
Before using the troubleshooting charts confirm:
whether or not service was recently performed on the melter or the

melter's settings were recently adjusted.
external inputs (if used) are functioning properly.
the standby or clock functions are not turned on (if not required or
expected at the current time).
Returning the Melter Setup to Factory Settings

By returning the melter to its factory setting many common melter problems
can be isolated to either a problem with the melter settings or the melter
hardware.
To return the melter to its factory settings, simultaneously press and hold the
Setup key and the right‐display DOWN arrow key, and then, while holding
down these keys, cycle the control switch off and on. When the melter
restarts, release the two keys.

Troubleshooting 6-3
Melter Faults
Table 6‐1 lists the four types of melter faults, potential causes, and expected
corrective actions.
Table 6‐1 Melter Faults

Display
Code/Sub‐code
The RTD for the
Replace RTD
component indicated
has failed or the
F1/None RTD Heaters turn off Check hose/gun
component was
connections
disconnected from
the melter.
of the component Check for conditions
indicated has dropped that may cause a drop
Under
F2/None Heaters turn off below the under in ambient temperature
temperature
temperature delta,
which was set using Replace RTD
parameter22.

of the component
indicated has increased
F3/None Over temperature Heaters turn off beyond the over Replace RTD
temperature delta,
which was set using
parameter21.
Melter stops
F4/1 RAM test Internal RAM failure Replace CPU
functioning
Heaters remain on,

Internal Clock
F4/2 but fault condition Internal clock failure Replace CPU
time
persists
RAM backup Clock does not Insufficient voltage from
F4/3 Replace CPU
battery function RAM backup battery
Internal clock Heaters remain on,

Battery‐backed RAM
F4/4 battery backed but fault condition Replace CPU
failure
RAM persists
Heaters remain on,
Internal clock Battery‐backed RAM
F4/5 but fault condition Replace CPU
battery battery dead
persists
Melter stops RTD analog‐to‐digital Replace main board or
F4/6 Analog‐to‐digital
functioning converter failed CPU
Continued...

6-4 Troubleshooting
Melter Faults (contd)
Table 6‐1 Melter Faults (contd)

Display
Code/Sub‐code
Failed hose or gun
Replace hose or gun.
Note: Set setpoint to
Analog‐to‐digital Melter stops RTD analog‐to‐digital zero to avoid F1 fault.
F4/7
calibration functioning converter could not be Replace main board or
calibrated (grounded ribbon cable, or CPU
RTD in system)
Main board Melter stops Replace main board,
F4/8 between main board
feedback functioning ribbon cable, or CPU
and CPU
Check the ribbon cable
Expansion board Melter stops connections between
F4/9 between expansion
feedback functioning the expansion board
board and main board
and the main board.
Melter stops Tank or manifold Replace thermostat, J7

F4/A Thermostat
functioning thermostat is open harness, or main board
Communications Heaters remain on, Communication failure

Replace the I/O card or
F4/d with optional I/O but fault condition between CPU and the
CPU
card persists optional I/O card
Alert output (if output
Fieldbus
option 6 is selected) Replace the Fieldbus
F4/E communications Fieldbus card failure.
Melter continues to card
failure
operate normally.

Troubleshooting 6-5
Motor Control Faults

Table 6‐2 lists the motor control fault codes that may appear on the pump
speed display(s).
Pump speed display
Table 6‐2 Motor Control Faults

Motor Control Fault Possible Cause Corrective Action
no EnA (motor control fault code Master pump enable key not Press the Master pump enable
shown on pump speed display) turned on key until the LED is illuminated.
hOt (motor control fault code Motor thermostat open Wait for the motor to cool, ensure
shown on pump speed display) that the pump speed setting is
not too low, and then restart the
pump. If the hOt code continues
to appear, troubleshoot the
problem that is causing the motor
to overheat, such as binding or
blockage in the pump, a locked
pump rotor, etc.
Displayed rpms do not match Pump speed display not Calibrate the pump speed
motor speed calibrated display. Refer to Calibrating the
Pump Speed Display.
Motor control not operating as Improper motor control Check motor control parameter
expected parameter settings settings. Refer to Changing a
Motor Control Parameter in this
section.

6-6 Troubleshooting
Changing a Motor Control Parameter

The motor control parameters are factory set and do not need to be changed.
Use this procedure only if a motor control parameter is inadvertently changed
and needs to be changed back to the factory setting shown in Table 6‐3. The
motor control parameters are changed through the motor control panels
located on the front of the melter.
To change the a motor control parameter

1. Place the main power switch in the OFF position.
2. Place the control switch in the OFF position.
Control switch
3. Press and hold both Pump speed arrow keys and then switch the
control switch back on. When the pump speed display indicates SEt,
release the keys.
4. Use the Pump speed arrow keys to select a value for the parameter
shown on the pump speed display. Refer to Table 6‐3 for a parameter list.

Troubleshooting 6-7
5. Press the Pump mode key to save the value and move to the next
parameter.
6. Repeat steps 3-4 for each parameter you want to change.
7. To exit the setup mode, press the Pump mode key one additional time
after the last parameter has been displayed.
Table 6‐3 Motor Control Parameter Factory Settings

Parameter Factory Setting Description Explanation
SEt 94 Maximum pump rpm This parameter controls the increment of
change in motor speed that occurs upon
each press of a pump speed up or down
arrow key when the melter is operating in
the manual mode. To change the rpm in
increments of 1, set this parameter to the
maximum pump rpm.
Srt 0 Motor start mode This parameter controls the method used
to start the motor(s):
To start a motor by pressing the pump
start/stop key on a motor control panel,
enter 0. This setting is typically used if a
melter has more than one motor.
If you want a motor to start when the
pump enable signal is activated, enter 1.
This setting is typically used if a melter
has only one motor.
LoS 0 Minimum pump speed If the melter will be operated in the
in gear‐to‐line mode manual mode, enter 0.
If the melter will operated in the
gear‐to‐line mode, enter a minimum line
speed. The motor speed will not fall
below this valve even if the signal drops
to 0 V.

6-8 Troubleshooting
Motor Drive Faults

The display on the motor drive located inside the electrical enclosure alerts
the operator to abnormal motor drive/motor operation. Motor drive faults
cause the pump to stop, refer to the motor drive Error Messages given later.
To clear a motor drive fault, correct the problem that caused the fault and
then remove power from the motor drive by turning the heaters off and wait
until the motor drive display is completely blank.
Figure 6‐1 Motor drive power LED and display

1. Motor drive Ready (RDY) LED 2. Motor drive Error (ERR) LED

Troubleshooting 6-9
LED Status Display

The motor drive has two LEDs, READY (RDY) and ERROR (ERR), see LED
location on Figure 6‐1. Refer to the following table to identify the motor drive
state:
RDY (Blue) ERR (Red) Motor Drive State

– – No supply voltage
– STO active
STO active, warning active
– Motor drive inhibited

Motor drive inhibited, DC Voltage not On OR Reset
Motor drive inhibited, Warning active
Motor drive inhibited, Fault active
– Motor drive released, drive running OR Quick Stop

Motor drive released, drive running, Warning active
Motor drive released, Trouble reaction active

6-10 Troubleshooting
Motor Drive Error History

Error History
The motor driver keypad is not shipped with the melter, to view the error
history you will need to order the keypad service kit (P/N 7411739)
separately.
Any time the motor drive experiences an Error condition during operation it is
captured in the motor drive non-volatile memory. For historical Error tracking
purposes the Errors can be viewed in P155.00. This parameter contains the
actual Error codes, the time (in running hours) that the Error occurred and the
count of Errors (in case of multiple instances of the same Error condition).
The Error History will retain the 32 most recent Errors.
The following figure explains each component in the Error History data:
Figure 6‐2 Explanation of the Error History data
NOTES:
Press to toggle between two screens.
Press and to navigate from Error 01 to Error 32.

Troubleshooting 6-11
The following is an example of how to navigate Error History :
Figure 6‐3 Navigating Error History

Error Messages
Error Code Error Code
Fault Type Keypad Description
(Hex) (Dec)
0x2220 8736 Fault OC power mod. CiA: Continuous over current (device internal)
0x2230 8752 Fault F.Ground short CiA: Short circuit/earth leakage (device internal)
0x2250 8784 Fault OC pm short CiA: Short circuit (device internal)
0x2351 9041 Configurable OL i2t motor CiA: Load level fault (I2t, thermal state)
0x2382 9090 Configurable F.ixt Ixt fault
0x2383 9091 Warning W.ixt Ixt warning
0x3000 12288 Fault F.Su02 Single phase fault
0x3210 12816 Fault F.OU DC link circuit over-voltage
0x3220 12832 Trouble F.LU DC link circuit under-voltage
0x4210 16912 Fault F.OH1 Power module overtemperature fault
0x4211 16913 Warning W.OH1 Power module overtemperature warning
0x4310 17168 Configurable OT motor Motor temperature has reached error level
0x4481 17537 Fault sens. heatSink Heat sink temperature sensor fault
0x5003 20483 Fault F.ID1 Motor parameter identification fault
0x5112 20754 Warning W.24V supply 24V supply level critical
0x5581 21889 Fault Programming err Power unit programming fault
0x5582 21890 Fault EPM full EPM full
0x5584 21892 Fault Eeprom fault On-board eeprom access failure
0x5585 21893 Fault EPM store E EPM data was not completely saved before power
down
0x6104 24836 Warning Watchdog reset Watchdog time-out
0x610A 24842 Fault F.dF12 Math error
0x6181 24961 Fault OL 125us task Calculation time overrun in 125us task
0x6182 24962 Fault OL 250us task Calculation time overrun in 250us task
0x6183 24963 Fault OL 1ms task Calculation time overrun in 1ms task
0x6184 24964 Fault OL 8ms task Calculation time overrun in 8ms task
0x6200 25088 Fault User set fault 1 Digital connection list user fault 1
0x6201 25089 Fault User set fault 2 Digital connection list user fault 2
0x6307 25351 Fault F.AL Assertion level fault
0x8100 33024 Configurable CAN bus off CAN bus off
0x8101 33025 Configurable CAN bus warning CAN warning
0x8109 33033 Configurable Stack init error Fieldbus communication stack initialization error
Continued...


