Manual DuraDrum Bulk Melters DD200

DuraDrumt
Bulk Melters
DD200
Manual P/N 7105731J
− English −
Issued 11/07
NORDSON ENGINEERING GMBH D LÜNEBURG D GERMANY

Note
This manual applies to the entire series.
Order number
P/N = Order number for Nordson products
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2005.
No part of this document may be photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained in this publication is subject to
change without notice.
© 2007 All rights reserved.
Trademarks
AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,
CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem,
Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry,
Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso-Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,
Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan,
OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus, ProBlue, Pro-Flo,
ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure,
Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure-Max,
Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray,
Walcom, Watermark, When you expect more. are registered trademarks − ® − of Nordson Corporation.
Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series,
CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat,
DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site, HDLV, Ink-Dot, iON,
Iso-Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, Minimeter, Multifil, Myritex, OptiStroke,
Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue,
Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix,
SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Viper, Vista, VersaDrum, VersaPail,
WebCure, 2 Rings (Design) are trademarks − T − of Nordson Corporation.
Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners’ rights.
P/N 7105731J DD200 E 2007 Nordson Corporation

Table of Contents I
Table of Contents
Nordson International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
Distributors in Eastern & Southern Europe . . . . . . . . . . . . . . . . O-1
Outside Europe / Hors d’Europe / Fuera de Europa . . . . . . . . . . . O-2
Africa / Middle East . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-2
Asia / Australia / Latin America . . . . . . . . . . . . . . . . . . . . . . . . . . O-2
Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-2
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Instructions and Safety Messages . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installation Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Maintenance and Repair Practices . . . . . . . . . . . . . . . . . . . . . . . 1-6
Equipment Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Relieving System Hydraulic Pressure . . . . . . . . . . . . . . . . . . 1-7
De-energizing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Disabling the Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
General Safety Warnings and Cautions . . . . . . . . . . . . . . . . . . . 1-9
Other Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
E 2007 Nordson Corporation DD200 P/N 7105731J

II Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unintended Use − Examples − . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Area of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Definition of Term(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Note on Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
ID Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Button Two-hand Control and Selector Raise/Lower Platen 2-6
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fan with Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Melting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Exhaust Hood (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Light Tower (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
High Drum Jacket for Cardboard Drums (Accessory) . . . . . . . 2-9
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Raising and Lowering Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Deaerating Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Aerating Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Melting Process and Material Flow . . . . . . . . . . . . . . . . . . . . . . . 2-11
Heating and Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Undertemperature Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Undertemperature Indication . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Overtemperature Indication / Shutdown . . . . . . . . . . . . . . . . 2-12
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Table of Contents III
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lifting (Unpacked System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lifting with a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mounting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Exhausting Material Vapors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Observe when Using Residual Current Circuit Breakers . . . . . 3-4
Laying Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
External Control and Switching Circuits . . . . . . . . . . . . . . . . . . . 3-5
Hose Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Assembly Handgun Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Additional Hose Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Second Open-jawed Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Connecting and Adjusting Compressed Air . . . . . . . . . . . . . . . . . . 3-7
Pneumatic Cylinder Working Pressure . . . . . . . . . . . . . . . . . . . . 3-7
Pressure Controller Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Compressed Air for Aerating Drum . . . . . . . . . . . . . . . . . . . . . . . 3-8
Adapting the System to the Drum Used . . . . . . . . . . . . . . . . . . . . . 3-8
Limiting How Far the Platen is Lowered . . . . . . . . . . . . . . . . . . . 3-8
Speed Setpoint and Output Quantity . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Overtravel Time When Drum Empty . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Setting Overtravel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Installing System Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Setting up an Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Installing System Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Setting up an Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Setting up Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Setting up the Bulk Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Selecting Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . 3-18
Reading or Editing Operating Parameters . . . . . . . . . . . . . . 3-19
Setpoint Temperature of the Platen, Hoses and Guns . . . . . . 3-24
Save and Restore Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Review Parameter and Setpoint Temperature Changes . . . . . 3-27
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Exhaust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
High Drum Jacket for Cardboard Drums . . . . . . . . . . . . . . . . . . 3-31
Timer Relay Overtravel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Installing the Timer Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Detaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

IV Table of Contents
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Heated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting the Bulk Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
To Start the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Monitoring the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Confirm that the System is Operating Correctly . . . . . . . . . . . . 4-5
Drum Empty LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Monitor Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . 4-6
To Check Component Temperatures
Using the Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
To Manually Check a Component’s Temperature . . . . . . . . 4-7
Monitoring Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
F1, F2 and F3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
F4 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Resetting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Monitoring the Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
To Reset the Service LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Adjusting Component Temperatures . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Recommended Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
To Adjust the Setpoint Temperature
Using the Global Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
To Adjust the Setpoint Temperature
Using the Global-by-component Method . . . . . . . . . . . . . . . . 4-16
To Adjust the Setpoint Temperature of an
Individual Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Enter Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Heater Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Pump Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Seven-day Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Standby Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Inserting and Replacing Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Raising Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lowering Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Principle Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Raising/Lowering Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Motor Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
LED in Selector Raise/Lower Platen . . . . . . . . . . . . . . . . . . . . . . 4-30
Switching System ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Daily Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Daily Switchoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Switching Off in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Settings Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Table of Contents V
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Relieving Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Important when Using Cleaning Agents . . . . . . . . . . . . . . . . . . . . . 5-2
Processing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Visual Inspection for External Damage . . . . . . . . . . . . . . . . . . . . . . 5-4
Changing Type of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Purging with Cleaning Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning Melting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fan and Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Activating the Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Checking for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tightening Gland Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tightening Fixing Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Motor / Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Changing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Compressed Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Draining Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Pressure Restrictor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Checking Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pressure Restrictor Valve for Aerating Drum . . . . . . . . . . . . 5-9
Pressure Restrictor Valve at Compressed Air Connection . 5-10
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Maintenance Record Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Some Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Light Tower (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
System does not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
One Channel (Heating Zone) does not Heat . . . . . . . . . . . . . . . 6-3
Control Panel does not Function . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
No Material (Motor does not Rotate) . . . . . . . . . . . . . . . . . . . . . 6-4
No Material (Motor Rotating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Too Little Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Material Pressure too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Material Pressure too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
LEDs of Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

VI Table of Contents
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Replacing Sealing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Replacing O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Replacing Platen Temperature Sensor and Thermostat . . . . . . . 7-4
Identifying Installed Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Replacing Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Installing Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How to Use Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Component Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Motors / Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Output Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Temperatures and Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Identifying Installed Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Material Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Air Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Exhaust Hood (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
General Instructions Regarding Working with

Application Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Risk of Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Vapors and Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Processing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
Seven-day clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15
To Set the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
PID Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Introduction O-1
Nordson International
http://www.nordson.com/Directory
Country Phone Fax
Europe
Austria 43-1-707 5521 43-1-707 5517
Belgium 31-13-511 8700 31-13-511 3995
Czech Republic 4205-4159 2411 4205-4124 4971
Denmark Hot Melt 45-43-66 0123 45-43-64 1101
Finishing 45-43-200 300 45-43-430 359
Finland 358-9-530 8080 358-9-530 80850
France 33-1-6412 1400 33-1-6412 1401
Germany Erkrath 49-211-92050 49-211-254 658
Lüneburg 49-4131-8940 49-4131-894 149
Nordson UV 49-211-9205528 49-211-9252148
EFD 49-6238 920972 49-6238 920973
Italy 39-02-904 691 39-02-9078 2485
Netherlands 31-13-511 8700 31-13-511 3995
Norway Hot Melt 47-23 03 6160 47-23 68 3636
Poland 48-22-836 4495 48-22-836 7042
Portugal 351-22-961 9400 351-22-961 9409
Russia 7-812-718 62 63 7-812-718 62 63
Slovak Republic 4205-4159 2411 4205-4124 4971
Spain 34-96-313 2090 34-96-313 2244
Sweden 46-40−680 1700 46-40-932 882
Switzerland 41-61-411 3838 41-61-411 3818
United Hot Melt 44-1844-26 4500 44-1844-21 5358
Kingdom
Finishing 44-161-495 4200 44-161-428 6716
Nordson UV 44-1753-558 000 44-1753-558 100
Distributors in Eastern & Southern Europe

DED, Germany 49-211-92050 49-211-254 658
E 2007 Nordson Corporation

All rights reserved
NI_EN_M-0307
O-2 Introduction
Outside Europe / Hors d’Europe / Fuera de Europa

S For your nearest Nordson office outside Europe, contact the Nordson
offices below for detailed information.
S Pour toutes informations sur représentations de Nordson dans votre

pays, veuillez contacter l’un de bureaux ci-dessous.
S Para obtener la dirección de la oficina correspondiente, por favor

diríjase a unas de las oficinas principales que siguen abajo.
Contact Nordson Phone Fax
Africa / Middle East

DED, Germany 49-211-92050 49-211-254 658
Asia / Australia / Latin America

Pacific South Division, 1-440-685-4797 −
USA
Japan
Japan 81-3-5762 2700 81-3-5762 2701
North America
Canada 1-905-475 6730 1-905-475 8821
USA Hot Melt 1-770-497 3400 1-770-497 3500
Finishing 1-880-433 9319 1-888-229 4580
Nordson UV 1-440-985 4592 1-440-985 4593

NI_EN_M−0307 All rights reserved
Safety 1-1
Section 1
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation,
operation, and maintenance (hereafter referred to as “use”) of the product
described in this document (hereafter referred to as “equipment”).
Additional safety information, in the form of task-specific safety alert
messages, appears as appropriate throughout this document.
WARNING: Failure to follow the safety messages, recommendations, and

hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.
Safety Alert Symbols

The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.
WARNING: Indicates a potentially hazardous situation that, if not avoided,

can result in serious personal injury, including death.
CAUTION: Indicates a potentially hazardous situation that, if not avoided,

can result in minor or moderate personal injury.
CAUTION: (Used without the safety alert symbol) Indicates a potentially

hazardous situation that, if not avoided, can result in damage to equipment
or property.

A1EN−01−[XX−SAFE]−10
1-2 Safety
Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information,
ensuring that all instructions and regulatory requirements for use of the
equipment are met, and for qualifying all potential users.
Safety Information
S Research and evaluate safety information from all applicable sources,
including the owner-specific safety policy, best industry practices,
governing regulations, material manufacturer’s product information, and
this document.
S Make safety information available to equipment users in accordance
with governing regulations. Contact the authority having jurisdiction for
information.
S Maintain safety information, including the safety labels affixed to the
equipment, in readable condition.
Instructions, Requirements, and Standards

S Ensure that the equipment is used in accordance with the information
provided in this document, governing codes and regulations, and best
industry practices.
S If applicable, receive approval from your facility’s engineering or safety
department, or other similar function within your organization, before
installing or operating the equipment for the first time.
S Provide appropriate emergency and first aid equipment.
S Conduct safety inspections to ensure required practices are being
followed.
S Re-evaluate safety practices and procedures whenever changes are
made to the process or equipment.
A1EN−01−[XX−SAFE]−10 E 2006 Nordson Corporation

Safety 1-3
User Qualifications
Equipment owners are responsible for ensuring that users:
S Receive safety training appropriate to their job function as directed

by governing regulations and best industry practices
S Are familiar with the equipment owner’s safety and accident
prevention policies and procedures
S Receive, equipment- and task-specific training from another qualified
individual
NOTE: Nordson can provide equipment-specific installation,
operation, and maintenance training. Contact your Nordson
representative for information
S Possess industry- and trade-specific skills and a level of experience

appropriate to their job function
S Are physically capable of performing their job function and are not
under the influence of any substance that degrades their mental
capacity or physical capabilities

1-4 Safety
Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in the
manner described in this document. The information provided here is not
meant to include all possible safety practices, but represents the best safety
practices for equipment of similar hazard potential used in similar industries.
Intended Use of the Equipment

S Use the equipment only for the purposes described and within the limits
specified in this document.
S Do not modify the equipment.
S Do not use incompatible materials or unapproved auxiliary devices.
Contact your Nordson representative if you have any questions on
material compatibility or the use of non-standard auxiliary devices.
Instructions and Safety Messages

S Read and follow the instructions provided in this document and other
referenced documents.
S Familiarize yourself with the location and meaning of the safety warning
labels and tags affixed to the equipment. Refer to Safety Labels and
Tags (if available) at the end of this section.
S If you are unsure of how to use the equipment, contact your Nordson
representative for assistance.

Safety 1-5
Installation Practices
S Install the equipment in accordance with the instructions provided in this
document and in the documentation provided with auxiliary devices.
S Ensure that the equipment is rated for the environment in which it will be
used and that the processing characteristics of the material will not
create a hazardous environment. Refer to the Material Safety Data
Sheet (MSDS) for the material.
S If the required installation configuration does not match the installation
instructions, contact your Nordson representative for assistance.
S Position the equipment for safe operation. Observe the requirements for
clearance between the equipment and other objects.
S Install lockable power disconnects to isolate the equipment and all
independently powered auxiliary devices from their power sources.
S Properly ground all equipment. Contact your local building code
enforcement agency for specific requirements.
S Ensure that fuses of the correct type and rating are installed in fused
equipment.
S Contact the authority having jurisdiction to determine the requirement for
installation permits or inspections.
Operating Practices
S Familiarize yourself with the location and operation of all safety devices
and indicators.
S Confirm that the equipment, including all safety devices (guards,
interlocks, etc.), is in good working order and that the required
environmental conditions exist.
S Use the personal protective equipment (PPE) specified for each task.
Refer to Equipment Safety Information or the material manufacturer’s
instructions and MSDS for PPE requirements.
S Do not use equipment that is malfunctioning or shows signs of a
potential malfunction.

1-6 Safety
Maintenance and Repair Practices

S Perform scheduled maintenance activities at the intervals described in
this document.
S Relieve system hydraulic and pneumatic pressure before servicing the
equipment.
S De-energize the equipment and all auxiliary devices before servicing the
equipment.
S Use only new or factory-authorized refurbished replacement parts.
S Read and comply with the manufacturer’s instructions and the MSDS
supplied with equipment cleaning compounds.
NOTE: MSDSs for cleaning compounds that are sold by Nordson are
available at www.nordson.com or by calling your Nordson
representative.
S Confirm the correct operation of all safety devices before placing the
equipment back into operation.
S Dispose of waste cleaning compounds and residual process materials
according to governing regulations. Refer to the applicable MSDS or
contact the authority having jurisdiction for information.
S Keep equipment safety warning labels clean. Replace worn or
damaged labels.

Safety 1-7
Equipment Safety Information

This equipment safety information is applicable to the following types of
Nordson equipment:
S hot melt and cold adhesive application equipment and all related
accessories
S pattern controllers, timers, detection and verification systems, and all
other optional process control devices
Equipment Shutdown
To safely complete many of the procedures described in this document, the
equipment must first be shut down. The level of shut down required varies
by the type of equipment in use and the procedure being completed. If
required, shut down instructions are specified at the start of the procedure.
The levels of shut down are:
Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulic
connection or seal. Refer to the melter-specific product manual for
instructions on relieving system hydraulic pressure.
De-energizing the System

Isolate the system (melter, hoses, guns, and optional devices) from all
power sources before accessing any unprotected high-voltage wiring or
connection point.
1. Turn off the equipment and all auxiliary devices connected to the
equipment (system).
2. To prevent the equipment from being accidentally energized, lock and

tag the disconnect switch(es) or circuit breaker(s) that provide input
electrical power to the equipment and optional devices.
NOTE: Government regulations and industry standards dictate specific

requirements for the isolation of hazardous energy sources. Refer to
the appropriate regulation or standard.

1-8 Safety
Disabling the Guns

All electrical or mechanical devices that provide an activation signal to the
guns, gun solenoid valve(s), or the melter pump must be disabled before
work can be performed on or around a gun that is connected to a
pressurized system.
1. Turn off or disconnect the gun triggering device (pattern controller, timer,
PLC, etc.).
2. Disconnect the input signal wiring to the gun solenoid valve(s).
3. Reduce the air pressure to the gun solenoid valve(s) to zero; then
relieve the residual air pressure between the regulator and the gun.

Safety 1-9
General Safety Warnings and Cautions

Table 1-1 contains the general safety warnings and cautions that apply to
Nordson hot melt and cold adhesive equipment. Review the table and
carefully read all of the warnings or cautions that apply to the type of
equipment described in this manual.
Equipment types are designated in Table 1-1 as follows:
HM = Hot melt (melters, hoses, guns, etc.)

PC = Process control
CA = Cold adhesive (dispensing pumps, pressurized container, and
guns)
Table 1-1 General Safety Warnings and Cautions

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

reactive (PUR) hot melt or solvent-based material through a
compatible Nordson melter, read and comply with the material’s
MSDS. Ensure that the material’s processing temperature and
HM
flashpoints will not be exceeded and that all requirements for safe
handling, ventilation, first aid, and personal protective equipment are
met. Failure to comply with MSDS requirements can cause personal
injury, including death.
WARNING: Reactive material! Never clean any aluminum component

or flush Nordson equipment with halogenated hydrocarbon fluids.
Nordson melters and guns contain aluminum components that may
HM
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

before breaking any hydraulic connection or seal. Failure to relieve
HM, CA
the system hydraulic pressure can result in the uncontrolled release of
hot melt or cold adhesive, causing personal injury.
WARNING: Molten material! Wear eye or face protection, clothing

that protects exposed skin, and heat-protective gloves when servicing
HM equipment that contains molten hot melt. Even when solidified, hot
melt can still cause burns. Failure to wear appropriate personal
protective equipment can result in personal injury.
Continued...