(Hex) (Dec)
0x8111 33041 Configurable TO RxPDO1 CAN time-out Rx PDO 1
0x8131 33073 Configurable CAN hbeat C1 CAN heartbeat time-out consumer 1
0x8141 33089 Configurable WD exprd Fieldbus watchdog expired
0x8142 33090 Configurable Cycl data left Fieldbus disruption of cyclic data exchange
0x8143 33091 Configurable Inval cycl data Fieldbus invalid cyclic process data
0x8190 33168 Configurable TO Modbus Modbus network time-out
0x8191 33169 Warning Modbus EC Modbus wrong request from master
0x8192 33170 Fault FLBS new module Fieldbus new module detected fault
0x8193 33171 Fault FLBS confg error Fieldbus module configuration mismatch fault
0x8286 33414 Configurable F.PDO mapping Fieldbus PDO mapping error
0xFF06 65286 Configurable OS motor Motor over speed
0xFF09 65289 Configurable F.VolPhases Motor phase failure
0xFF0A 65290 Configurable F.VolPhaseU Motor phase failure phase U
0xFF0B 65291 Configurable F.VolPhaseV Motor phase failure phase V
0xFF0C 65292 Configurable F.VolPhaseW Motor phase failure phase W
0xFF0D 65293 Configurable OC motor Motor over current
0xFF10 65296 Configurable F.AIn01 Analog input 1 fault
0xFF13 65299 Configurable F.AIn02 Analog input 2 fault
0xFF15 65301 Warning W.UV dc link DC link circuit under-voltage warning
0xFF16 65302 Warning F.AOut01 Analog output 1 fault
0xFF18 65304 Warning W.OV dc link DC link circuit over-voltage warning
0xFF19 65305 Warning F.AOut02 Analog output 2 fault
0xFF40 65344 No response TMO no reaction Test monitor generated no reaction
0xFF41 65345 Warning TMO warning Test monitor generated warning
0xFF42 65346 Trouble TMO trouble Test monitor generated trouble
0xFF43 65347 Fault TMO fault Test monitor generated fault
0xFF44 65348 Fault TMO fault delay Test monitor generated fault with fault reset delayed
0xFF45 65349 Fault TMO fault block Test monitor generated fault with fault reset blocked
0xFF48 65352 Fault Safety fault Safety supervision fault
0xFF49 65353 Fault EPM invalid data EPM contains invalid user data
0xFF50 65360 Fault EPM not present EPM not present
Continued...

Error Messages (contd)

(Hex) (Dec)
0xFF51 65361 Fault id tag error PU Load error of the id tag calibration data power unit
0xFF52 65362 Fault id tag error CU Load error of the id tag calibration data control unit
0xFF53 65363 Fault Improper connect Connection list wrong connected
0xFF54 65364 Configurable F.fdb open circ Feedback system open circuit
0xFF56 65366 Warning OL modbus tx Modbus transmit message ring buffer error
0xFF57 65367 Configurable OL diag. rx Diagnosis receive message ring buffer error
0xFF58 65368 Configurable OL diag. tx Diagnosis transmit message ring buffer error
0xFF59 65369 Fault EPM access fault EPM access failure
0xFF60 65376 Warning F.fan heatsink Heat sink fan fault
0xFF61 65377 Warning F.fan internal Internal fan fault
0xFF62 65378 Warning Reverse protect Reverse direction protection warning
0xFF63 65379 Fault F. pole ident Pole position identification fault
0xFF64 65380 Trouble Sync error CU PU Power stage communication is out of synchronization
0xFF65 65381 Fault PSCOM mismatch Power stage communication protocol version
mismatch
0xFF66 65382 Trouble Rx error CU Power stage communication receive error on control
unit
0xFF67 65383 Fault rx error PU Power stage communication receive error
0xFF68 65384 Fault PSCOM SDO Power stage communication SDO abort
abort
0xFF69 65385 Fault F.PU generic Power unit generic fault
0xFF70 65392 Fault F.PU uC supply Power unit uC supply voltage drop down
0xFF71 65393 Configurable W.OC12 Brake resistor overload warning
0xFF72 65394 Configurable F.OC12 Brake resistor overload fault
0xFF73 65395 Fault Auto run inhibit Automatic start inhibited
0xFF74 65396 Warning TO.OBEE OBEE job timer overrun
0xFF75 65397 Warning TO.EEPROM.EPM EPM job timer overrun
0xFF76 65398 Warning I2C conn lost I2C connection lost
0xFF77 65399 Warning I2C bus error I2C bus error
0xFF80 65408 Fault Trouble overflow Maximal allowed troubles exceeded
0xFF81 65409 Warning W. powUp voltage DC link voltage to low for power up
0xFF82 65410 Warning EPM is blank Installed EPM is blank
0xFF83 65411 Fault Keypad removed Keypad removed fault
0xFF84 65412 Fault AC user fault AC control user fault
0xFF85 65413 Fault Netwrk user flt1 Network user fault 1
0xFF86 65414 Fault Netwrk user flt2 Network user fault 2
0xFF87 65415 Fault NetWordIN1 Setup NetwordIN1 duplicate bit connection fault

Changing a Motor Drive Parameter

Keypad
The motor drive parameters are pre‐set at the factory. You need the motor
drive keypad with display to view and change the motor drive parameters.
Install the keypad on the front of the motor drive.
An explanation of the keypad button functions is given in the following table.
Keypad Buttons Description

Menu navigation
Adjust parameter values
An a l o g I n p u t 1
Enter (sub-) menu/parameter
LOC
PAR 430
REM MAN AUTO SET8
Confirm parameter
Exit (sub-) menu/parameter
Stop motor drive
Release motor drive
Display
An explanation of the display parameters is given in the following table.
Display Item Description

1 Status and unit
2 Speed, Parameter value, and Fault code
LOC – Local start button on keypad is active
Vel:Run:FWD Hz 1 (stop button is always active)
LOC REM
20. 0
MAN AUTO SET
2
3
REM – Local start button is inactive (start is
initiated remotely)
MAN – Up/Down arrows are active and control
3 speed
AUTO – Up/Down arrows are inactive (speed
control is external)
SET8 – The blinking indicates that a setting or
value has changed and needs to be entered.
Once the settings are saved, the icon is steady

Display (contd)
Every parameter has a hexadecimal address. Parameters which are visible
on the keypad also have a display code. In the Easy Starter Display Code
and hexadecimal address are visible. Every parameter can have
sub-parameters.
Example Display code Address

V/f base frequency P302.02 0x2B01:002
Start control P200.00 0x2824:000
The parameters are organized into groups 0 through 7:
Group Name Group Name

0 Favorites menu 4 Function and I/O menu
1 Diagnostics 5 Network setup menu
2 Basic setup 6 Process control menu
3 Motor setup 7 Auxiliary function menu
The favorites menu contains links to the most commonly used parameters for
initial commissioning and monitoring of the motor drive for general
applications.

Favorites Group Navigation

Screen Type Display Parameters Keypad Button Selection
Operating Screen VEL:FLEX:AIN1
Press
STOP
REM AUTO SETS
Groups Screen Favorites Press

GROUP 0
REM AUTO SETS
Parameter Screen Actual Frequency Press ten (10)
P100.00 times
REM AUTO SETS
Parameter Screen Max Frequency Press

P211.00
REM AUTO SETS
Setting Screen P211/000 Hz Press until 87.0
50.0
is displayed
REM AUTO SETS
Setting Screen P211/000 Hz Press
87.0
REM AUTO SETS
Parameter Screen
Press
Max Frequency
P211.00 NOTE: Use the Up and Down buttons to

REM AUTO SETS
navigate to other parameters in Group 0.
In this example, the BACK button is used
to return to Group list.
Groups Screen
Press
Favorites
GROUP 0 NOTE: Use the Up and Down buttons to

REM AUTO SETS
navigate to other groups. In this example,
the BACK button is used to return to the
Operating Screen.
Continued...

Favorites Group Navigation (contd)

Operating Screen VEL:FLEX:AIN1 We are at the Operating Screen.
STOP
REM AUTO SETS
Saving the Settings

VEL:FLEX:AIN1
Savingp After the adjustments are complete, press for three (3) seconds to save
REM AUTO all the settings to memory.
The SET8 icon blinks when the settings are not saved. Once the
settings are saved, the icon is steady.
VEL:FLEX:AIN1
PSAVED
REM AUTO

Navigation Group 1‐7

Operating Screen VEL:FLEX:AIN1
STOP
REM AUTO SETS
Enter menu
Exit menu
Groups Screen I/O Setup
GROUP 4
REM AUTO SETS
Press or to select Group.
Enter Parameter
Exit Parameter
Parameter Screen Digital Outputs
P420.00
REM AUTO SETS
Press or to select
Parameter.
Enter Sub‐Parameter
Exit Sub‐Parameter
Sub‐Parameter Screen Digital Outputs 1
NOTE: If Sub‐Parameter
screen is not available, the
SUB 002
REM AUTO SETS
Direct Setting Screen will Press or to select
display. Sub‐Parameter.
Enter Setting
Exit Setting
Confirm Setting
Setting Screen Ready to run
51
Press or to change
parameter value.
REM AUTO SETS
Saving the Settings

VEL:FLEX:AIN1
STOP After all the adjustments are complete, press for three (3) seconds to
REM AUTO save all the settings to memory.
Press > 3S (Saving Parameter) The SET8 icon blinks when the settings are not saved. Once the
settings are saved, the icon is steady.
VEL:FLEX:AIN1
PSAVED
REM AUTO

Motor Drive Parameter Factory Settings

Code Pr. Description Setting
GROUP2 P211:00 Max Frequency 102Hz
GROUP3 P303:01 Base Voltage 230V
GROUP3 P303:02 Base Frequency I02Hz
GROUP3 P315:01 Slip Compensation 5%
GROUP3 P320:04 Motor Speed 1350
GROUP3 P320:05 Motor Frequency 102
GROUP3 P320:06 Motor Power 0.25
GROUP3 P320:07 Motor Voltage 230
GROUP3 P320:08 Motor cos PHi 0.6
GROUP4 P430:03 Frequency at max signal 102Hz

Calibrating the Pump Speed Display

The melter is shipped with the pump speed display calibrated to show the
pump rpm. If recalibration becomes necessary, follow this procedure.
1. Ensure that the motor is running at 50 percent speed or higher.

2. Press and hold both Pump speed arrow keys.
3. When the pump speed display indicates CAL, release the keys.
4. Enter the actual pump rpm.
5. Press the Pump mode key.

Troubleshooting Tables
Melter Not Functioning
Possible Cause Possible Fault / Troubleshooting Corrective Action

1. No line voltage — Connect line voltage
2. Main power switch — Place main power switch in ON
not switched on position
3. Main power switch — Replace main power switch
defective
4. Main circuit breaker — Switch on main circuit breaker
activated
5. Main circuit breaker Check for short circuit in melter or —
activated again accessories
6. 24 VDC power supply — Replace
defective
7. Frequent melter Electromagnetic compatibility Add mains filter
shutdown disruptions
One Channel (Heating Zone) Does Not Heat

1. Channel is disabled / — Enable / switch on
switched off
Control Panel Does Not Function
Problem Possible Cause Corrective Action

1. Display is blank SPS broad‐band cable not Connect
connected

No Material (Motor Does not Rotate)

1. Melter not yet ready — Wait until the melter has heated up
for operation (heatup and the green indication lamp is lit
phase)
2. Melter at present not Material was refilled Wait until the melter has heated up
ready for operation and the green indication lamp is lit
(undertemperature
during operation)
3. Motor not enabled — Enable motor
4. Speed (rpm) not set — Set speed (rpm)
5. Standby entered — Exit or wait until standby period has
expired
6. Motor overheated Ambient temperature too high Decrease ambient temperature by
cooling or airing out
Fan cap dirty Clean
Pump blocked by foreign matter Replace pump
Pump operates too sluggish Replace pump
Material too cold Set temperature accordingly
7. Motor defective — Replace
8. Motor not supplied — Technical inspection
with voltage
9. Motor drive fault — Switch melter off and on again with
main power 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 6.
matter, pump too sluggish, material
too cold)
10. Motor drive defective — Replace

No Material (Motor Rotating)

1. Tank empty — Fill tank
2. Filter cartridge — Clean or replace filter screen
clogged
3. Material supply hole — Detach pump and clean supply hole
to pump or pump or suction hole
suction hole clogged
4. Pressure control — Replace pressure control valve
valve defective
5. Safety valve defective — Replace safety valve
6. Pump defective — Replace pump
7. Pressure control — Adjust pressure control valve
valve setting too low
Too Little Material

1. Material supply hole — Detach pump and clean supply hole
to pump or pump or suction hole
suction hole partially
clogged
2. Filter cartridge partly — Clean or replace filter screen
clogged
3. Pressure control — Clean or replace
valve defective
4. Processing — Correct temperature setting
temperature set too
low
5. Pump block is worn — Replace pump
6. Safety valve defective — Replace safety valve
7. Pump defective — Replace pump
8. Pressure control — Adjust pressure control valve
valve setting too low

Material Pressure Too High

1. Pressure control — Disassemble and clean or replace
valve dirty and thus
blocked
2. Pressure control — Replace
valve defective
3. Pressure control — Set to default
valve set incorrectly
Material Pressure Too Low

1. Pump is worn — Replace pump
valve does not close
any more
3. Pressure control — Disassemble and clean or replace
valve dirty and thus
clogged
valve defective
5. Pressure control — Set to default
valve set incorrectly

Material Residue in Tank

1. Tank setpoint — Correct temperature setting
temperature set too
high
Material of low quality or not Consult material supplier
appropriate for application
(temperature resistance poor)
Material Hardens in Tank

1. Tank setpoint — Correct temperature setting
temperature set too
high/too low
Others
Problem Possible Cause Corrective Action

1. Leakage at pump Pump shaft seal is worn Tighten the gland bolt
shaft seal — Replace pump
2. Material pressure too Pump is worn Replace pump
low, output quantity
too low
3. Pump blocked Processed material too cold Correct temperature setting (observe
data sheet of material manufacturer)
Foreign material in pump Replace pump
4. Leakage at gun Safety valve does not open Replace safety valve
during heat‐up phase (expansion pressure)

Parts 7-1
Section 7
Parts
Using the Illustrated Parts List

The parts lists provided in this section are organized into the following
columns:
Item—Identifies illustrated parts that are available from Nordson

Corporation.
Part—Provides the Nordson Corporation part number for each saleable

part shown in the illustration. A series of dashes in the parts column
(‐ ‐ ‐ ‐ ‐ ‐) means the part cannot be ordered separately.
Description—Provides the part name, as well as its dimensions and
other characteristics when appropriate. Bullets in the description, indicate
the relationships between assemblies, subassemblies, and parts.
Quantity—The quantity required per unit, assembly, or subassembly.

The code AR (As Required) is used if the part number is a bulk item
ordered in quantities or if the quantity per assembly depends on the
product version or model.

7-2 Parts
Melter Part Numbers

Part Description
7401355 DuraBlue II,20L,SN0773,6HG,NI,400V WYE
7401356 DuraBlue II,45L,SN0773,6HG,NI,400V WYE

Parts 7-3
Frame Assembly
Melter Frame Parts
See Figure 7‐1.
Item Part Description Quantity Note

‐‐‐‐‐‐‐ MODULE,ENCL,1 MOTOR,DURABLUE II
1 ‐‐‐‐‐‐‐ CTL BOX,1 M,WITH FRONT PANEL, 1
DURABLUE II
2 ‐‐‐‐‐‐‐ PANEL,MOTORS CHAMBER,LEFT,EZ 1
3 ‐‐‐‐‐‐‐ PANEL,ELEC CABINET,DURABLUE II 1
4 ‐‐‐‐‐‐‐ PANEL,MOTORS CHAMBER,FRONT, 2
EZ
5 ‐‐‐‐‐‐‐ PANEL,HYDRAULIC,FRONT,EZ 2
6 ‐‐‐‐‐‐‐ FRAME,HYDRAULIC,FRONT,EZ 1
7 ‐‐‐‐‐‐‐ FRAME,HYDRAULIC,BACK,EZ 1
8 ‐‐‐‐‐‐‐ PANEL ASSY,HYDRAULIC,RIGHT,EZ 1
9 ‐‐‐‐‐‐‐ PANEL,COVER,MANIFOLD,EZ 2
10 ‐‐‐‐‐‐‐ HOOP,GUARD,HOSE CONNECTOR, 1
EZ
11 7411745 LID ASSY,HOPPER,EZ 1
1 11
8
10
4
4 5
2 3 7
Figure 7‐1 Sheet metal assembly parts

7-4 Parts
Manifold Assembly
1‐Single Stream Manifold Assembly
See Figure 7‐2.

— ‐‐‐‐‐‐‐ MODULE,MANIFOLD,1SS,20L,EZ —
101 7410539 SUPPORT,HYDRAULIC,EZ 2
102 7410538 SUPPORT,MANIFOLD,SS,EZ 4
103 ‐‐‐‐‐‐‐ MANIFOLD ASSY,EZ,2SS,20L 1
104 7410544 PLATE,INSULATOR,MANIFOLD, 1
EZ
105 ‐‐‐‐‐‐‐ SCR,HEX,CAP,M8X70,ZN 4
106 ‐‐‐‐‐‐‐ SCR,SKT,M8X1.25X25,BL 4
107 ‐‐‐‐‐‐‐ SCR,PAN,REC,M5X12,BL 8
108 ‐‐‐‐‐‐‐ SCR,SKT,M5X10,BL 6
109 ‐‐‐‐‐‐‐ WASHER,LK,M,SPT,M8,STL,ZN 8
110 ‐‐‐‐‐‐‐ WASHER,FLT,M,REG,M8,STL,ZN 4
111 ‐‐‐‐‐‐‐ WASHER,FLT,M,REG,M5,STL,ZN 8
112 ‐‐‐‐‐‐‐ WASHER,LK,M,SPT,M5,STL,ZN 8
113 ‐‐‐‐‐‐‐ SCR,SHCS,M4X6,BL 2
114 1028305 UNIT,FILTER,ASSEMBLY,100 MESH 1
115 ‐‐‐‐‐‐‐ PLUG ASSY,FILETER,EZ 1
116 1021270 PLATE,FILTER,ANTI ROTATE 2
117 ‐‐‐‐‐‐‐ SCR,PAN,REC,M4X8M,ZN 2
118 ‐‐‐‐‐‐‐ WASHER,LK,M,EXT,M4,STL,ZN 2
119 ‐‐‐‐‐‐‐ BALL, 8 MM 2
120 ‐‐‐‐‐‐‐ SCREW, DRAIN VALVE 2
121 ‐‐‐‐‐‐‐ RETAINING RING,INT,51,BASIC 2
122 7410566 VALVE,SHUT OFF,20L,EZ,SS 2
123 7410541 O-RING 24x2 VITON 2
124 7410534 PLATE,STOP,SHUT OFF VALVE, 2
EZ
125 985127 PIN,DOWEL,M3X12,H&G 2
127 900344 LUBRICANT, NEVER SEEZ, 8 OZ CAN 1
128 900223 LUBRICANT, O‐RING, PARKER, 4 OZ, 1
30122-5
129 7410580 SERVICE KIT,HEATER, 240V,800W, 1/2 X 16L 3
130 ‐‐‐‐‐‐‐ WASHER,FLT,M,OVERSIZED,6,STL,Z 3
131 207932 SAFETY VALVE 85 BAR VB/DB FIX 2
132 1058990 KIT,CORDSTOCK,3MM OD,VITON,75D 1
133 1024618 THERMOSTAT,OOR,500DEG F,PUSH-ON 1
TERM
134 1030564 PLATE, CAPTURE, RTD 1
136 7411485 COVER,BOTTOM,MANIFOLD,EZ 1

Parts 7-5
Figure 7‐2 Manifold assembly parts

7-6 Parts
Hopper Assembly
The hopper assembly parts vary depending on the size of the melter:
one/two‐pump, three/four‐pump, or 100L. Refer to the correct parts list for
your melter.
Melter Hopper Parts

See Figure 7‐3.

— ‐‐‐‐‐‐‐ MODULE, HOPPER —
201 ‐‐‐‐‐‐‐ HOPPER, EZ, 20L 1
‐‐‐‐‐‐‐ HOPPER, EZ, 45L 1
202 7410545 GASKET, HOPPER, EZ, 20L 1
203 ‐‐‐‐‐‐‐ SCR, SKT, M6 X 20, BL 12
204 ‐‐‐‐‐‐‐ WASHER, LK, M, SPT, M6,STL,EZ 12
205 ‐‐‐‐‐‐‐ WASHER, FLT, M, SPT, M6,STL, 12
EZ
SERVICE KIT, HEATER, 240V, 800W, 1/2 X 3
206 7410581
9.0 L
207 ‐‐‐‐‐‐‐ SCR, SKT, M5 X 10, BL 5
209 ‐‐‐‐‐‐‐ WASHER, M6, FLT, SPECIAL BIG, STL, ZP, 3
GB96
210 1024618 THERMOSTAT,OOR,500DEG F,PUSH-ON 1
TERM
211 ‐‐‐‐‐‐‐ WASHER, LK, M, EXT, M4,STL,EZ 2
212 ‐‐‐‐‐‐‐ SCR, SHCS, M4 X 6, BL 2
214 1030564 PLATE, CAPTURE, RTD 1
215 900298 COMPOUND, HEAT SINK,5 OZ TUBE 1
216 7410542 INSULATION,HOPPER,EZ,20L 1

Parts 7-7
202
216
201
205
215 206 204
209 207 203
210
214
212 211
207
207
Figure 7‐3 Melter hopper assembly parts (20L hopper shown)

7-8 Parts
Pump Assemblies
Drive Module Parts
See Figure 7‐4.