1-10 Safety
General Safety Warnings and Cautions (contd)
Table 1-1 General Safety Warnings and Cautions (contd)
Equipment
WARNING: Equipment starts automatically! Remote triggering

devices are used to control automatic hot melt guns. Before working
on or near an operating gun, disable the gun’s triggering device and
HM, PC
remove the air supply to the gun’s solenoid valve(s). Failure to
disable the gun’s triggering device and remove the supply of air to the
solenoid valve(s) can result in personal injury.
WARNING: Risk of electrocution! Even when switched off and

electrically isolated at the disconnect switch or circuit breaker, the
equipment may still be connected to energized auxiliary devices.
HM, CA, PC 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 should not be used
with solvent-based adhesives that can create an explosive
HM, CA, PC atmosphere when processed. Refer to the MSDS for the adhesive to
determine its processing characteristics and limitations. The use of
incompatible solvent-based adhesives or the improper processing of
solvent-based adhesives can result in personal injury, including death.
WARNING: Allow only personnel with appropriate training and

experience to operate or service the equipment. The use of untrained
HM, CA, PC or inexperienced personnel to operate or service the equipment can
result in injury, including death, to themselves and others and can
damage the equipment.
Continued...

Safety 1-11
Equipment
CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces
of guns, hoses, and certain components of the melter. If contact can
HM 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 MSDS 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.
HM Certain hot melt materials can react with Type R fluid and form a solid
gum that can clog the equipment. Before using the equipment,
confirm that the hot melt is compatible with Type R fluid.

1-12 Safety
Other Safety Precautions

S Do not use an open flame to heat hot melt system components.
S Check high pressure hoses daily for signs of excessive wear, damage,
or leaks.
S Never point a dispensing handgun at yourself or others.
S Suspend dispensing handguns by their proper suspension point.
First Aid
If molten hot melt comes in contact with your skin:
1. Do NOT attempt to remove the molten hot melt from your skin.
2. Immediately soak the affected area in clean, cold water until the hot melt
has cooled.
3. Do NOT attempt to remove the solidified hot melt from your skin.
4. In case of severe burns, treat for shock.
5. Seek expert medical attention immediately. Give the MSDS for the hot
melt to the medical personnel providing treatment.

Introduction 2-1
Section 2
Introduction
Intended Use
Bulk melters of the series DuraDrum − hereafter also referred to as system
− may only be used to melt and feed suitable materials. When in doubt,
seek permission from Nordson.
CAUTION: Only undamaged and suitable drums may be used (Refer to

Technical Data).
CAUTION: PUR material may be processed only in models with exhaust

hood (accessory)!
Any other use is considered to be unintended. Nordson will not be liable for
personal injury or property damage resulting from unintended use.
Intended use includes the observance of Nordson safety instructions.
Nordson recommends obtaining detailed information on the materials to be
used.
Unintended Use − Examples −

The systems may not be used under the following conditions:
S In defective condition
S With electrical cabinet door open
S In a potentially explosive atmosphere
S With unsuitable operating/processing materials
S When safety valves and pressure restrictor valves are not lead-sealed
S When the values stated under Technical Data are not complied with.
The systems may not be used to process the following materials:
S Explosive and flammable materials
S Erosive and corrosive materials
S Food products.

2-2 Introduction
Area of Use
The system is designed for use in industrial areas.
When using in industrial areas and in small businesses, the system may
cause interference in other electrical units, e.g. radios.
Residual Risks
In the design of the system, every measure was taken to protect personnel
from potential danger. However, some residual risks can not be avoided.
Personnel should be aware of the following:
S Risk of burns from hot material
S Risk of burns from hot system components
S Risk of burns when conducting maintenance and repair work for which
the system must be heated up
S Risk of burns when attaching and removing heated hoses
S Material fumes can be hazardous. Avoid inhalation
S Risk of pinching parts of the body between platen and drum or drum
jacket / bracket.
S The safety valve may malfunction due to hardened or charred material.
Definition of Term(s)
The safety valve is also referred to as bypass and bypass valve in Nordson
literature.
Note on Manual
S This manual is valid only in conjunction with all documents included in
the complete set of documentation (blue binder)
S When the system has special features, customer specifications and/or
supplements or a higher-ranking system description may be added to
this manual
S The position numbers in the illustrations do not correspond to the
position numbers in the technical drawings and parts lists. Refer to
separate document Parts List for details.

Introduction 2-3
ID Plate
DuraDrum 1 2
3
Nordson Engineering GmbH
4 Lilienthalstr. 6
D 21337 Lüneburg − Germany
Serial No: 5 Year www.nordson.com
Fig. 2-1
1 Bulk melter designation

2 Order number
3
4 Electrical connection, operating voltage, line voltage frequency, bulk melter fuse protection
5 Serial number

2-4 Introduction
Description
12
11
10
1
2
3 4 5 6 7 8 9
Fig. 2-2 Operating side

1 Electrical cabinet 4 Drum jacket 10 Pneumatic cylinder
2 Drum aeration (tube and hose) 5 Safety valve 11 Motor
3 Pressure controller Pneumatic 6 Pump / Adapter plate 12 Hose holder
cylinder 7 Drum deaeration
8 Drum aeration (rod)
9 Hose connection

Introduction 2-5
1
2
3
4
7 5
6
Fig. 2-3 Back

1 Cable gland Power supply 3 Additional hose receptacles 5 Hose receptacles (XS10, XS11)
2 Compressed air connection 4 Pressure controller 6 Receptacles Assembly handgun
Aerating drum (XS18, XS19)
7 Bracket

2-6 Introduction
Electrical Cabinet
2 2
3
7
6 4
Fig. 2-4
1 − 5 Air filter / Fan with filter
2 Button Two-hand control 6 Door lock
3 Selector Raise/lower platen 7 Control panel
4 Main switch
Button Two-hand Control and Selector Raise/Lower

Platen
Used to raise and lower the platen.
WARNING: The two-hand control may only be operated by one person

using both hands!

Introduction 2-7
Main Switch
The main switch is used to switch the system on and off.
Position 0/OFF = System is switched off.
Position I/ON = System is switched on.
Padlocks can be used to protect the main switch from being turned on by
unauthorized personnel.
Fan with Filter

The fan reduces the temperature inside of the electrical cabinet. The filter
must be serviced regularly. Refer to Maintenance.
Door Lock
The electrical cabinet can be opened for installation, maintenance and
repair. Store the included key such that it is accessible only to qualified and
authorized personnel. The system may not be operated when the electrical
cabinet is open.
Control Panel
1 2 3
10
8 7 6
Fig. 2-5 Control panel

1 Fault LED 4 Keypad 8 Left display and scroll key
2 Ready LED 5 Serial interface 9 Function keys
3 Component keys / LEDs 6 Right display and scroll keys 10 Service LED
7 Drum empty LED

2-8 Introduction
Platen
The platen consists of a heating punch, a melting plate and sealing rings.
NOTE: Models for cardboard drums have only the lower sealing ring on the
platen.
Fig. 2-6
1 Heating punch 2 Sealing rings 3 Melting plate
Melting Plates
Depending on what the bulk melter is used for, one of these melting plates
is used. The melting plates are all release coated.
Smooth melting plate Fine blade melting plate Axial melting plate
Fig. 2-7

Introduction 2-9
Exhaust Hood (Accessory)

If the system is used to process polyurethane hot melt adhesives (PUR),
fumes are created that should be suctioned off directly at the drum. An
exhaust hood is attached to the bulk melter for this purpose.
The exhaust hood must be connected to the customer’s exhaust device
(Also refer to Installation, Exhausting Material Vapors and Technical Data ).
Light Tower (Accessory)

The light tower shows the system operating modes.
White Switched on
Green Ready for operation
Yellow Drum empty
Red General alarm
Also refer to Troubleshooting and Installation.
High Drum Jacket for Cardboard Drums (Accessory)

CAUTION: Do not use metal drums with this model! The drum jacket is
desgned only for cardboard drums!
platen.

2-10 Introduction
Function
Raising and Lowering Platen

The pneumatic cylinders raise and lower the platen. When lowering the
platen, a two-hand control must be operated for safety reasons until the
platen is in the drum.
The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa /
108.75 psi) by a pressure restrictor valve.
Deaerating Drum
For the air to be able to escape as the platen is lowered into the drum, the
1 drum deaeration valve must be opened with the lever (1). Also refer to
section Operation, Lowering Platen.
Aerating Drum
To prevent a vacuum from forming with the platen is lifted out of the drum,
the drum must be aerated. Refer to section Operation, Raising Platen.
The air pressure in the drum is limited to 1.0 bar by a pressure restrictor
valve.
Air
Platen Platen
Compressed air
Drum Drum
Deaerating Aerating
Fig. 2-8

Introduction 2-11
Melting Process and Material Flow

The material is melted only directly below the melting plate (4). A gear pump
(1) feeds the melted material to the hose connection (3). From there it flows
through a heated hose to a gun or an assembly handgun, possibly to a
melter, to fill that unit.
A safety valve (2) limits the material pressure generated by the pump and
keeps it constant.
1 2
Fig. 2-9 Prinziple drawing

2-12 Introduction
Heating and Temperature Control

The platen is heated by cast-in heating elements.
Temperatures are measured by sensors and electronically controlled.
Undertemperature Interlock
The undertemperature interlock prevents the system from being started up
before the material has exceeded the temperature setpoint minus
undertemperature value. However, every time initial heating occurs, the
interlock is not released until the actual temperature is 3 °C (5.4 °F) below
the temperature setpoint.
The undertemperature interlock locks the motor, solenoid valves and, in
some cases, other components of the application system. Refer to the
wiring diagram to determine which components are locked.
Undertemperature Indication
If during operation the actual temperature falls below the setpoint minus the
undertemperature value, the relay output General alarm switches and the
fault LED lights up on the control panel (Refer to Fig. 2-5). The system
continues to operate despite the fault.
Overtemperature Indication / Shutdown

The independently operating overtemperature shutdown mechanisms
protect the system and the material from overheating. For overtemperature
shutdown, the heater and motor are switched off.
S Overtemperature indication through temperature controller: When the
temperature setpoint plus overtemperature value has been reached, the
relay output General alarm is switched and the fault LED lights up on the
control panel. The system continues to operate or remains ready despite
the fault.
S Overtemperature shutdown by temperature controller: The temperature
controller switches the heater off if the temperature is more than 30 °C
above the highest temperature setpoint.
S Overtemperature shutdown by thermostat(s): Serves as an emergency
switch OFF in case the overtemperature shutdown of the temperature
controller does not function properly. Refer to section Technical Data for
shutdown value.
WARNING: When the overtemperature shutdown is triggered, there is

either a fault in settings or system malfunction. Switch off the system and
have the fault remedied by qualified personnel.
Standby
Serves to protect the material and save energy during interruptions in
production or work stoppages. Standby value and standby period are
adjustable.

Introduction 2-13
Modes
DuraDrum bulk melters operate in the following modes:
Normal Mode
When the system is first switched on, it is in normal mode. In normal mode
the system checks the current temperature of the platen, the hoses and the
guns to verify that they are within the set temperature ranges.
Standby
The temperatures of the platen, the hoses and the guns are lowered from
their operating temperature (hereafter referred to as setpoint temperature)
by a set number of degrees.
Setup
Setup mode (configuration) is used to configure the control options and
features of the system as well as to check the saved operating data. The
system is protected by password from unauthorized changes to the
configuration.
Fault
The system alerts the user when a fault occurs, e.g. a sensor fault (RTD) or
a temperature that is not within the permitted range.

2-14 Introduction

Installation 3-1
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
Unpacking
Unpack carefully and check for damage caused during transport. Save
pallet and fastening and packing material for later use, or dispose of
properly according to local regulations.
Lifting (Unpacked System)

Refer to Technical Data for weight. Lift only with a suitable floor conveyor
(lift truck or fork lift) or a crane.
Lifting with a Crane

There are four eye bolts in the base plate of the bulk melter.
CAUTION: Guide the ropes such that they do not damage the bulk melter.
Transport
S Refer to Technical Data for weight. Use only suitable transport devices.
S If possible, use the pallet on which the system was delivered, and fasten
the system to the pallet.
S Protect from damage, moisture and dust with suitable packing material.
S Avoid jolts and vibrations.

3-2 Installation
Storage
Do not store system outside! Protect from humidity, dust and extreme
temperature fluctuations (formation of condensation).
Mounting the System

S Mount only in an environment that corresponds to the stated Degree of
Protection (Refer to Technical Data). Do not mount in a potentially
explosive atmosphere!
S Protect from vibration. Remove transport protection (if present).
S Ensure that there is sufficient clearance around the system, especially
above it. Refer to Technical Data for dimensions.
Fig. 3-1

Installation 3-3
Exhausting Material Vapors

Ensure that material vapors do not exceed the prescribed limits. Always
observe the safety data sheet for the material to be processed.
If necessary, exhaust material vapors and/or provide sufficient ventilation of
the location of the system. On systems with exhaust hoods, material vapors
are suctioned off directly at the drum.
NOTE: The exhaust hood must be connected to the customer’s exhaust
device. Also refer to Technical Data.
Customer’s
System without exhaust hood System with integrated exhaust hood
Fig. 3-2 Prinziple drawing

3-4 Installation
Electrical Connections
WARNING: Risk of electrical shock. Failure to observe may result in
personal injury, death, or equipment damage.
Observe when Using Residual Current Circuit Breakers

Local regulations in some geographic areas or industrial branches may
require residual current circuit breakers.
Then observe the following points:

S The residual current circuit breaker is to be installed only between the
power supply and the bulk melter.
S Only residual current circuit breakers sensitive to pulsating current or
universal current (> 30 mA) may be used.
Laying Cable
WARNING: Use only temperature resistant cable in the heating part of the
system. Ensure that cables do not touch rotating and/or hot parts. Do not
pinch cables and check regularly for damage. Replace damaged cables
immediately!
Line Voltage
WARNING: Operate only with the line voltage stated on the ID plate.
NOTE: Permitted deviation from the rated line voltage is +5% / -10%.
NOTE: The power connection cable must have a cross-section matching
the power consumption Pmax . (Refer to ID Plate).
Power Supply
The system must be installed securely (permanent power supply
connection). Refer to wiring diagram for connecting arrangement.

Installation 3-5
External Control and Switching Circuits

WARNING: Connect external control and switching circuits using suitable
NEC class I cables. In order not to cause short circuits lay cables such that
they do not touch any printed circuit boards.
Hose Receptacles
The hose receptacles (XS10 and XS11) are located in the terminal box (1).
1 For electrical connection values, refer to Technical Data.
Assembly Handgun Operation

The receptacles for assembly handguns (XS18 and XS19) are located in
the terminal box (1).
Additional Hose Receptacles

Depending on the model, two or four additional receptacles are available
(1). Two heating zones (usually for hose and gun) can be controlled via
each receptacle.

3-6 Installation
Installing Hoses
WARNING: Hot! Risk of burns. Wear heat-protective gloves.
Second Open-jawed Wrench

Use a second open-jawed wrench when connecting and disconnecting the
hose. This prevents the hose connection from turning.
Connecting
If cold material can be found in the hose connection, the components (2, 3)
1 2 3
must be heated until the material softens (approx. 70 °C (158 °F),
depending on material).
1. First connect the hose (3) electrically to the unit. For more than one
hose: Every hose connection is allocated to a corresponding receptacle.
Do not mistakenly exchange!
2. Heat the system and hose to approx. 80 _C (176 °F).
3. Screw the hose onto the unit.
NOTE: Close unused hose connections with Nordson port plugs.
Disconnecting
WARNING: System and material pressurized. Relieve system pressure
before disconnecting hoses. Failure to observe can result in serious burns.
Relieving Pressure
1. Switch off motor.
2. Place a container under the nozzle(s) of the gun/assembly handgun.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly handgun. Repeat this procedure until no more material
flows out.
4. Properly dispose of material according to local regulations.

Installation 3-7
Connecting and Adjusting Compressed Air

Connect dry, clean and non-lubricated compressed air to the compressed
air receptacle on the back of the system (2).
Minimum air pressure: 2.5 bar / 0.25 MPa / 36.25 psi
The pressure restrictor valve (1) behind the compressed air receptacle limits
the air pressure to 7.5 bar / 0.75 MPa / 108.75 psi.
1 2
Pneumatic Cylinder Working Pressure

Set the pneumatic cylinder working pressure to approx. 5 bar (0.5 MPa /
72.5 psi) on the pressure control valve with condensate collector (3)
The setting must be modified according to the material processed
(max. 7.5 bar / 0.75 MPa / 108.75 psi).
Pressure Controller Up
4 6
Set the compressed air to raise the platen to approx. 1.5 bar
(0.15 MPa / 21 psi) with the pressure controller (4, behind the cover (6)).
The pressure restrictor valve limits the pressure to 2.0 bar (0.2 MPa /
29 psi).

3-8 Installation
Compressed Air for Aerating Drum

Adjust the compressed air for aerating the drum with the pressure controller
5 6 (5, behind the cover (6) ). The pressure restrictor valve limits the air
pressure to 1,0 bar (0,1 MPa / 14,5 psi).
Adapting the System to the Drum Used
Limiting How Far the Platen is Lowered

The proximity switch Drum empty (-197B5) limits how far the platen is
lowered:
S Drum is not completely emptied:
Slide proximity switch down
S Drum empty is not indicated:
Slide proximity switch up
-197B5

Installation 3-9
Speed Setpoint and Output Quantity

WARNING: Disconnect the system from line voltage before opening the
electrical cabinet.
The speed is set with the terminal blocks (1 and 2) in the electrical cabinet.
1 2
Fig. 3-3
1. Terminal 1 2. Terminal 3
The resulting output quantity is a factor of the pump used.

NOTE: Refer to separate document Parts List to identify the pump used.
Pump / Output quantity in kg/h

Terminal 1 Terminal 3 Speed SN0371 SN0773 PU15/85 PU 25/85 PU35/85 PU50/85
(PR12m2) (PR25m2)
In Out 50 min−1 11 23 48 81 108 159
Out In 65 min−1 14,5 30 62 105 140 206
In In 129 min−1 29 60 124 210 280 412
Out Out 0 min−1 0 0 0 0 0 0

3-10 Installation
Overtravel Time When Drum Empty

If the accessory Timer relay is used, an Overtravel time can be set. During
the overtravel time, feeding can continue despite the Drum empty indication.
NOTE: The accessory Timer relay must be installed for the function
Overtravel time. Refer to Accessories, Timer Relay Overtravel Time.
Setting Overtravel Time

1. Locate the timer relay -197K4 in the electrical cabinet.

2. Verify that the selectors Time range and Mode on the timer relay are set
as shown in the wiring diagram.
3. Set time as required.
CAUTION: Do not operate Nordson pumps without material. For this

reason, the overtravel time should be set as short as possible. If necessary,
slide the proximity switch Drum empty (-197B5) up somewhat so that the
indication Drum empty occurs when there is still some material in the drum.
-197B5

Installation 3-11
Page remains empty.

3-12 Installation
Installing System Inputs

DuraDrum bulk melters are equipped with four standard inputs.
Fig. 3-4 XL2

The customer wires each input all the way to the system and then
configures it for one of the following control options:
S Change system to standby

S Switch heaters on or off
S Enable or disable a certain hose or gun
S Switch motor on or off
The inputs can be activated with the 24VDC signal (terminal 20) via the
external relay contact.
WARNING: The operator can bypass the inputs via the function keys on
the control panel. Ensure that the control unit for external devices that
transmit a signal to the system is programmed such that unsafe conditions
can not occur when the operator bypasses an external input on the system.

Installation 3-13
Setting up an Input
Set up the parameter control option for each input connected to the system.
Table 3-1 shows the control options available. Information on selecting
operating parameters and editing control options can be found under
Setting up the Bulk Melter.
Tab. 3-1 Input data

Terminals Operating
Input Control options Note
XL2 parameter
Standard inputs
NOTE: Terminals 9, 11, 13, 14, 18, 19 (0VDC) are jumpered at the factory. Refer to wiring diagram
0 - Input disabled
1 - Enter/exit standby
2 - Heaters on/off
3 - Enable/disable motor 1 A
4 - Enable/disable hose/gun 1
1 8 and 9 30
10 - Automatic standby (default) B
11 - Enable/disable motor 2
0 - Input disabled
1 - Enter/exit standby (standard)
2 - Heaters on/off
A
2 10 and 11 31 5 - Enable/disable hose/gun 2
3 12 and 13 32 Like parameter 31 (default = 2)
4 7 and 14 33 Like parameter 31 (default = 4)
NOTE A: If control option 3 is selected, the motor will not turn on—even if you press the pump key—if voltage is
not present on the input’s contacts.
B When control option 10 is selected for the input, a time must be set in parameter 24.

3-14 Installation
Installing System Outputs

The system has three outputs that the customer can configure as needed.
The outputs are used to exchange data with the customer’s production
equipment and control hardware such as a PLC.
NOTE: If a light tower (accessory) is installed, the outputs are already

assigned and can not be used otherwise.
Fig. 3-5 XL2

The customer wires each output and then configures it in the system’s
firmware for one of the following control options:
S System ready
S A fault has occurred
S Material level low
S Service LED on
S A potential fault is detected
Refer to wiring diagram for connecting arrangement.

Installation 3-15
Setting up an Output
Set up the parameter control option for each output connected to the
system. Table 3-2 shows the control options available. Information on
selecting operating parameters and editing control options can be found
under Setting up the Bulk Melter.
CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must be
set to the default.
Tab. 3-2 Output data

Terminals Operating
Output Control options Note
XL2 parameter
Standard outputs
NOTE: Terminals 1, 3, 5, 15, 20 (24VDC) are jumpered at the factory. Refer to wiring diagram
1 1 and 2 40 0 - Output disabled
1 - Ready (default)
2 - Ready and the motor is ON
3 - Fault
4 - Drum empty
5 - Service LED is ON
6 - Alert C
2 33 and 34 41 Same as parameter 40 (Default=3, may not be modified)
3 5 and 6 42 Same as parameter 40 (Default=4)
NOTE A:
B:
C: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6
are both used, then both a fault output and an alert output signal will be present when the fault LED
turns on.

3-16 Installation
Setting up Communication
With a computer connected to the system’s serial interface (1), all settings
1 can be displayed and changed, settings can be transferred between
systems and the system’s operating firmware can be up- and downgraded.
Setting up the Bulk Melter

The system can be set up to suit your manufacturing process, meaning that
the settings can deviate from the factory setup. System setup consists of
enabling or making changes to factory-set operating parameters that affect
the use and function of the system. The operating temperature (setpoint) of
the platen, each hose and each gun is established during setup.
The system is shipped from the factory with the most commonly used
operating parameters already set up. The factory setup can be modified at
any time to suit your manufacturing process.
Quick Setup
Table 3-3 describes the most commonly used operating parameters and
their factory settings. Review the table to determine whether the factory
settings for each parameter will support your manufacturing process. If the
default values for the operating parameters are appropriate for your
manufacturing process, then no system setup is required. To complete the
installation process, refer to Setpoint Temperature of Platen, Hoses and
Guns.
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.

Installation 3-17
Tab. 3-3 Common operating parameters

Parameter Parameter name Purpose Default value
A timer that delays enabling of the ready LED for a

pre-defined time period after the platen, hoses and
guns have reached the desired setpoint temperature.
4 Ready delay time The ready delay timer will only enable if the 0 minutes
temperature of the platen, at the time the system is
turned on, is below its assigned setpoint temperature
by 27 °C (50 °F) or more.
A timer that turns on a service LED when the value

set for the timer equals the number of hours that the
5 Service interval 500 hours
heaters have been on. The service LED signals 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.
Switches the pump on automatically as soon as the

8 Automatic pump on system is ready. Prerequisite: The pump has been Enabled
enabled by pressing the pump key.
Sets a password that must be entered before any

11 Create password operating parameter or setpoint temperature can be 5000
changed.
Sets the units of the temperature display to degrees

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

Overtemperature
21 component can exceed its assigned setpoint 15 °C (25 °F)
delta
temperature before an overtemperature fault occurs.
Sets the number of degrees that any heated

Undertemperature
22 component can drop below its assigned setpoint 25 °C (50 °F)
delta
temperature before an undertemperature fault occurs.
Sets the number of degrees that the temperature of all

23 Standby delta heated components will be decreased when the 50 °C (100 °F)
system enters the standby mode.
Sets the amount of time that the system will remain in

26 Manual standby time Disabled
the standby mode after the standby key is pressed.
A group of parameters that control the system’s clock.

50 to 77 Seven-day clock The clock is used to automatically turn the heaters on Disabled
and off and to enter standby.

3-18 Installation
Operating Parameters
The system uses operating parameters to store noneditable and editable
values. Noneditable values are those that provide information about the
historical performance of the system. Editable values are either a numeric
setpoint or a control option setting. Control option settings affect the display
of information or the function of the system.
Operating parameters are stored in the system’s firmware in the form of a
sequentially numbered list. The list is divided into the groups described in
table 3-4.
Tab. 3-4 Parameter groups

Group Parameters Description
Standard 0 to 11 Frequently used parameters
Temperature Control 20 to 29 Controls heater function
Input setup 30 to 38 Configure the standard and optional inputs
Output setup 40 to 46 Configure the standard and optional outputs
Seven-day clock 50 to 77 Configure the clock function
PID selection 80 to 91 Changes preset PID settings
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 3-5 lists all 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 effect on the system, 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 3-5 and
Appendix B.

Installation 3-19
Reading or Editing Operating Parameters

Regardless of whether a parameter’s value is editable or not, the procedure
for accessing each parameter in order to read or edit its current value is the
same.
To Read or Edit a Parameter

1. Switch on the system.
The system performs a startup check.
2. Press Setup key.
Parameter 1 flashes in the left display.
3. Use the keypad to enter the number of the desired parameter. Refer to
Table 3-5 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, then re-enter the correct
parameter number.
When you have finished entering the one- or two-digit parameter

number, the right display indicates the parameter’s current value.
4. Do one of the following:
S If the value is noneditable, refer to Monitoring the System in

Clear/Reset key section 4, Operation.
S If the value is editable, proceed to step 5.
5. Press the Enter key.
The right display flashes.
6. Use the keypad to enter the desired numeric setpoint or control option in
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 information you entered does not appear in the right
display, the system is protected by a password. You must enter a valid
password before parameters can be edited. Refer to section 4
Operation, Enter Password.

3-20 Installation
To Read or Edit a Parameter (contd.)
The system checks that the new value or control option is acceptable.
S If the numeric setpoint or control option is accepted, the left and right
displays show the next parameter number and value.
S If the numeric setpoint or control option is not accepted, the right
display shows dashes (----) for three seconds and then changes
back to the original value.
8. Repeat steps 5 to 7 to read or change the next parameter number, or

press the Setup key to exit the setup mode.
Tab. 3-5 Operating parameters

Parameter Name Value range Default value
Standard
0 Enter password 0 to 9999 4000
1 Total hours with heater on
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 0 to 8736 hours 500 hours
6 Service LED heater hours 0 to 9999 hours 0
7 Motor off delay 0 to 360 seconds 0 seconds
8 Automatic pump on 0 (disabled) or 1 (enabled) 1 (enabled)
10 Enable or disable password 0 (disabled) or 1 (enabled) 0 (disabled)
11 Create password 0 to 9999 5000
Change hose 1 output to electric gun
12 0 (disabled) or 1 (enabled) 0 (disabled)
activation
Change hose 2 output to electric gun
13 0 (disabled) or 1 (enabled) 0 (disabled)
activation
Continued...

Installation 3-21
Temperature control
20 Temperature units (degrees _C or _F) C (degrees Celsius) or F
C (degrees Celsius)
(degrees Fahrenheit)
21 Overtemperature delta 5 _C (10 _F) to 60 _C (110 _F) 15 _C (25_F)
22 Undertemperature delta 5 _C (10 _F) to 60 _C (110 _F) 25 _C (50_F)
23 Standby delta 25 _C (50 _F) to 190 _C (350
50_C (100_F)
_F)
24 Automatic standby timeout 0 to 1440 minutes 0 (disabled)
25 Automatic heaters off time 0 to 1440 minutes 0 (disabled)
26 Manual standby time 0 to 180 minutes 0 (disabled)
27A Hose standby delta 1 _C to 190_C (1_F to 350_F) 0 (disabled)
28A Gun standby delta 1 _C to 190_C (1_F to 350_F) 0 (disabled)
29A Internal zone temperature offset 0 _C to -15 _C (0 _F to -30 _F) 0_C (0_F)
Input setup
30 Standard input 1 10 (Automatic
0–11
standby)
31 Standard input 2 1 (Enter/exit
0–9, 11
standby)
32 Standard input 3 0–9, 11 2 (Heaters on/off)
33 Standard input 4 4 (Hose/gun 1
0–9, 11
enable/disable)
Output setup
40 Standard output 1 1–6 1 (Ready)
41 Standard output 2 1–6 3 (Fault)
42 Standard output 3 1–6 4 Low level
Continued...

3-22 Installation
Seven-day clock
50 Current day 1 to 7 (1 = Monday) —
51 Current time 0000 to 2359 —
55 Schedule 1 Heaters on 0000 to 2359 06:00
56 Schedule 1 Heaters off 0000 to 2359 17:00
57 Schedule 1 Enter standby 0000 to 2359 —:—
58 Schedule 1 Exit standby 0000 to 2359 —:—
60 Schedule 2 Heaters on 0000 to 2359 —:—
61 Schedule 2 Heaters off 0000 to 2359 —:—
65 Schedule 3 Heaters on 0000 to 2359 —:—
66 Schedule 3 Heaters off 0000 to 2359 —:—
71 Schedule for Monday 0−7 0
72 Schedule for Tuesday 0−7 0
73 Schedule for Wednesday 0−7 0
74 Schedule for Thursday 0−7 0
75 Schedule for Friday 0−7 0
76 Schedule for Saturday 0−7 0
77 Schedule for Sunday 0−7 0
PID Settings
0 or 1 (depending on
PID selection for receptacles, 0=hose; 1=standard gun;
80–91 selected
hose/gun 1 and 2 2=large gun; 3=air heater
component)
NOTE A: Only with software version 2.023 and higher

Installation 3-23
You can exit the setup mode at any time

by pressing the Setup key.
Parameter numbers that are not

applicable are skipped when scrolling
through the operating parameter list in
the left display.
When the right display is flashing, you
can set the value of the current
parameter to its lowest possible value by
simultaneously pressing both of the right
display scroll keys.
If no key is pressed for two minutes while

in setup mode, the system will return to
the normal mode.
You can also use the right display scroll
keys to enter or change a parameter’s
value or control option. After entering the
parameter number in the left display,
press either of the right display scroll
keys to change the value or control
option.
Using a personal computer that is

connected to the system through the
serial interface, you can view and change
all of the operating parameters.
If password protection is enabled, the Appendix B, Parameter 10
system will return to the password
protected mode whenever you exit the
setup mode.

3-24 Installation
Setpoint Temperature of the Platen, Hoses and Guns

The system is shipped from the factory with the platen setpoint temperature
at 175 °C (350 °F) and the hose and gun setpoint temperature at 0 degrees
(turned off).
Before the system can be used, a setpoint temperature must be assigned to
the platen, hoses and guns. Setpoint temperatures are assigned with any of
the following methods:
S Global — The platen and all hoses and guns are set to the same
setpoint temperature.
S Global-by-component group — All of the hoses or all of the guns are
set to the same setpoint temperature.
S Individual component — The setpoint temperature of the platen and
each hose and gun is set individually.
Since most manufacturing processes require the platen, hoses and guns to
be set to the same temperature, only the global method of assigning
setpoint temperatures is described in this section. For information about the
other two methods, refer to Adjusting Component Temperatures in
Section 4, Operation.
As with operating parameters, setpoint temperatures can be saved and
restored, and past changes that were made to setpoint temperatures can be
reviewed.

Installation 3-25
To Assign a Global Setpoint Temperature
1. Press and hold the Platen key for three seconds.
The left display flashes 1.
Platen key
2. Scroll the left display to 0.
The right display shows dashes (----) and the LEDs on the platen, hose
and gun keys turn green.
4. Use the keypad to enter the setpoint temperature recommended by the

Left display and
scroll key manufacturer of the material.
Refer to the data sheet provided by the manufacturer of the material for
the optimal setpoint temperature.
5. Press the Platen key.
Each component begins to heat or cool to the new global setpoint

Enter key
temperature, and the system returns to normal mode.
When all of the components have reached their global setpoint
temperature, the ready LED turns on (green).
Ready LED

3-26 Installation
Save and Restore Settings

The current value of all editable operating parameters and the setpoint
temperature of each component can be saved and, if necessary, restored at
a later time. When saved settings are restored, they 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 the system is to be
returned to its original state.
To Save Current Settings

With the system in normal mode, simultaneously press the number key 1
and the Setup key.
S-1 appears briefly in the right display.
+
Saving current settings
To Restore Saved Settings
CAUTION: All settings will be deleted! Before restoring saved settings,

ensure that use of the restored settings will not disrupt the current process
or create unsafe operating conditions.
With the system in normal mode, simultaneously press the number key 2
and the Setup key.
+
S-2 appears briefly in the right display.
Restoring saved settings
If the restore feature is used before the

save feature is used for the first time, the
factory default setpoint temperatures will
be restored. This will cause the hoses
and guns to stop heating.
Settings can be transferred from one

system to another using the Nordson
Configuration Manager software utility.

Installation 3-27
Review Parameter and Setpoint Temperature Changes

The system stores in a change history log a record of the last ten changes
that were made to either operating parameters or setpoint 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 Log History
1. Press Setup key.

Setup key Operating parameter 1 flashes in the left display.
2. Press the left display scroll key to change the display to parameter 3
(change history log).
The following occurs:
S If the last change was to an editable parameter, all of the component

key LEDs remain off.
Left display and or
scroll key
S If the last change was to a setpoint temperature, the LED on the
associated component key(s) turns on.
and
S The right display shows the four-digit log entry associated with the
last change that was made.
Table 3-6 indicates the meaning, from left to right, of each digit in the
log entry. Two sample log entries are shown following the table.
Component key LEDs
3. Press a right display scroll key to review each of the remaining nine log
entries. Each time a scroll key is pressed, a progressively older log entry
appears.
4. Press the Setup key to return to the normal mode.
Scrolling through the log

3-28 Installation
Tab. 3-6 Change history log

Second
First digit Third and fourth digit
digit
P Indicates the number of the parameter that was changed

(Parameter)
Used in conjunction with the LEDs on the component keys to indicate the location
and method of a setpoint temperature change.
When this LED is And the fourth The change was And the method
on.. digit indicates.. to.. of change was..
Platen key 1 Platen Individual
− Hose key 1– 6 A single hose Individual

S (Setpoint)
Gun key 1– 6 A single gun Individual
All keys 0 All components Global
Global-by-
Hose key 0 All hoses
component
Global-by-
Gun key 0 All guns
component
Change History Log Examples

Example 1:
Parameter 4 (ready delay) was changed.

Example 2:
If the LED on the gun key is on, then this display would
indicate that the global-by-component method was used to change the
temperature of the guns.

Installation 3-29
Unused log entries in the change history

log are indicated by ”P-_” in the right
display.
To view how many heater hours have
elapsed since the last change,
simultaneously press both of the right
display scroll keys.

3-30 Installation
Accessories
The following components can also be installed later as accessories:
Light Tower
Installing Kit
WARNING: Disconnect the system from the line voltage.
4 1
Fig. 3-6
CAUTION: If a light tower (accessory) is installed, the outputs 1 - 3 must be
set to the default.