— ‐‐‐‐‐‐ EZ,MOTOR DRIVE,45L&20L, 1DS,EZ —
301 ‐‐‐‐‐‐ MOTOR UNIT,W/BRACKET,EZ,R 1 A
302 ‐‐‐‐‐‐ BLANK ASSY,PUMP,DS,EZ 1 A
303 7402299 COUPLING,M24,DAN/NORMAL 1
304 ‐‐‐‐‐‐ SCR,SKT,M8X30,BL 4
305 ‐‐‐‐‐‐ WASHER,FLT,M,REG,M8,STL,EZ 4
306 ‐‐‐‐‐‐ WASHER,LK,M,SPT,M8,STL,EZ 4
307 900344 LUBRICANT, NEVER SEEZ, 8 OZ CAN 1
390 ‐‐‐‐‐‐ DUAL‐STREAM GEAR PUMPS 1 B
NOTE A: Refer to Motor Assembly Parts.
B: Refer to Gear Pumps Parts.
302 303 390 307 4X 4X 4X

304 305 306
301
Figure 7‐4 Pump module parts

Parts 7-9
Single‐Stream Gear Pumps

See Figure 7‐5.

— 729107 GEAR PUMP SN0773 1
Figure 7‐5 Single‐stream gear pumps

7-10 Parts
Safety Valve Parts

See Figure 7‐6.

— 207932 VALVE, SAFETY, 85 BAR 1
— 394592 SERVICE KIT 1
1 ‐‐‐‐‐ O‐RING 11 X 2 1
2 ‐‐‐‐‐ O‐RING 9 X 2 1
— ‐‐‐‐‐ HIGH‐TEMP. GREASE, GLS 595/N2, 10G 1
Figure 7‐6 Safety valve parts

Parts 7-11
Control Valve Assemblies

The control valve assemblies vary depending on the type of pressure control
valve: pressure control valve, pneumatic pressure control valve, circulation
control valve, or blank. Refer to the correct parts lists for your melter.
Control Valve Module Parts

See Figure 7‐7.

— ‐‐‐‐‐‐‐ MODULE,PRESSURE CONTROL —
401 203059 PRESSURE CTRL VALVE 590 BAR VB/DB 2
— 1070961 VALVE, CIRCULATION CONTROL, ALTABLUE 2
— ‐‐‐‐‐‐‐ PLUG, PRESSURE REGULATOR VALVE VB/DB 2
NOTE A: Refer to Pressure Control Valve Parts.
B: Refer to Circulation Control Valve Parts.
401
Figure 7‐7 Pressure control module parts

7-12 Parts
Filter Cartridge Parts

See Figure 7‐8.

01 1031235 FILTER, WITH O-RING, 50-MESH 1
— 1028305 FILTER, WITH O-RING, 100-MESH 1
— 1031236 FILTER, WITH O-RING, 200-MESH 1
01
Figure 7‐8 Filter cartridge parts

Parts 7-13
Pressure Control Valve Parts

See Figure 7‐9.

— 203059 Valve, pressure control, adjustable, 90 bar 1
1 ‐‐‐‐‐ Body, valve 1
2 ‐‐‐‐‐ Piston, valve, supporting ring 1
3 ‐‐‐‐‐ Set screw, black, 90 bar 1
4 ‐‐‐‐‐ Compression spring, 2.2 x 7.4 x 34.4 1
5 ‐‐‐‐‐ O‐ring, 6 x 2 1
6 ‐‐‐‐‐ O‐ring, 11 x 2 1
7 ‐‐‐‐‐ O‐ring, 9 x 2 1
8 ‐‐‐‐‐ Supporting ring, Da10, Di6.7, spiral 1
— 394600 SERVICE KIT Pressure control valve 1
6 ‐‐‐‐‐ O‐ring 11 x 2 1
7 ‐‐‐‐‐ O‐ring 9 x 2 1
— ‐‐‐‐‐ High‐temp. grease, GLS 595/N2, 10 g 1
6 8
7 5
Figure 7‐9 Pressure control valve parts

7-14 Parts
Motor Assembly
See Figure 7‐10.

— ‐‐‐‐‐‐ MOTOR UNIT, W/BRACKET —
1 7410582 SERVICE KIT,MOTOR,NDS-005 0.25KW 1
2,3,4 7410583 KIT,MOTOR BRACKET,ADJUST, 1
EZ
5 ‐‐‐‐‐‐ SCR, SKT, M8X30, BL 4
6 ‐‐‐‐‐‐ WASHER, FLT, M, REG, M8, STL, ZN 4
7 ‐‐‐‐‐‐ WASHER, LK, SPT, M8, STL, ZN 4
8 7402299 COUPLING, M24, DAN/NORMAL 1
2
3
4
5 6 7
Figure 7‐10 Motor assembly parts (four‐pump melter shown)

Parts 7-15

7-16 Parts
Electrical Enclosure Panel Assemblies

The electrical enclosure panel assembly parts vary depending on the size of
the melter: one/two‐pump, three/four‐pump, or 100L. Refer to the correct
parts lists for your melter.
Melter Left Panel Parts ‐ 400V
See Figure 7‐11.

— ‐‐‐‐‐‐‐ 400V ASSEMBLY, ELECTRICAL, PANEL, LEFT, —
ONE/TWO‐PUMP
1 ‐‐‐‐‐‐‐ PLATE ASSY,ELEC CABINET,LEFT,EZ 1
2 7411712 CIRCUIT BREAKER 32A 1‐POLE 4
3 7411708 BOARD,BREAKOUT,RSMA-20D0CD,TB,20POS, 1
EZ
4 7411710 CIRCUIT BREAKER 50A 3‐POLES 1
5 7411711 CONTACTOR, 40A 1
6 7410952 RELAY, DC 24V 1
7 777630 BASE, RELAY (OMRON) 1
8 ‐‐‐‐‐‐‐ CLIP,RELAY 2
9 207396 SOLID-STATE RELAY, G3PE 100-260V MAX. 15A 4
10 7400070 SOLID STATE RELAY,100-260VAC,35A,DC TRIG 2
11 ‐‐‐‐‐‐‐ TERMINAL BLOCK POWER 400V WYE 1
12 ‐‐‐‐‐‐‐ TERMINAL BLOCK, ZDU 16 4
13 ‐‐‐‐‐‐‐ TERMINAL BLOCK, ZPE 16 1
14 ‐‐‐‐‐‐‐ TERMINAL BLOCK, END PLATE, ZAP/TW, ZDU 16 1
15 ‐‐‐‐‐‐‐ TERMINAL BLOCK, ZDU, 2.5 20
16 ‐‐‐‐‐‐‐ EW35 12
17 ‐‐‐‐‐‐‐ TERMINAL BLOCK, END PLATE ZAP/TW1 5
18 ‐‐‐‐‐‐‐ TERMINAL CONNECTOR, ZQV2, 5/2 3
19 ‐‐‐‐‐‐‐ HEXNUT, FLANGED, SERRATED, M5 2

Parts 7-17
06
07
16 04 05 16 02 08 10 03 09 01
11
19
16 12 13 14 15 17
18
Figure 7‐11 Left panel assembly parts (400V melter shown)

7-18 Parts
Melter Back Panel Parts ‐ 400V

See Figure 7‐12.

— ‐‐‐‐‐‐‐ 400V ASSEMBLY, ELECTRICAL, PANEL, BACK, —
ONE/TWO‐PUMP
1 ‐‐‐‐‐‐‐ PLATE ASSY,ELEC CABINET,BACK, EZ 1
2 7411713 CIRCUIT BREAKER 16A 1‐POLE 1
3 7411735 SERVICE KIT,MOTOR CONTROL,EZ 1 or 2
4 ‐‐‐‐‐‐‐ TERMINAL BLOCK, ZDU, 2.5 8
5 ‐‐‐‐‐‐‐ EW35 4
6 ‐‐‐‐‐‐‐ TERMINAL BLOCK, END PLATE ZAP/TW1 1
7 ‐‐‐‐‐‐‐ TERMINAL CONNECTOR, ZQV2, 5/2 2
8 ‐‐‐‐‐‐‐ HEXNUT, FLANGED, SERRATED, M5 2
01 02 05 08 03
07 05 04 06
DETAIL A
DETAIL A
Figure 7‐12 Melter back panel assembly parts (400V melter shown)

Parts 7-19

7-20 Parts
Melter Right Panel Parts ‐ 400V

See Figure 7‐12.

— ‐‐‐‐‐‐‐ 400V ASSEMBLY, ELECTRICAL, PANEL, BACK, —
ONE/TWO‐PUMP
1 ‐‐‐‐‐‐‐ PLATE ASSY,ELEC CABINET,BACK, EZ 1
2 1122064 SVCE KIT,MAIN,PCA 1
3 1122974 SVCE KIT, DURABLUE, EXPANSION PCA 1
4 1031175 SVCE KIT, DURABLUE, 2H TO 4H CONVERSION 1
5 7410952 RELAY,DC24V 1
6 777630 BASE, RELAY (OMRON) 1
7 7400010 CLIP,RELAY 2
8 227569 Jumper3/N/PE,AC 400-230V 1
9 ------- TERMINAL BLOCK,28POS,I/O 1
10 ------- terminal block ZDK 2,5/1,5 PE 1
11 ------- terminal-end-plate ZAP/TW ZDK2,5/1,5 1
12 ------- TERMINAL BLOCK,ZPE 4 1
13 ------- TERMINAL BLOCK,END PLATE,ZAP/TW 4 DB 1
14 ------- EW35 1
15 ------- HARNESS,1PH PWR,EXP-LE,ADVANTAGE 1
16 ------- HARNESS,RELAY PWR,EXP-LE,DURABLUE 1
17 7400352 RIBBON CABLE ASSY,20POS,2 HEATERS,400V 1
18 ------- HARNESS,ENABLE RELAY TO EXP J1,ALTABLUE 1
19 ------- HARNESS I/O,EZ 1
20 ------- HARNESS XT2 TO J4 J5,6HG,EZ 1
21 ------- EXPANSION BOARD XT5 WIRES ASSY. EZ 1
22 ------- FERRULE,WIRE,22AWG,INS,WHITE 18
23 ------- SCR,PAN,REC,W/WASHER,M4X10,ZN 4
24 ------- SCR,PAN,REC,M3X8,ZN 7
25 ------- LOCKWSHRM,EXT,M3,STL,ZN 7
26 ------- SCR,PAN,REC,M4X10,ZN 4
27 ------- WASHER,LK,M,EXT,M4,STL,ZN 4
28 ------- HEXNUT,FLANGED,SERRATED,M5 2
29 ------- SCR,PAN,SLT,M3X10,ZN 2
30 ------- WASHER,FLT,M,REG,M3,ZINC PLATE 2

Parts 7-21
25
01 24 03 23 02
12
10 11 13 14
08
04
29
26
30
27
05
06
07
DETAIL A
28
SEE DETAIL A
09
Figure 7‐13 Melter right panel (400V melter shown)

7-22 Parts
Melter Right Panel Parts ‐ 400V (contd)
1A
RV10
+ C35
RV13
RV12
RV11
C10
RV9
RV7
C8
C3
C4
C9
C5
C36
C23
C24
C25
C26
C27
C28
C29
R95
C30
R71
C44 R85 C56
R93 R5 R19 R17 R81 RV6 R20
C55
R80
C50 C43 C1 R18
R82
C54
R79
U16 R26 R22 J1
R86
R90
Q22
D17 R84 C60 C53 XP5
1
RN4 RN6 C31 Q20 C2233 51
C21 C20
L1 R63 R15 JP1
R88
R121
C74
R101 6 2
HSNK1 RN3 Q19
D16 C58
RN2
RN9
U2
C75
+ U3
D3 C7 R99
RN10
RN7
C45 C46 Q18
C37
C18
RN5
RN1
C42 C47 U7 R119
U4 Q17
C6
C41 U14 R120
RN11
C19R77
T1
R96
R72
L4
DS4
L3
+ XP6 U1
JP2
R87
U17 U5 C17
RV8
R134 R135
C63 C12 +
C16 C15
R124
C52 R89
++ R92 D8 DS15 +
F4 C66 D4
D18
2A R91 R133 DS17 Q26 R127 D6
C48 C49 C57 C2
D7 R129
R33
K1 D1 L2 R4 RV5
F3
R122 R128 R3 C11
+
2A D2 R1 R2 RV4
XT1 DS16
R38 C76
D12 D10 D11 J2 1 D14
XP4
Q13 R130 C51
+
U22 1
C77
C40
C65
R75 U12 U23

R132 R45 R44 RV3
+
C59 U25
XP1
C64 R131 R46 R43 C78

XP2
R100
C84
C83
R68
R67
R66
C61 R76
C32
U21
R123
U26
X6 R136 U9 R73
R102
R69
D5 R74
+
C82
C80
R83 RV1
R37 C62
F1 X7
F2 XP3
10A
10A
F11 F7 C39 1
F6 F5 Q24
6.3A 6.3A U24 R40R41RV2
5A 5A F9 DS14
R42 R39 C67
R114
F12 F8 F10 6.3A R115
6.3A 6.3A 6.3A R116
U15 Q14
DS10
R6
R8
R9
R59
R60
DS3 DS2
R7
R16
R12
R13
R10
R11
R57
R14 DS7 DS5 DS6
Q16
U18
12 12 DS11
R78
R64
3 3 R94
X4 X5 U13 Q7
X1 DS9
R53
R54
X2
X3
R51
1 1 Q5
U10
DS8
1
R48
R47
1
R35
U19 Q12
DS12
R113
R56
R62
R34
R97
R98
R50
R105
R112
R108
R117
R58
R65
R52
R36
R110
R106
C79 C70 C71 C69 C68C73 C72
R109
Q9
R118
R55
R49
R111
R70
R61
U20
DS13
R107
R103
R104
Q25 Q15 Q23 Q8 Q6 Q10 Q11
Figure 7‐14 Location of the shunt on the main board

Parts 7-23

7-24 Parts
Control Panel Assembly

See Figure 7‐15.

1 7411737 KIT,SERVICE,CPU, BOARD, EZ 1
2 7411750 PCA, MOTOR, ALTABLUE 1
3 1025743 MEMBRANE PANEL, W/KEYPAD, FINAL, EZ 1
4 1085183 MEMBRANE PANEL MOTOR CONTROL,STD ALTA 1
5 1017947 SWITCH,ROCKER,SPST,250V,16A,GOLD 1
6 1029938 CABLE ASSY, RIBBON, SERIAL PORT, 9‐POS, DURA 1
7 ------- CAP,D‐SHELL CONNECTOR,9 PIN,FEM 1
8 ------- THRDSPCRMM,MALE/FEM,SS,HEX,M3,8MMLG 7
9 ------- WASHER,LK,M,INT,M3,STL,ZN 7
10 ------- CONNHDWE,SCREWLOCK,#4‐40,D‐SUB 2
CONNECTOR
09
06 05
04 03 02 08 01
10
07
REAR VIEW
Figure 7‐15 Control panel assembly parts

Parts 7-25
Sensor Assembly
See Figure 7‐16. The sensors on your melter may be one of two types:
120‐ohm nickel or 100‐ohm platinum.

01 7411749 HARNESS RTD & THERMOSTAT,EZ 1
01
Figure 7‐16 Sensor assembly parts

7-26 Parts
Optional Fittings
See Figure 7‐17. These fittings can be used at the melter end of a hose.
Fitting Fitting Size, Fitting Size,

Hose Size Fitting Type
PartNumber Melter Side HoseSide
7400333 Straight M16 x 1.5 9/ ‐18 JIC
16
8‐mm 7400337 45‐degree M16 x 1.5 9/ ‐18 JIC
16
7400335 90‐degree M16 x 1.5 9/ ‐18 JIC
16
7401279 Straight M16 x 1.5 3/ ‐16 JIC
4
12‐mm 7401278 45‐degree M16 x 1.5 3/ ‐16 JIC
4
7401277 90‐degree M16 x 1.5 3/ ‐16 JIC
4
7400334 Straight M22 x 1.5 11/16 JIC
16‐mm (see Note) 7400338 45‐degree M22 x 1.5 11/16 JIC
7400336 90‐degree M22 x 1.5 11/16 JIC
1 2 3
Figure 7‐17 Typical non‐swivel fittings
1. Straight fitting 2. 45‐degree fitting 3. 90‐degree fitting

Parts 7-27
Recommended Spare Parts

Part Description
Hydraulic Parts
7402299 COUPLING, M24, DAN/NORMAL
7410580 SERVICE KIT,HEATER, 240V,800W,1/2 X 16L
7410581 SERVICE KIT,HEATER,240V,900W,1/2 X 9.0L
207932 SAFETY VALVE, 85 BAR, VB/DB
1058990 CORDSTOCK, 3 MM OD, VITON, 75D
7410545 GASKET,HOPPER,EZ,20L
7410543 GASKET,HOPPER,EZ,45L
7410582 SERVICE KIT,MOTOR,NDS-005 0.25KW
7410542 INSULATION,HOPPER,EZ,20L
7410540 INSULATION,HOPPER,EZ,45L
Electrical Parts
7411700 HARNESS, HOSE/GUN HC L1,EZ
1026662 CABLE ASSY,RIBBON,34 POS,3 HEADERS
7400352 RIBBON CABLE ASSY,20POS,2 HEATERS,400V
7411739 KEYPAD,MOTOR DRIVER,EZ
7411704 HARNESS, HOSE/GUN HC H5,EZ
7411705 HARNESS, HOSE/GUN HC H6,EZ
7411731 HARNESS, HOSE/GUN HC H5,240V,EZ
7411732 HARNESS, HOSE/GUN HC H6,240V,EZ
7411735 SERVICE KIT,MOTOR CONTROL,EZ
7411712 CIRCUIT BREAKER,32A 1-POLE
7411708 BOARD,BREAKOUT,RSMA-20D0CD,TB,20POS,EZ
7411710 CIRCUIT BREAKER,50A 3-POLES
7411711 CONTACTOR,40A
7410952 RELAY,DC24V
777630 BASE, RELAY (OMRON)
207396 SOLID-STATE RELAY, 100−260 VAC, 15 A,DC TRIGGER
7400070 SOLID-STATE RELAY, 100−260 VAC, 35 A,DC TRIGGER
7411713 CIRCUIT BREAKER,16A,1-POLE
1122064 SVCE KIT,DURABLUE,MAIN,PCA
1122974 SVCE KIT, DURABLUE, EXPANSION PCA
1031175 SVCE KIT, DURABLUE, 2H TO 4H CONVERSION
7400010 CLIP,RELAY
227569 JUMPER3/N/PE,AC 400-230V

7-28 Parts

Technical Data 8-1
Section 8
Technical Data
General Data
Storage temperature - 45° C to + 75 ° C
- 49 ° F to + 167 ° F
Type of heating Cartridge‐type resistance heating elements
Temperature sensor Ni120 " 1 °C
— Measuring precision
Material pressure 5 to 85 bar 0.5 to 8.5 MPa 72.5 to 1233 psi
Melting capacity 1 tank‐full per hour
Degree of protection IP 33
Noise emission 1 motor: 60 dBA
2 motors: 66 dBA
Motor type 3 ph AC motor
Gear box type Helical gear
Motor/pump speeds 94 rpm
Heatup time <45 min
Temperatures
Min. ambient temperature - 5 °C 23 °F
Max. ambient temperature 40 ° C 104 °F
Humidity 10 to 95 %, not condensing
Min. operating temperature 40 ° C 100 °F
(setpoint)
Max. operating 230 ° C 450 °F
temperatures
Overtemperature shutdown 260 ° C 500 °F
by thermostat

8-2 Technical Data
Electrical Data
WARNING! The unit is designed for only one operating voltage. Operate
only at the operating voltage shown on the ID plate.
Available operating 400 VAC 3‐phase with neutral (star — WYE)

voltages
Maximum melter power 20L 14740 W

requirements
45L 16540 W
Operating voltage 50/60 Hz
frequency
Fuse protection Refer to ID plate
Melter Internal Heater 20L 45L
Power Wattage
Grid: 3x900 W Grid: 5x900 W
Manifold: 3x800 W Manifold: 3x800 W
Max. load per hose 1000 W, any single hose or applicator
receptacle 1200 W, any hose/applicator pair
2000 W, sum of hose/applicator pairs 1 and 2
2000 W, any single hose, or applicator 5 or 6
2000 W, hose/applicator pair 5 or 6
NOTE: Total external wattage must not exceed 8,000 W.
Mechanical Data
Item 20L 45L
Weight 205 kg (451 lb) 240 kg (529 lb)
Tank opening (length and 170 x 250 mm 170 x 250 mm
width)
Melter Appearance (length, 1250 x 600 x 1230 mm 1250 x 600 x 1230 mm
width and height)
Approximate tank volume 20 L 45 L
Number of hose connections Single‐stream manifolds: 2 connections per pump stream

Technical Data 8-3
Electrical Schematics
Refer to the electrical schematics provided with the melter.