Installation 3-31
1. Break out the plate from the top of the tower (1, Fig. 3-6) along the
punched lines and remove.
2. Swivel tower open.
3. Guide cable through the resulting hole.
4. Use the two screws M5 to fasten the light tower.
5. Guide the cable through the top opening of the tower and to the inside
wall (drum side) of the electrical cabinet.
6. Release knurled nut (4) from the bracket Cable duct (3). Slide bracket
up in the slot.
7. Guide the cable through the resulting opening to the terminal blocks
(6, Fig. 3-7) in the electrical cabinet door.
6
8. Place wire ends and bridges according to their designations (e.g. no. 5
to terminal 5). Refer to wiring diagram.
9. Use a cable tie to fasten the cable to one of the metal teeth (5) below
the bracket Cable duct.
10. Slide the bracket down and tighten knurled nut.
11. Close tower.
Fig. 3-7
Exhaust Hood
If the system is used to process polyurethane hot melt adhesives (PUR),
fumes are created that should be suctioned off directly at the drum. An
exhaust hood is attached to the bulk melter for this purpose.
The exhaust hood must be connected to the customer’s exhaust device
(Also refer to Installation, Exhausting Material Vapors and Technical Data ).
High Drum Jacket for Cardboard Drums

CAUTION: Do not use metal drums with this model! The drum jacket is
desgned only for cardboard drums!
NOTE: Bulk melters for cardboard drums have only the lower sealing ring
on the platen.

3-32 Installation
Timer Relay Overtravel Time

If the accessory Timer relay is used, an Overtravel time can be set. During
the overtravel time, feeding can continue despite the Drum empty indication.
Installing the Timer Relay

1. Refer to Fig. 3-8, A: Find the relay -197K4 in the electrical cabinet.
NOTE: The relay -197K4 is not standard until April 2005. The timer
relay can not be used in older systems.
2. Refer to Fig. 3-8, B: Release the clips (1) and extract the relay.
3. Press the strap (3) down with a screwdriver and remove the relay base
from the top hat rail (2).
4. Remove the clips and insert the new, longer clips.
5. Put the relay base back into place and secure with the strap.
6. Refer to Fig. 3-8, C: Verify that the selectors Time range and Mode on
the timer relay are set.
7. Insert the timer relay and secure with the clips.
8. Set the overtravel time. Refer to Overtravel Time When Drum Empty.
A B C
X
TIME RANGE
X
1 X
MODE
X
-197K4
2 3
Fig. 3-8

Installation 3-33
Initial Startup
After the system has been correctly installed, initial startup may begin. Refer
to section Operation.
Detaching
1. Convey all material out of the system and remove drum.
2. When system will not be used for longer periods of time, purge with
cleaning agent if necessary (Refer to Maintenance).
3. Wipe off sealing ring and clean melting plate (Refer to Maintenance).
4. Disconnect all lines to the system, and allow system to cool.
Disposing
When your Nordson product has exhausted its purpose and/or is no longer
needed, dispose of it properly according to local regulations.

3-34 Installation

Operation 4-1
Section 4
Operation
Initial Startup
NOTE: Some of the following steps are described in detail in this section.
1. Set selector Raise/lower platen to 0.
2. Set main switch to I/ON.
3. Operator panel: Set values and parameters.
4. Wait until the system has heated up and is ready for operation (LED on
the control panel lights up green).
5. Insert drum.
6. Pre-select motor and switch on.
7. Optimize settings and record in settings record form.
NOTE: All system functions were tested before the system left the factory.
Special test material was used. There may be residue from this material on
the melting plate, in the pump, etc. To remove such residue, melt and feed
several kilograms of material before starting production.

4-2 Operation
Heated Components
The system contains three groups of heated components: the platen, the
hose group and the gun 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 number of the platen is fixed at 1. Hose and gun
position numbers are automatically assigned based on the hose/gun
receptacle they are connected to. For example, the position numbers of a
hose/gun pair that is connected to the second receptacle would be hose
Component keys position 2 and gun position 2.
(platen, hose and gun)
NOTE: In some installations, auxiliary devices (such as a heated air
manifold) may be connected to a hose/gun receptacle. In such cases, you
should label (or otherwise identify) the auxiliary device as to the hose or gun
position number that represents the device. The control panel will identify
such devices as a hose or gun, regardless of what the device actually is.
Pump
After initial startup check the pump for leakage; tighten the gland bolt if
necessary. Refer to Maintenance.

Operation 4-3
Starting the Bulk Melter

Before starting the system for the first time, confirm that
S The system is fully installed, including any required inputs and

outputs, gun drivers, pattern controllers or timers.
S The system’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 System

1. Switch on the system.
The system
S Tests the control panel LEDs
S Turns on the heaters (the heater LEDs turn green)
S Begins to automatically scan through and display the actual
temperature of the platen, hoses and guns. The sequence of the
automatic scan is: platen, each hose/gun pair and then back to the
platen.
S Turns on the ready LED (green) when the platen and all of the hoses
Heater LED and guns are within 3 _C (5 _F) of their assigned setpoint
temperature.
CAUTION: Do not operate pump without material. Before switching on the

motor, ensure that the system is equipped with a filled drum.
2. Press the pump key (1) to enable the pump.

Automatic scan sequence S If the system has not reached the system-ready state at the time that
the pump key is pressed, the LED on the pump key will turn yellow,
indicating that the pump is enabled but not started. The pump will
start automatically when the system-ready state is reached.
S If the system has reached the system-ready state at the time that the
Ready LED pump key is pressed, the pump will start and the LED on the pump
key will turn green, indicating that the pump is running.
NOTE: You can change the way the pump key operates by changing
parameter 8 (automatic pump on). Refer to Appendix B, Operating
Parameters.
NOTE: The key for pump 2 has no function.
1
Pump key

4-4 Operation
If the system is switched on when the temperature Appendix B, Parameter 4

of the platen is 27 _C (50 _F) or greater below its
assigned setpoint temperature (cold start condition),
the Ready LED will not turn on until the ready delay
(defined when the system was set up) has elapsed.
The time remaining on the ready delay (in minutes) Appendix B, Parameter 4
appears in the right display at the end of every scan
cycle. When less than one minute remains in the
ready delay time, the right display counts down in
seconds.
You can bypass the ready delay time by pressing

the Heater key twice.
The appearance of F4 in the right display Monitoring Faults

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

immediately after starting the system indicates that
a hose or gun cordset may be loose or
disconnected.
If the system is set up for manual pump activation Appendix B, Parameter 7

and the parameter 7 (motor off delay) has been
changed from the default, the pump will not stop
until a user-specified amount of time has elapsed.
The (logical) state of one or more inputs may Installing System Inputs in section
prevent the heaters from being turned on. 3, Installation
If the seven-day clock feature was set up and turned Function Keys
on when the system was last switched off, the clock
will automatically turn on the next time the system is
switched on.
If a power failure occurs, the system will restart in its

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

Operation 4-5
Monitoring the System

The system has display elements that
S Quickly confirm that the system is operating correctly

S Monitor the actual temperature of the melting plate and each hose
and gun
S Identify faults
S Alert the operator when service is required.
S Indicate Drum empty.
The system automatically determines the number and location of all hoses
and guns that are connected to it. Refer to Heated Components, earlier in
this section, for information on the identification of heated components.
A computer can also be used to monitor the system.
Confirm that the System is Operating Correctly

The ready LED turns on (green) when all of the heated components are
within 3 _C (5 _F) of their assigned setpoint temperature.
The ready LED will not turn on, or will turn off, if any of the following events
occur:
Ready LED S The ready delay is still counting down

S The operator or a remote input places the system in standby mode
S The seven-day clock places the system in standby mode
S There is a fault (the fault LED will turn on).
S Drum is empfty.
Refer to Monitoring Faults and Function Keys later in this section for
information on system faults and using the seven-day clock and standby
functions. Refer to Appendix B for information on the ready delay.
Drum Empty LED

When the platen is far enough down a proximity switch on the pneumatic
cylinder closes and the Drum empty LED (yellow) will turn on.
Drum empty LED

4-6 Operation
Heated components with a setpoint temperature of

zero degrees are skipped during the automatic scan
cycle.
The time remaining on the ready delay appears in Appendix B, Parameter 4

the right display at the end of every scan cycle.
You can override the seven-day clock at any time. If Function Keys
the clock has turned the heaters off, pressing the
heater key will turn the heaters back on. If the clock
has placed the system in standby mode, pressing
the standby key will return the heated components
to their assigned setpoint temperatures.
Monitor Component Temperatures

The actual temperature of each heated component − platen and each hose
and gun − can be checked using the normal mode or by manually selecting
and checking each component.
By default, the system remains in the normal mode except when:
S The system is in setup mode

S The setpoint temperature of all hoses and guns is set to zero
degrees
S A fault occurs.
To Check Component Temperatures Using the Normal

Mode
1. When the Ready LED is on, observe the LEDs on the component keys.
2. When the LED on the key that represents the desired component group
(platen, hose or gun) turns on, observe the left display until it shows the
position number of the specific component to be checked.
3. When the position number of the desired component appears in the left
display, the right display shows the component’s actual temperature.
LEDs on component keys

Operation 4-7
To Manually Check a Component’s Temperature

1. Press the key (platen, hose or gun) that represents the component
group to be checked.
The automatic scan stops and the left display indicates the number of
the first sequential component in the selected component group. The
right display shows the component’s actual temperature.
Left display and
scroll key NOTE: When the platen key is pressed, the left display does not show a
component number (blank display).
2. If the first sequential component is not the component to be checked,

use the left display scroll key to move to the correct component number.
The right display shows the actual temperature of the selected

component.
Component temperature display
3. Press the Setup key twice to return to the normal mode.
When you scroll the left display past the number of

the last sequential component on a component
group, the number of the first component in the next
group appears.
The systems returns to normal mode two minutes

after the last key is pressed.
The default for the temperature display is degrees Appendix B, Parameter 20

Celsius (C). This may be changed to degrees
Fahrenheit with parameter 20.
The LEDs on each component key will change from

green to yellow if any component in the group drops
more than 3 _C (5 _F) below its assigned setpoint
temperature.
The setpoint temperature of a component can be

checked at any time by pressing the right display
UP scroll key. Holding down the scroll key while the
system is in normal mode reveals the setpoint of
each component that is scanned.

4-8 Operation
Monitoring Faults
The system alerts the operator to the faults listed in Table 4-1.
Tab. 4-1 Fault codes

Fault code Type of fault Description
RTD (resistance The RTD for the component indicated has failed or the component was
F1
temperature detector) disconnected from the system.
The actual temperature of the component indicated has dropped below the
F2 Undertemperature
undertemperature delta, which was set using parameter 21.
The actual temperature of the component indicated has increased beyond the
F3 Overtemperature
overtemperature delta, which was set using parameter 21.
Problem with a board, cable harness or control component. The sub-code in

F4 Electrical or control failure
the left display shows the failed component or the cause of the fault.
F1, F2 and F3 Faults

When the system detects an F1, F2 or F3 fault:
1. The automatic scan stops and the system begins to monitor the
potential fault for up to two minutes. The ready and heater LEDs remain
on during the two minute period. If the system detects during this time
that the fault condition no longer exists, the system returns to normal
mode.
2. The LED on the affected component key (platen, hose or gun) turns on
to indicate the type of component that has, or is, failing.
3. The right display indicates the type of fault (F1, F2 or F3).
4. The left display indicates the component that has, or is, failing.
Typical error code display
S If the LED on the heater key is lit, the left display shows either 1 for
the platen or 2 for the pump.
S If the LED on the hose or gun key is lit, the left display shows the
number of the affected hose or gun.
5. If the fault condition still exists at the end of the two minutes, the Ready
LED turns off, the red fault LED lights up and the system records the
fault in the fault log. Refer to section Fault Log in this section.
Fault LED (red)
To be able to put the system back into operation, the fault must be remedied
and the system reset (reset key). Refer to section 6, Troubleshooting for
information on diagnosis and remedies. Also refer to Resetting System.

Operation 4-9
To view the temperature of a heated component

when an F2 or F3 fault exists, simultaneously press
and hold down both of the right display scroll keys.
An F1 fault (RTD) can be temporarily dismissed and

the system returned to normal mode by pressing the
Clear/reset key. The heaters will remain off. If the
fault condition still exists two minutes after pressing
the clear/reset key, the fault LED will light up again.
When an F1 fault code appears, you can determine

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

(458 _F), an immediate F3 fault will occur (no two
minute monitoring period).
F4 Fault
When the system detects an F4 fault:
1. The Ready LED turns off and the red fault LED lights up.
2. All of the component key LEDs (platen, hose and gun) turn off.
Fault LED (red)
3. The right display indicates F4.
4. The left display shows a fault subcode. The subcode identifies the faulty
component or the specific source of the fault.
NOTE: If the F4 fault is nonfatal (subcode 3, 4 or 5 in the left display),

the fault LED lights up for five seconds and the system returns to normal
mode. Nonfatal F4 faults affect only the functions dependent on the
seven-day clock.
5. The system records the fault in the fault log. Refer to Fault Log in this
section.
To be able to put the system back into operation, the fault must be remedied
and the system reset (reset key). Refer to section 6, Troubleshooting for
information on diagnosis and remedies. Also refer to Resetting System.

4-10 Operation
Resetting System
1. Correct the fault. Refer to section 6, Troubleshooting for information on
diagnosis and remedies.
2. Return the system to normal mode by pressing the Setup key twice.
Clear/Reset key
3. Press the Clear/Reset key.
4. Press the Heater key to switch on the heaters.
Heater key
If the clock key is pressed when a nonfatal F4 fault

has occurred, the right display shows F4 and the
clock does not work.

Operation 4-11
Fault Log
1. Hold down Setup key.
The automatic scan stops, and parameter 1 appears in the left display.
2. Scroll the left display to parameter 2 (fault log).

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

First digit Second and third digit Fourth digit
Component: Type of fault:
1 = Platen or hose/gun 1 0 = Unused log entry

2 = Pump or hose/gun 2 1 = RTD (open or short)
-F
3 = Hose 3 or gun 3 2= Component undertemperature
4 = Hose 4 or gun 4 3 = Component overtemperature
5 = Hose 5 or gun 5 4 = Processor or electrical failure
6 = Hose 6 or gun 6
Subcode for fault type F4:

Assigned by Nordson

4-12 Operation
Fault Log Examples
Example 1:
Unused log entry
Example 2:
If the LED on the platen key is lit, the log entry indicates
platen undertemperature. If the LED on the hose key is lit, the log entry
indicates hose 1 undertemperature.
To view the number of heater hours since the last

log entry, simultaneously press both of the right
display scroll keys. The hours appear in the right
display.
The system will return to the normal mode if the

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

being disconnected from the system, two fault log
entries are created. The first entry is for the gun, the
second for the hose.

Operation 4-13
Monitoring the Service Interval

The system can be set up such that the service LED on the left side of the
control panel lights up after a customer-defined time period has elapsed.
The service LED can be used to signal any customer-specified maintenance
task. When maintenance is completed, the service LED must be reset.
To Reset the Service LED

Press the Clear/Reset key to turn off the service LED and reset the service
interval.
Service LED (yellow)
Clear/Reset key
The default setting for the service interval is Appendix B, Parameter 5

500 hours.

4-14 Operation
Adjusting Component Temperatures

The setpoint temperatures of the heated components can be adjusted as
follows:
S Global − The platen and all hoses and guns are set to the same
setpoint temperature.
S Global-by-component group − All of the hoses or all of the guns
are set to the same setpoint temperature.
S Individual component − The setpoint temperature of the platen and
each hose and gun is set individually.
Before adjusting setpoint temperatures, verify that each hose/gun pair is

connected to the correct receptacle. For example, hose/gun pair 1 should
be connected to receptacle 1. Refer to Heated Components, earlier in this
section, for information on hose/gun positions.
Recommended Temperatures
The temperature setting is determined by the processing temperature
prescribed by the material supplier. The maximum operating temperature for
the system and heated components described here may not be exceeded.
CAUTION: Nordson will grant no warranty and assume no liability for
damage resulting from incorrect temperature settings.
Platen Prescribed processing temperature

(Material quantity used < 50 g/min: up to 10 °C (up to 18 °F) below
prescribed processing temperature)
Undertemperature value 10 °C (18 °F) below set processing temperature
(warning)
Undertemperature value 15 °C (18 °F) below set processing temperature
(fault)
Overtemperature value 10 °C (18 °F) above set processing temperature
(warning)
Overtemperature value (fault) 15 °C (27 °F) above set processing temperature
Gun (accessory) Prescribed processing temperature
Hose (accessory) Prescribed processing temperature

Operation 4-15
To Adjust the Setpoint Temperature Using the Global

Method
1. Press and hold the Platen key for three seconds.
The left display flashes 1.
Platen key
2. Scroll the left display to 0 (flashing).
The right display shows dashes (----) and the LEDs on all components
turn green.
Left display and

scroll key 4. Use the keypad to enter the setpoint temperature recommended by the
manufacturer of the materal. Refer to the data sheet provided by the
manufacturer of the materal for the optimal setpoint temperature.
NOTE: If the keypad or the right display scroll keys have no effect on
the right display, the system is protected by a password. Enter a valid
password before changing the setpoint temperatures. Refer to Enter
Password in this section.
Enter key
5. Press the Platen key.
All of the components begin to heat or cool to the new global setpoint
temperature. When all of the components have reached their setpoint
temperatures, the Ready LED lights up (green).
Ready LED

4-16 Operation
To Adjust the Setpoint Temperature Using the

Global-by-component Method
1. Press and hold the Hose or Gun key for three seconds.
The left display indicates the number of the first sequential hose or
gun. The right display indicates the current setpoint temperature of the
hose or gun.
2. Scroll the left display to 0.
Platen, hose and gun keys The right display indicates all dashes (- - - -).

The hoses or guns begin to heat or cool to the new global setpoint
temperature.

Operation 4-17
To Adjust the Setpoint Temperature of an Individual

Component
1. Press and hold the Platen, Hose or Gun key for three seconds.
If the platen key has been pressed, the left display flashes 1. If a hose or
gun key was pressed, the left display flashes the number of the first
sequential hose or gun. The right display then indicates the current
setpoint temperature of the component shown in the left display.
2. Scroll the left display to the number of the desired component.
The right display then indicates the current setpoint temperature of the
component selected in the left display.

5. Do one of the following:
S To register the new setpoint temperature and then move on to

change the setpoint temperature of the next sequential component,
press the Enter key. Then repeat steps 4 and 5.
S To register the new setpoint temperature and return to normal mode,

go to step 6.
6. Press any component key (platen, hose or gun).
The selected component begins to heat or cool to its new setpoint

temperature.

4-18 Operation
If you enter a valid setpoint temperature for a hose/gun

that is not connected to the system or if you enter a
setpoint temperature that is out of range, the right display
will indicate dashes (----) for three seconds and then
change back to the original setpoint temperature.
When the right display is flashing, you can change the

current setpoint temperature to 0 degrees by
simultaneously pressing both of the right display scroll
keys.
If the global or global-by-component method is used to set

the setpoint temperature and then a hose or gun is added
later, the setpoint temperature of the hose or gun must be
adapted or adjusted. If a hose or gun is removed, use the
individual component method to set the setpoint tempera-
ture of the removed component to 0 degrees. This will
avoid an F1 fault. When a hose or gun is added, use the
individual component method to set the desired tempera-
ture.
The factory setpoint temperature of the platen is 175 _C

(350 _F). The factory setpoint temperatures of all other
components is zero degrees (off).
When the temperature unit is set to degrees Celsius, the

minimum and maximum setpoint temperatures are 40 _C
and 230 _C. When the temperature unit is set to degrees
Fahrenheit, the minimum and maximum setpoint
temperatures are 100 _C and 450 _C.
When a setpoint temperature is set with the right scroll

keys, the right display automatically jumps from 0 to
175 _C or from 0 to 350 or 450 _F.
If you make a mistake while changing a setpoint

temperature but have not yet pressed the Enter key, press
the Clear/Reset key to reset the right display to the
original temperature.
The systems exits setup mode and returns to normal

mode two minutes after the last key is pressed.
A global setpoint temperature of zero degrees (Celsius or

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

display, component numbers assigned to unused
hose/gun receptacles are skipped.
The system stores a record of the last ten changes made Section 3, Installation, Review
to setpoint temperatures (and operating parameters) in a Parameter and Setpoint
change history log. Temperature Changes
Changes to setpoint temperatures can be saved by Section 3, Installation, Save

simultaneously pressing the keys 1 and Setup. and Restore Settings

Operation 4-19
Enter Password
If a system is password protected, a valid password must be entered before
any setpoint temperature can be entered or any parameter changed.
1. Press Setup key.
Parameter 0 flashes in the left display, and the right display shows 4000.
The right display begins to flash.
3. Enter the password with the keypad.
NOTE: The password is created and enabled/disabled during system

setup.
Then the following occurs:

S If the password is correct, the left display indicates parameter 1.
S If the password is incorrect, the left display remains at 0, while the
right display briefly indicates dashes (----) then returns to 4000.
If the password is incorrect, reenter it and then press the Enter key.
The system reverts to password protected mode

2 minutes after the last key (any key) is pressed. To
return to password protected mode before 2 minutes
have elapsed, press the Setup key twice.
The password is created and enabled/disabled during Setting Up the System in section
system setup. 3, Installation

4-20 Operation
Function Keys
The control panel provides the following standard and special function keys:
Standard function keys

S Heater
S Pump
S Setup
Special function keys
S Seven-day clock
S Standby
VORSICHT: Unintentionally activating function keys can have undesirable

effects on the system or the manufacturing process. Only personnel familiar
with the system’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 heater control by the seven-day clock
feature or a remote input. The LED on the heater key is lit when the heaters
are on.
Heater key
When a fault occurs (Refer to Monitoring 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.

Operation 4-21
Pump Key
Press the pump key (1) to enable, start or stop the pump. The LED on the
pump key is yellow when the pump is enabled (not yet running) and green
when the pump is running. Switching the pump on or off has no effect on the
1 heater control.
If the automatic pump on feature (parameter 8) is disabled, then the pump

Pump key key must be used to start the pump when the system is ready.
If any of the inputs are set up to use the pump enable/disable control option
(option 3 and option 11), the pump motor will not start until the pump is
enabled and the correct voltage is applied to the input contacts. If the pump
is enabled but the input voltage is not present, the pump LED will flash
green.
NOTE: The key for pump 2 has no function.
Setup Key
The setup key is used to place the system into and take the system out of
setup mode. In setup mode the automatic scan stops. The left and right
displays are used to select, read and edit operating parameters.
Setup key

4-22 Operation
Seven-day Clock Key

Use the seven-day clock key to turn the 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.
Four clock schedules are available to accommodate daily shift work and
non-working days. Three of the schedules are used to specify when the
Seven-day clock key heaters should turn on or when the system should enter and exit standby
mode. The fourth schedule determines the days on which the system
should be switched off.
When the heaters switch on as dictated by the schedule, they are regulated
to their assigned setpoint temperatures. When the clock activates the
standby mode, the setpoint temperatures are all temporarily reduced by a
preset standby delta.
For information about setting up the seven-day clock and the standby delta,
refer to Setting up the Bulk melter in section 3, Installation as well as to
appendix B, Operating Parameters.
If the system is switched off while the clock is on,

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

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

faulting or in setup mode.
If F4 appears in the right display when the clock key

is pressed, the clock function has failed. Contact
Nordson customer service to remedy the fault.

Operation 4-23
Standby Key
The standby key is used to enter and exit standby mode. Using the standby
mode during periods when no material is being fed helps to conserve
energy and allows heated components to quickly return to their setpoint
temperatures when the system is once again needed.
Standby key
When the system enters standby mode, the temperatures of all components
are reduced from their setpoint temperatures by a preset standby delta. The
system remains in standby mode until the standby key is pressed or one of
the operating parameters causes the system to exit standby mode.
If the system was set up to use the manual standby timer (parameter 26),
pressing the standby key places the system in standby mode for the period
of time specified by the timer. After the manual standby time has expired,
the system once again begins heating all of the components to their
assigned setpoint temperatures.
Using the standby key overrides the control of the system (on or off) by the
seven-day clock or a remote input.
For information on setting the standby delta and the standby timer, refer to
Setting up the Bulk Melter in section 3, Installation as well as to appendix B,
Operating Parameters.
The system may be set up to automatically enter Appendix B, Parameters 25, 26,
standby mode using a variety of operating 30–33, 57, 62 and 67
parameters.
Whenever manual standby is activated, the standby Appendix B, Parameter 26

LED flashes.

4-24 Operation
Inserting and Replacing Drum

CAUTION: Place only undamaged, suitable drums in the system; otherwise
the platen sealing ring will be damaged. Always keep the base plate of the
system clean so that the drum is positioned straight.
WARNING: Risk of burns! Hot material can splash out when the platen
exits the drum. Hot material may flow out of the deaeration valve. Wear
suitable protective clothing!
1. Raise platen (Refer to the next page). If there is no drum in place − e.g.
upon initial startup − the two hand control must be operated to raise the
punch:
a. Set selector Raise/lower platen to Raise.
b. Operate the two hand control until the platen is higher than the base
plate by more than the height of one drum.
2. Set selector Raise/lower platen to 0/Stop.
3. Insert or replace drum.
4. Lubricate sealing ring. Refer to Processing Materials in the section
Maintenance.
5. Lower platen (Refer to the page after next).
6. Properly dispose of empty drum according to local regulations.

Operation 4-25
Raising Platen
NOTE: Refer to Principle Wiring Diagrams in this section.
1
2
3
4
5
Fig. 4-1
If the platen is inside of the drum, the drum must be aerated to support
raising. Aerating means that compressed air is forced under the platen.
1. Verify that the selector Raise/lower platen (1) is set to 0.
2. Screw the rod (4) out of the aeration connection (5).
3. Screw in the aeration tube (3).
4. Open the shutoff valve Compressed air to aerate drum (2).
5. Set selector Raise/lower platen to Raise.
The air pressure in the drum is limited to 1.0 bar (100 kPa / 14.5 psi) by a
pressure restrictor valve.

4-26 Operation
Lowering Platen
NOTE: Refer to Principle Wiring Diagrams on the following pages.
CAUTION: If the platen is lowered when no drum is inserted − e.g. to
transport the system − place a squared timber underneath. This protects the
sensor Drum inserted from damage.
Fig. 4-2

Operation 4-27
2
3
4
Fig. 4-3
The drum must always be deaerated when the platen is moved into the
drum. When the drum is deaerated, the air that is under the platen escapes.
1. Set selector Raise/lower platen (1) to Lower.
2. Place the drip pan (3) in front of the deaearation valve (4).
3. Open the deaeration valve with the lever (2).
4. Press both buttons on the two-hand control at the same time (within
0.5 seconds) until the platen is inside of the drum. Lowering continues
automatically as soon as the platen reaches the material. The green
LED on the selector Raise/lower lights up when the platen reaches the
material.
5. Close deaeration valve when material flows out free of bubbles.
6. Properly dispose of material according to local regulations.

4-28 Operation
Principle Wiring Diagrams
Raising/Lowering Platen
24 VDC
Proximity switch
Drum empty Drum not empty
P Pressure switch Two hand Sensor

control Drum in place
Selector Selector
Lower Raise
LED Solenoid valve Solenoid valve

Drum empty Lower Raise
Fig. 4-4

Operation 4-29
Motor Enable
Proximity switch
Drum empty Drum not empty
Pressure switch
Enable motor to
motor controller
Fig. 4-5

4-30 Operation
LED in Selector Raise/Lower Platen
Pressure switch
Selector LED
Platen has contact with adhesive
Fig. 4-6

Operation 4-31
Switching System ON/OFF

NOTE: Before initial startup, read and observe the instructions in Initial
Startup. Start up only as described under Initial Startup.
NOTE: The main switch must be set to I/ON (switched on) when using the
week timer.
Daily Startup
NOTE: Do not operate Nordson pumps without material. Before switching
on motor, ensure that a drum that is not empty is in the system and that the
platen has contact with the material.
1. Set main switch to I/ON.
2. Set selector Raise/lower platen to Lower.
3. Wait until system is ready.
4. Switch on motor.
Daily Switchoff
1. Set main switch to 0/OFF and protect from unauthorized access with
padlocks if necessary.
2. Set selector Raise/lower platen to 0/stop.
3. Perform daily maintenance.
Switching Off in an Emergency

WARNING: Immediately switch off the system in any emergency situation.
1. Set main switch to 0/OFF.

2. Set selector Raise/lower platen to 0/stop.
3. After standstill and before switching the system back on, have the fault
remedied by qualified personnel.

4-32 Operation
Settings Record
Production information:
Material: Manufacturer
Processing temperature
Viscosity
Cleaning agent: Manufacturer

Flash point
Reference channel: Factory-set
Processing temperatures (setpoint temperatures)

Platen
Hose (accessory) 1) 2) 3) 4)
Gun (accessory) 1) 2) 3) 4)
Assembly handgun (accessory) 1) 2) 3) 4)
Motor/pump speeds:
Motor/pump
Air pressure: bar MPa psi

Operating pressure
Notes:
Name Date

Maintenance 5-1
Section 5
Maintenance
NOTE: Maintenance is an important preventive measure for maintaining

operating safety and extending the lifetime of the unit. It should not be
neglected under any circumstances.
Risk of Burns
Some maintenance work can only be done when the system is heated up.
WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective
gloves.
Relieving Pressure
WARNING: System and material pressurized. Relieve system of pressure
before disconnecting hoses, guns and hot melt handguns. Failure to
observe can result in serious burns.
1. Switch off motor.

2. Place a container under the nozzle(s) of the gun/assembly handgun.
3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger
of the assembly handgun. Repeat this procedure until no more material
flows out.
4. Re-use the material or dispose of properly according to local
regulations.

5-2 Maintenance
Important when Using Cleaning Agents

S Use only a cleaning agent recommended by the hot melt material
manufacturer. Observe the Material Safety Data Sheet for the cleaning
agent.
S Properly dispose of cleaning agent according to local regulations.
Processing Materials
Before using, read the included EU safety data sheet.
Designation Order number Use

High temperature grease To be applied to O-rings and
threads
S Can 10 g P/N 394 769
NOTE: The grease may not be
S Tube 250 g P/N 783 959 mixed with other lubricants.
Oily/greasy parts must be cleaned
S Cartridge 400 g P/N 402 238 before application.
Grease Centoplex H0 P/N 285 600 Lubricating platen sealing ring
S 1kg
Temperature-resistant Secures screw connections
adhesive Loctite 640
S 50 ml P/N 230 359
Heat transfer compound To improve heat conducting of
temperature sensors
S 500 g P/N 257 326

Maintenance 5-3
Preventive Maintenance
The maintenance intervals are general guidelines based on experience.
Depending on the surrounding conditions, production conditions and
operating time of the system, other maintenance intervals may prove
necessary.
NOTE: Coupling and motor controller are maintenance-free.
System part Activity Interval Refer to

Complete system External cleaning Daily 5-4
Inspect for external damage 5-4
Power cable Inspect for damage −
Air hoses Inspect for damage −
Melting plate Check melting plate for charred Every time the drum is changed 5-5
material, clean if necessary
Base plate Check base plate for material Every time the drum is changed −
residue or other impurities, clean if
necessary
Pressure switch Check that the green LED on the Every time the drum is changed −
selector Raise/lower lights up
when the platen reaches the
material.
Electrical cabinet Clean fan screens, clean or Daily, if dust accumulation is 5-5
ventilation replace filter severe
Safety valve Activate the safety valve piston Weekly 5-6
Pump Tighten gland bolt After initial startup 5-6
Check for leakage, tighten gland Dependent on hours of
bolt if necessary operation, pump speed and
pump temperature
Recommendation: Monthly
Tighten fixing screws Every 500 hours of operation
Motor / gear box Clean fan cover Depending on dust −
accumulation; daily if necessary
Change lubricant Every 15 000 hours of operation 5-7
or every 2 to 3 years
Compressed air filter Drain condensate Weekly 5-8
Clean filter element Every three months
Cleaning condensate collector When cleaning filter element
Pressure restrictor Performance check Every six months 5-9
valves Clean When not functioning correctly

5-4 Maintenance
External Cleaning
External cleaning prevents pollution created by production from causing
system malfunctions.
CAUTION: Observe the unit’s Degree of Protection when cleaning (Refer
to section Technical Data).
CAUTION: Do not damage or remove safety labels. Damaged or removed

safety labels must be replaced by new ones.
Remove material residue only with a cleaning agent recommended by the

material supplier. Heat with an air heater if necessary.
Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.
Visual Inspection for External Damage

WARNING: When damaged parts endanger the operating safety and/or the
safety of personnel, switch off the system and have the damaged parts
replaced by qualified personnel. Use only original Nordson spare parts.
Changing Type of Material

NOTE: Before changing the material type, determine whether the old and
new material can be mixed.
S May be mixed: Remaining old material can be flushed out using the new
material.
S May not be mixed: Purge thoroughly and clean melting plate with a
cleaning agent recommended by the material manufacturer (Refer to
Cleaning Melting Plate).
NOTE: Properly dispose of the old material according to local regulations.

Maintenance 5-5
Purging with Cleaning Agent

Insert drum filled with cleaning agent for purging the system. Feed cleaning
agent until it comes out free of adhesive residue.
CAUTION: Use only a cleaning agent recommended by the hot melt
material manufacturer. Observe the Material Safety Data Sheet for the
cleaning agent.
Before starting production again, flush out residue of the cleaning agent
using the new material.
NOTE: Properly dispose of cleaning agent according to local regulations.
Cleaning Melting Plate

The melting plate is standardly release-coated. This makes it easy to clean.
Cooled material can usually be pulled off of the melting plate; if necessary,
first heat to approx. 60 °C / 140 °F.
CAUTION: Do not use hard or metallic tools to clean. Do not use wire
brushes! This could damage the release coating. Use only soft aids
(wooden or Teflon spatula or soft brush).
Fan and Air Filter

Depending on dust accumulation, the air filters in the fan and for the air
outlet must be cleaned (knocked out) or replaced.
Refer to separate document Parts List for filter order numbers.
Fig. 5-1
1 Fan 2 Air filter, air outlet

5-6 Maintenance
Safety Valve
Activating the Piston

NOTE: Activating the piston helps to prevent adhesive from causing
blockage.
Operate the system at maximum motor speed and with hose connections
closed. Switch the motor on and off several times.
Pump
Checking for Leakage

The pump is equipped with a self-sealing pump shaft seal. Material may
seep out of the seal at irregular intervals. The gland bold must then be
tightened.
NOTE: When the pump shaft seal needs to be replaced, Nordson
recommends replacing the pump and sending the old one in to be repaired.
Only trained personnel can replace the pump shaft seal.
Tightening Gland Bolt

NOTE: Tighten only when the system is warm.
Tighten the gland bolt approx. ¼ of a revolution in the operating direction of

the pump. If tightening is no longer possible, the pump must be replaced.
Fig. 5-2
Tightening Fixing Screws

Normal heat cycling (heating and cooling) can cause the fixing screws to
become loose.
NOTE: Tighten the fixing screws only using a torque wrench (25 Nm /
220 Ibin) and only when the system is cold.