8-4 Technical Data
Hydraulic Schematic
ADHESIVE
HOPPER
GRID
PUMP
MOTOR
CONTROL
GEAR
MOTOR
PRV
FILTER DRAIN
VALVE
CV
Figure 8-1 Hydraulic system schematic

Calculating Melter Power Requirements A-1
Appendix A
Calculating Melter Power Requirements
Before locating the melter on the production floor or attaching hoses and
guns to the melter, you must calculate the electrical power required by the
hoses and guns and confirm that the required power does not exceed
maximum allowable wattages. Properly calculating melter power
requirements will prevent damage to the melter and identify the maximum
allowable distance between the melter and the point at which the hot melt is
dispensed.
The following three maximum wattages must be considered when calculating

melter power requirements.
Single‐component maximum — The wattage of any single hose or

gun
Hose/gun pair maximum — The combined wattage of any hose and
gun (hose/gun pair)
Two hose/gun pair maximum — The combined wattage of
hose/gun pairs 1 and 2 or hose/guns pairs 3 and 4
If your Nordson representative has already calculated the hose/gun power
requirements and confirmed that the maximum allowable wattages will not be
exceeded, then no further calculation is necessary. However, you should
re‐evaluate the hose and gun power requirements before you:
add a new hose or gun to the melter that was not factored into the
original wattage evaluation
replace an existing hose with a longer hose or an existing gun with a
larger gun

A-2 Calculating Melter Power Requirements
Evaluate Hose/Applicator Power Requirements

1. Identify all hose/applicator pairs based on the hose/applicator receptacle
to which they are connected.
2. Examine the identification tag or plate on each hose and applicator and
record the wattage of each in Column A of Table A‐1. Enter a zero for any
hose or applicator that is not installed.
3. Add the wattages of each hose/applicator pair and place the sum in
Column B of Table A‐1.
4. Add the wattages of the hose/applicator pairs and place the sum in
Column C of Table A‐1.
5. Compare each of the wattages tabulated in Columns A, B, and C of Table
A‐1 with the associated maximum allowable wattages in TableA‐2, as
appropriate.
If each of the wattages calculated in step 5 do not exceed the
associated maximum allowable wattages listed in Table A‐2, then the
power required by the hoses and applicators is within acceptable
limits.
If any of the wattages calculated in step 5 does exceed an associated
maximum allowable wattage listed in Table A‐2, then the
configuration or position of the hose/applicator pairs must be
rearranged, shorter hoses must be used, or lower power applicators
must be used in order to reduce the power requirement.

Calculating Melter Power Requirements A-3
Table A‐1 Hose/Applicator Wattages

A B C
Component Two
Type/Size Component Hose/Applicator
Number Hose/Applicator
Wattage Pair Wattage
Pair Wattage
Hose 1
Applicator 1
Hose 2
Applicator 2
Hose 3
Applicator 3
Hose 4
Applicator 4
Hose 5
Applicator 5
Hose 6
Applicator 6
Table A‐2 Maximum Allowable Hose/Applicator Wattages

Column in
Component Maximum Wattage
Table A‐1
A Any single hose or applicator 1000 W
B Any hose/applicator pair 1200 W
Sum of hose/applicator pairs 1 2000 W
and 2
C
Sum of hose/applicator pairs 3 2000 W
and 4
Any single hose, or applicator 5
D 2000 W
or 6
E Hose/applicator pair 5 or 6 2000 W
Sum of hose/applicator pairs 5
F 4000 W
and 6
NOTE: Total external wattage must not exceed 8,000 W.

A-4 Calculating Melter Power Requirements

Operating Parameters B-1
Appendix B
Operating Parameters
Operating parameters are organized in this appendix according to the logical
groups listed in Table B‐1. For information about selecting and editing
operating parameters, refer to Section 3, Installation, Setting Up the Melter.
NOTE: Parameter numbers that are reserved or that are not used do not
appear in this appendix.
Table B-1 Parameter Groups

Group Parameters Description
Standard 0 to 13 Frequently used parameters
Temperature
20 to 29 Control heater function
Control
Input Setup 30 to 33 Configure the inputs
Output Setup 40 to 42 Configure the outputs
Seven‐day
50 to 77 Configure the clock feature
Clock
PID Selection 80 to 91 Change preset PID settings

B-2 Operating Parameters
Standard
0 Enter Password
Description: A user‐defined password that prevents unauthorized changes to set‐point
temperatures and operating parameters.
Value: 0 to 9999
Resolution: 1
Default Value: 4000
Format: —
Use: This parameter only appears if a password is created using parameter 11 and
then enabled using parameter 10.
NOTE: The melter remains in the password‐protected mode for two minutes
after the last key press. After exiting the setup mode, attempting to re‐enter the
setup mode, even before two minutes has elapsed, will require you to re‐enter
the password.
1 Total Hours with Heaters On (Noneditable)
Description: A non editable value that indicates the total number of hours that the heaters
have been on.
Value: 9999 (control panel) and 999,999 on the web browser
Resolution: 1 hour
Default Value: 0
Format: —
Use: The display registers up to 9999 hours and then rolls over to 0000.
2 Fault Log (Noneditable)
Description: Stores a record of the last ten faults.

Value: —
Resolution: —
Default Value: _‐F0 (unused log entry)
Format: F1, F2, F3, and F4
Use: Use the right‐display scroll keys to review the log entries for the last ten faults.
Empty log entries are indicated by “_‐F0.” Refer to Monitor the Melter in Section
4, Operation.

3 Change History Log (Noneditable)
Description: Records the last ten changes made to either the set‐point temperatures or the
operating parameters.
Value: —
Resolution: —
Default Value: P‐_ (unused log entry)
Format: Refer to Section 3, Installation. Review Parameter and Set‐point Temperature
Changes.
Use: Use the right‐display key to review the log entries for the last ten changes that
were made to the operating parameters or the set‐point temperatures. Empty log
entries are indicated by “P‐_.”
4 Ready Delay Time

Description: The amount of time that will elapse after all of the components have reached
their set‐point temperature before the ready LED will turn on. The ready delay
time only functions when the temperature of the tank, at the time the melter is
turned on, is more than 27 C (50 F) from its set‐point temperature. The ready
delay time begins when all components are within 3 C (5 F) of their respective
Value: 0 to 60 minutes
Resolution: 1 minute
Default Value: 0 minutes
Format: —
Use: The ready delay allows the contents of the tank an additional amount of time to
heat before pump turns on.
NOTE: The time remaining on the ready delay is indicated in minutes in the right
display at the end of every automatic scan cycle. When the delay time reaches 1
minute, the time remaining appears in seconds.
5 Service Interval Time

Description: The number of heater‐on hours that must elapse before the service LED turns
on.
Value: 0 hours (disabled) to 8736 (one year)
Resolution: 1 hour
Default Value: 500 hours
Format: —
Use: Set the service interval time to signal a user‐defined service check or
maintenance event, such as changing the filter. The service LED will turn on
after the pre‐set time elapses. With the melter in the scan mode, press the
Clear/Reset key to turn off the service LED and reset the time.

Standard (contd)
6 Service LED Heater Hours

Description: A timer indicates how many more hours the heaters need to remain on before
the service LED illuminates (service required).
Value: 0 hours (disabled) to 9999

Resolution: 1 hour
Default Value: 0
Format: —
Use: The service interval time (parameter 5) must be enabled before this parameter
will work.
Note: Heater hours accumulate whenever the heaters LED is illuminated.
7 Motor Off Delay

Description: Not being used, only displayed.
10 Enable or Disable the Melter Password

Description: Activates or deactivates the melter password. When password protection is
activated, component set‐point temperatures or melter operating parameters
cannot be changed until a valid password is entered using parameter 0.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default Value: 0
Format: —
Use: A password must first be created using parameter 11 before it can be enabled or
disabled using parameter 10.
11 Create Password
Description: A user‐defined password that prevents unauthorized changes to operating
parameters or set‐point temperatures.
Value: 0 to 9999
Resolution: 1
Default Value: 5000
Format: —
Use: Refer to Section 4, Operation, Enter Password.
NOTE: When the password is created and enabled, parameter 10 will not
appear again in the right display until the password is entered.

20 Temperature Units
Description: Sets the units for temperature display.
Value: C (degrees Celsius) or F (degrees Fahrenheit)
Resolution: 0 = Celsius
1 = Fahrenheit
Default Value: 0
Format: —
Use: —
21 Over Temperature Delta

Description: The number of degrees that the temperature of any component can increase
over its assigned set‐point temperature before an over temperature fault (F3) will
occur.
Value: 5 C (10 F) to 60 C (110 F)
Resolution: 1C
1F
Default Value: 15 C (25 F)
Format: —
Use: —
22 Under Temperature Delta

Description: The number of degrees that the temperature of any component can decrease
from its set‐point temperature before an under temperature fault (F2) occurs.
Value: 5 C (10 F) to 60 C (110 F)

Resolution: 1C
1F
Format: —
Use: —

Standard (contd)
23 Standby Delta
Description: The number of degrees by which all heated components will be decreased when
the melter is placed into the standby mode.
Value: 25C to 190C (50F to 350F)

Resolution: 1C
1F

Format: —
Use: A standby delta should be selected that results in a balance between melter
energy savings during periods of inactivity, the amount of time and energy
required to bring the melter back up to set‐point temperature, and a temperature
at which the hot melt can be held in the tank for extended periods of time without
charring. Refer to Section 4, Operation, Function Keys.
NOTE: The standby delta does not affect the under temperature delta
(parameter 22).
24 Automatic Standby Timeout

Description: The amount of time that must elapse after the last signal (applicator driver) is
sent to input 1 before the melter will enter the standby mode. The automatic
standby timeout feature saves energy by allowing the melter to automatically go
into the standby mode if the melter detects that the guns are no longer firing.
Value: 0 to 1440 minutes (24 hours)
Default Value: 0 (disabled)
Format: —
Use: 1. Change parameter 23 if required.
2. Set the control option for parameter 30 (input 1) to option 10 (automatic
standby)
NOTE: Only enable parameter 24 when a 24 VDC signal voltage is connected to
input 1. If there is no voltage on the input contacts when the melter is ready, the
melter will enter the standby mode after the automatic standby time.
25 Automatic Heaters Off Time

Description: The amount of time that must elapse after the automatic standby time elapses
(parameter 24) before the heaters turn off.
Value: 0 to 1440 minutes (24 hours)
Default Value: 0 (disabled)
Format: —
Use: Set parameter 24 (automatic standby timeout) to the desired value before setting
parameter 25.

26 Manual Standby Time

Description: The amount of time that the melter will remain in the standby mode after the
standby key is pressed.
Value: 0 to 180 minutes

Default Value: 0
Format: —
Use: Set the standby time when you want the operator to be able to place the melter
into the standby mode for a limited period of time (break, lunch, etc.). When
manual standby is enabled (value greater than 0 minutes), the standby LED
blinks.
Set the standby delta (parameter 23) to the desired value before setting
parameter 26.
Note: When a time value equal to or greater than 1 minute is entered, the
standby LED will flash to indicate that the manual standby timer is counting
down.
27 Hose Standby Delta

Description: The number of degrees by which all heated hoses will be decreased when
the applicator is placed into the standby mode.
Value: 1 C to 190 C (1 F to 350 F)

Resolution: 1 C
1 F
Default Value: 0
Format: —
Use: This parameter functions like parameter 23 except when it is set to 0, in
which case it reverts to the setting for parameter 23.
(parameter 22).
28 Applicator Standby Delta

Description: The number of degrees by which all heated guns will be decreased when
the applicator is placed into the standby mode.
Value: 1 C to 190 C (1 F to 350 F)

Resolution: 1 C
1 F
Default Value: 0
Format: —
Use: This parameter functions like parameter 23 except when it is set to 0, in
which case it reverts to the setting for parameter 23.
(parameter 22).