Maintenance 5-7
Motor / Gear Box
Changing Lubricant
NOTE: Use only the stated lubricant or one that has proven to be
equivalent. Using any other lubricant can result in premature wear and/or
damage to the gear box.
NOTE: Drain lubricant when warm.
Unscrew gear box from motor to change lubricant. Wash out casing with
suitable cleaning agent and remove lubricant residue.
NOTE: Properly dispose of the old lubricant according to local regulations.
Lubricant Changing Interval

Operating temperature < 100°C / 212°F:
Every 15 000 hours of operation or at least every 2 to 3 years.
Capacity
The lubricant quantity is indicated on the power plate. Ensure that the upper
gears and rolling bearings are properly lubricated.
NOTE: Never mix different types of lubricants.
Lubricant Selection
Lubricant manufacturer Mineral oil CLP 220
AGIP Blasia 220
ARAL Degol BMB 220 or Degol BG 220
BP Energol GR-XP 220
DEA Falcon CLP 220
ESSO Spartan EP 220 or GP 90
KLÜBER Klüberoil GEM 1-220
OPTIMOL Optigear 220
SHELL Omala Oil 220
TEXACO Geartex EP-A SAE 85 W-90

5-8 Maintenance
Compressed Air Filter

The compressed air filter dehydrates and cleans the compressed air.
Draining Condensate
Drain condensate before it reaches a level approx. 10 mm below the filter
disk.
To do this, open the condensate drain valve (7).
7
10 mm
Cleaning Filter Element

Under normal conditions, clean filter element (5) approx. every three
months. Clean sooner if compressed air filter outlet pressure falls.
1
1. Shut off compressed air supply and release residual pressure by
opening the condensate drain valve (7).
2 2. Unscrew condensate collector (6).
3 3. Unscrew filter element (5) by turning to the left.
4. Rinse filter element (5) with suitable cleaning agent. Then blow out from
4 the inside. The condensate collector (6) may not come into contact with
the cleaning agent!
5. Clean condensate collector (6) if necessary. Use only water!
5 6. Reassemble compressed air filter.

Maintenance 5-9
Pressure Restrictor Valve

The factory-set, lead-sealed pressure restrictor valves prevent
unpermissibly high pressurization of subsequent pneumatic components.
When the factory settings are exceeded, compressed air audibly escapes.
Checking Function
Functioning of the pressure restrictor valves should be checked approx.
every six months. When functioning is not correct, a pressure restrictor
valve should be cleaned. If it still does not function, it must be replaced.
NOTE: A defective pressure restrictor valve may be replaced only with an
original spare valve. Repairs to the pressure restrictor valve may be made
only by the manufacturer!
Pressure Restrictor Valve for Aerating Drum

If the customer’s equipment has a pressure gauge with a 1/4’’ fitting:
1. Reduce compressed air to 0 bar on pressure controller (1).
2. Release the fitting (2) on the tube (3) far enough that it can be turned
forward.
3. Replace the tube with a pressure gauge (4).
4. On the pressure controller, increase the compressed air to higher than
1.0 bar and observe whether the pressure restrictor valve (behind the
cover (5)) opens.
3 4
Fig. 5-3

5-10 Maintenance
Pressure Restrictor Valve for Aerating Drum (contd.)

If the customer’s equipment has no pressure gauge with a 1/4’’ fitting:
1. Reduce compressed air to 0 bar on pressure controller.
2. Unscrew cover (5, Fig. 5-3).
3. Detach the pressure restrictor valve (6).
6 4. Check pressure restrictor valve functioning outside of the system, in the

customer’s compressed air system.
Pressure Restrictor Valve at Compressed Air

Connection
On the compressed air connection (2), increase the compressed air to
higher than 7.5 bar and observe whether the pressure restrictor valve (1)
opens.
1 2

Maintenance 5-11
Cleaning
Impurities that have penetrated seat surfaces and conical nipples can be
removed by unscrewing the entire top piece − without changing the
minimum operating pressure. Use a sickle wrench to unscrew.
ÂÂ
ÂÂ
Â
Performance check Unscrewing top
Fig. 5-4

5-12 Maintenance
Maintenance Record Form

System part Date / name Date / name Date / name
Electrical cabinet ventilation
Compressed air filter
Pressure restrictor valves
Safety valve
Pump
Motor / gear box

Troubleshooting 6-1
Section 6
Troubleshooting
WARNING: Troubleshooting activities may sometimes have to be carried

out when the system is energized. Observe all safety instructions and
regulations concerning energized unit components (active parts). Failure to
observe may result in an electric shock.
Some Tips
Before systematic troubleshooting is begun, the following should be
checked:
S Are all parameters set correctly?
S Do all plug connections have sufficient contact?
S Have circuit breakers been activated?
S Are external, inductive loads (e.g. solenoid valves) equipped with
recovery diodes? The recovery diodes must be directly allocated to the
inductive load.
Light Tower (Accessory)

S White = Switched ON. After switching on and during the heatup phase,
at first only the white indication lamp is lit (normal condition). A fault has
only occurred when the temperature does not increase (observe
temperature display) and when the green indication lamp is not lit after
the heatup phase has ended (1 hour and longer).
S Green = Ready. The green indication lamp lights when all channels have
reached their setpoint temperatures.
S Orange = Drum empty.
S Red = General alarm.

6-2 Troubleshooting
Troubleshooting Tables
The troubleshooting tables serve as an orientation for qualified personnel.
They cannot, however, replace targeted fault location with the help of wiring
diagrams and measuring instruments. They also do not include all possible
problems, only those which most typically occur.
Fault Codes
Display
Affect on
Code/Sub- Name Cause Corrective Action
System
code
The RTD for the component Replace RTD
indicated has failed or the Check hose/gun connections
F1/None RTD
component was disconnected from
the system.
The actual temperature of the Check for conditions that may

component indicated has dropped cause a drop in ambient
below the under temperature delta, temperature
Under tempera-
F2/None Heaters turn off which was set using parameter 22.
ture Raise the set-point temperature of
the component
Replace RTD
The actual temperature of the Replace RTD

Over tempera- component indicated has increased
F3/None
ture beyond the over temperature delta,
which was set using parameter 21.
System stops Internal RAM failure Replace CPU

F4/1 RAM test
functioning
Internal Clock Internal clock failure Replace CPU

F4/2
time
Internal Clock Internal time failure Replace CPU

F4/3
time Heaters remain
on, but fault
Internal clock condition Battery-backed RAM failure Replace CPU
F4/4 battery backed persists
RAM
Internal clock Battery-backed RAM battery dead Replace CPU

F4/5
battery
Analog-to-digi- RTD analog-to-digital converter Replace main board or CPU

F4/6
tal failed
Analog-to-digi- RTD analog-to-digital converter Replace main board or ribbon

F4/7
tal calibration could not be calibrated cable, or CPU
Main board Communication failure between Replace main board, ribbon cable,
F4/8
feedback main board and CPU or CPU
System stops
Expansion functioning Communication failure between Replace expansion board, ribbon
F4/9
board feedback expansion board and CPU cable, or CPU
Tank or manifold thermostat is Replace thermostat, J7 harness, or

F4/A Thermostat
open main board
Expansion Faulty connection between Check or replace four single wires

F4/C board connec- expansion board and CPU between main board and
tion expansion board

Troubleshooting 6-3
Display
Affect on
Code/Sub- Name Cause Corrective Action
System
code
Communica- Heaters remain Communication failure between Replace the I/O card or CPU
tions with on, but fault CPU and the optional I/O card
F4/d
optional I/O condition
card persists
Alert output (if Fieldbus card failure. Replace the Fieldbus card
output option 6
Fieldbus com- is selected)
F4/E munications
failure System contin-
ues to operate
normally
NOTE: Sub-code F4/b does not exist. Thus, confusion with F4/6 is avoided.
System does not Function
Problem Possible Cause Corrective Action

1. No line voltage − Connect line voltage
2. Main switch not − Switch on main switch
switched on
3. Main switch defective − Replace main switch
4. Main circuit breaker − Switch on main circuit breaker
activated
5. Main circuit breaker Check for short circuit in system or −
activated again accessories
6. System has no There is no compressed air Connect compressed air
pneumatic function
One Channel (Heating Zone) does not Heat

1. Channel is disabled / − Enable / switch on
switched off

6-4 Troubleshooting
Control Panel does not Function

1. Display is blank PLC broad-band cable not Connect
connected
No Material (Motor does not Rotate)

1. System not yet ready − Wait until system is heated up.
for operation (heatup
phase)
2. Motor not switched − Switch on motor
on
3. Proximity switch Cable pulled off Connect
Drum empty does not Switch defective Replace
switch
4. Pressure switch does Switch defective Replace
not switch
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 controller − Replace
defective

Troubleshooting 6-5
No Material (Motor Rotating)

1. Drum empty − Replace drum
2. Material supply hole − Remove pump and clean supply hole
to pump or pump or suction hole
suction hole clogged
Too Little Material

1. Material supply hole − Remove pump and clean supply hole
to pump or pump or suction hole
suction hole partially
clogged
2. Processing − Correct temperature setting
temperature set too
low
3. Pump block is worn − Replace pump
Material Pressure too High

1. Safety valve dirty and − Disassemble and clean or replace
thus clogged
2. Safety valve defective − Replace
3. Too much pressure − Reduce pressure
applied to safety
valve

6-6 Troubleshooting
Material Pressure too Low

1. Pump is worn − Replace pump
2. Safety valve does not − Replace
close any more
Others

1. Leakage at pump Pump shaft seal is worn Tighten 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 heatup phase (expansion pressure)
5. Platen lifts the drum Lifting speed too high Refer to Installation, Adapting the
6. Drum is not Proximity switch Drum empty is set System to the Drum Used
completely emptied incorrectly
7. Drum empty is not
indicated

Troubleshooting 6-7
LEDs of Motor Controller

During operation the operating mode of the motor controller is displayed by
two LED’s on the front of the unit.
Fig. 6-1 LEDs
LED display Operating mode

Green Red
On Off Motor controller enabled
On On Mains switching and automatic start blocked
Flashing Off Motor controller blocked
Off Flashing (every 1 s) Fault message
Off Flashing (every 0.4 s) Undervoltage shutdown
Off Off Programming mode or no voltage supply

6-8 Troubleshooting

Repair 7-1
Section 7
Repair
WARNING: Hot! Risk of burns. Wear appropriate protective

clothing/equipment. Some maintenance work can only be done when the
system is heated up.
WARNING: System and material pressurized. Relieve system of pressure

before disconnecting hoses, guns and hot melt handguns. Failure to
observe can result in serious burns.
General Notes
S Material hoses can not be repaired. However, defective hoses can be
exchanged for overhauled hoses with full guarantee through Nordson’s
AT program (replacement program).
S The processed material must be soft for disassembly of some
components. Heat the system to softening temperature. Use a hot air
fan if necessary.
S Use only original Nordson spare parts. Refer to separate document
Parts List for details.
S Also refer to separate manuals for the individual components.

7-2 Repair
Replacing Sealing Ring

platen (configurations code: Box 16 = F).
1. Heat platen to operating temperature.
2. Aerate drum.
3. Set pneumatic switch to Raise until the platen exits the drum.
4. Set pneumatic switch to 0/Stop.
5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) on
the drum under the melting plate.
6. Set pneumatic switch to Lower until the melting plate reaches the resting
surface.
8. Cut old sealing rings with a knife and dispose of it properly.
CAUTION: Do not damage release coating.
9. Heat solid rubber or Teflon-coated sealing rings in an oven.

10. Clean and lubricate grooves. For information on lubricant refer to
Processing Materials in section Technical Data.
11. Put heated sealing rings into place on heated platen with two people.
180 - 200 °C
356 - 392 °F
Fig. 7-1

Repair 7-3
Replacing O-rings
When leakage occurs, e.g. at the hose connections, the O-rings must be
replaced. Observe the following:
S Clean and lubricate O-ring groove. Nordson recommends
high-temperature grease; refer to Processing Materials in section
Maintenance.
S Also lubricate O-ring.
S Do not use removed O-rings again.
S Tighten hose connection and blind covers with a torque wrench to
9.5 Nm.

7-4 Repair
Replacing Platen Temperature Sensor and Thermostat

1. Heat platen to operating temperature.

2. Aerate drum.
3. Set pneumatic switch to Raise until the platen exits the drum.
5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) on
the drum under the melting plate.
6. Set pneumatic switch to Lower until the melting plate reaches the resting
surface.

8. Disconnect the system from the line voltage.

9. Remove the cover (1).
3 2
Fig. 7-2

Repair 7-5
NOTE: If the temperature sensor is defective: Continue with step 16.

10. Remove thermostat (2) along with fastening screws and spring washers.
11. Extract connecting cable from porcelain terminals.
12. Apply heat transfer compound to contact surfaces of the new thermostat
(Refer to Processing Materials in section Technical Data), then install
the thermostat with spring washers and screws.
13. Connect thermostat wires to porcelain terminals.
14. Screw on cover.
15. Start up system.
Replacing Temperature Sensor

First perform steps 1 to 9.
16. Remove temperature sensor (3).
17. Apply heat transfer compound to the new temperature sensor, then
fasten the sensor.
18. Attach cover again (1).
19. Start up system.
Identifying Installed Thermostat

NOTE: Refer to section Parts to identify the thermostat installed.

7-6 Repair
Replacing Control Panel

Installing Service Kit

Service kit P/N: 394734

Required tools:
Electrical cabinet key
Open-jawed or box wrench, size 7
1. Set main switch to 0/OFF.
2. Open electrical cabinet door.
3. Unplug bus cable from old control panel.
4. Release the M4 hexagon nuts and remove with the tooth lock washers.
5. Press old control panel and old seal forwards and out of the electrical
cabinet door.
6. Insert new control panel with new seal.
7. Screw on new control panel. Use tooth lock washers.
8. Plug bus cable into new control panel.
9. Close the electrical cabinet door.
NOTE: When a new control panel has been installed, two default settings
must be renewed:
1. Simultaneously turn on the main switch and hold down the key Motor 2
and the scroll key on the control panel until the LEDs on the control
2 panel light up.
2. Switch off main switch.
3. Simultaneously turn on the main switch and hold down the key Heater
and the platen icon on the control panel until the LEDs on the control
panel light up.

Parts 8-1
Section 8
Parts
How to Use Illustrated Parts List

The parts lists in the separate document Parts List are divided into the
following columns:
Item— Identifies illustrated parts that can be obtained from Nordson.

Part— Nordson part number for each spare part shown in the
illustration. A row of hyphens in the column Part (- - - - -) indicates that
this part can not be ordered separately.
Description— This column contains the name of the part and, when
appropriate, its dimensions and other properties. The points in the
column Description show the relationship between assemblies,
subassemblies and single parts.
Quantity— The quantity needed per unit, assembly or subassembly.
The abbreviation AR (as required) is used when this item is a bulk item
or when the quantity per assembly depends on the product version or
model.
NOTE: Refer to separate document Parts List, P/N 7135705.
Fasteners
Fasteners are shown as Fx in every illustration, whereby ”x” indicates the
number of the fastener in the list Schedule of Fasteners at the end of the
separate document Parts List.
Component Designation
The electrical components are labeled in accordance with DIN 40719,
part 2.

8-2 Parts

Technical Data 9-1
Section 9
Technical Data
General Data
Type of heating Cast-in electrical resistance heating elements
Temperature sensor Ni 120
Heating time 30 to 60 minutes, depending on system, material
used and ambient temperature
Noise emission < 72 dBA
Electrical Data
WARNING: Operate only at the operating voltage shown on the ID plate.
Operating voltage Refer to ID plate

Operating voltage frequency 50/60 Hz
Fuse rating Refer to ID plate
Power consumption P Refer to ID plate
Power consumption Pmax Refer to ID plate
Max. load per hose receptacle (2 channels) 1 000 W per individual hose or gun
1 200 W per hose/gun pair
2 000 W total, hose/gun pairs 1 and 2
2 000 W total, hose/gun pairs 3 and 4
Degree of protection IP 54

9-2 Technical Data
Motors / Speed
Motor Fixed speeds
3-phase AC motor with helical gear 50 min−1 65 min−1 129 min−1
Output Quantity
Note: The maximum output quantity is a Max. 270 kg/h Max. 595 lb/h
factor of the pump type used and different
parameters. Refer to Installation, Speed
Setpoint and Output Quantity
Temperatures and Thermostats

Temperatures System / components °C °F
Min. ambient temperature − 10 50
Max. ambient temperature − 40 104
Min. operating temperature − 50 122
Identifying Installed Thermostat

NOTE: Refer to separate document Parts List to identify the thermostat
used.

Technical Data 9-3
Material Pressures
Motor/pump model (standard) bar MPa psi
3-phase AC motor with gear pump 5 to 60 0.5 to 6 72.5 to 870
Note: Safety valve setting is decisive for maximum 35 3,5 507,5
outlet pressure. Factory setting:
Dimensions
Drum diameter Max. drum height
567 or 571 mm, depending on the melting plate
900 mm
used. Refer to separate document Parts List
1830,00
max.
2497
1570,00 760,00
Fig. 9-1

9-4 Technical Data
Weight
Weight Approx. 663 kg (depending on accessories)
Air Consumption
Per cycle (platen down and up) Approx. 600 l
Exhaust Hood (Accessory)

Nominal air quantity (recommendation) 510 m3/h
Pressure loss at nominal air quantity Approx. 180 Pa
Connecting sleeve ∅ 150 mm

General Instructions Regarding Working with Application Materials A-1
Appendix A
General Instructions Regarding Working
with Application Materials
Definition of Terms
Application materials can be e.g. thermoplastic hot melt materials, adhe-
sives, sealants, liquid adhesives and similar application materials. They are
referred to as materials.
NOTE: The materials that may be processed with your Nordson product
are described in the manual under Intended Use and Unintended Use.
When in doubt, please contact your Nordson representative.
Manufacturer Information
Materials may be processed only when the manufacturer’s product descrip-
tions and Safety Data Sheets (MSDS) are observed.
They provide information, amongst other things, on correct processing of
the product, transport, storage and disposal. Information regarding reactivity
and potentially hazardous decomposition products, toxic properties, flash
points, etc. can also be found there.
Liability
Nordson is not be liable for danger or damage resulting from the materials.

A-2 General Instructions Regarding Working with Application Materials
Risk of Burns
There is a risk of burns when handling heated materials. Work carefully and
wear appropriate protective clothing/equipment.
Vapors and Gases

Ensure that vapors and gases do not exceed the prescribed limits. If neces-
sary, exhaust vapors and gases and/or provide sufficient ventilation of the
work space.
Substrate
The substrate should be free of dust, grease and moisture. The suitable ma-
terial, optimum working conditions, and possible pre-treatment of the sub-
strate must be determined by testing.
Processing Temperature
When materials require heating, adherence to the prescribed processing
temperature is imperative to ensure the quality of the application. It may not
be exceeded! Overheating can cause material coking or cracking, resulting
in malfunctioning or unit failure.
Material should always be melted gently. Extended, unnecessary tempera-
ture load should be avoided. The temperature should be reduced during
breaks in work. The temperature in the tank should be attuned to the mate-
rial consumption. Thus it is close to the prescribed processing temperature
for high material consumption and lower for lower consumption.
When materials are processed cold, take into consideration the shear heat
and the ambient temperature; cool if necessary.

Operating Parameters B-1
Appendix B
Operating Parameters
The operating parameters are organized in this appendix according to the
logical groups listed in Table B-1. For information on selecting and editing
operating parameters, refer to Setting up the Bulk Melter in section 3,
Installation.
NOTE: Parameter numbers that are reserved or that are not used do not
appear in this appendix.
Tab. B-1 Parameter groups

Group Parameters Description
Standard 0 to 11 Frequently used parameters
Temperature control 20 to 29 Controls heater function
Input setup 30 to 38 Configure the standard and optional inputs
Output setup 40 to 46 Configure the standard and optional outputs
Seven-day clock 50 to 77 Configure the clock function
PID selection 80 to 91 Changes preset PID settings

B-2 Operating Parameters
Standard
0 Enter Password
Description: A user-defined password that prevents unauthorized changes to setpoint
temperatures and operating parameters.
Value: 0 to 9999
Resolution: 1
Default: 4000
Format: —
Use: This parameter only appears if a password is created using parameter 11 and
then enabled using parameter 10.
NOTE: If a password is entered to change a setpoint temperature, always exit
setup mode by pressing one of the component keys. If the setup key is used
to exit setup mode, the system immediately reverts to password protected
mode.
1 Total Hours with Heater On (Noneditable)

Description: Noneditable value. Shows the total number of hours that the heaters were on.
Value: 9999 (control panel) and 999.999 on web browser
Resolution: 1 hour
Default: 0
Format: —
Use: The display registers up to 9999 hours and then rolls over to 0000. The
register on the web browser rolls over after 999,000 hours.
2 Fault Log (Noneditable)

Description: Stores a record of the last ten faults.
Value: —
Resolution: —
Default: _−F0 (unused log entry)
Format: F1, F2 F3 and F4
Use: Press the right display scroll keys to review the last ten faults in the log. Empty
log entries are indicated by ”_ −F0”. Refer to Monitoring the System in section
4, Operation.

3 Change History Log (Noneditable)

Description: Records the last ten changes made to either the setpoint temperatures or the
operating parameters.
Value: —
Resolution: —
Default: P-_ (unused log entry)
Format: Refer to section 3, Installation. Review Parameter and Setpoint Temperature

Changes.
Use: Use the right display scroll key to review the last ten changes made to either
the setpoint temperatures or the operating parameters. 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 setpoint temperatures before the ready LED turns on. The ready delay
timer only functions if the temperature of the platen, at the time the system is
turned on, is below its assigned setpoint temperature by 27 °C (50 °F) or
more. The ready delay time begins when all components are within 3 °C
(5 °F) of their respective setpoint temperature.
Value: 0 to 60 minutes
Resolution: 1 minute
Default: 0 minutes
Format: —
Use: The ready delay allows the platen additional time to heat up before the pump
starts up.
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 one minute, the time remaining appears in seconds.
5 Service Interval
Description: The number of hours of heater operation that must elapse before the service
LED lights up.
Value: 0 hours (disabled) to 8736 hours (one year)
Resolution: 1 hour
Default: 500 hours
Format: —
Use: Set the service interval time to signal a user-defined service check or
maintenance task, such as checking functioning of the pressure restrictor
valve. The service LED lights up after the preset time has elapsed. Press the
Clear/reset key to turn off the service LED and reset the service interval time.

6 Service LED Heater Hours

Description: A counter indicates how many more hours the heaters may remain on before
the service LED lights up (service required).
Value: 0 (disabled) to 9999 hours
Resolution: 1 hour
Default: 0
Format: —
Use: Enable the service interval (parameter 5) for this parameter to work.
Note: Heater hours are counted whenever the heater LED is illuminated.
7 Motor Off Delay

Description: Determines the amount of time that the motor will remain on after the switching
device turns off.
Value: 0 to 360 seconds

OR
- - - - (infinite)
Resolution: Seconds
Default: 0 seconds
Format: —
Use: This parameter functions only when a switching device (handgun with switch,
foot switch, etc.) is connected to the switch receptacle.
8 Automatic Pump On
Description: Determines whether the pump can be enabled before the system is ready.
Value: 0 (disabled) or 1 (enabled)
Resolution: —
Default: 1 (enabled)
Format: —
Use: If the function is enabled, the pump can be enabled before the system is
ready.
If the function is disabled, the pump must be started by pressing the pump key
when the system is ready.
NOTE: If Automatic pump on is disabled (0) while one of the pumps is
running, the pump will remain on until the key for this pump is pressed.

10 Enable or Disable Password

Description: Enables or disables the password. When password protection is activated,
component setpoint temperatures or system operating parameters can not be
changed until a valid password is entered using parameter 0.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default: 0
Format: —
Use: A password must first be created using parameter 11 before it can be enabled
or disabled with parameter 10.
11 Create Password
Description: A user-defined password that prevents unauthorized changes to setpoint
temperatures and operating parameters.
Value: 0 to 9999
Resolution: 1
Default: 5000
Format: —
Use: Refer to Section 4, Operation, Enter Password.

NOTE: When the password is created and enabled, parameter 10 will not
appear again in the right display until the password is entered.
12 Change Hose 1 Output to Electric Gun Activation

Description: Changes the proportioned 240 VAC current that is provided to the hose 1
heater to a switched 240 VAC current that is used to activate a
manifold-mounted electric gun.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Default: 0 (disabled)
Format: —
Use: Use only when a Nordson manifold-mounted electric gun is installed and a
switching device is connected to the bulk melter’s switch receptacle. Refer to
the electric gun manual for information on mounting and using the gun.

13 Change Hose 2 Output to Electric Gun Activation

Description: Changes the proportioned 240 VAC current that is provided to the hose 2
heater to a switched 240 VAC current that is used to activate a
manifold-mounted electric gun.
Value: 0 (disabled)
1 (enabled)
Resolution: —
Format: —
Use: Use only when a Nordson manifold-mounted electric gun is installed and a
switching device is connected to the bulk melter’s switch receptacle. Refer to
the electric gun manual for information on mounting and using the gun.

Temperature Control
20 Temperature Units
Description: Sets the units for temperature display.
Value: C (degrees Celsius) or F (degrees Fahrenheit)
Resolution: 0 = Celsius
1 = Fahrenheit
Default: 0
Format: —
Use: —
21 Overtemperature Delta
Description: The number of degrees that a component can exceed its assigned setpoint
temperature before an overtemperature fault (F3) occurs.
Value: 5 _C (10 _F) to 60 _C (110 _F)
Resolution: 1_C
1_F
Default: 15 _C (25_F)
Format: —
Use: —
22 Undertemperature Delta
Description: The number of degrees that a component can fall below its assigned setpoint
temperature before an undertemperature fault (F2) occurs.
Value: 5 _C (10 _F) to 60 _C (110 _F)
Resolution: 1_C
1_F
Format: —
Use: —

23 Standby Delta
Description: The number of degrees that the temperature of all heated components will be
decreased when the system enters the standby mode.
Value: 25_C to 190_C (50_F to 350_F)
Resolution: 1_C
1_F
Format: —
Use: A standby delta should be selected that results in a balance between system
energy savings during periods of inactivity, the amount of time and energy
required to bring the system back up to setpoint temperature, and a
temperature at which the material can be held in the tank for extended periods
without charring. Refer to Section 4, Operation, Function Keys.
NOTE: The standby delta does not affect the undertemperature delta
(parameter 22).
24 Automatic Standby Timeout

Description: The amount of time that must elapse after the last signal (gun driver) is sent to
input 1 before the system enters standby mode. The automatic standby
timeout feature saves energy by allowing the system to automatically enter
standby mode as soon as the guns are no longer applying material.
Value: 0 to 1440 minutes (24 hours)
Format: —
Use: 1. Change parameter 23 if required.
2. Set the control option for parameter 30 (input 1) to option 10 (automatic

standby).
NOTE: Only enable parameter 24 when a 24 VDC signal voltage is connected
to input 1. If there is no voltage on the input contacts when the system is
ready, the system will enter 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)
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 system will remain in the standby mode after the
standby key is pressed.
Value: 0 to 180 minutes
Default: 0
Format: —
Use: Set the standby time when the operator is to cause the system to enter
standby for a limited period (break, lunch, etc.). Whenever manual standby is
activated (value greater than 0 minutes), the standby LED flashes.
Set the standby delta (parameter 23) to the desired value before setting
parameter 26.
Note: When a value greater than 0 minutes is set, the remaining time in
standby mode appears in the right display.
27 Hose Standby Delta

Software version 2.023 and higher
Description: The number of degrees that the temperature of all hoses will be decreased
when the system enters standby mode.
Value: 1 _C to 190_C (1_F to 350_F)

Resolution: 1 _C
1_F
Format: —
Use: This parameter works the same as parameter 23, except when it is set to 0.
Then it returns to the setting for parameter 23.
(parameter 22).
28 Gun Standby Delta

Description: The number of degrees that the temperature of all guns will be decreased when
the system enters standby mode.
Value: 1 _C to 190_C (1_F to 350_F)

Resolution: 1 _C
1 _F
Format: —
Use: This parameter works the same as parameter 23, except when it is set to 0.
Then it returns to the setting for parameter 23.
(parameter 22).

29 Internal Zone Temperature Offset

Description: NOTE: Parameter 29 is not used with DuraPail.
Difference in degrees with which the bulk melter’s internal zones work. If
this parameter is used, the primary internal zone (Platen) works at a
lower temperature than the secondary internal zone (Pump), as defined
by the value of this parameter.
Value: 0 _C to -15 _C (0 _F to -30 _F)
Resolution: 1 _C
1 _F
Default: 0
Format: —
Use: Used when different temperatures are needed for the melting plate and
the pump.
Setpoint Platen + Internal zone temperature offset = Setpoint Pump
Example: 150 _C + (−15 _C) = 135 _C

Input Setup
30 Standard 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 enabled/disabled
4 − Hose/gun 1 enabled/disabled
10 − Automatic standby
11 − Motor 2 enabled/disabled
Resolution: 1
Default: 10
Format:
Use: If Motor enabled/disabled (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 System 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).

31 Standard Input 2

Resolution: 1
Default: 1
Format: —
Use: If Motor enabled/disabled (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 Standard Input 3

Resolution: 1
Default: 2
Format: —
setting up inputs.
are de-energized (Multiple inputs set to the same input value are logical ORed).

33 Standard Input 4

Resolution: 1
Default: 4
Format: —
setting up inputs.
34 – 39 Optional Inputs 1, 2, 3, 4, 5 and 6

Description: Control options that determine the function of the six optional inputs, provided
the optional I/O expansion card is installed on the main board.

Resolution: 1
Default: 1 (all optional inputs)
Format: —
Use: If Motor enabled/disabled (3) is selected, the motor will turn on only when the
setting up inputs.

Output Setup
Standard Outputs 1, 2 and 3

40 − 42
(Do not Edit)
Description: Determines the function of the output.
Value: 0 = Output disabled

1 = Ready
2 = Ready and pump on
3 = Fault
4 = Low level (not available)
5 = Service LED lit
6 = Alarm (voltage fault)
Resolution: 1
Default: Output 1 = 1
Output 2 = 3
Output 3 = 4
Format: —
Use: Refer to Installing System Outputs in section 3, Installation for information

about setting up outputs.
When control options 6, Alarm, is selected, the output is active as soon as the
system 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, Monitoring Faults for information on fault
monitoring.
NOTE: If a light tower (accessory) is installed, the outputs 1 - 3 must be set to
the default.
43 − 46 Optional Outputs 4, 5, 6, and 7

Description: Control options that determine the function of the four optional outputs,
provided the optional I/O expansion card is installed on the main board.
Value: 0 = Output disabled

1 = Ready
2 = Ready and pump on
3 = Fault
4 = Low level (not available)
5 = Service LED lit
6 = Alarm (voltage fault)
Resolution: 1
Default: 0 (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 options 6, Alarm, is selected, the output is active whenever the
system 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, Monitoring Faults.

Seven-day clock
Before setting the clock, refer to Function Keys in section 4, Operation, to
familiarize yourself with the function and use of the clock feature.
If you are unfamiliar with the procedure for accessing and editing operating
parameters, refer to Setting Up the Bulk Melter in section 3, Installation.
To Set the Clock

1. Enter the current day of the week with parameter 50.
2. Enter the current time of day with parameter 51.
3. Create schedule 1:
a. Set parameters 55 and 56 to the time of day that the heaters should
turn on and off.
b. Set parameters 57 and 58 to the time of day that the system should
enter and exit standby mode.
4. Repeat step 3 to create schedules 2 and 3 with parameters 60 to 68.
5. Determine which of the four schedules should be used on each day of

the week with parameters 71 to 77. Up to three schedules can be
assigned for each day (to support three work shifts). Each of the eight
control options (0 to 7) available in parameters 71 to 77 offers a different
combination of the three schedules. Option 0 is used to hold the system
in the state dictated by the last clock transition until the next clock
transition occurs,
6. Press the Clock key.
Seven-day clock key
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 to 77).
To prevent unintentional activation of the clock, the

default setting for parameters 71 to 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 effect on the system.

Example 1
Switch heaters on at 0600 and turn them off at 0015 every day of the week:
Par 55 = 0600
Par 56 = 0015
Par 60 = − − − −
Par 61 = − − − −
Par 71 to 77 = 1
Example 2
Switch heaters on at 0700 and off at 1700 Monday through Friday, and
switch heaters off Saturday and Sunday:
Par 55 = 0700
Par 56 = 1700
Par 57 = − − − −
Par 58 = − − − −
Par 71 to 75 = 1
Par 76 and 77 = 0
Example 3
Switch heaters on at 0600 each morning, go into standby for lunch at 1130,
come out of standby after lunch at 1230, and switch the heaters off at 1600
at the end of the day, every day of the week:
Par 55 = 0600
Par 56 = 1600
Par 57 = 1130
Par 58 = 1230
Par 71 to 75 = 1
Par 71 and 77 = 1

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: —
Format: —
Use: For information about the use and effects of the seven-day clock, refer to
Function Keys in Section 4, Operation.
51 Current time
Description: Used to set the time.
Value: 0000 to 2359 (European time format)
Default: (Time set at factory)
Format: Hour, 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: 0600
Use: Set the desired time for the heaters to switch on.
To disable this parameter, set the parameter’s value to ”- - - -” by
simultaneously pressing both of the right display scroll keys.
56 Schedule 1 Heaters off

Description: Used to set the time that the clock will turn off the heaters during schedule 1.
Value: 0000 to 2359, - - - -
Default: 1700
Use: Set the desired time for the heaters to switch off.

57 Schedule 1 Enter Standby

Description: Used to set the time that the system will enter standby mode during schedule
1.
Value: 0000 to 2359, - - - -
Default: ----
Use: Set the time that the system will enter 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 system can not enter
standby mode when the heaters are off.
58 Schedule 1 Exit Standby

Description: Used to set the time that the system will exit standby mode during schedule 1.
Value: 0000 to 2359, - - - -
Default: ----
Use: Set the time that the system will exit standby mode during schedule 1.
Note: Do not set an exit standby time that is outside of the time period defined
by the schedule’s heater on and off time. The system can not enter standby
mode when the heaters are off.
Value: 0000 to 2359, - - - -
Default: ----


Value: 0000 to 2359, - - - -
Default: ----

2.
Value: 0000 to 2359, - - - -
Default: ----

Value: 0000 to 2359, - - - -
Default: ----

Value: 0000 to 2359, - - - -
Default: ----

Value: 0000 to 2359, - - - -
Default: ----

3.
Value: 0000 to 2359, - - - -
Default: ----


Value: 0000 to 2359, - - - -
Default: ----
71 - 77 Schedules for the Days of the Week

Description: Used to select which schedule(s) should be used each day.
Value: 0 – Remain at last clock transition

1 – Use only schedule 1
4 – Use schedules 1 and 2
7 – Use schedules 1, 2 and 3
Resolution: 1
Default: 0
Format: —
Use: Selects the active schedules for the day.

NOTES: If schedule 0 is used, the heaters will not switch on again until the
next scheduled heaters on time arrives.

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

Glossary C-1
Appendix C
Glossary
Advance Distance
Distance between initiator and gun.
Angel Hair
Fine threads of adhesive that are created when adhesive is incorrectly
transferred from the nozzle to the substrate. This could be caused e.g. by
poor shaving of high viscosity material at the nozzle.
Application System, Hot Melt

An arrangement of units and components that melt, feed, meter and apply
hot melt adhesive, e.g. bulk melter, melter, gear metering pump station, gun,
coating stand and heated hoses.
Application Weight
The weight (grammage) of the application material applied to a surface unit
of the substrate.
Determining the application weight: A circle cutter is used to cut several

100 mm2 sized circles from the uncoated substrate. The cut out sections
should be evenly distributed on the substrate. The samples are each
weighed to exactly 0.01 g, and the average weight is calculated. The same
is done with the coated substrate. The number of samples taken depends
on how much the weights of the samples differ. The application weight is the
difference between the coated and uncoated substrate. The application
weight is usually stated in g/m2.
Assembly Handgun
Manually operated system component used to apply material as a bead,
dot, surface or spray application.
bar
Legal unit for pressure. The SI unit is Pascal (Pa). The unit commonly used
in the USA is psi. Refer to Conversions.