Standard (contd)
29 Internal Zone Temperature Offset

Description: The difference in the number of degrees by which the melter's internal
zones will operate. If this parameter is used, the primary internal zone will
operate at a lower temperature than the secondary internal zone as
determined by the value of this parameter.
Value: 0 C to ‐15 C (0 F to ‐30 F)
Resolution: 1 C
1 F
Default Value: 0
Format: —
Use: Melter internal zones are designated as follows:
DuraBlue D10/D16: primary=tank; secondary=pump
DuraBlue D4L/D10L/D16L: primary=tank; secondary=pump
AltaBlue TT: primary=tank; secondary=pump
DuraBlue 25/50/100: primary=grid; secondary=reservoir
AltaBlue 15/30/50/100: primary=grid; secondary=reservoir
DuraBlue II Melter: primary=grid; secondary=reservoir
DuraDrum: primary=platen; secondary=pump

Input Setup
30 Input 1
Description: Control options that determine the function of input 1.
Value: 0 - Input Disabled
1 – Standby On/Off
2 – Heaters On/Off
3 – Motor 1 Enable/Disable
4 – Hose/Applicator 1 Enable/Disable
10 – Automatic standby
Resolution: 1
Default Value: 10
Format:
Use: If Motor Enable/Disable (3) is selected, the motor will turn on whenever voltage
is present on the input contacts. To require that the pump key be pressed (pump
enabled) and that there be voltage on the input contacts before the motor can
turn on, set the value of parameter 8, Automatic Pump On to 0 (disabled).
Refer to Installing Melter Inputs in Section 3, Installation, for information about
setting up inputs.
NOTE: Only Input 1 offers control option 10.

Multiple inputs can be set to the same input value. After one or more inputs that
have the same input value are energized, the input functionality will not be
considered inactive (off) until all of the inputs with the same input value are
de‐energized (Multiple inputs set to the same input value are logical ORed.).

Input Setup (contd)
31 Input 2
Resolution: 1
Default Value: 1
Format: —
Use: If Motor Enable/Disable (3) is selected, the motor will not turn on unless the
pump is enabled and the correct voltage is present on the input contacts.
setting up inputs.
NOTE: Multiple inputs can be set to the same input value. After one or more
inputs that have the same input value are energized, the input functionality will
not be considered inactive (off) until all of the inputs with the same input value
are de‐energized (Multiple inputs set to the same input value are logical ORed.).
32 Input 3
Resolution: 1
Default Value: 2
Format: —
setting up inputs.

33 Input 4
2 – Motor 1 On/Off
3 – Motor Enable/Disable
Resolution: 1
Default Value: 4
Format: —
setting up inputs.
34 – 39 Optional Inputs 5, 6, 7, 8, 9, and 10

Description: Control options that determine the function of the six optional inputs provided
when the optional I/O expansion card is installed on the main board.
2 – Motor 1 On/Off
3 – Motor Enable/Disable
Resolution: 1
Default Value: 0 (Disable)
Format: —
setting up inputs.
NOTE: When more than one input is set to the same value, the controller follows
the state of the active input.

Output Setup
40 - 42 Outputs 1, 2, and 3
Description: Determines the function of the output.
Value: 0 = Output Disabled
1 = Ready
2 = Ready and Pump is on
3 = Fault
4 = Low level
5 = Service LED is on
6 = Alert
Resolution: 1
Default Value: Output 1 = 1
Output 2 = 3
Output 3 = 4
Format: —
Use: Refer to Installing Melter Outputs in Section 3, Installation, for information on
setting up outputs.
When control option 6, Alert is selected, the output is active whenever the melter
enters the two minute fault monitoring period. If the potential fault condition
clears before the end of the two minute period, the output signal ends. Refer to
Section 4, Operation, Monitor Melter Faults, for information about fault
monitoring.
43 - 46 Optional Outputs 4, 5, 6, and 7

Description: Control options that determine the function of the four optional outputs provided
when the optional I/O expansion card is installed on the main board.
Value: 0 = Output Disabled
1 = Ready
2 = Ready and Pump is on
3 = Fault
4 = Low level
5 = Service LED is on
6 = Alert (Potential fault)
Resolution: 1
Default Value: 1 (all optional outputs)
Format: —
Use: Refer to the instruction sheet provided with the optional I/O expansion card for
information about wiring and setting up the optional outputs.
When control option 6, Alert is selected, the output is active whenever the melter
enters the two minute fault monitoring period. If the potential fault condition
clears before the end of the two minute period, the output signal ends. Refer to
Section 4, Operation, Monitor Melter Faults, for information about fault
monitoring.

Seven‐day Clock
Before setting up the clock, refer to Function Keys in Section4, Operation, to
familiarize yourself with the function and use of the clock feature.
If you are unfamiliar with the procedure for accessing and editing operating
parameters, refer to Section 3, Installation, Setting Up the Melter.
To Set the Clock
1. Use parameter 50 to select the current day of the week.

2. Use parameter 51 to set the current time of day.
3. Create schedule 1 by:
a.. Setting parameters 55 and 56 to the time of the day that the heaters
should turn on and off.
b.. Setting parameters 57 and 58 to the time of the day that the melter
should enter and exit the standby mode.
4. Using parameters 60 through 68, create schedules 2 and 3 by repeating
step 3.
5. Use parameters 71 through 77 to assign which of the four schedules
should be used on each day of the week. Up to three schedules may be
assigned each day (to support three work shifts). Each of the eight
control options (0 to 7) that is available in parameters 71 through 77
assigns a different combination of the three schedules. Option 0 is used
hold the melter in the state dictated by the last clock transition until the
next clock transition occurs.
In order for the clock to operate continuously

throughout the week, a valid schedule must be
assigned to every day of the week (parameters
71 through 77).
To prevent unintentional activation of the clock

the default setting for parameters 71 through
77 is schedule 0. which has no time values
assigned to it. With the default set to schedule
0, unintentionally pressing the clock key will
have no affect on the melter.

50 Current Day
Description: Used to set the current day of the week.
Value: 1 to 7 (1 = Monday, 2 = Tuesday, etc.)
Resolution: 1
Default Value: —
Format: —
Use: Refer to Section 4, Operation, Function Keys, for information about the use and
affects of the seven‐day clock feature.
51 Current Time
Description: Used to set the local time of the day.
Value: 0000 to 2359 (European time format)
Default Value: (Time set at factory)
Format: Hours, Hour: Minute, Minute
Use: This setting only needs to be made once for all daily schedules
55 Schedule 1 Heaters On
Description: Used to set the time that the clock will turn on the heaters during schedule 1.
Value: 0000 to 2359, ‐ ‐ ‐ ‐
Default Value: 0600
Use: Set the desired time for the heaters to turn on.
To disable this parameter, set the parameter's value to “‐ ‐ ‐ ‐” by simultaneously
56 Schedule 1 Heaters Off

Description: Used to set the time that the clock will turn off the heaters during schedule 1.
Value: 0000 to 2359, ‐ ‐ ‐ ‐
Default Value: 1700
Use: To disable this parameter, set the parameter's value to “‐ ‐ ‐ ‐” by simultaneously

57 Schedule 1 Enter Standby

Description: Used to set the time that the melter will enter the standby mode during schedule
1.
Value: 0000 to 2359, ‐ ‐ ‐ ‐

Default Value: ‐ ‐ ‐ ‐
Format: Hour, Hour: Minute, Minute
Use: Set the time that the melter will enter the standby mode during schedule 1.
Note: Do not set an enter standby time that is outside of the time period defined
by the schedule's heater on and off time. The melter cannot enter the standby
mode when the heaters are off.
58 Schedule 1 Exit Standby

Description: Used to set the time that the melter will exit the standby mode during schedule 1.
Value: 0000 to 2359, ‐ ‐ ‐ ‐
Use: Set the time that the melter will exit the standby mode during schedule 1.
Note: Do not set an exit standby time that is outside of the time period defined
Value: 0000 to 2359, ‐ ‐ ‐ ‐

Seven‐day Clock (contd)

Value: 0000 to 2359, ‐ ‐ ‐ ‐

2.
Value: 0000 to 2359, ‐ ‐ ‐ ‐


Value: 0000 to 2359, ‐ ‐ ‐ ‐

Value: 0000 to 2359, ‐ ‐ ‐ ‐

Value: 0000 to 2359, ‐ ‐ ‐ ‐

3.
Value: 0000 to 2359, ‐ ‐ ‐ ‐

Seven‐day Clock (contd)

Value: 0000 to 2359, ‐ ‐ ‐ ‐
71- Schedules for the Days of the Week

77
Description: Used to select which schedule(s) should be used on a specific day of
the week.
Value: 0 – Remain at last clock transition

1 – Use just schedule 1
4 – Use schedule 1 and 2
7 – Use schedule 1, 2, and 3
Resolution: 1
Default Value: 0
Format: —
Use: Selects the active schedule(s) for the day.
NOTES: If the 0 schedule option is used, the heaters will not turn on
again until the next scheduled heaters on time arrives.

PID Selection
PID Selection for Receptacles, Hose/Applicator 1, 2, 3

80-91
and 4
Description: Used to change the preset PID selections. Use parameter 80 to select the value
for hose1, parameter 81 to select the value for applicator 1, and so on.
Value: 0 = Hose
1 = Standard gun
2 = Large gun
3 = Air heater
Resolution: —
Default Value: 0 or 1 depending on the channel type (hose or gun)
Format: —
Use: Consult your Nordson representative before changing PID settings.


Melter Communications C-1
Appendix C
Melter Communications
This appendix describes the installation and use of the Nordson
Configuration Manager (NCM) communications utility. With this utility you
can:
transfer operating parameters and temperature set‐points between

melters
upgrade or reload your melter's firmware
Software Availability
If you do not already have the NCM utility, you can download it from
http://emanuals.nordson.com/adhesives/software/BlueSeriesSoftware.html.
System Requirements
The following hardware and software requirements are necessary to install
and run Blue Series software:
Any DuraBlue II, AltaBlue, ProBlue, or DuraBlue 10/16 adhesive

melter
Serial cable
Personal Computer with:
‐ CD-RW drive or 3.5-inch floppy drive
‐ Available COM port
‐ 640 x 480 color monitor
‐ Windows 95, 98 (second edition), ME, XP, or 2000
‐ Internet Explorer version 4.0 or later (IE 5.0 is recommended)
‐ Administrative privileges (Windows XP, 2000, and NT)

C-2 Melter Communications
Installing the Software

To meet your specific installation conditions, two versions of the software are
available. Refer to Table C‐1 to determine which version you need.
Table C-1 Blue Series Software Versions

Version Use When...
Single installation file: You are downloading the software from www.enordson.com and the PC you are
downloading onto is connected or can be connected to the melter
BlueSeries.exe
OR
You are downloading the software from www.enordson.com onto a PC that can not be
connected to the melter, but the PC does have a CD‐RW and the PC that is connected to
the melter does have a CD drive
OR
You have a CD with the software and you have a PC with a CD drive that can be
connected to the melter
Self‐extracting span diskette set: You are downloading the software from www.enordson.com onto a PC that cannot be
connected to the melter and the PC that is connected to your melter only has a 3.5‐inch
BlueSeriesSpan.exe floppy drive
When the installation file is executed, an installation wizard will detect your
operating system and start the installation routine.
NOTE: Installing the NCM for the first time also installs the latest version of
the melter's firmware.