C-2 Glossary
Bd (Baud)
Rate of data transfer: Bit/s.
Bead Size
The width of a bead of material applied to a substrate. The size refers to the
bead before it is compressed by the two parts.
CAN Bus
The Controller Area Network is an internationally standardized serial bus
system. With Nordson melters, control components such as temperature
controllers, motor controllers and pressure sensors exchange data with the
industrial PC via the CAN bus. The CAN bus is used as an internal network
for Nordson unit control and is not intended to be an interface for the
customer’s control units.
Cast-in Heater
A resistance heating element that is cast into a tank or melting plate. This
fixed connection provides optimal heat conducting.
Charring
Decomposition of a synthetic material, particularly through heat influence.
Can occur when processing temperature is too high.
Class of Protection
Protective measures are required to ensure electrical safety of the units.
The measures prevent accessible metal parts from conducting voltage
when a fault occurs. Assignment of classes of protection indicates the
protective measures.
Class of Symbol Precaution

protection
1 All accessible metal parts are conductively connected to one another and
are linked to the mains ground conductor.
2 The unit is insulated such that there are no accessible metal parts that
could conduct voltage in the event of a fault. There is no ground
conductor.
3 The unit is operated with extra-low voltage up to 42 V from a safety
isolating transformer or a battery.

Glossary C-3
Component
1. System component:
This term designates a single unit (e.g. melter) that is part of an
application system.
2. Unit component:
This term designates a single part (e.g. coupling, EMERGENCY OFF
button) or a group of parts that forms a functional unit (e.g. inert gas
equipment).
Controller
Used to control proportional valves (pressure control unit) or solenoid valves
and guns (pattern controller) dependent on the speed of the parent
machine.
ControlNet
Internationally standardized serial field bus with scanner and adapter
subscribers. Nordson melters (adapter) with a ControlNet interface can be
controlled remotely by the customer’s control unit (scanner).
Control Voltage
Electrical cabinet internal voltage for electrical components such as
temperature controllers, PLC, etc. The control voltage in Nordson electrical
cabinets is usually 230 VAC or 24 VDC.
Conversions
In mesh In mm In mesh In mm
2,5 8,0 50 0,30
3 6,73 60 0,25
5 4,0 80 0,18
8 2,38 100 0,149
10 2,0 140 0,105
14 1,41 170 0,088
18 1,0 200 0,074
20 0,84 270 0,053
30 0,59 325 0,044
40 0,42 400 0,037
Table: U.S. Bureau of Standards

C-4 Glossary
Conversions (contd.)
Unit Multiplied by Result
Density SI unit: [kg/m3]
Kilograms per cubic meter kg/m3 1,0 x 10−3 Kilograms per liter kg/l
Kilograms per cubic meter kg/m3 8.35 x 10−3 Pounds per gallon (US) lb/gal
Kilograms per liter kg/l 8,35 Pounds per gallon (US) lb/gal
Pounds per gallon (US) lb/gal 0,12 Kilograms per liter kg/l
Torque SI unit: [Nm]
Newtonmeter Nm 8,85 Pound inch (US) lbin
Newtonmeter Nm 0,74 Pound foot (US) lbft
Pound inch (US) lbin 0,113 Newtonmeter Nm
Pound foot (US) lbft 1,36 Newtonmeter Nm
Pressure SI unit: Pascal [Pa = N/m2]
Pascal Pa 1,0 x 10−5 Bar bar
Pascal Pa 0.69 x 10−6 Pounds per square inch (US) psi
Bar bar 14,5 Pounds per square inch (US) psi
Pounds per square inch (US) psi 0,069 Bar bar
Speed SI unit: [m/s]
Meters per second m/s 196,89 Feet per minute ft/min
Feet per minute ft/min 5.1 x 10−3 Meters per second m/s
Length SI basic unit: Meter [m]
Meter m 3,2808 Foot ft
Foot ft 0,3048 Meter m
Centimeter cm 0,3937 Inch in
Inch in 2,54 Centimeter cm

Glossary C-5
Conversions (contd.)
Unit Multiplied by Result
Ground SI basic unit: Kilogram [kg]
Kilogram kg 2,2046 Pound (US) lb
Pound (US) lb 0,4536 Kilogram kg
Gram g 0,0353 Ounce oz
Ounce oz 28,35 Gram g
Temperature SI basic unit: Kelvin [K]
Degrees Celsius °C (°C x 1,8) + 32 Degrees Fahrenheit °F
Degrees Fahrenheit °F (°F − 32) 1,8 Degrees Celsius °C
Viscosity, dynamic SI unit: Pascal second [Pas]
Pascal second Pas 1,0 x 103 CentipioseA cP
CentipioseA cP 1,0 x 10−3 Pascal second Pas
Viscosity, kinematic SI unit: [m2/s]
Square meters per second m2/s 1,0 x 10−6 CentistokeA cSt
CentistokeA cSt 1,0 x 106 Square meters per second m2/s
Volume SI unit: [m3]
Cubic meter m3 1. 0 x 103 Liter l
Cubic meter m3 264,2 Gallon (US) gal
Liter l 0,2642 Gallon (US) gal
Gallon (US) gal 3,7853 Liter l
NOTE: A: Has not been a legal unit since 1986.
dB (A)
Unit for the sound intensity level, measured according to the internationally
standardized evaluation curve A, which measures sound in a way similar to
how it is perceived by the human ear.

C-6 Glossary
Degree of Protection
According to IEC 529/DIN 40 050.
The degrees of protection of electrical components through metal protection
are stated as an abbreviation such as IP 54. The first numeral stands for the
contact and impurity protection, and the second numeral indicates water
protection. The third numeral, which indicates impact protection, is usually
not stated.
1. numeral 2. numeral 3. numeral

IP Contact and impurity Water protection Impact protection
protection
Protection from... Protection from... Protection from impact strength
up to...
0 − − −
1 Foreign object > 50 mm Water dripping vertically 0,225 J = Impact of 150 g from a
height of 15 cm
2 Foreign object > 12 mm Water dripping diagonally 0,375 J = Impact of 250 g from a
height of 15 cm
3 Foreign object > 2.5 mm Spray water 0,5 J = Impact of 250 g from a
height of 20 cm
4 Foreign object > 1 mm Splash water −
5 Dust accumulation Water stream 2,0 J = Impact of 500 g from a
height of 40 cm
6 Dust penetration Upon flooding −
7 − When dipped 6,0 J = Impact of 1.5 kg from a
height of 40 cm
8 − When submerged −
9 − − 20 J = Impact of 5 kg from a height
of 40 cm
Drop-off Delay
1. The time between the signal to switch off the gun and the end of
material application.
2. The time that a delay relay remains engaged after it has been switched
off.
Encoder
The encoder compiles the line speed of the parent machine. It supplies a
certain number of electrical pulses per revolution. The frequency is a
measure of line speed. Refer to Line Speed Signal.

Glossary C-7
Firmware
Internal software that cannot be changed by and that is not accessible to
the customer.
Flap Valve
A valve through which material can only flow in one direction. The valve
closes automatically when the flow direction changes.
Free-wheeling Diode
Electronic component that protects electronic assemblies from power
surges that occur when relays or solenoid valves are switched off.
Grammage
Refer to Application Weight.
Gun, Hot Melt

System component used to apply material as a bead, dot, surface or spray
application.
Heater Cartridge
A replaceable, cylindrical resistance heating element. It is inserted into a
hole in the component to be heated.
Hopper
Unheated tank extension, used to increase tank volume.
Host
Higher-order control unit.
Hot Melt
Synonym for hot melt adhesive.
Hot Melt Adhesive

Hot melt adhesives are thermoplastic synthetic materials. They are
processed in a liquid state. They bond by solidifying.

C-8 Glossary
Inert Gas
Refer to Protective Gas.
Initiator
Component that generates a signal when an object is in a certain area of its
surroundings. Possible models are e.g. proximity initiators and light beam
photo cells.
Intermittent Mode
Mode of operation for guns. Instead of material application being
continuous, it occurs with pauses to create the desired application pattern.
LED
Light Emitting Diode.
Line Speed Signal

A signal generated by the parent machine (voltage, current or frequency) to
control the melter.
Line Voltage
Voltage in the customer’s network. It may need to be converted to operating
voltage by a transformer.
Machine Enable
A control unit is enabled by a signal from the parent machine. In Nordson
literature the enable feature is also referred to as Parent Machine Interlock
or Security.
Master-Slave
The configuration of two or more units in which one assumes control of one
or more slaves.
Example: Nordson melters on the PROFIBUS are slaves that are controlled
by the customer’s master.

Glossary C-9
Material
General Nordson term for application materials such as thermoplastic hot
melt adhesives, adhesives, sealants, cold glue, etc.
Melter
Melts and feeds hot melt adhesives or similar materials.
Menu
Branched program structure from which the operator selects the desired
functions/features.
min −1
min−1 = 1/min. Revolutions per minute (rpm).
MSDS
Material Safety Data Sheet.
Ni 120
Abbreviation for a nickle based resistance temperature sensor. At a
temperature of 0° C (32° F), it has an electrical resistance of 120 W.
Nm
Newtonmeter, SI unit for energy and torque. Refer to Conversions.
Noise Emission
Noise level that a unit produces in the immediate vicinity. The noise
emission is stated in dB (A).
Nominal Air Quantity

States suction volume of exhaust hoods. The pressure drop from the
exhaust hood to the customer’s fan must also be taken into consideration.
Nozzle
The component through which the material leaves the gun. The nozzle
determines the volume, shape and direction of the material outlet.

C-10 Glossary
Open Time
The maximum time in which bonding can occur between application of the
material to the substrate and pressing on the second part. Factors such as
application temperature, substrate, adhesive properties and amount of
adhesive are relevant to open time.
Operating Air Pressure

The customer’s compressed air supply is usually reduced by pressure
controllers in the units. The operating air pressure is the reduced pressure
at which pneumatic components are operated.
Operating Voltage
The voltage used to operate the unit. The operating voltage is indicated on
the ID plate. A transformer may be required to adapt the melter to the
customer’s line voltage.
Output Quantity
The material volume fed by the pump. Stated e.g. in cm3/min.
Pa
Pascal, SI unit for pressure. Refer to Conversions.
Parameter
Variably adjusted values that must be entered into a control unit, a PLC
control or the control system.
Parent Machine
The user’s machine that generates the line speed signal for key-to-line
mode. Refer to Line Speed Signal.
Pas
Pascal second, SI unit for dynamic viscosity.

Glossary C-11
PID Controller
A type of controller that combines different control characteristics of
proportional, integral and differential aspects.
The controller should be calibrated such that the controlled variable (output
variable) and the manipulating variable (input variable) fluctuate as little as
possible and the time needed for the manipulating variable to stabilize is as
short as possible.
PLC
Programmable Logic Controller.
Polyamide
A term used by Nordson to describe polyamide-based hot melt adhesives.
Other common designations are polyamide resin and polyamide hot melt
adhesive.
Polyurethane Hot Melt Adhesive

Moisture interlaced hot melt adhesive. Common abbreviations are PU and
PUR. When processing polyurethane adhesives, additional safety
instructions must be observed.
Power Consumption P
The electrical power consumption (wattage) of the unit (motor, heater and
the electrical components in the electrical cabinet).
Power Consumption Pmax

The maximum electrical power consumption (wattage) of the unit and the
connected accessories. It is calculated as the product of the connected
voltage and the maximum current protected by fuse.
Processing Temperature
The processing temperature is prescribed or recommended by the material
manufacturer. It can be found in the product information and/or in the
Material Safety Data Sheet (MSDS).
PROFIBUS
Internationally standardized serial field bus with master-slave subscribers.
Nordson melters (slave) with a PROFIBUS DP interface can be controlled
remotely by one of the customer’s control units (master).

C-12 Glossary
Proper Disposal
Disposal of all types of waste in compliance with all local regulations.
Proportional Pressure Control Valve

Electropneumatic component that enables control of pneumatic pressure
with an electrical variable (usually control voltage).
Protective Gas
Gas (e.g. nitrogen) used to protect the adhesive from contact with humidity
and therefore from undesired reactions. Protective gas is also referred to as
inert gas.
Pt 100
Abbreviation for a platinum based resistance temperature sensor. At a
temperature of 0° C (32° F), it has an electrical resistance of 100 W.
Pull-in Delay
1. The time between the signal to switch on the gun and the beginning of
material application.
2. The time between when the voltage is turned on and when the delay
relay is actually engaged.
PUR
Refer to Polyurethane Hot Melt Adhesive
Rated Current
The setpoint for current to a unit, determined by standards or as agreed
upon by the manufacturer and the customer.
Release Coating
Largely prevents hot melt adhesive from burning onto the surface and
makes it easier to clean the application system parts coming into contact
with the adhesive.

Glossary C-13
Residual Risks
Hazards that can pose a danger to the user, even when all safety
regulations for manufacturing a product are followed and when the unit is
used only as intended. Residual risks are noted - as extensively as the
manufacturer is aware of them - in the manual and/or with waning signs on
the unit.
Resistance Temperature Sensor

Component with an electrical resistance, the value of which changes as a
factor of the temperature. Nordson units use the models Pt 100 and Ni 120.
Reverse Mode
A pump motor operates counter to the direction of material feeding.
Prevents material from dripping.
RPM
Revolutions per minute, same as min−1 = 1/min.
Safety Valve
A valve that prevents the material pressure from exceeding a preset value.
Safety Valve Plate

A component in which material circulates when the installed safety valve is
open.
Set Time
The amount of time that the adhesive needs from application to complete
hardening.
SI
Système International d’ Unités (international standardization system).
Solenoid Valve
Usually part of the gun. A control valve that is activated by an
electromagnetic coil.

C-14 Glossary
Solid State Relay

Electronic assembly without mechanical parts but with the function of an
electromechanical relay.
Solvent
Solvents are liquid, organic materials and their compounds, used to clean
adhesive off of surfaces. Solvents are slightly volatile. Special regulations
must be followed when using solvents.
In Nordson literature, the solvent is always the substance prescribed by the
hot melt manufacturer.
Substrate
The product − fabric, foil, etc. − to which a material is applied.
Tach Generator
A component that generates electrical voltage (pilot voltage). The voltage is
proportional to the speed at which the tach generator is driven.
Temperature Sensor
Also referred to as temperature detector.
A part of a temperature control system that compiles the temperature and
transmits it to the control system. Resistance temperature sensors are used
in Nordson units.
Thermostat
Component that regulates temperature. It is usually an electrical switch that
switches at a certain or set temperature. The difference between the
temperatures at which the unit switches on and off is called hysteresis.
Transformer
Voltage converter.
Used in Nordson units to convert the customer’s line voltage to the
operating voltage.
VAC
Abbreviation for Alternating Current.

Glossary C-15
VDC
Abbreviation for Direct Current.
Viscosity
Strength; an indication of the force that must be generated to move a liquid:
1. Viscosity (also called dynamic viscosity). Unit: Pas (Refer to
Conversions).
2. Kinematic viscosity (dynamic viscosity divided by material density). Unit:
m2/s (Refer to Conversions).

C-16 Glossary

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NORDSON ENGINEERING GMBH D LÜNEBURG D GERMANY

© 2007 All rights reserved.

P/N 7105731J DD200 E 2007 Nordson Corporation

E 2007 Nordson Corporation DD200 P/N 7105731J

P/N 7105731J DD200 E 2007 Nordson Corporation

E 2007 Nordson Corporation DD200 P/N 7105731J

P/N 7105731J DD200 E 2007 Nordson Corporation

E 2007 Nordson Corporation DD200 P/N 7105731J

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

General Instructions Regarding Working with

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

P/N 7105731J DD200 E 2007 Nordson Corporation

Distributors in Eastern & Southern Europe

E 2007 Nordson Corporation

Outside Europe / Hors d’Europe / Fuera de Europa

S Pour toutes informations sur représentations de Nordson dans votre

S Para obtener la dirección de la oficina correspondiente, por favor

Contact Nordson Phone Fax

Africa / Middle East

Asia / Australia / Latin America

E 2007 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

E 2006 Nordson Corporation

Responsibilities of the Equipment Owner

Instructions, Requirements, and Standards

A1EN−01−[XX−SAFE]−10 E 2006 Nordson Corporation

S Receive safety training appropriate to their job function as directed

S Possess industry- and trade-specific skills and a level of experience

E 2006 Nordson Corporation

Applicable Industry Safety Practices

Intended Use of the Equipment

Instructions and Safety Messages

A1EN−01−[XX−SAFE]−10 E 2006 Nordson Corporation

E 2006 Nordson Corporation

Maintenance and Repair Practices

A1EN−01−[XX−SAFE]−10 E 2006 Nordson Corporation

Equipment Safety Information

Relieving System Hydraulic Pressure

De-energizing the System

2. To prevent the equipment from being accidentally energized, lock and

NOTE: Government regulations and industry standards dictate specific

E 2006 Nordson Corporation

Disabling the Guns

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

A1EN−01−[XX−SAFE]−10 E 2006 Nordson Corporation

General Safety Warnings and Cautions

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

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

Table 1-1 General 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

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

E 2006 Nordson Corporation

General Safety Warnings and Cautions (contd)

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

WARNING: Equipment starts automatically! Remote triggering

WARNING: Risk of electrocution! Even when switched off and

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