To install Blue Series software

If you are installing using the single file installation, locate and
double‐click on the file BlueSeries.exe.
If you are installing from the span diskette set, insert Disk 1, and
then locate and double‐click on the file Setup.exe.
The Blue Series Software Setup wizard appears.

2. Click Next, and then follow the on‐screen instructions. If you are installing
from the span disk set, you will be prompted to insert additional diskettes
(2 through 5) as required by your operating system.
NOTE: When prompted to select an installation location, Nordson

Corporation recommends that you select the default location offered.
3. When the installation complete message appears, click Finished.

Removing the Software from Your PC

Use the Remove feature provided by the Blue Series InstallShield Wizard
to remove the software from your PC. Removing Blue Series software from
your PC will not remove melter settings files that you have saved using the
NCM. Settings files (.ncm extension) are stored in your Windows My
Documents folder.
NOTE: Windows XP, 2000, and NT users must have administrator rights in
order to remove software from their PC.
To remove Blue Series software

1. From the Windows Start menu, select Settings > Control Panel, and then
double‐click Add/Remove Programs.
The Add/Remove Programs dialog box appears.
2. Select Blue Series Software from the list, and then click Remove.

Connecting the PC and the Melter
Connect a serial cable between the PC COM port (selected during the
9 software installation routine) and the serial port connection (COM port) on
4 5 6
your melter's control panel.
1 2 3
Serial port

Using Nordson Configuration Manager

Configuration Manager is launched from your Windows desktop using the
icon shown to the left.
Use Configuration Manager when you want to...

Configuration Manager
desktop icon copy melter settings from one melter to another melter
create and save more than one version of melter settings
upgrade or restore a melter's firmware
Configuration Manager communicates with your melter through a PC
connected to your melter's serial port. Once connected, Configuration
Manager offers the choice of saving settings, restoring settings, or upgrading
the melter's firmware.
The first time you download and install Configuration Manager, the latest
version of the melter's firmware is also downloaded.
Saving and Restoring Melter Settings

Saving settings copies all current set‐point and operating parameter values
to your PC. Saved settings can be transferred back to the same melter or to
any other compatible Blue Series adhesive melter.
To save melter settings

1. Place the melter into the configuration mode by simultaneously pressing
the Standby and Setup keys.
“COnF” appears in the right display.
2. Double‐click the NCM icon on the Windows desktop.
The NCM dialog box appears.
3. Click Select Device.
The Select Product dialog box appears.
4. Select your melter from the list, and then click Ok.
The Select COM Port dialog box appears.
5. Select the COM port you are using to connect to the melter, and then
click Ok.
The PC and melter establish communications and a picture of the melter
you selected appears in the device status area. The right side of the
status area indicates “CONNECTED”.
6. Click Save Settings.
The Save As dialog box appears.
NOTE: The default location for saving settings files is Windows My

Documents folder. To avoid loosing saved settings files, Nordson
Corporation recommends that you do not change the default save
location.

7. Type a file name to identify the group of settings you are saving, and then
click Save.
The save settings progress bar indicates the status of the save. When the
save is complete, the melter automatically returns to the scan mode.
NOTE: If you are using the NCM to save multiple variations of melter
settings, use a file naming convention that will allow you to easily
associate each settings file (.ncm extension) with its related process or
end‐use.
8. Click Ok to close the NCM.
To restore melter settings

1. Follow steps 1 through 5 of To save melter settings.
2. Click Restore Settings.
The Open dialog box appears.
3. Select the settings file (.ncm extension) that you want to restore, and then
click Open.
The Restore Settings progress bar indicates the status of the restore.
When the restore is complete, the melter automatically returns to the
scan mode.
Upgrading or Restoring Melter Firmware

Use the NCM to upgrade your melter to a newer version of firmware or reload
the current version of the firmware. The version of Blue Series adhesive
melter firmware that is currently available is posted on the Internet at
http://emanuals.nordson.com/adhesives/software/BlueSeriesSoftware.html.
NOTE: The version of firmware that is loaded on your melter appears on the
control panel when the melter is first switched on.
During the upgrade process, all current melter settings are downloaded and
saved on your PC. After upgrading or restoring a melter's firmware, you can
use the NCM to restore the pre‐upgrade settings.
CAUTION! The upgrade process returns the melter's settings to factory

configuration, with the exception that current heater hours data is saved.
Data in both the fault log and the change log is lost after upgrading the
firmware.

Upgrading or Restoring Melter Firmware (contd)
To upgrade or reload melter firmware

1. Connect your PC to the melter. Refer to Connecting the PC and the
Melter earlier in this guide.
2. Place the melter into the upgrade mode by switching the melter off and
then on again, and then immediately pressing and holding both the
Setup and left display Scroll key.
UPLOAd appears in the right display.
3. Double‐click the NCM icon on the Windows desktop.
The NCM dialog box appears.
4. Click Select.
The device dialog box appears.
5. Select your melter from the list, and then click Ok.
click Ok.
status area indicates Connected.
7. Click Upgrade.
The Select Upgrade dialog box appears.
8. In the Available Upgrades list, select the firmware version you want to
upload to the melter, and then click Ok.
The upgrade warning message appears.
9. Click OK.
The Upgrade in Progress dialog box appears. The upgrade can take as
long as 12 minutes. When the upgrade is complete, the Success dialog
box appears and the melter restarts.

To upgrade or reload melter firmware (contd)
CAUTION! Once the uprade progress bar appears, do not interrupt the
upgrade process for any reason. Interupting the upgrade can corrupt the
melter's firmware, which will require replacement of the IC chip
(IC service kit P/N 1018817).
10. Click OK.

The communications link between the melter and the PC is terminated.
To restore pre‐upgrade melter settings, go to To restore pre‐upgrade
melter settings.
To close the NCM, click Exit.
To restore melter settings other than the settings that were in use by
the melter before the upgrade, go to Saving and Restoring Melter
Settings earlier in this guide.
To restore pre‐upgrade melter settings

1. Place the melter into the configuration mode by simultaneously pressing
the Standby and Setup keys.
“COnF” appears in the right display.
2. Click Connect.
click Ok.
status area indicates “CONNECTED”.
4. Click Restore Pre‐Upgrade Settings.
The pre‐upgrade settings are restored and the melter returns to the scan
mode.
5. Click Exit to close the NCM.

Troubleshooting
Using Nordson Configuration Manager
Symptom/Message Action
After selecting a device and the COM port, an Access Denied PC‐to‐Blue communications may be running or another
message appears. application may be using the COM port. Close Internet Explorer
and end the communications connection (if prompted). Close all
other applications.
Melter in UPLOAd mode, the update process has not been Cycle power to the melter at the local power disconnect switch.
initiated, and you want to stop and exit the UPLOAd mode, but you CAUTION: Ensure that the firmware update process is not running
cannot get the melter out of UPLOAd. before taking power off of the melter.
UPLOAd does not appear on the melter's display when you press You must cycle the control switch while holding the Setup and left
the Setup and left display scroll keys. display scroll keys.
Attempted a firmware update, but the melter display still indicates Using the local power disconnect switch, cycle power to the
UPLOAd. melter, and then re‐attempt the update.
OR If the update is unsuccessful or the melter will not reboot, the
Attempted a firmware update, but the PC has stopped responding central processor chip may be corrupted. Replace the CPU board.
or was interrupted during the update process.

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DuraBlue II Adhesive Melters

This document contains important safety information.

NORDSON CORPORATION  DULUTH, GEORGIA  USA

Address all correspondence to:

Part 1126931_01 2018 Nordson Corporation

2018 Nordson Corporation Part 1126931_01

Part 1126931_01 2018 Nordson Corporation

Adjusting Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐18

2018 Nordson Corporation Part 1126931_01

Changing a Motor Drive Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐15

Part 1126931_01 2018 Nordson Corporation

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Melter Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

2018 Nordson Corporation Part 1126931_01

This page intentionally left blank.

Part 1126931_01 2018 Nordson Corporation

WARNING! Failure to follow the safety messages, recommendations, and

Safety Alert Symbols

WARNING! Indicates a potentially hazardous situation that, if not avoided,

CAUTION! Indicates a potentially hazardous situation that, if not avoided,

CAUTION! (Used without the safety alert symbol) Indicates a potentially

2018 Nordson Corporation Issued 4-15

Responsibilities of the Equipment Owner

Instructions, Requirements, and Standards

Issued 4−15 2018 Nordson Corporation

receive safety training appropriate to their job function as directed by

possess industry‐ and trade‐specific skills and a level of experience

Applicable Industry Safety Practices

Intended Use of the Equipment

2018 Nordson Corporation Issued 4-15

Instructions and Safety Messages

Issued 4−15 2018 Nordson Corporation

Maintenance and Repair Practices

Equipment Safety Information

2018 Nordson Corporation Issued 4-15

Relieving System Hydraulic Pressure

De‐energizing the System

Disabling the Applicators

All electrical or mechanical devices that provide an activation signal to the

1. Turn off or disconnect the applicator triggering device (pattern controller,

Issued 4−15 2018 Nordson Corporation

General Safety Warnings and Cautions

Equipment types are designated in Table 1‐1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

Table 1‐1General Safety Warnings and Cautions

WARNING! Hazardous vapors! Before processing any polyurethane

WARNING! Reactive material! Never clean any aluminum component

WARNING! System pressurized! Relieve system hydraulic pressure

2018 Nordson Corporation Issued 4-15

Table 1‐1General Safety Warnings and Cautions (contd)

WARNING! Molten material! Wear eye or face protection, clothing that

WARNING! Equipment starts automatically! Remote triggering devices

WARNING! Risk of electrocution! Even when switched off and

WARNING! Risk of fire or explosion! Nordson adhesive equipment is

WARNING! Allow only personnel with appropriate training and

Issued 4−15 2018 Nordson Corporation

NOTE: Permitted deviation from the rated line voltage is 10%.